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BACKGROUND OF THE INVENTION
This invention relates to a bobbin lead roving machine and more particularly to a method for controlling the take-up or winding tension placed on the roving through adjustment of the r.p.m. of the bobbin, and an apparatus for carrying out such method.
In a roving machine, the rate of increase in the bobbin diameter relative to the increase in the number of roving layers on the bobbin is changed with spinning conditions such as the kind and weight of the fibers to be roved, the r.p.m. of the flyer, or the number of twists. Thus, when a single set of cone drums are used, it is difficult to adjust the roving machine so that the roving take-up tension may be constant from the beginning until the end of winding on a bobbin under any spinning conditions. Since fluctuations in the roving tension may cause fluctuations in the weight of the roving and in the number of roving, higher skill and experience on the part of the operators are required for adjusting the tension placed on the roving to an optimum value.
So far, various methods and devices have been proposed to effect the roving operation under a constant roving tension. Thus the devices shown in the Japanese Patent Publication No. 48652/1977 and the Japanese Utility Model Publication No. 13376/1977 are being used practically in a roving machine making use of cone drums as means for changing the speed of rotation of the bobbin. In known devices, a tentative roving operation is performed under given spinning conditions. During such tentative spinning, the state of tension on the roving travelling between the front roller and the flyer top is checked several times from the beginning until the end of winding for adjusting the cone drum belt shift compensation device and changing the cone drum belt position by means of a belt shifter. When the desired r.p.m. of the bobbin is reached, the position of the belt shifter of the compensation device is set for fixing the relation between the number of the roving layers and the corresponding cone drum belt position or displacement. The actual spinning operation is contemplated to be performed under a constant roving tension by observing the above relation during spinning.
In this known method, the relation between the number of the roving layers and the cone belt position is fixed on the assumption that the relation between the cone drum belt position and the r.p.m. of the bobbin can be fixed unequivocally by thus fixing the relation between the number of the roving layers and the belt position. However, the same r.p.m. of the bobbin may not be necessarily obtained for the same belt positions because of other factors such as changes in the load status, decrease in the power of transmission due to prolonged use of the transmission belt, and changes in belt tension.
It is therefore a principal object of the present invention to provide a method and apparatus for controlling the take-up tension on the roving whereby the tension on the roving may be kept constant under any spinning conditions or states of the roving machine.
SUMMARY OF THE INVENTION
With the above object in view, this invention resides in a method for controlling the roving take-up tension in a bobbin lead roving machine comprising the steps of finding in advance a target r.p.m. (N°n) of the bobbin for each of a plurality of arbitrarily selected layers (n) taken up on a bobbin and setting plural sample sets of (N°n)-(n) in a micro-computer; finding by automatic measurement an actual r.p.m. (Nn) of the bobbin for each of the layers (n) in the subsequent actual spinning; comparing the target values (N°n) to the actual values (Nn) in said micro-computer for respective ones of the layers (n) and issuing, in case the resulting difference has exceeded the present control limit value, a signal for correcting the actual r.p.m. towards said target r.p.m., thereby to speed up or slow down the bobbin rotation for automatically compensating the take-up tension on the roving.
Furthermore, the present invention resides in a device for controlling the roving take-up tension in a bobbin lead roving machine, said device comprising a sensor for measuring the r.p.m. of the bobbin; means for counting the number of layers of the roving; a micro-computer designed to receive the outputs from said sensor and counting means to compare said outputs with the values of the r.p.m. of the bobbin related to preset ones of the roving layers and to issue a compensation signal when the result of such comparison has exceeded a preset control limit value; relaying means operable in response to said compensation signals; and means responsive to actuation of said relaying means to change the r.p.m. of the bobbin.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims specifically pointing out and distinctly claiming the subject matter of the invention, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying drawings, wherein:
FIGS. 1 and 2 are diagrams showing the numbers of layers of the roving on the bobbin versus the r.p.m. of the bobbin for illustrating the process of controlling the r.p.m. of the bobbin according to the present invention;
FIG. 3 is a block diagram for illustrating the same process; and
FIG. 4 shows the overall roving tension control device according to a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For providing a constant roving tension, it is necessary in a known manner to control the r.p.m. of the bobbin to provide roving take-up speeds related to variations in the number of roving layers or in the bobbin diameter.
Roving tension is changed with the spinning speed to take-up speed ratio, resistance offered from the flyer to the roving and the status of roving. Thus it is difficult to set the roving tension by an advance operation such as calculation. According to conventional practice, the relative position between the upper and lower cone drums, the starting belt position and the belt displacement per roving layer are set by a skilled practitioner as he checks the status of the roving travelling between the front roller and the flyer top to eliminate excess tension or slack in the roving for possibly arriving at the optimum status of the roving and the appropriate r.p.m. of the bobbin. However, it is difficult to satisfy varying spinning conditions with a given set of cone drums of a specific configuration. Thus, according to the method of the present invention, a tentative spinning operation is performed with the roving of a given description. In the course of this tentative spinning, the roving tension is adjusted to occasional optimum values for various numbers n of the roving layers on the bobbin, where n designates integers 1, 2, 3 . . . , and the r.p.m.'s of the bobbin corresponding to these optimum values of the roving tension N°n where n designates integers 1, 2, 3 . . . . The relation between the number of roving layers n and the corresponding r.p.m.'s of the bobbin is stored in a micro-computer. Such relation need not be taken for each layer of the roving on the bobbin. As a matter of fact, it is only necessary to take such relation for a suitable plural number of the layers during spinning from the beginning until completion of winding. In this case, the relation between the number of layers n and the bobbin r.p.m. N°n may be directly inputted to the micro-computer for the roving of a specific description. Alternatively, the relation between n and N°n is recorded in advance and the relation thus recorded is inputted occasionally to the micro-computer so as to be used in a subsequent spinning operation which is to be effected under the same spinning conditions. Still alternatively, the relation between n and N°n is stored in advance in a micro-computer for each of plural descriptions of the roving so that a desired one of such relations may be resorted to when the occasion may demand. The preparatory step for the actual spinning is now completed.
The control process for the bobbin r.p.m. in the course of the actual spinning operation is now described in detail. It is assumed that Nn designates the bobbin r.p.m. as measured for a certain number of the roving layers n. The value Nn is inputted to the micro-computer for comparison with the stored value N°n, and a signal is issued when the resulting difference has exceeded a preset control threshold value. This signal is used for driving a bobbin speed compensation electric motor through an output relay for automatically changing the bobbin r.p.m. N° in the direction of the preset r.p.m. N°n for realizing the targeted roving tension. Such change of the bobbin r.p.m. in the desired direction may be effected by advancing or receding the belt position in case of a roving machine having a cone drum type speed change system, or by increasing or decreasing the rotary angle of a speed change cam in case of a roving machine having a positive infinitely variable (P.I.V.) speed change system. FIGS. 1 and 2 illustrate the process for controlling the r.p.m. of the bobbin. In FIG. 1, the numbers n of the roving layers are plotted on the abscissa, where a, b, c, . . . designate the numbers of layers stored in the micro-computer. The r.p.m.'s of the bobbin N°n, Nn are plotted on the ordinate. In these Figures, a curve So represents the design setting of the bobbin r.p.m. for the various numbers of the layers, while a curve S the changes of the bobbin r.p.m. for the various numbers of the layers when the bobbin r.p.m. is not placed under control. ΔNa, ΔNb, ΔNc . . . designate offsets of Nn from N°n for the numbers of layers a, b, c, . . . . In FIG. 2, the relation between the numbers of the layers n and the magnitude of the above offset is shown to an enlarged scale about the preset bobbin r.p.m. as reference. In this Figure, the numbers n are plotted on the abscissa and the offset ΔNn is plotted on the ordinate. 00' represents the preset bobbin r.p.m.. An upper control limit (U.C.L.) and a lower control limit (L.C.L.) represent the control limit threshold values +δN° and -δN°. A curve Q shown in solid line represents a change in ΔNn when the bobbin r.p.m. is not placed under control. A curve Q' shown in dotted line represents a similar change that takes place when a device for compensating the bobbin r.p.m. is in operation. Referring to this curve Q', when the micro-computer has detected that the offset ΔNn has exceeded at Pa the lower control limit line at number a, the device for compensating the bobbin r.p.m. comes into operation for compensating the bobbin r.p.m. towards the central setting 00' at P'a. The curve Q' then proceeds similarly to the curve Q from P'a to Pb and again exceeds the lower control limit line at Pb at number b. Bobbin r.p.m. is again compensated at this point. The bobbin r.p.m. is controlled to be within the predetermined control limit by repeating the foregoing process steps.
FIG. 3 is a block diagram for control of the bobbin r.p.m. where A shown in double-dotted chain line designates a micro-computer section. The control limit for the bobbin r.p.m. for a predetermined number n of the roving layers where n designates any arbitrary number from unity to a maximum number of the roving layers to be wound on the bobbin, expressed as a, b, c, . . . . In FIG. 2, this control limit is shown as design setting level. The number n is measured by a measuring device on the basis of the vertical movement of the bobbin rail and inputted into the micro-computer. The control part of the micro-computer operates only when the inputted number n has coincided with the number a, b, c, . . . previously stored in the computer. The actual r.p.m. of the bobbin Nn is measured by a measurement device and inputted to the micro-computer. A signal is issued for each of the numbers a, b, c, . . . from a comparator and amplified. The signal thus amplified operates to drive the operating electric motor in the forward or reverse direction through the output relay for compensating the bobbin r.p.m. by operation of a bobbin speed change device. The bobbin r.p.m. resulting from such compensation is again measured and inputted to the micro-computer according to feedback control mode.
Reference is made to FIG. 4 for illustrating an embodiment of a device for carrying out the method of the present invention, as applied to a roving device having a bobbin speed change device making use of a pair of cone drums as conventionally. In a bobbin lead roving machine, the roving is taken up on the basis of the difference between the r.p.m. of a bobbin 1 and that of a flyer 27 which is less than that of the bobbin. A sensor 2 for sensing the bobbin r.p.m. is mounted in a drive system for the bobbin 1 for measuring the actual bobbin r.p.m. which is inputted into the micro-computer A. The means for measuring the number n is a counter 4 making use of a non-contact relay or a microswitch that is turned on or off based upon vertical travel of a bobbin rail 3. The bobbin 1 is rotated with a variable speed under a combined rotary motive power supplied from a differential device 9 to which are supplied a rotary power from a main electric motor 5 and a rotary power from a bottom cone drum 8, which is rotated from the main motor 5 through a top cone drum 6 and a transmission belt 7 with a variable speed related to the bobbin diameter. Referring to an embodiment of the bobbin speed change device, there is shown in FIG. 4 a system for displacing the transmission belt 7 associated with the cone drums. In this system, a differential gearing H is annexed to the conventional belt shifter device for providing the conventional belt shifting and the compensation belt shifting simultaneously. Referring to the conventional belt shifting, a rack 11 having a belt shifter 10 meshes with a gear 14 on a shaft 13 that is rotated in a known manner by descent of a weight 12. The gear 14 is connected to a gear 16 mounted on the same shaft 13, a planetary gear 16, a gear 18 on a shaft 17 aligned with shaft 13, and a ratchet wheel 20 connected in turn to the shaft 17 through pinions 19. Whenever a pawl, not shown, engaging with the ratchet wheel 20 is disengaged due to a change in the number of roving layers, the gear 14 is rotated intermittently for displacing the belt 7 a predetermined distance in the direction shown by the arrow mark so as to change the number of revolutions of the cone drum 8 and thereby change the r.p.m. of the bobbin. On the other hand, when the offset ΔNn of the r.p.m. of the bobbin has exceeded the control limit, the operating electric motor 21 forming an essential portion of the device for controlling the r.p.m. of the bobbin is rotated in the forward or reverse direction to effect compensation belt shifting. A worm 22 meshing with a worm wheel 23 is rotated by rotation of the motor 21 for rotating the planetary gear 16 about axes of the aligned shafts 13, 17. Since the shaft 17 is stationary by operation of the ratchet wheel 20 and the pawl meshing therewith, rotation of the gear 16 causes rotation of the shaft 13 and thereby the belt 7 is advanced or receded a predetermined distance through gear 14, rack 11 and belt shifter 10 to effect the compensation of the r.p.m. of the bobbin. It is to be noted that any other means or devices for compensation belt shifting than the one shown and described in the above may be applied to the present invention.
The method for setting the r.p.m. of the bobbin N°n with relation to the number of roving layers on the bobbin is now described with reference to the drawings. In FIG. 4, A, B and C designate micro-computer section, amplifier section and output relay section, and D designates a manual switch section for the operating electric motor 21. During trial spinning, the state of tension on the roving 26 travelling between a front roller 24 and a flyer top 25 is judged on the basis of slack in the roving 26. If the tension state is judged to be inadequate, the switch D is operated for driving the motor 21 and adjusting the position of the belt 7 so as to change the r.p.m. of the bobbin 1. When the tension on the roving is judged to be optimum, the r.p.m. of the bobbin N°n prevailing at this time is stored in the micro-computer as a sample set with the corresponding number of the layers n previously stored in the micro-computer. By repeating this procedure from the beginning until the end of winding of the roving on the bobbin, design values of the r.p.m. of the bobbin N°a, N°b, N°c, . . . coordinated to the number of layers a, b, c, . . . can be stored in the micro-computer. A control limit value δN°n for the offset ΔNn is then stored in the micro-computer. The actual spinning operation is then performed in the manner described above. Display means for the numbers of the layers n, design r.p.m. N°n and actual r.p.m. may preferably be included in the micro-computer.
Although the foregoing description has been made in connection with a roving machine employing a pair of cone drums, the present invention can be applied to a roving machine having a bobbin r.p.m. control device in which an operating cam is associated with a PIV speed change system. According to the control method of the present invention, a linear cone drum can be used instead of the conventional hyperboloid cone drum to obviate manufacture difficulties.
The present invention may be distinguished from the conventional method in which the r.p.m. of the bobbin is controlled indirectly through controlling the belt position according to the program setting in that the number of layers on the bobbin and the r.p.m. of the bobbin are measured as sample sets in accordance with the setting program for the r.p.m. of the bobbin for directly controlling the r.p.m. of the bobbin. Thus a micro-computer may be utilized for calculation of the offsets in the r.p.m. of the bobbin. In this manner, an optimum tension may be maintained on the roving under any spinning conditions and operating states of the roving machine.
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Described is a bobbin lead roving machine in which target r.p.m. values for the bobbin are found in advance for each of arbitrarily selected numbers of the layers of the roving taken up on the bobbin and are stored in a micro-compouter, there r.p.m. values are compared to actual r.p.m. values for respective ones of said arbitrarily numbers of the layers, and compensation is made automatically for any offsets resulting from such comparison for causing the r.p.m. of the bobbin to be within a control limit, in a manner that the take-up tension placed on the roving is kept constant during spinning since the beginning until the end of winding on the bobbin for producing the roving of uniform weight (with a constant weight/unit length).
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BACKGROUND OF THE INVENTION
The present invention relates to scanning of an addressed point in space.
More particularly, the invention relates to a more rapid means of scanning an addressed point in space with programable angular relationships, with only rotary motion for angle and reduced motion for position in two or three dimensions, or with simply rotary motion for displacement with a consistent angular relationship in two or three dimensions.
The means for implementing scanning of an addressed point in space have heretofore been rather elaborate and the operation relatively cumbersome. This invention aims to overcome these disadvantages.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome prior-art disadvantages.
A more particular object of the invention is to provide a more rapid manner of scanning an addressed point in space with programable angular relationships.
A concomitant object is to achieve the above objects, using either merely rotary motion for angle and reduced motion for position in two or three dimensions, or merely rotary motion for displacement with a consistent angular relationship in two or three dimensions.
The above objects, and still others which will become apparent hereafter, are achieved in an arrangement for scanning an addressed point in space, comprising a light source; a camera at which light from the light source is directed; deflector means interposed between the source and camera and through which light can pass from the source to the camera and rotary addressing mirror means in the path of the light intermediate said deflector means and camera, so that light from the source is deflected by the addressing mirror means to the deflector means, from there to the addressed point in space, and from there via the deflector means and the addressing means to the camera.
The invention will hereafter be described with reference to exemplary embodiments, as illustrated in the appended drawings. However, these are to be understood as being for purposes of explanation only and not to have any limiting intent or effect.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic illustration showing one embodiment of the invention;
FIG. 2 is a view similar to FIG. 1 but showing the embodiment in another operating position;
FIG. 3 is another diagrammatic view of yet a further embodiment;
FIG. 4 is similar to FIG. 3 but showing another embodiment;
FIG. 5 is similar to FIG. 1, but of still an additional embodiment; and
FIG. 6 is a view analogous to FIG. 4 but illustrates yet another embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
In the embodiment of FIG. 1 the reference numeral 5 identifies an addressed point in space (i.e. anywhere in three-dimensional space, not limited to so-called "outer" space). An addressing mirror 3 is rotatable about a fixed axis and is surrounded with clearance by a parabolic, spherical, etc., mirror 1. With rotary mirror 3 positioned at 45° to the optical axis of the mirror 1, the output angle bisector 6 will be located on the main optical axis.
FIG. 1 shows the technique operating in two dimensions; however, motion into or out of the plane of FIG. 1 can be used by employing a three-dimensional (spherical, parabolic, etc.) mirror 3 in order to accomplish three-dimensional rotation of the output angle bisector about the point 5. This is particularly useful when it is desired to find a three-dimensional point on a shiny object, where light returns to the camera 4 only when the angular bisector 6 coincides with a line normal to the shiny surface. Reference numeral 2 identifies the plane (if scanning is two-dimensional) or the ray of light (if scanning is three-dimensional) of a light projector having its output directed towards the mirror 3 through an appropriate opening in the mirror 1.
Changing the address point 5 in space by either moving the entire system or moving just the items 2, 3 and 4 within the image space of mirror 1, will facilitate reduced address motion. It will be appreciated by those skilled in the art that image points occur to the left of the mirror's focal point, as drawn. Angles may be calculated or, preferably may be calibrated by taking samples and later using a computer-memory as a reference table.
FIG. 5 shows the same embodiment, which is why all elements have the same reference numerals as before. However, here the rotary mirror 3 has been rotated to a 30° angle relative to the optical axis of the main mirror 1, so that the angular bisector 6 is no longer located on the main optical axis, but has rotated around the addressed point 5 in space.
In the embodiment of FIG. 3 the reference numeral 7 identifies a camera or photocell, reference numeral 8 a light projector which projects a light plane (two-dimensional, cylindrical geometry) or a ray of light (for three-dimensional, spherical geometry).
A rotary mirror is identified by reference numeral 9 and reference numeral 10 is the point of rotation (of mirror 9) and focal point of the light. Element 11 is a lens which is cylindrical for two-dimensional applications but must be spherical for three-dimensional applications. Numeral 12 is the output focal point of the arrangement and 13 is the output angle bisector.
In this embodiment a rotation of mirror 9 about point 10 causes the output angle bisector 13 to rotate about focal point 12. The utility of this embodiment is the same as in FIGS. 1 and 2. If both the camera 7 and the projector 8 are mounted on a common fixture which is capable of rotating the point 10, then the mirror 9 can be omitted; this is preferable in those cases where the embodiment is intended for three-dimensional applications.
The embodiment of FIG. 4 uses a projector 14, a camera 15, two rotary mirrors 16 and 17 associated with projector 14 and the camera 15, respectively, and two lenses 19 and 20. The addressed point in space is identified with reference numeral 18 and the direction of the light flow is designated by the arrowheads. This embodiment is thus a modification of the one in FIG. 3.
In FIG. 5 the projector, camera and addressed point in space are again identified with reference numerals 14, 15 and 18, respectively. There are two spherical mirrors 50 and 51, although parabolic or other convex mirrors may also be used with a different angle-to-displacement formula.
Each of the mirrors 50, 51 has the usual opening for passage of light rays and mounted within the confines of the mirrors are rotary (i.e. tilt) mirrors 52, 53 respectively. Both the projector light beam and the camera light beam each travel through the focal point of their associated mirrors 50, 52. Note that light entering the mirror's focal point must leave parallel to the mirror's principal axis, but that the reverse is true of received light.
Each of the mirrors 50, 51 has the usual opening for passage of light rays and mounted within the confines of these mirrors are rotary (i.e. tilt) mirrors 52, 53, respectively. Both the projector light beams and the camera light beam each travel through the focal point of their associated mirrors 50, 51. Note that light entering the mirror's focal point must leave parallel to the mirror's principal axis, but that the reverse is true of received light.
The displacement D for an ideal spherical lens can be calculated by the formula SIN (θ/2). The preferred (because more accurate) method is to calibrate displacement distance versus angle, using e.g. a computer memory.
The embodiment of FIG. 6 is different in that it uses lenses 60, 61; the other reference numerals denote like elements as in FIG. 4. Light passing through the focal point of the lens emanates from the respective lens parallel to its principal axis. Displacement from the axis D is calculated to be D=ƒ* TAN (θ).
While the invention has herein been described with reference to specific embodiments, it is not to be limited thereto inasmuch as any modifications within the skill of the art are intended to be encompassed within the scope of the appended claims.
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An arrangement is disclosed, in form of various embodiments, for more rapid scanning of an addressed point in space with programmable angular relationships, using either merely rotary motion for angle and reduced motion for position in two or three dimensions, or simply rotary motion for displacement with a consistent angular relationship in two or three dimensions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a still-picture imaging apparatus suitable for use with, e.g., an electronic still video camera.
2. Related Background Art
Human eyes have an adaptability to recognize a color of a white subject as white even when the light with which a field is irradiated changes. Contrastingly, for instance, in an electronic still video camera, if the irradiation light ambient to the field changes, the color also changes. Then, it is required that a white-balance be adjusted.
FIG. 4 shows processing in a conventional electronic still video camera. This processing starts with bringing a release button (unillustrated) of the electronic still video camera into a half-pushed state. Then, photometry is conducted in step S1. That is, a brightness of a field is detected. Next in step S2, a color measuring process is performed; i.e., a color temperature ambient to the field is measured. After effecting these two processes, the action proceeds to step S3. Whether or not the release button is finally turned ON (the release button is full-pushed) is judged.
When the release button is not yet full-pushed, the action proceeds to step S4. Whether or not the half-pushed state is kept is judged. If the half-pushed state is kept, the action goes back to step S1. The actions after step S1 are repeatedly executed. In step S4, if the half-pushed state is canceled, the action further proceeds to step S5. In step S5, if is judged whether or not a predetermined time (e.g., 16 seconds) has elapsed since the half-pushed state was canceled. Then, if the predetermined time has not yet passed, the action returns to step S1. Namely, even when the half-pushed state is canceled, the half-pushed state is substantially held for 16 seconds. In step S5, if the predetermined time has elapsed, the action is ended.
In step S3, if the release button is judged to be full-pushed, the action proceeds to step S6. The AE control is performed corresponding to a photometric result obtained in step S1. That is, an aperture and a shutter speed are set to predetermined values, and an exposure action is executed. The action next proceeds to step S7, wherein the white-balance is controlled. To be more specific, the white balance is adjusted corresponding to the color measured result given in step S2. Thereafter, the action goes to step S8 where imaging process is executed, and the data read from an image sensing device (not shown) such as a CCD are converted into video signals. Then, the action further proceeds to step S9, wherein the video data are recorded on a video floppy disk (magnetic disk).
The conventional apparatus is constructed with a flash device which illuminates the field with a flash of light. In this apparatus, a memory previously stores items of white-balance adjusting data for adjusting the white-balance in the case of employing the flash device. The white-balance is adjusted corresponding to the data stored in this memory when using the flash device.
In the conventional apparatus, as explained above, when half-pushing the release button, the photometric and color measuring actions are repeated. This results in an increase consumption of the electric power. Consequently, there arises a problem in that the battery is quickly consumed particularly in an apparatus of such a type that the color is measured by use of an imaging portion, the electric power consumed during the color measurement becomes remarkably larger than in the case of providing a color measuring element for an exclusive use. The consumption of the electric power is large enough not to be ignorable.
Further, according to the conventional apparatus, the white-balance is adjusted corresponding to the data stored beforehand in the memory in the case of using the flash device. In practice, however, color temperature differs among different types of flash devices. This therefore leads to such a problem that the white-balance is hard to adjust accurately. Especially in the case of taking a shot by employing the flash device when the external light is bright, it is difficult to properly adjust the white-balance.
Still further, according to the conventional apparatus, even when immediately brought into the full-pushed state subsequent to the half-pushed state, a judgement of being in the full-pushed state is made after completing the photometric and color measuring actions. It is thus impossible to take a shot quickly, and the photographer may therefore be unable to capture a brief exposure opportunity.
SUMMARY OF THE INVENTION
It is a primary object of the present invention to provide an imaging apparatus capable of reducing the electric power consumed and capable of accurately measuring a color temperature or adjusting a white-balance.
It is another object of the present invention to provide an imaging apparatus capable of reducing the electric power consumed and capable of eliminating missed exposure opportunities.
According to a still-picture imaging apparatus of this invention, when half-pushing a release button, a photometric action is carried out. When full-pushing the release button, an exposure state is controlled corresponding to the photometric result, thereby imaging a field. A color temperature ambient to the field is measured for a duration of the exposure. After completing the imaging action, the white-balance of video signals obtained as a consequence of the imaging action is adjusted according to the measured color temperature.
According to a still-picture imaging apparatus of this invention, the photometric action is effected when half-pushing the release button. When full-pushing the release button, the exposure state is controlled corresponding to the photometric result, thereby imaging the field. When starting the exposure, the color temperature ambient to the field is measured for a predetermined period. After completing the imaging action, the white-balance of the video signals obtained as a result of the imaging action is adjusted according to the measured color temperature.
According to a still-picture imaging apparatus of this invention, when half-pushing the release button, the photometric action is conducted. When full-pushing the release button, the field is irradiated with a flash of light. Simultaneously, the exposure state is controlled corresponding to the photometric result, thereby imaging the field. The color temperature ambient to the field is measured for a duration of the irradiation of the flash of light. After completing the imaging action, the white-balance of the video signals obtained as a result of the imaging action is adjusted according to the measured color temperature.
In these still-picture imaging apparatuses, the video signals and the data on the measured color temperature can be recorded on a recording medium instead of adjusting the white-balance.
In the still-picture imaging apparatus of the present invention, after the release button has been brought into the full-pushed state, the color temperature ambient to the field is measured for a full duration of the exposure or for a predetermined period after starting the exposure. Hence, the color is not measured when half-pushing the release button. The electric power consumed can be reduced correspondingly.
Further, in the still-picture imaging apparatus of the present invention, after turning ON the release button, there is measured the color temperature ambient to the field during the irradiation of the flash of light. It is therefore possible to adjust the white-balance and accurately measure the color temperature in the case of using the flash device.
According to the still-picture imaging apparatus of this invention, when half-pushing the release button, a photometric action is carried out. When full-pushing the release button, the color temperature of the field is measured. At the same time, the exposure state is controlled corresponding to the photometric result, thereby imaging the field. After completing the imaging action, the white balance of the video signals obtained as a result of the imaging action is adjusted according to the measured color temperature.
According to the still-picture imaging apparatus of this invention, the photometric action is effected when half-pushing the release button. When full-pushing the release button, the color temperature ambient to the field is measured. Simultaneously, the exposure state is controlled corresponding to the photometric result, thereby imaging the field. After completing the imaging action, the video signals obtained as a consequence of the imaging action and the data corresponding to the measured color temperature are recorded on the recording medium.
According to the still-picture imaging apparatus of the present invention, after the release button has been put into the full-pushed state, the color temperature ambient to the field is measured. Accordingly, when the release button is in the half-pushed state, no photometric action is effected. The electric power consumed can be reduced correspondingly. Also, it is possible to take a shot quickly.
In addition, according to the still-picture imaging apparatus of the present invention, after bringing the release button into the full-pushed state, the data corresponding to the measured color temperature is recorded on the recording medium. Hence, the white-balance can be accurately adjusted by use of this item of data.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent during the following discussion in conjunction with the accompanying drawings, in which:
FIGS. 1 and 9 are block diagrams illustrating constructions of an electronic still video camera in embodiments of the present invention;
FIG. 2 is an explanatory flowchart showing the operation in the embodiment of FIG. 1;
FIG. 3 is an explanatory flowchart showing other operations in the embodiment of FIG. 1;
FIG. 4 is an explanatory flowchart showing the operation in a conventional electronic still video camera;
FIG. 5 is an explanatory flowchart showing the operation in another embodiment;
FIG. 6 is an explanatory flowchart showing the operation still another embodiment; and
FIGS. 7, 8 and 10 are explanatory flowcharts showing the operation in a further embodiments.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a block diagram illustrating a construction in one embodiment of an electronic still video camera to which a still-picture imaging method of this invention is applied. Rays of light coming from a subject (unillustrated) are incident on an imaging portion 205 via an optical member 201 consisting of lenses, a stop member 202 and a shutter 204. This imaging(image picking-up) portion 205 comprises a solid-state image sensing device consisting of, e.g., a CCD or a MOS device. The imaging portion 205 also comprises a sampling circuit for sampling output signals from this solid-state image sensing device at a predetermined timing.
The imaging portion 205 outputs R-, G- and B-signals. The R-signal among those signals is inputted to an image processing portion 207 via a variable amplifier 206R. The B-signal is supplied to the image processing portion 207 via a variable amplifier 206B. Contrastingly, the G-signal is supplied directly to the image processing portion 207. The image processing portion 207 adjusts a gain, a set-up level, gamma and knee of the inputted signals. The image processing portion 207 converts the R-, G- and B-signals into video signals and outputs these video signals to a recording portion 208. The recording portion 208 records the inputted video signals on a video floppy disk (magnetic disk) (not shown).
A microcomputer-based control portion 210 controls the optical member 201, the stop member 202, a mirror 203, the shutter 204, the imaging portion 205, the variable amplifiers 206R, 206B, the image processing portion 207 and the recording portion 208. In addition, the control portion controls a flash device 209 to irradiate the subject with a flash of light at a predetermined timing. The mirror 203 reflects, towards a photometric portion 230, the light coming from the field and incident via the optical member 201 and the stop member 202. The light thus falls on the photometric portion 230. The photometric portion 230 detects a brightness of the subject from this incident light and outputs a detected result thereof to the control portion 210. On the other hand, a photometric portion 215 receives the reflected light from the imaging portion 205 for so-called TTL control when using a strobe. The photometric portion 215 outputs a signal corresponding to the brightness of the subject during an exposure to the control portion 210.
Further, a color measuring portion 240 measures a color temperature of the subject and outputs a measured result thereof to the control portion 210. Stored in an AWB control table 220 are a color temperature detected by the color measuring portion 240 and a white-balance adjustment value corresponding thereto. The gains of the variable amplifiers 206R, 206B are controlled corresponding to the data stored in this table. An X-terminal detecting portion 214 detects a timing at which the exposure is started with tripping of a leading curtain (not illustrated) of the shutter 204. The X-terminal detecting portion 214 outputs a detection signal thereof to the control portion 210.
Further, switches 211, 212 are turned ON when a release button (unillustrated) is half-pushed and full-pushed, respectively . A switch 213 is turned ON when using the flash device 209. The control portion 210 detects a manipulated state of the release button from outputs of the switches 211, 212. The control portion 210 thus judges whether or not the flash device 209 is required to be driven from an output of the switch 213.
Next, the operation will be explained with reference to a flowchart of FIG. 2. The action shown in the flowchart starts with half-pushing the release button and turning ON the switch 211. The control portion 210 at first, when the switch 211 is turned ON, executes a photometric action in step S21. More specifically, a brightness of the field is detected by the photometric portion 230. The light coming from the field falls on the photometric portion 230 via the optical member 201, the stop member 202 and the mirror 203. The photometric portion 230 detects the brightness of the field from this incident light and outputs the detected result thereof to the control portion 210.
Judged next in step S22 is whether or not the release button is full-pushed, i.e., released (whether or not the switch 212 is turned ON). If the switch 212 is not turned ON, the action proceeds to step S23 to judge whether the release button remains half-pushed or not. If half-pushed (the switch 211 is kept ON), the action goes back to step S21, wherein the photometric action is repeated. If the half-pushed state of the release button is judged to be canceled (switch 211 turned OFF) in step S23, the action proceeds to step S24. Judged therein is whether or not a predetermined time (e.g., 16 seconds) has elapsed since the switch 211 was turned OFF. If the time has not elapsed, the action returns to step S21, where in the photometric action is repeated. If the time has elapsed, the action is ended.
In this manner, the photometric action is repeated for a duration of half-pushing of the release button or until the time of 16 seconds has elapsed after canceling the half-pushed state. Then, the photometric action (processing) is terminated just when the time of 16 seconds has elapsed after canceling the manipulation of the release button.
If the release button is judged to be full-pushed in step S22 (the switch 212 is judged to be turned ON), the action goes forward to step S25. An aperture is controlled therein. Namely, the control portion 210 sets the stop member 202 to a predetermined value corresponding to the photometric result obtained in step S21. Next, the action proceeds to step S26 where the leading curtain (not shown) of the shutter 204 is tripped, thereby starting the exposure. To be more specific, the control portion 210 at this moment causes the mirror 203 to flip up off the light path, whereby the leading curtain of the shutter 204 is tripped. The light coming from the field is thereby incident on the imaging portion 205 via the optical member 201, the stop member 202 and the shutter 204. An image of the subject is thus formed.
Further, a signal from the X-terminal is detected in step S27. The color measuring portion 240 also measures a color temperature ambient to the field at this time in step S28. The color measuring portion 240 outputs a measured result thereof to the control portion 210. That is, the control portion 210 causes, when the X-terminal detecting portion 214 outputs the detection signal of the trip of the shutter leading curtain, the color measuring portion 240 to execute a color measuring process. Then, the action proceeds to step S29. After an exposure time (shutter speed) corresponding to the photometric result obtained in step S21 has elapsed, a trailing curtain (not illustrated) of the shutter 204 is tripped, thus finishing the exposure.
The action proceeds to step S30 next to step S29, wherein the AWB control is executed. More specifically, the control portion 210 reads, from the AWB control table 220, a white-balance adjustment quantity (a gain adjustment quantity of the variable amplifiers 206R, 206B) corresponding to the color temperature outputted by the color measuring portion 240. The gains of the variable amplifiers 206R, 206B are thereby adjusted. As a consequence, the brightness data (R-, G- and B-signals) obtained in the imaging process by the solid-state image sensing device of the imaging portion 205 undergo sampling at a predetermined timing in the control portion 210. The sampled data are supplied to the image processing portion 207.
The G-signal among the R-, G- and B-signals outputted by the imaging portion 205 is supplied directly to the image processing portion 207. The R- and B-signals are, however, adjusted to the gains set by the variable amplifiers 206R, 206B and supplied to the image processing portion 207. Next, the action proceeds to step S31. The image processing portion 207 processes and converts the R-, G- and B-signals of which the white balances are adjusted into video signals. Then, the action goes further to step S32 where a recording process is executed. That is, the control portion 210 at this moment controls the image processing portion 207 and the recording portion 208 as well. The video signals outputted from the image processing portion are thereby FM-modulated and recorded on the video floppy disk.
Note that in the embodiment discussed above, after tripping the leading curtain in step S26, the color measuring process is executed in step S28 during a period until the trailing curtain is tripped in step S29. As a result, it follows that a color measurement operating time varies corresponding to an operating time (shutter speed) of the shutter 204. Of course, the process may be such that after the leading curtain has been tripped in step S26, the color measuring process in step S28 is executable for only a predetermined time.
Next, the operation in the case of employing the flash device will be explained with reference to a flowchart of FIG. 3. Processes of steps S41 through S47 are the same as those of steps S21 through S27 in FIG. 2.
The switch 213 is turned ON. If it is commanded beforehand that the flash device 209 be used, the control portion 210 moves, after detecting the signal from the X-terminal in step S47, to step S48 where flash control is executed.
More specifically, the control portion 210 calculates an aperture and a shutter speed corresponding to the photometric result given in step S41. The aperture is set in step S45, while the shutter speed is set in step S50 (tripping of the trailing curtain) which will be mentioned later as well as in step S46 (tripping of the leading curtain). These values are, however, set corresponding to the result of the photometry effected in a non-flashed state. The flash device 209 is therefore controlled to adjust a flashing quantity so that a proper exposure is performed with the set aperture at the set shutter speed.
The control portion 210 further controls, after proceeding to step S49, the color measuring portion 240 to execute the measurement of a color ambient to the field irradiated with a flash of light at a high speed. As a result, the color measurement corresponding to the flash of light actually employed can be conducted irrespective of a driving voltage and a type of the lamp used for the flash device 209.
The action proceeds to step S50 next, where the trailing curtain is tripped and the exposure is completed. The processes of steps S51 through S53 subsequent to step S50 are the same as those of steps S30 through S32 in FIG. 2.
In the above-mentioned embodiment, the white-balance is adjusted by the variable amplifiers 206R, 206B, and thereafter the adjusted video signals are recorded on the video floppy disk. However, the video signals processed by the image processing portion 207 can be also recorded directly on the video floppy disk through the recording portion 208 without adjusting the white-balance by the variable amplifiers 206R, 206B. At this time, the white-balance adjusting data (e.g., gain adjustment quantities of the variable amplifiers 206R, 206B, or color temperature data themselves) outputted by the control portion 210 are correspondingly recorded on the video floppy disk. In this case, when regenerating the data from the video floppy disk, the white-balance is adjusted according to the color temperature data recorded on this video floppy disk.
Further, in the embodiment discussed above, the arrangement is such that the mechanical shutter 204 is disposed in front of the imaging portion 205. The present invention is, however, applicable to an apparatus for controlling the exposure time through an electronic shutter.
As discussed above, according to the still-picture imaging apparatus of this invention, after bringing the release button into the full-pushed state, the white-balance of the video signals is adjusted corresponding to the color temperature measured for a full duration of the exposure or for a predetermined time in the exposure. Hence, when the half-pushing the release button, the color measuring action is not executed, and the electric power consumed can be reduced correspondingly. As a result, a life-span of the battery can be increased.
Further, according to the still-picture imaging apparatus of the present invention, the color measuring action is executed for a duration of flashing after full-pushing the release button. It is therefore possible to detect an accurate color temperature corresponding to the flash of actually irradiated light. Accordingly, the white-balance can be accurately adjusted.
Moreover, according to the still-picture imaging apparatus of this invention, after full-pushing the release button, the data corresponding to the measured color temperature is recorded on the recording medium. The white-balance can be therefore accurately adjusted by use of this item of data.
Next, another embodiment of the present invention will be described with reference to FIG. 5.
Note that the actions up to step S22 in FIG. 5 are the same as those in the embodiment of FIG. 2. Therefore, the explanation skips over the actions up to step S22 but concentrates on those after step S22.
In step S22, if the release button is judged to be full-pushed (the switch 212 is Judged to be turned ON), the action proceeds to step S125 where the color measuring action and AE control are simultaneously executed. Namely, the color measuring portion 240 measures a color temperature ambient to the field at that time and outputs a measured result thereof to the control portion 210.
Further, the control portion 210 controls the stop member 202 and a speed of the shutter 204, corresponding to the photometric result given in step S21. The exposure is thereby executed. At this moment, the control portion 210 causes the mirror 203 to flip up off the light path, thus opening the shutter 204 for a predetermined time. The light coming from the field is thereby incident on the imaging portion 205 via the optical member 201, the stop member 202 and the shutter 204.
The action proceeds to step S126 next wherein the AWB control is executed. To be more specific, the control portion 210 reads, from the AWB control table 220, the white-balance adjustment quantity (the gain adjustment quantity of the variable amplifiers 206R, 206B) corresponding to the color temperature outputted by the color measuring portion 240. The gains of the variable amplifiers 206R, 206B are thereby adjusted. As a consequence, the brightness data (R-, G- and B-signals) obtained in the imaging process by the solid-state image sensing device of the imaging portion 205 undergo sampling at a predetermined timing in the control portion 210. The sampled data are supplied to the image processing portion 207.
The G-signal among the R-, G- and B-signals outputted by the imaging portion 205 is supplied directly to the image processing portion 207. The R- and B-signals are, however, adjusted to the gains set by the variable amplifiers 206R, 206B and supplied to the image processing portion 207. Next, the action proceeds to step S127. The image processing portion 207 processes and converts the R-, G- and B-signals of which the white balances are adjusted into video signals. Then, the action goes further to step S128 where a recording process is executed. That is, the control portion 210 at this moment controls the image processing portion 207 and the recording portion 208 as well. The video signals outputted from the image processing portion are thereby FM-modulated and recorded on the video floppy disk.
In the above-mentioned embodiment, the white-balance is adjusted by the variable amplifiers 206R, 206B, and thereafter the adjusted video signals are recorded on the video floppy disk. However, the video signals processed by the image processing portion 207 can be also recorded directly on the video floppy disk through the recording portion 208 without adjusting the white-balance by the variable amplifiers 206R, 206B. At this time, the white-balance adjusting data (e.g., the gain adjustment quantities of the variable amplifiers 206R, 206B, or the color temperature data themselves) outputted by the control portion 210 are correspondingly recorded on the video floppy disk. In this case, when regenerating the data from the video floppy disk, the white-balance is adjusted according to the color temperature data recorded on this video floppy disk.
In the embodiment discussed above, the arrangement is such that the mechanical shutter 204 is disposed in front of the imaging portion 205. The present invention is, however, applicable to an apparatus for controlling the exposure time through an electronic shutter.
As discussed above, according to the still-picture imaging apparatus of this invention, after bringing the release button into the full-pushed state, the color temperature is measured. The white-balance of the video signals is adjusted according to the measured color temperature. Hence, when the half-pushing the release button, the color measuring action is not executed, and the electric power consumed can be reduced correspondingly. As a result, the life-span of the battery can be increased.
Further, there decreases a time until a judgement as to whether or not the release button is put into the half-pushed state and thereafter into the full-pushed state. A quicker shot can therefore be taken without missing an exposure opportunity.
According, to the still-picture imaging apparatus of the present invention, the color temperature is measured after full-pushing the release button, and data corresponding to the measured color temperature can be recorded on the recording medium. It is therefore possible to precisely adjust the white-balance by use of this item of data.
The following is an explanation of still further embodiments of the present invention with reference to FIGS. 6 and 7.
Referring to FIG. 6, the actions up to step S45 and after step S49 are the same as those in the flowchart of FIG. 3. The explanation thereof is accordingly omitted. In step S45, the aperture is controlled, and, thereafter, a leading curtain start signal is outputted in step S146. Specifically, a start of the leading curtain is commanded corresponding not to the detection of the signal from the X-terminal but to a high-to-low variation of the leading curtain signal. FP flash is controlled in step S148 subsequent thereto.
Referring further to FIG. 7, the actions up to step S44 and after step S50 are the same as those in the flow chart of FIG. 3, and, therefore, their explanation is omitted. If judged to be released in step S42, the aperture control is started in step S245. In subsequent step S246, a mirror-up is started. With a completion thereof, a mirror-up completion signal is outputted. In step S247, the outputted mirror-up completion signal is detected. In subsequent step S248, pre-flash control is performed. In step S249, a color ambient to the field is measured based on the pre-flash. The tripping of the leading curtain is started in step S46 subsequent thereto. Main flash control is conducted (S48) with a detection of the signal from the X-terminal (S47).
An explanation of a further embodiment of this invention is given with reference to FIG. 8, wherein the color measurement is performed during flashing by trailing curtain flash sync. Note that the actions up to step S45 and after step S51 are the same as those in the flowchart of FIG. 3, and hence the explanation thereof is omitted. After the aperture has been controlled in step S45, the leading curtain is tripped in step S346. In subsequent step S347, a trailing curtain start signal varies from high to low. In step S348, the flash control is conducted in synchronization with tripping of the trailing curtain. The color is measured in step S349.
Next, another variation will be explained referring to FIGS. 9 and 10. FIG. 9 illustrates a part of variant form of the embodiment of FIG. 1. The respective components are the same as those in FIG. 1 and therefore marked with the like numerals. The explanation thereof is omitted.
FIG. 10 is a flowchart showing an example of modification of FIGS. 2, 3 and 5. The action shifts to step S301 in FIG. 10 from the processes of steps S29, S50, S126 shown in FIGS. 2, 3 and 5.
In step S301, the R-, G- and B-signals defined as an imaging information without the white-balance are transmitted from the imaging portion 205 to the image processing portion 207. That is, the gains of the variable amplifiers 206R, 206B are set to 1. Then, the action shifts, after converting the R-, G- and B-signals into video signals, to step S302. A recording process is executed in step S302. More specifically, the control portion 210 controls the image processing portion 207 and the recording portion 208. The video signals outputted from the image processing portion 207 are FM-modulated. Then, the FM-modulated signals are recorded on the floppy disk. The action shifts to step S303.
In step S303, the control portion 210 prepares AWB information on the basis of the information outputted from the color measuring portion 240. The action then shifts to step S304. The control portion 210 supplies the recording portion 208 with the AWB information in step S304. The AWB information is recorded on the recording portion 208, thus finishing the process.
The imaging information and the AWB information are recorded on the recording portion 210 by performing the process in this mode. When regenerating a photographed result, an unillustrated photographing device adjusts the white balance based on the imaging information and the AWB information as well. Therefore, the properly color-corrected image can be regenerated without effecting even the AWB control during the imaging process.
Note that the video signals are, after being FM-modulated, recorded on the floppy disk in step S302. However, the arrangement may be such that the signals outputted from the image processing portion 207 are A/D converted, and the digital data are recorded on an opto-magnetic disk, an IC memory or other recording medium. It is apparent that a wide range of working modes can be made in keeping with principles and spirit of this invention, the scope of which is defined in the appended claims.
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A still-picture imaging apparatus includes a manually operable photography starting switch to output a start-of-imaging signal. A control circuit operates dependent upon the start-of-imaging signal to actuate an image pick up device and a color measuring sensor, which measures color temperature for purposes of white-balancing. The control circuit may control an adjuster to adjust white-balance of an image signal from the image pick up device based on a color temperature signal from the color measuring sensor.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. Patent Application Ser. No. 09/552,040 filed on Apr. 19, 2000 and benefit is claimed under 35 U.S.C. §120.
BACKGROUND OF THE INVENTION
Most buildings today are constructed with numerous drawbacks such as excessively long construction time, expensive specialized labor and equipment, poor workmanship, lack of fire-resistance and inefficient heating, cooling and ventilation systems. This invention relates to a series of simple, easy to install steel fittings and profiles to create framing for any type of building. In addition, the invention comprises special panel units to form floor, wall, ceiling and roof cladding to achieve improved radiant heating/cooling, ventilation and fire-resistance at a lower cost than present methods.
SUMMARY OF THE INVENTION
A universal building unit is provided comprising a plurality of members joined to each other by at least one connector. There is also at least one panel connected to the plurality of members. In this case, the plurality of members, the connectors, and the panels all join together to form a universal building unit that can be repeatedly constructed and combined with adjacent building units to form a building structure. These building units also contain a heating and cooling system for heating and cooling the occupants of the structure. These connectors can be set in position and adjusted in order to fit the building units to any desired length or height.
Further, these units can be combined in any manner to create stairs, walls, doors, fixed and movable partitions, windows, roofs, or any other type of building component. These building units also comprise a series of inexpensive, easy to install steel fittings and profiles to create framing for any structure. These building units could even be used as scaffolding to erect a building as well. In addition, because this building unit is assembled from parts that can be handled by individuals, no cranes are needed to complete the construction of a building unit or a building structure made from these building units.
The closed circuit heating/cooling system includes a series of tubes within the structural members. These tubes are connected to a water pump, hot water heater and cold water chiller. Further, the system includes a three-way mixing valve, and thermostat for controlling the temperature of the water flowing through the tubes.
The structure is erected with a plurality of members connected to an adjustable header or plate. For example, the adjustable header or plate is connected to the first member at each end of this member. Successive members are connected to the adjustable headers or plates and positioned as required to achieve the desired height and length of the final assembled building unit. The members are connected to the adjustable headers or plates by bolting or welding.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings, which disclose several embodiments of the present invention. It should be understood, however, that the drawings are for the purpose of illustration only and not as a definition of the limits of the invention.
In the drawings wherein similar reference characters denote similar elements throughout the several views:
FIG. 1A is a side view of the building unit;
FIG. 1B is a cross-section through a building unit member;
FIG. 2 is a side view of the adjustable plate connected to two members;
FIG. 3 is a side view of two members bolted together;
FIG. 4A is a cross-sectional view of two members bolted together back to back;
FIG. 4B is a cross-sectional view of two members bolted together back to back with a tightening nut in between;
FIG. 4C is a cross-sectional view of two members welded together back to back;
FIG. 4D is a cross-sectional view of two members bolted together face to face;
FIG. 5 is a top view of the clip attachment of panels to members on one side forming a building unit;
FIG. 6 is a cross-section view of the clip attachment of panels to a member;
FIG. 7 is a cross-sectional view of panels, members and insulation;
FIG. 8 is a side view of a spring loaded pivot for a frameless door;
FIG. 9 is a top view of the spring loaded pivot for a door; and
FIG. 10 shows the glass panes being placed together; and
FIG. 11 is a schematic block diagram of the heating and cooling system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now in detail to the drawings, FIG. 1A represents a side view of a structural portion of building unit 10 comprising a plurality of members 12 connected directly to each other via a series of nuts and bolts or connected to each other via adjustable plates 30 . Members 12 can be inserted into the ground so that this building unit 10 does not need a foundation. Instead, once a first set of members 12 have been sunk into the ground, additional members 12 can be attached to these members to form a building unit.
Members 12 are made from 12 gauge cold rolled, pickled and oiled steel struts that are preferably made from AISI 1021 grade steel that is 1⅝ inches wide high×varying depths: {fraction (13/16)}, 1, 1⅜, 1⅝ and 2{fraction (7/16)} inches deep, of any length, fabricated with a precision of ±{fraction (1/16)}″. The steel has a yield strength of 50,000 to 55,000 PSI and a tensile strength of between 70,000-80,000 psi. The steel members are hot-rolled flat billets cold-formed into G-shaped strut profiles.
As shown in FIG. 1B, members 12 have a base section 14 , arms 16 , face section 17 , and crimped sections 18 forming grooves 19 on both sides of member 12 . Inside of these members are tubing 20 that can be made from rubber tubing, nylon 11 , cross-linked polyethylene and can be secured inside members 12 .
Coupled to member 12 is a back plate 36 which has a base section 37 and two opposite spaced flanges 38 extending substantially perpendicular to base section 37 . Flanges 38 extend into grooves 19 within member 12 . Back plate 36 couples to a connector plate 40 via nut 24 and bolt 26 .
Tubing 20 coupled with members 12 form a temperature control system that can either raise or lower the temperature of a room through radiant heating or radiant cooling. Tubing 20 is filled with temperature controlled water which reacts with members 12 by either transferring heat to members 12 or by drawing heat away from members 12 .
Members 12 are connected to each other at an angle which gives this building unit a series of advantages. First, the same basic length of members 12 can swivel to provide any desired height of wall or partition. Second, members 12 become self-bracing, eliminating the need for cross-bridging or blocking associated with rectilinear framing systems. Third, the skewed positioning of members 12 affords easy insertion and turning of the heat/cool tubing 20 , eliminating the need for the installation of labor-intensive tube fittings and their concomitant danger of leaking.
Adjustable plates 30 can be connected to members 12 via a nut 24 and bolt 26 . In addition, members 12 can be connected to each other directly via nut 24 and bolt 26 . Adjustable plates 30 can be slid along a substantially horizontal member 12 so that the height of a structural unit can be controlled.
FIG. 2 shows a cross-sectional view taken along the line II—II on FIG. 1A which shows two members 12 joined together via adjustable plate 30 . As shown, nuts 24 and bolts 26 connect base 14 of members 12 to plate 30 . Bolts 26 slide through pre-drilled holes on both plate 30 and members 12 . Bolts 26 are held in place by washers 25 in combination with nuts 24 ′ and 24 ″.
FIG. 3 shows a cross sectional view taken along line III—III in FIG. 1A which shows two members 12 joined together back to back in a crossing manner. In this view, bolt 26 connects members 12 together with three nuts 24 ′, 24 ″, and 24 ′″. Nuts 24 ′ and 24 ′″ are disposed within members 12 while nut 24 ″ is disposed between members 12 . There are also a plurality of washers 25 which are disposed between nuts 24 ′, 24 ″, and 24 ′″, and members 12 . Members 12 can be tightened together using a socket wrench turning nut 24 ″ which will then turn bolt 26 within nuts 24 ′ and 24 ′″.
FIGS. 4A, 4 B, 4 C and 4 D show how members 12 can be coupled together. For example, in FIG. 4A, members 12 can be coupled so that bases 14 are pressed together with bolt 26 coupling both bases together via nuts 24 ′ and 24 ′″. FIG. 4B shows members 12 being coupled together as shown previously in FIG. 3 . FIG. 4C shows members 12 with bases 14 being coupled together via welding or any other type adhesive. Finally, FIG. 4D shows face sections 17 of members 12 being coupled together via bolt 26 , nuts 24 ′ and 24 ′″ and back plate 36 .
FIG. 5 shows a top view of a building unit showing double paned glass panels 50 being fixed to members 12 via connector 40 . Double paned glass panels 50 consist of a first pane 52 , and a second pane 54 . Disposed between both panes is an adhesive bond 56 that secures both panes together. Once bond 56 dries, it forms a gap 58 (see FIG. 6) so that connector 40 can fit therein and secure panes 50 to member 12 . Panels 50 are coupled to member 12 via connector 40 which is fastened to member 12 via back plate 36 , nut 24 and bolt 26 . As nut 24 is tightened, connector 40 pulls flanges 38 into a back face of face section 17 . Panel 52 is also pulled into a front face of face section 17 .
FIG. 6 shows a cross sectional view of member 12 which shows back plate 36 coupling to panels 50 via connector 40 . Connector 40 has a base section 42 , a first prong section 44 coupled to back plate 36 and a second prong section 46 including opposite spaced prongs 46 ′ and 46 ″. Opposite spaced prongs 46 ′ and 46 ″ fit inside of gaps 58 in panels 50 to secure panels 50 to member 12 . Once connector 40 is secured to members 12 , panels 50 are slid on to prongs 46 ′ and 46 ″ to secure panels 40 to face sections 17 of members 12 .
FIG. 7 shows a top view of a building unit comprising a three-layer system of members 12 . With this design, there are a series of panels 80 made from Viroc cement board. Disposed between these panels 80 is insulation 81 made from mineral wool to create a fire resistant building unit 10 that forms a two-hour fire rated building structure. Panels 80 include two separate part panels 82 and 84 coupled together via an adhesive 86 . These panels are coupled together to form an air tight water resistant seal. Thus, once each building is constructed, it forms a waterproof building unit that can be repeatedly stacked to form a waterproof building structure. As in FIG. 5, back plate 36 , along with connector 40 , nut 24 and bolt 26 work together to couple back plate 36 to panels 80 .
FIG. 8 shows a door 90 formed by member 12 , and two spring based pivots 100 disposed inside of member 12 and panels 80 coupled to members 12 . Spring based pivots 100 comprise a base plate 102 that secures to member 12 and a spring loaded insert 104 that snaps into a recess in a door frame. A door can be coupled to the door frame by lining up spring loaded insert 104 with the recess so that insert 104 snaps into this recess. In addition, FIG. 9 shows a top view of door 90 including pivot 100 . Pivot 100 includes spring loaded member 104 , which is disposed within member 12 .
The building units formed by members 12 and either glass panels 50 or V-rock panels 80 can form a self enclosed heating and cooling unit as well. For example, as shown in FIG. 10, glass panels 52 and 54 which are joined together with adhesive 56 form an insulated double paned system that traps heat inside the structure in the winter and keeps the heat out in the summer. As shown in FIG. 10, panel 52 , has a first side 52 ′ and a second side 52 ″ while panel 54 has a first side 54 ′ and a second side 54 ″. With this design faces 1 and 4 , which comprise sides 52 ′ and 54 ″ are coated with a pyrolitic low E coating. Normally, clear glass has an Emissivity value of 0.84 while glass having a pyrolitic low E coating has an Emissivity value of 0.15. Essentially the lower the Emissivity value of the glass, the better it performs in reducing the emission of infrared radiation.
For example, an uncoated glass surface facing the interior of a building would permit most of the heat in the form of infrared radiation to pass through it to the exterior of the building. Similarly, an uncoated glass surface facing the exterior of the building would permit most of the solar radiation to pass through it to the interior of the building. However, if both the interior or the exterior glass surfaces have a pyrolitic low E coating, most of the interior building radiant energy would stay there and little of the solar radiant energy would enter the building.
FIG. 11 shows a schematic block diagram of a heating and cooling or temperature control system 130 that includes a series of tubes or tubing 20 for handling water. This temperature control system is designed to heat or cool a room through radiant heating or radiant cooling. For example, on a warm sunny day, cool water at approximately 60 degrees Fahrenheit is pumped through these tubes 20 to cool the adjacent members 12 and panels 80 coupled thereto. This cool water is enabled by a water chiller 150 and a stainless steel water pump 160 and/or by using ground water or direct earth cooling of the water. In contrast, during cooler months, such as the wintertime, water pump 160 circulates warm water through tubes 20 . These members 12 and panels 80 can then reach a surface temperature of approximately 81 degrees Fahrenheit to heat people in a room through radiant heating. The heat source is a water heater 180 feeding hot water via water pump 160 . There is precise temperature control in the system using a three-way mixing valve 185 actuated by non-electric thermostat 192 graduated in numerals instead of temperature settings. This design allows fine tuning of the comfort zone to suit the needs of specific occupants.
Once the water leaves either the cold water chiller 150 or the hot water heater 180 , it is fed through a three way valve 182 and then through an expansion tank 184 before it is sent to three way mixing valve 185 to heat or cool a room.
In cold weather, warm water circulates through the tubing within the steel profiles transmitting heat to the floor, wall and ceiling surfaces which creates their surface temperature at 81 degrees Fahrenheit which is ideal for human comfort. This heat radiates into each room to heat the occupants. Similarly, summer cooling occurs through the circulation of cool water at 60 degrees Fahrenheit whereby the occupants lose heat through radiant cooling to these same surfaces. The building is heated and cooled by its own structural fabric so that there are no radiators, ducts or grilles.
This design can also be used to create a self heating structure whereby tubes 20 are placed just inside an exterior panel surface. This exterior level of tubing could be separate from an interior level of tubing disposed adjacent to the interior panels via a radiant heat barrier. This design will enable all the exterior surfaces of the building such as roofs, walls and even driveways to efficiently and invisibly absorb solar radiant energy thus obviating the necessity for obtrusive glass solar energy sources.
Accordingly, while several embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims.
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A universal building unit comprising a plurality of members connected to each other by at least one adjustable plate. There is also at least one panel connected to the plurality of members. In this case, the plurality of members, the adjustable plate, and the panels all connect together to form a universal building unit that can be repeatedly constructed and combined with adjacent building units to form a building structure. These building units also contain a heating and cooling system for heating and cooling each unit within the structure. In addition, these units can be combined in any manner to create stairs, walls, doors, fixed and movable partitions, windows, roofs, or any other type of building component. These building units comprise a series of simple, easy to install fittings and steel profiles to create framing for any type of building.
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BACKGROUND OF THE INVENTION
The present invention relates to an equalizer which is provided in a receiver that is used for digital radio communication, digital mobile radio communication, etc.
FIG. 5 shows one example of the arrangement of conventional equalizers, disclosed, for example, in "Instrumentation and Control" Vol. 25, No. 12 (Dec. 1986), pp. 22-28.
In the figure: reference numeral 1 denotes a received signal input terminal; 10 to 13 delay elements each of which delays by a time T a signal that is inputted through the terminal 1; 20 to 23 weight circuits which multiply the input signal and the signals delayed through the delay elements 10 to 13 by weights (hereinafter referred to as "tap coefficients") a o (n) to a N (n), respectively, and output the results; 30 an adder which adds together the outputs of the weight circuits 20 to 23 and outputs the result; 40 an output terminal from which is outputted the result of the addition in the adder 30; 50 a reference signal input terminal from which is inputted a reference signal d(n), which is a known signal sequence; 31 an adder which obtains a difference between the reference signal, i.e., known signal sequence; that is inputted through the terminal 50 and the output from the adder 30; and 60 an error signal output terminal from which is delivered the output of the adder 31 as being an error signal ε(n). A section in this arrangement which comprises the delay elements 10 to 13, the weight circuits 20 to 23 and the adder 30 is referred to as an equalizing circuit 80.
Examples of equalizer structures include, in addition to the feedforward type equalizer shown in FIG. 5, a feedback type equalizer shown in FIG. 6, a decision feedback type equalizer shown in FIG. 7, and a decision feedback type equalizer that is a combination of the two equalizer structures, shown in FIGS. 5 and 7, i.e., that uses both a feedforward section and a feedback section. In FIGS. 6 and 7, the same reference numerals as those shown in FIG. 5 denote the same elements or portions.
Reference numeral 70 in FIG. 7 denotes a decision element, which, in the case of binary decision, decides between binary data, that is, +1 and -1, by judging to which one of the binary data (+1 and -1) the output of the adder 30 is closer. The decision element 70 defines the result of the decision as an output signal y(n) and also as an input signal to the delay element 10 in the feedback section.
The feedback type equalizer that is shown in FIG. 6 does not employ a decision element, such as that employed in the arrangement shown in FIG. 7, but uses the output of the adder 30 as an input signal to the delay element 10 in the feedback section without making a decision.
FIG. 8 shows the arrangement of packet data that comprises a known signal sequence and a random data sequence for estimation of transmission channel characteristics.
The operation will next be explained.
In an equalizer that has an arrangement such as that shown in FIG. 5, a received signal x(n) (n is a parameter representative of discrete time t=n) that is inputted to the input terminal 1 is divided into two, one of which is inputted to the delay element 10, and the other of which is inputted to the weight circuit 20 that has a tap coefficient a o (n), where it is weighted and then outputted. Similarly, the output of the delay element 10 is defined as a received signal x(n-1) at t=(n-1), which is then divided into two, one of which is inputted to the delay element 11, and the other of which is inputted to the weight circuit 21 that has a tap coefficient a 1 (n), where it is weighted and then outputted. If this operation is carried out with respect to all of N delay elements and N+1 weight circuits, the output y(n) of the adder 30 at the time n is given by ##EQU1## This is a linear time varying filter, and the z-transform of the transfer function of this time varying filter is given by ##EQU2##
Incidentally, in the case of an unknown transmission channel whose characteristics vary continuously, for example, a fading channel, it is necessary in order to obtain excellent transmission quality to continuously compensate for the distortion caused by introducing an equalizer. That is, the tap coefficient a 1 (n) (i=0, 1, . . . , N) shown in Expressions (1) and (2), which is a function of the parameter n that represents time, must be adaptively controlled so as to optimally compensate for the distorted channel, for each time.
A typical example of this adaptive control employs a reference signal d(n), that is a known signal sequence, which is inputted through the reference signal input terminal 50 in the arrangement shown in FIG. 5. This reference signal is a known signal sequence that is sent in advance of data, as shown in FIG. 8. While this known signal sequence is being sent, the characteristics of the transmission channel are estimated and the tap coefficients are decided to realize ideal transmission characteristics. In general, the error signal ε(n), which is given by the difference between the reference signal d(n) and the output signal y(n), is defined by
ε(n)=d(n)-y(n) (3)
By using the error signal ε(n), the tap coefficients are adaptively controlled so that an error is minimized.
Various algorithms, such as those mentioned below, may be used for adaptive control of the tap coefficients according to various purposes. For example, the LMS (Least Mean Square) algorithm is expressed as follows:
a(n+1)=a(n)+με(n)×(n) (4)
where μ is a parameter which is known as step size parameter, and ε(n) is an error value that is given by Expression (3).
The Kalman filter algorithm is expressed as follows: ##EQU3## where the superscript T denotes transposition of the matrix.
With an adaptive control algorithm such as those described above, the transmission channel characteristics are estimated and the tap coefficients are determined.
After the transmission channel characteristics are estimated and the tap coefficients are compensatively controlled on the basis of the reference signal, which is a known signal sequence, a random data sequence that is sent after the known signal sequence, as shown in FIG. 8, is subjected to equalization. To effect the equalization, the following two methods may be employed: a first equalization method wherein the tap coefficients of the equalizer that are determined by the reference signal, which is a known signal sequence, are fixed and not updated and, in this state, equalization of the random data section is effected; and another equalization method wherein the output signal y(n) for the random data section is decided by using as initial values the tap coefficients which have been determined by the received signal corresponds to a known signal sequence, and with the result of the decision being regarded as a reference signal d(n), the equalization of the random data section is adaptively effected. With these methods, the equalization of the random data section is conducted.
The conventional equalizers that are arranged as described above involve various problems described below. For example, when the change of transmission channel characteristics is rapid, an equalizer, which estimates the transmission channel characteristics only on the basis of a known signal sequence and effects equalization of the data section with the tap coefficients being fixed, becomes unable to track the rapid change of the characteristics as the equalization progresses toward the trailing end of the data section, resulting in a performance degradation of the received signal. In an equalizer which adaptively equalizes the data section by using as initial values tap coefficients that are set on the basis of a known signal sequence, the amount of computational complexity that is required to update the tap coefficients becomes enormous, which limits the rate at which data can actually be transmitted.
SUMMARY OF THE INVENTION
In view of the above described problems of the prior art, it is an object of the present invention to provide an equalizer which is capable of tracking rapid changes in the characteristics of the transmission channel without limiting the data transmission rate and capable of supplying good data quality.
It is another object of the present invention to provide an equalizer which is capable of adaptively equalizing the data section by using as initial values tap coefficients that are obtained by use of a known signal sequence, without a large increase in the amount of computational complexity and a limit in the data transmission rate.
A first feature of the equalizer according to the present invention resides in that the equalizer comprises a first computing section in which transmission channel characteristics are estimated and tap coefficients are set on the basis of a known signal sequence and in accordance with a first algorithm, with which tap coefficients converge quickly, and a second computing section in which tap coefficients are set in accordance with a second algorithm, which involves a relatively low computational complexity, on the basis of a signal that has been equalized and decided by using as initial values the tap coefficients set in the first computing section, thus updating the tap coefficients by the two computing sections having different algorithms.
With the above-described arrangement, the equalizer of the present invention is capable of tracking changes in the characteristics of the transmission channel and it is also possible to reduce the amount of computational complexity required and eliminate the limitation on the data transmission rate. Thus, the equalizer of the present invention is capable of coping with high speed data transmission.
A second feature of the equalizer according to the present invention resides in that updating of the tap coefficients is executed by use of at least two different kinds of tap-coefficient update algorithms, one of which executes computation for every symbol, and the other of which executes computation by an intermittent operation with a relatively long period, i.e., at a relatively low frequency.
In the present invention, at least two different kinds of tap-coefficient-update algorithms are employed. That is, at least one is a fast converging algorithm by which tap coefficients are determined by making an estimation of the characteristics of the transmission channel by use of a known signal sequence, resulting in initial tap coefficients, and in regard to the data section, the other is an algorithm which updates the set tap coefficients once per every several symbols, thereby enabling the tap coefficients to track relatively slow changes in the characteristics of the transmission channel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a first embodiment of the equalizer according to the present invention;
FIG. 2 is a timing chart showing the operation of the first embodiment of the present invention;
FIG. 3 is a block diagram of a second embodiment of the equalizer according to the present invention;
FIG. 4 is a timing chart showing the operation of the second embodiment of the present invention;
FIG. 5 is a block diagram of a conventional feed-forward type equalizer;
FIG. 6 is a block diagram of a conventional feedback type equalizer;
FIG. 7 is a block diagram of a conventional decision feedback type equalizer; and
FIG. 8 shows one example of the arrangement of packet data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described below with reference to the accompanying drawings.
FIG. 1 shows the arrangement of a first embodiment of the equalizer according to the present invention. In the figure, reference numeral 1 denotes a received signal input terminal, 10 to 15 delay elements, 20 to 27 weight circuits, 30 to 32 adders, 40 an output terminal, and 70 a decision element. Description of those portions of this arrangement which are the same as the corresponding portions shown in FIG. 5 is omitted. Reference numerals 100 and 101 denote computing sections. The computing section 100 computes tap coefficients C i (n) (120) (i=0, 1, . . . , N1) which are to be outputted to a feedforward section 200 and tap coefficients D j (n) (130) (j=0,1, . . . , N2) which are to be outputted to a feedback section 300, on the basis of an input signal x(n) (110) which is the same as the received signal that is inputted to the input terminal 1 and in accordance with a predetermined tap-coefficient update algorithm. Similarly, the computing section 101 computes tap coefficients C i '(n) (121) which are to be outputted to the feedforward section 200 and tap coefficients D j '(n) (131) which are to be outputted to the feedback section 300, on the basis of an input signal x(n) (111) which is the same as the received signal that is inputted to the input terminal 1 and in accordance with another predetermined tap coefficient update algorithm. N1+1 represents the number of taps in the feedforward section 200, and N2+1 represents the number of taps in the feedback section 300. A switch 150 selects either an output signal from the decision element 70 or a reference signal d(n), as being an input to the feedback section 300. A switch 150', which interlocks with the switch 150, inputs an equalizer output signal to the computing sections 100 and 101 selectively. The feedforward section 200 and the feedback section 300, which are the same as the equalizer circuits that are shown in FIGS. 5 and 7, are combined together to form a decision feedback type equalizer.
The operation will next be explained.
First, a received signal x(n) that is inputted to the input terminal 1 is filtered through the feedforward section 200 and outputted from the adder 30, as shown in Expression (1). That is, the output of the adder 30 is given by ##EQU4## The delay elements 10 to 12 have a delay quantity Tp which is expressed as T/Tp=p (an integer), where T is one symbol period. When p=1, the system is equivalent to that of the prior art shown in FIG. 5. On the other hand, the decision element 70 makes a decision about an equalizer output that is delivered to the output terminal 40 and outputs the result of the decision, in the same way as in the prior art shown in FIG. 7.
When the estimation of the transmission channel characteristics is to be made by use of a reference signal, which is a known signal sequence, to set tap coefficients, the switch 150 allows a reference signal, which is a known signal sequence, to be inputted to the feedback section 300, and the switch 150' connects the equalizer output signal to tap-coefficient update algorithm (A) computing section 100. When an equalization of a random data sequence is to be executed, the switch 150 operates so that the result of the decision made in the decision element 70 is inputted to the feedback section 300. The switch 150' operates in interlocking relation to the switch 150 connecting the equalizer output signal to tap-coefficient update algorithm (B) computing section 101.
The equalizer of the present invention incorporates two computing sections 100 and 101 which respectively execute two different kinds of tap coefficient-update algorithms. Thus, packet data is processed by the two tap coefficient update algorithm computing sections which have algorithms corresponding to two different signal sequence of the packet data, as shown in FIG. 2. First, the tap coefficient update algorithm (A) computing section 100 estimates the transmission channel characteristics for each symbol in the known signal sequence by use, for example, of the adaptive control algorithm of Kalman filter, described in connection with the prior art, which is an algorithm that has a fast convergence property at the cost of increased computational complexity, thereby determining the tap coefficients C i (l) (120) for the feedforward section and the tap coefficients D j (l) (130) for the feedback section at the time t=l at which the known signal sequence is terminated, as follows:
C.sub.i (l)={C.sub.O (l), . . . , C.sub.N1 (l) }
D.sub.i (l)={D.sub.O (l), . . . , D.sub.N2 (l) }
By use of the above-described algorithm, the transmission channel characteristics can be estimated on the basis of a short known signal sequence and it is therefore possible to improve the data transmission efficiency.
Next, equalization of the random data section is effected by using as initial values the feedforward section tap coefficients C i (l)(120) and the feedback section tap coefficients D j (l)(130), which have been set in the tap coefficient update algorithm (A) computing section 100. At this point of time, the compensation of the tap coefficients for the transmission channel characteristics has almost been completed, and the tap coefficient-update algorithm (B) computing section 101 therefore needs to compensate for only relatively slow changes of the channel characteristics, such as Doppler frequency. More specifically, the computing section 101 is only required to effect compensation by use of an algorithm which necessitates a relatively low computational complexity at the cost of slow convergence property, for example, a gradient algorithm, as a data section equalizing algorithm, thereby determining C i '(l), which are the tap coefficients (121) for the feedforward section, and D j '(l), which are the tap coefficients (131) for the feedback section. Thus, the required computation period for updating tap coefficients does not constitute a factor that determines the upper limit of the data transmission rate, and the equalizer is capable of tracking relatively slow changes in the transmission channel characteristics.
As has been described above, the estimation of the transmission channel characteristics and the updating of the tap coefficients to equalize the received signal are executed by two computing sections based on two different kinds of algorithm.
Although in this embodiment a value, which is computed from the equalizer output value and a resulting decision value thereof in the tap-coefficient-update algorithm computing section 101, is employed as an error signal that corresponds to Expression (3), it is also possible to employ a value that is computed in the decision element 70 shown in FIG. 1 on the basis of values which are inputted to and outputted from it.
Although in this embodiment the Kalman filter algorithm and the gradient algorithm are employed as two different kinds of tap-coefficient-update algorithms., it should be noted that the present invention is not necessarily limited to the mentioned algorithms and that other algorithms may also be employed, provided that employed algorithms satisfy the required characteristics regarding the respective processings.
Although in this embodiment two tap coefficient update algorithm computing sections are disposed in parallel to take charge of updating tap coefficients, respectively, the arrangement may also be such that a DSP (Digital Signal Processor), for example, is employed to constitute a tap-coefficient update computing section and software is changed in accordance with two different kinds of tap-coefficient update algorithm in the same hardware. With this alternative arrangement, the same advantageous effects are obtained.
Although in the foregoing embodiment the present invention has been described with respect to a decision feedback type equalizer that incorporates both a feedforward section and a feedback section, the equalizer may comprise either a feedforward section or a feedback section only.
Although an arrangement that is modeled on the baseband transmission system is shown in the foregoing embodiment, for a modulation system such as an orthogonal modulation system, the described arrangement may be expanded on the basis of a two-dimensional baseband model that comprises two components, i.e., in phase and quadrature components, to arrange an equalizer by taking into account the interference between the in phase and quadrature components. This alternative arrangement also provides advantageous effects which are similar to those provided by the described embodiment.
Thus, the first embodiment of the present invention comprises the first computing section in which the transmission channel characteristics are estimated and tap coefficients are set on the basis of a known signal sequence and in accordance with the first algorithm, which has a fast convergence property, and the second computing section in which tap coefficients are determined in accordance with the second algorithm, which involves a relatively low computational complexity, by use of an output signal from a decision element that is obtained on the basis of the tap coefficients set in the first computing section, thus updating the tap coefficients by the two computing sections having different algorithms. It is therefore possible to track changes in the characteristics of the transmission channel and also possible to reduce the computational complexity required and eliminate the limitation on the data transmission rate. Thus, the equalizer of the present invention is capable of coping with high speed data transmission.
FIG. 3 is a block diagram showing the arrangement of a second embodiment of the equalizer according to the present invention. In the figure, the same reference numerals as those shown in FIG. 1 denote the same or corresponding elements or portions. That is, reference numerals 10 to 15 denote delay elements, 20 to 27 weight circuits, 30 to 32 adders, and 70 a decision element. Computing sections 100 to 101 compute tap coefficients C i (n) and D i (n) in accordance with predetermined tap-coefficient update algorithms from an equalizer output that is outputted to an output terminal 40 and input signals x(n), denoted by-110 and 111, which are the same as a received signal that is inputted to an input terminal 1. A switch 150 selects either an output signal from the decision element 70 or a reference signal d(n), as being an input to a feedback section 300. A feedforward section 200 and the feedback section 300, which are the same as the equalizer circuits shown in FIGS. 5 and 7, comprise in combination a decision feedback type equalizer.
The operation of the second embodiment will next be explained. However, the portion of the operation that is the same as that of the first embodiment is omitted and only a portion which features the second embodiment will be explained.
In the equalizer of this embodiment, the switch 150' that is employed in the first embodiment is eliminated, and adaptive equalization is realized by estimating the transmission channel characteristics and then executing an intermittent tap coefficient update algorithm as described below.
Referring to FIG. 3, when a known signal sequence is employed as an input signal to the feedback section 300, the switch 150 selects a known signal sequence that is inputted through the reference signal input terminal 50, whereas, when equalization of the data section is to be executed, the switch 150 selects the output of the decision element 70.
In this embodiment also, the equalizer incorporates two algorithm computing sections 100 and 101 having two different kinds of tap coefficient update algorithms. It is assumed that the estimation of the transmission channel characteristics is made for each symbol in the known signal sequence in the tap coefficient update algorithm (A) computing section 100 and tap coefficients at the time T=l at which the known signal sequence is terminated are determined to be C(l)= {C o (l), C 1 (l), . . . , C N1 (l)} and D(l)= {D o (l), D 1 (l), . . . , D N2 (l)}. N1+1 represents the number of taps in the feedforward section 200, and N2+1 represents the number of taps in the feedback section 300.
Next, in the tap-coefficient update algorithm (B) computing section 101, the data section is equalized by using the tap coefficients C(l) and D(l) as initial values. At this point of time, the compensation of the tap coefficients for the transmission channel characteristics has almost been completed, and the tap coefficient update algorithm (B) computing section 101 therefore needs to compensate for only relatively slow changes of the channel characteristics, such as Doppler frequency. Accordingly, it is only necessary to estimate the rate of the change and update the tap coefficients intermittently. More specifically, assuming that updating of the tap coefficients is executed once every 5 symbols, for example, the updating is effected by use of symbols in the data section whose ordinal numbers are multiples of 5, i.e., the 5th symbol, the 10th symbol, the 15th symbol . . . in the data section. In other words, since the transmission channel has no rapid change in 2 to 4 symbols, it is possible to satisfactorily track slow changes in the transmission channel characteristics even by such an intermittent operation.
FIG. 4 shows one example of the processing of packet data in this operation.
Incidentally, an algorithm that has a fast convergence property is required to update the tap coefficients since it is necessary to increase the data transmission efficiency by using a short known signal sequence for the estimation of the transmission channel characteristics. The Kalman filter algorithm that is mentioned in connection with the prior art is a typical example of such an algorithm. It is well known that the convergence of the Kalman filter algorithm is extremely fast, but the computational complexity required for this algorithm is enormous. However, if this algorithm is employed only for the short known signal sequence to effect the estimation for each symbol and an intermittent operation which is performed once every n symbols is employed for the data section, then the computational complexity required for each symbol is 1/n. Accordingly, the computational complexity required for the tap coefficient update algorithms has no significant effect on the data transmission rate.
In this embodiment also, the modifications that are mentioned at the end of the description of the first embodiment are applicable. Although in this embodiment the Kalman filter algorithm is employed, algorithms which are usable in the present invention are not necessarily limitative thereto. For example, adaptive algorithms such as the LMS algorithm and the learning identification algorithm may also be employed.
Although in this embodiment two tap coefficient-update algorithm computing sections are employed, the number of computing sections used is not necessarily limitative thereto. It is also possible to employ three or more computing sections; in such a case, one of them is appropriately selected.
Thus, according to the second embodiment of the present invention, the equalizer is provided with a plurality of computing sections having different computing periods for computing respective tap coefficient update algorithms. It is therefore possible to track changes in the characteristics of the transmission channel and also possible to reduce the computational complexity required and cope with high speed data transmission.
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"An adaptive equalizer comprising a computer unit which receives a known signals sequence to estimate transmission channel characteristics and effect compensatory control of tap coefficients by use of a first algorithm that has fast convergence property, and a tap coefficient computing unit for making compensation for relatively slow changes in a random data input after the compensation for the transmission channel characteristics, which either employs an algorithm that involves a relatively low computational complexity or intermittently executes computation."
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[0001] This application claims priority to U. S. Provisional Patent Application No. 60/475,550, titled “Flattened Mode Cylindrical And Ribbon Fibers And Amplifiers,” filed Jun. 3, 2003 and incorporated herein by reference.
[0002] The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG-48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to diffraction limited fiber lasers, and more specifically, it relates to fiber lasers characterized by almost constant electric field intensity over the entire core region of the fiber.
[0005] 2. Description of Related Art
[0006] For applications requiring high beam quality radiation from efficient, compact and rugged sources, diffraction limited fiber lasers are ideal, and to date have been demonstrated at average CW power levels exceeding 100 W with near diffraction limited output and a narrow bandwidth light signal. For conventional single-core step-index single-mode fibers, this power level represents the scaling limit because of nonlinear and laser damage considerations. Higher average powers would exceed nonlinear process thresholds such as the Raman and stimulated Brillouin scattering limit, or else damage the fiber due to the high intensity level in the fiber's core. The obvious way to increase the average power capability of fibers is to increase the area of their core [ 1 ]. Simply expanding the core dimensions of the fiber allows a straightforward power scaling due to enhanced nonlinear and power handling characteristics that scale directly with the core area. Femtosecond, chirped-pulse, fiber lasers with pulse energies greater than 1 mJ have been demonstrated in the literature [ 2 ] using this technique. This output energy was still limited by the onset of stimulated Raman scattering. However, the enhanced power handling capability that obtains through this route comes at the expense of beam quality, as increasing the core diameter in standard step index fibers permits multiple transverse modes to lase simultaneously. Although this problem of multimode operation can be mitigated to some extent by appropriately designing the fiber's waveguide structure, limitations such as bend radius loss, sensitivity to thermally induced perturbations of the waveguide structure, and refractive index control, all become more stringent as the core diameter grows, limiting the extent to which the core diameter can be grown and still enabling single mode operation from the fiber.
[0007] The spatial mode character of the radiation supported by the fiber is of concern. Conventional single mode fibers have an electric field that falls of continuously as the radius increases. In the core, the electric field in conventional single mode fibers has a zero-order-Bessel-function-of-the-first-kind radial dependence, and outside the fiber core, a modified-Bessel-function-of-the-second-kind radial dependence. This means that in conventional fibers, the electric field intensity on the fiber axis is higher than in other parts of the core.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide fiber lasers characterized by almost constant electric field intensity over the entire core region of the fiber
[0009] This and other objects will be apparent based on the disclosure herein.
[0010] The present invention addresses the limitations described above and enables a new approach to single transverse mode operation of large mode area (LMA) fibers, providing a route to high average powers exceeding 1 kW from a single aperture in a Strehl-ratio-optimizing flat-topped output beam.
[0011] The approach described herein is radical in that it eliminates the single-mode fiber on-axis intensity peak through appropriately engineering both the refractive index profile and the gain profile to realize large mode area (LMA) fiber structures that, while supporting several transverse modes, only allow a preferred flat-topped mode to lase. This is due to the modal gain discrimination that is engineered in during the fabrication of the structure. These special flat-topped modes are characterized by almost constant electric field intensity over the entire core region of the fiber.
[0012] The present invention has applications in many areas. Some examples are:
[0013] Scaled power fiber lasers;
[0014] Laser defense applications;
[0015] Short pulse laser sources and amplifiers;
[0016] Front end pulse generation and amplification system for the National Ignition Facility (NIF) laser system at Lawrence Livermore National Laboratory;
[0017] Transport fiber and fiber laser sources for telecommunication applications;
[0018] Optical power distribution networks; and
[0019] Various materials processing and machining applications, including the following:
[0020] Metal cutting;
[0021] Metal brazing;
[0022] Deep penetration metal welding;
[0023] Plastic welding; and
[0024] Soldering.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1A shows the radial refractive index profile of a 50 μm diameter cylindrically symmetric fiber according to an embodiment of the present invention.
[0026] [0026]FIG. 1B shows the radial gain profile of the fiber of FIG. 1A (0 indicates no gain and 1 indicates gain).
[0027] [0027]FIG. 2 shows the only allowed m=0 eigenmode of the index modulated structure shown in FIG. 1A. Also indicated is the gain and the index profile (not to scale).
[0028] [0028]FIG. 3A shows the only allowed m=1 eigenmode of the fiber structure shown in FIG. 1A. Also indicated is the gain profile and the index profile (not to scale).
[0029] [0029]FIG. 3B shows the only allowed m=2 eigenmode of the fiber structure shown in FIG. 1A.
[0030] [0030]FIG. 4 shows a one-dimensional flattened-mode structure that can be constructed from soft glasses and is compatible with refractive index control at the level of 1×10 −3 .
[0031] [0031]FIG. 5 shows that the one-dimensional waveguide structure of FIG. 4 supports the flat-topped mode shown here. Also indicated is the gain profile and the index profile (but not to scale).
[0032] [0032]FIG. 6 shows the calculated overlap of the eigenmodes of the one-dimensional waveguide shown in FIG. 4 with the gain-loaded portion of the waveguide, as a function of the eigenmodes' effective index value.
[0033] [0033]FIG. 7 is an end on view of a ribbon fiber containing elevated index tabs in the strips located at the top and bottom of the waveguide region. These tabs enable the vertical transverse dimension of the waveguide to be increased while still ensuring flat-topped mode operation in that dimension as detailed above.
[0034] [0034]FIG. 8A shows the refractive index profile and preferred mode of a cylindrically symmetric LFM fiber.
[0035] [0035]FIG. 8B shows a comparison of the intensity profiles of a step index fiber and a cylindrically symmetric LFM fiber with the same total power.
[0036] [0036]FIG. 9A shows output energy vs. pump diode current for the step index control fiber and the LFM fiber.
[0037] [0037]FIG. 9B shows Raman peak spectral power as a function of the pump diode current for the same fibers.
[0038] [0038]FIG. 10 shows an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0039] The present invention reduces the intensity of light propagating in the core by distributing it more evenly across the core area via careful design of the refractive index profile [ 3 ]. The primary issue that results from scaling the core is addressed. The enhanced power handling capability comes at the expense of beam quality, as increasing the core diameter in standard step index fibers permits multiple transverse modes to lase simultaneously. Although this problem of multimode operation can be mitigated to some extent by appropriately designing the fiber's waveguide structure, limitations such as bend radius loss, sensitivity to thermally induced perturbations of the waveguide structure, and refractive index control, all become more stringent as the core diameter grows, limiting the extent to which the core diameter can be grown and still ensure single mode operation from the fiber. The large flattened mode fiber of the present invention addresses some of these limitations and enables a new approach to single transverse mode operation of large mode area (LMA) fibers, providing a route to high average powers exceeding 1 kW from a single aperture in a Strehl-ratio-optimizing flat-topped output beam.
[0040] There are two degrees of freedom in the way modal gain discrimination can be managed in cylindrically symmetric fibers. Both the refractive index profile and the gain profile can be modulated radially to first promote specific modal fields, and then to favor some subset of the total supported mode spectrum of the structure. As an example, FIG. 1A shows a specific refractive index profile and FIG. 1B shows a gain profile that together support a flattened-mode. A very low numerical aperture (NA) structure is utilized to limit the total number of modes that are guided by the fiber.
[0041] The particular design shown in FIGS. 1A and 1B corresponds to a 50 μm diameter fiber core and uses refractive index values that are conveniently accessible in fused silica. The gain is confined to an interior region having a radial extent of 22.2 μm, leaving a 2.8 μm wide outer undoped annular ring with a refractive index elevated from the outer cladding by 5×10 −4 . The specific choice of the index structure shown in FIG. 1A limits the total number of supported transverse modes to only three, and as will be shown, one of these has the desired flat-topped irradiance profile. The gain profile shown in FIG. 1B is then designed to strongly favor this preferred flat-topped mode over the other supported modes. Importantly, the fiber design in FIG. 1A uses index step variations of 1×10 −4 , which are within the control limits of today's fused silica based fiber preforms from which fibers are pulled.
[0042] [0042]FIG. 2 shows the only allowed m=0 eigenmode 10 , where m refers to the azimuthal quantum number of the eigenmode (e imφ ), of the optical structure shown in FIG. 1A. Also indicated at 12 is the gain and at 14 the index profile (not to scale).
[0043] The elevated index in the annular ring between 22.8 μm and 25 μm is present to ensure the mode shown in FIG. 2 is confined. Additionally, the width and height of this elevated index ring is chosen to engineer the confined mode in FIG. 2 so as to have a nearly flat irradiance profile within the central portion of the fiber. Because a flat-topped profile is the aperture distribution that gives the highest Strehl ratio, this feature of the present fiber design is very important for any application requiring optimized on-axis laser intensity in the far field. Additionally, the flat-topped mode benefits damage considerations, as there are no local regions having peaked irradiance. The effective mean field diameter of the m=0 mode in FIG. 2 is 54 μm and was chosen to maintain robust single mode behavior in the presence of the thermal gradients that will be set up in the actively pumped structure. This design consideration will be discussed in more detail below.
[0044] The gain experienced by different laser modes is proportional to the overlap factor, Γ, of the mode's intensity envelope with the gain-loaded portion of the fiber,
Γ = ∫ E ( r , θ ) 2 g ( r ) rdr θ ∫ E ( r , θ ) 2 rdr θ ( 1 )
[0045] where g(r) is a function with value unity in those portions of the fiber that are gain loaded and 0 where there is no gain loadingand where E(r, θ) is the electric field of the mode in for with the gain overlap is being calculated expressed in a cylindrical co-ordinate system across the cross section of the fiber and r and θ are the usual radial and azimuthal coordinates common in a cylindrical co-ordinate system. This is a straightforward calculation once the eigenmode fields are known. In addition to the m=0 eigenmode shown in FIG. 2, the optical structure shown in FIG. 1A also supports a single m=1 eigenmode 16 and a single m=2 eigenmode 22 , which are shown respectively in FIGS. 3A and 3B. FIG. 3A also shows gain 18 and index profile 20 . FIG. 3B also shows gain 24 and index profile 26 .
[0046] The eigenmodes depicted in FIGS. 2, 3A and 3 B are the only allowed eigenmodes supported by the optical structure in FIG. 1A. The eigenmode shown if FIG. 2 fills the aperture and is nearly flat-topped in profile, which means it will have a high Strehl ratio, and for this reason is the desired mode to favor in the operation of the device. Locating the gain along the center of the fiber, coinciding with the index well there, as shown in FIG. 1A, gives a gain discrimination between the allowed modes that favors the flat-topped mode; the overlap of the flat-topped mode shown in FIG. 2 is 0.79, while that of the modes shown in FIG. 3A is only 0.58 for the m=1 mode and in FIG. 3B is only 0.33 for the m=2 mode.
[0047] The same design rationale that went into engineering a cylindrical index profile to ensure it supported a flat-topped mode can also be applied to ribbon structures in the transverse dimension perpendicular to the ribbon-guiding dimension. An example of such a flat-topped enabling one transverse dimension index structure is shown in FIG. 4.
[0048] The connection with the two-dimensional cylindrically symmetric fiber shown in FIG. 1 is evident The elevated index tabs at the edge of the waveguide region are engineered in their height and width to specifically support the flat-topped mode that is depicted in FIG. 5. FIG. 5 shows the eigenmode 50 , the index profile 52 , and the gain 54 .
[0049] The graph in FIG. 6 plots the calculated overlap of the eigenmodes supported by the one-dimensional waveguide structure of FIG. 4, the gain-loaded portion of the waveguide, the Γ factor given by equation 1 above, as a function of the eigenmodes' effective index value. This is a straightforward calculation once the eigenmode fields are known. The effective index values, n eff , associated with the various eigenmodes of the structure is defined by,
β = n eff ω c , ( 2 )
[0050] where β is the longitudinal wavevector associated with the eigenmode, ω is the radial frequency of the light propagating in the fiber core and c is the speed of light in vacuum. From equation 2 above it is seen that c/n eff is just the phase velocity associated with the eigenmode as it propagates in the ribbon structure. The two parameters, n eff and Γ, completely define an eigenmode in terms of its wave-optics propagation and energetics behavior. The spectrum of values of n eff and Γ for a given structure completely defines its modal properties, which can be conveniently summarized in a plot such as FIG. 6. Examining FIG. 6, the highest effective index eigenmode, which corresponds to the flat-topped mode plotted in FIG. 5, is also the mode with the highest gain overlap. The larger number of eigenmodes supported by the one-dimensional structure of FIG. 4 compared to the cylindrically symmetric fiber structure of FIG. 1 is a result of the larger Δn (index variations) used in its design. Even so, the highest gain mode in FIG. 6 has an overlap with the gain region that is discriminated by 5% from the next highest gain mode, a level that should be sufficient to measure experimentally. FIG. 7 illustrates how this approach is applicable to the thin dimension of a ribbon fiber 70 , and shows elevated index tabs 72 and waveguide region 74 .
[0051] [0051]FIG. 8A shows experimentally obtained refractive index profile 80 for the flat-topped fiber mode 82 . FIG. 8B shows the intensity distribution of a large flattened mode fiber design (LFM) 84 and a control standard step index profile fiber 86 of the same core diameter normalized such that the total power contained in the two modes is the same. (i.e., The two intensity distributions contain the same total power after the integration over the full cross sectional area is performed.) The LFM design decreases the peak intensity on axis by a factor of 2.46, which should lead to a significant decrease in the amount of stimulated Raman scattering for a given pulse energy, while not compromising the power handling capability.
[0052] In one test, the inventors purchased a 30 μm core, 0.06 NA, step-index, control fiber (Nufern) with a 400 μm hexagonal cladding with a low index polymer coating (pump clad NA=0.37). The core was doped with Yb 3+ such that there was an effective core absorption of 120 dB/m at 977 nm. Also purchased was a nearly identical fiber from Nufern, but with the raised ring that gives the LFM fiber its distinctive index profile. The inner core diameter of the LFM was 25.3 μm and the outer core diameter was about 30 μm FWIIM, the effective NA of the structure was approximately 0.06. The outer cladding and Yb 3+ doping were the same as for the control fiber.
[0053] The present inventors then coupled 1.2 ns, 1075 nm, 10 Hz stretched mode-locked laser pulses into 9.1 m of the control fiber and 8.3 m of the LFM fiber. The input energy coupled into the fiber cores was 15 μJ. Pump light at 977 nm from a 10W diode laser array was counter propagated through the fiber to pump the Yb 3+ ions. The diode light was pulsed at 10 Hz for 1 ms timed to precede the arrival of the signal light FIG. 9A shows the amplified output energy of the control fiber 90 and the LFM fiber 92 as measured with a Molectron energy meter. As expected, they produce roughly the same output energy as a function of pump diode current FIG. 9B, however, plots the percentage of the signal power contained in the first stokes spectra of the fibers of FIG. 9A as measured with an Ocean Optics fiber coupled spectrometer. The LFM fiber shows significantly less Raman energy build up as a function of diode current than the control fiber. This is in agreement with what was expected from the design. In addition, greater than 0.6 mJ output pulses were achieved from the LFM amplifier with less than 5% of the energy in the Raman spectral band by utilizing pulses stretched to 3 ns. With straightforward scaling of Yb 3+ doping concentration to reduce the amplifier length, increasing the core size to 50 μm and increasing the pump energy, an optimized design could yield output pulses with greater than 10 mJ of energy and virtually no degradation due to stimulated Raman scattering.
[0054] For present invention fibers with similar core sizes, doping concentrations and lengths, the present inventors have shown a significant decrease in the amount of Raman scattering in the LFM fiber over a standard step-index fiber. The inventors believe these fibers can be scaled to output energy in excess of 10 mJ in a straightforward fashion as shown in the table below.
Pulse Pulse Core Fiber Fiber energy length size length gain (mJ) (ns) (μm) (m) (dB) Comments 1.2 0.4 50 2.6 26 Galvanauskas, et al. [1] 0.6 3 30 8.3 8 LFM result from this report Higher gains yield increase output energy before the onset of Raman scattering. Our result was hurt by low gain. 9 3 50 2.6 26 Estimated (assumes one overcomes Raman scatter- ing using Galvanauskas system and increasing pulse stretch to 3 ns) 21.6 3 50 2.6 26 Estimated from above base on using LFM design to further increase the Raman scattering threshold
[0055] In a high power optical fiber amplifier embodiment, the invention can be used to amplify either pulsed laser light or laser light that more closely approximates a continuous wave laser signal. A schematic of the amplifier is shown in FIG. 10.
[0056] An embodiment of the optical fiber amplifier shown in FIG. 10 consists of a signal input 100 consisting of a 1053 nm light source, which may consist either of chirped pulses from a 1053 nm mode-locked laser or continuous wave light from, e.g., a 1053 nm DFB laser. The signal light is focused through the first focusing lens 102 , whose focal length is chosen to optimize the coupling of the signal light to the large flattened mode of the LFM fiber waveguide 104 core. The LFM fiber 104 consists of a core with the waveguide and gain profiles shown in FIGS. 1A and 1B, which support a large flattened mode at 1053 nm. The raise ring shown in FIG. 1A is fused silica doped with a standard co-dopant (for raising the index of the fiber such) as germania, phosphorous or alumina. The center region is fused silica doped with Yb 3+ , co-doped with aluminum and other dopants as needed to adjust the refractive index appropriately. The Yb 3+ concentration is such that 976 nm light propagating in the waveguide experiences a small signal absorption of greater than 120 dB/m. The fused silica outer cladding is hexagonal in shape with 400 μm between flats of the hexagon. Polymer outer coating on the fiber is a low index fluorinated acrylate creating a multimode pump light waveguide in the 400 mm cladding with an numerical aperture greater than 0.35. The fiber is 10 m long and wound around a cylindrical mandrel with a radius of about 4 cm, which is chosen such that signal light propagating in the large flattened mode experiences minimal bend induced attenuation, but signal light propagating in the higher order waveguide modes experiences significant bend induced attenuation. Variations in the manufacture of the fiber against the preferred ideal may alter this preferred radius, which may need to be determined experimentally for each lot of optical fiber. The particular fiber used in this reduction to practice was manufactured by Nufern to custom specifications. In order to suppress undesirable back reflections from the fiber endfaces into the amplifier, these end faces are preferentially angle cleaved or polished in a plane whose normal is 8 degrees off the cylindrical axis of the fiber. The signal light is amplified in the fiber and exits the opposite end, where it is collimated by a second lens 106 and reflected from a dichroic mirror 108 that has a high reflectivity at 1053 nm and high transmission at 976 nm. A high power pump diode 108 , such as a 976 nm LIMO 25 W fiber coupled laser diode with a spot size of 400 mm and an NA of 0.22, is imaged through a lens 110 , traverses the dichoric mirror and is imaged through the output collimation lens for the signal into the pump dadding of the fiber. Light from the pump laser is absorbed by the Yb 3+ ions and provides the energy for the amplification of the signal light
[0057] One skilled in the art can see that there are many variations on this amplifier that can easily be made without changing the basic design. These include varying the rare earth ion, pump laser and signal wavelength to achieve an amplifier in other wavelength bands. These also indude deliberately providing feedback to the amplifier in place of a signal input in order to create a laser oscillator said feedback may be Q-switched or employ a saturable absorber to generate pulsed laser light as well as continuous wave laser oscillation. Such a laser could be frequency doubled or frequency mixed with a second similar laser to achieve a source of light at shorter wavelengths. This shorter wavelength light source could then be used as a pump laser source for other lasers or for optical parametric oscillators or amplifiers.
[0058] Further, an integrated chirped pulse amplifier could be made based on FIG. 10 by adding a pulse stretcher at the signal input One skilled in the art can also recognize that the optical amplifier may be altered to include a second pump laser at the fiber input, to be pumped only at the fiber input, may include one or more optical isolators to prevent feedback into the amplifier from optical components in other parts of a bigger system, etc.
[0059] References:
[0060] 1. M. E. Fermann, “Single-mode excitation of multimode fibers with ultrashort pulses”, Optics Letters, vol. 23, pp. 52, (1998).
[0061] 2. A. Galvanauskas, Z. Sartania, M. Bischoff, “Millijoule femtosecond all-fiber system”, CLEO 2001, Baltimore, Md., paper CMA1.
[0062] 3. A. K. Ghatak, I. C. Goyal, R Jindal, “Design of waveguide refractive index profile to obtain flat modal field” SPIE Proceedings vol. 3666, pp. 40 (1998).
[0063] The above references are incorporated by reference.
[0064] The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments disclosed were meant only to explain the principles of the invention and its practical application to thereby enable others skilled in the art to best use the invention in various embodiments and with various modifications suited to the particular use contemplated. The scope of the invention is to be defined by the following claims.
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Large area mode operation of fibers with Strehl-ratio-optimizing flat-topped output beams is enabled. The approach entails both refractive index profile engineering and gain profile engineering to realize fiber structures that while supporting several transverse modes only allow a preferred flat-topped mode to lase due to the modal gain discrimination that is engineered in during the fabrication of the structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to data storage in computer systems. More particularly, the present invention relates to the validation of data that has been stored in random access memory during periods when the data is susceptible of becoming corrupted, or in mission critical computer systems where tolerance for error is low.
[0005] 2. Background of the Invention
[0006] Almost all computer systems include a processor and a system memory. The system memory functions as the working memory of the computer system, where data is stored that has been or will be used by the processor and other system components. The system memory typically includes banks of dynamic random access memory (DRAM) circuits. According to normal convention, a memory controller interfaces the processor to a memory bus that connects electrically to the DRAM circuits. The system memory provides storage for a large number of instructions and/or a large amount of data for use by the processor, providing faster access to the instructions and/or data than would otherwise be achieved if the processor were forced to retrieve data from a disk or drive.
[0007] Because system memory typically is constructed of dynamic random access memory circuits, the contents of the memory are volatile. To preserve the integrity of the data stored in system memory, a periodic refresh signal must be sent to each memory cell to refresh the voltage levels of each cell, where the data is stored. Failure to timely refresh the memory cells of system memory causes the data to be lost. Thus, when power is turned off to a computer, the contents of system memory are lost. Data that is to be stored long-term on a computer system thus is stored in other non-volatile memory devices. Most computer systems include a hard drive which is capable of permanently storing data on magnetic tape. Other removable drives, such as zip drives, CD-ROMs, DVD-ROMs, and the like, may also be used for long-term storage of data. In these types of media, the data is preserved, even when power is removed from the computer system.
[0008] Almost all portable computers, and some desktop computers, may be placed in a low power state to preserve power. Preservation of power is especially important in portable computers, where operating power may be provided from batteries. To extend the life of batteries in portable computers, and thus extend the amount of time that a user can operate a portable computer without recharging the batteries or finding an electrical source, most portable computers are capable of going into a sleep mode where minimal power is consumed. The sleep mode permits the computer system to be placed in standby, so that operation can resume when the user is ready, without requiring the system to boot.
[0009] As power management of portable computer systems has evolved, two different low power modes have been developed and used commercially. The first low power mode is known as “hibernation” or “hibernation to disk.” In this mode, which is the lowest power mode of the computer system other than power-off, the computer system consumes minimal energy. The hibernation mode can be analogized to a no-power bookmark of the existing state of the computer system. When the hibernation mode is entered, the system hardware state is copied to the hard drive. Because the hard drive is non-volatile memory, all power can then be removed from the system. Upon resume, the entire system state is copied from the hard drive image and restored to system memory and to the devices whose state was copied. Hibernation to disk typically is referred to as the “S 4 ” state by the ACPI nomenclature.
[0010] In hibernation mode, the system memory (or RAM) is not powered. Hibernation to Disk has been referred to as “Zero volt suspend” because no power is required to sustain the system contents. Thus, the data in system memory is no longer available once the system enters the hibernation mode because the memory cells are not refreshed. When resuming from hibernation, a delay period is encountered as the working data is reloaded from the hard drive back to the system memory. The time required to access data from the hard drive is significantly longer than accessing data from system memory. Thus, there is a perceptible delay that occurs when data is loaded form the hard drive to the system memory after the hibernation mode is exited. In many instances the resume process from hibernation mode can take between 30 seconds to 1 minute, as the system memory and system devices are completely restored from the relatively slow hard drive memory.
[0011] Conventional Hibernation to Disk is implemented by powering down the system in response to a system event. The system event can be the manual selection of an icon or menu entry, the selection of one or more keys, or system inactivity. Because the hibernation mode results in the removal of power, the context of all system peripherals is read and then stored to the hard drive. Next, the contents of the system memory are copied to the hard drive. A hard drive file that is equal to the size of the memory to be stored is created, which holds a mirror image of the system memory. After the contents of system memory are backed up, a flag is set in non-volatile memory indicating that the system context has been completely saved. Once the flag is set, the power is removed causing the contents of volatile memory (such as DRAM and the context of peripheral devices) to be lost. When the system resumes operation, the system BIOS or operating system polls the nonvolatile flag bit that indicates that the hard drive contains valid system context. If the flag bit is set, the BIOS or operating system restores the system context from the hard drive before resuming system operation.
[0012] The second low power state is referred to as the “suspend” mode or “Suspend to RAM” mode. In the suspend mode, the system memory remains powered while the system is taken to a non-operational state. The advantage of keeping the system memory powered is that when operation is resumed, the system is ready within a very short period for operation, in the state last used by the operator. Thus, resuming from a suspend mode only takes a few seconds, because very little system context is moved. Suspend to RAM generally is preferred as a bookmark feature because of its “instant on” low latency resume time. Suspend to RAM is also called the S1, S2, or S3 power state by the ACPI nomenclature.
[0013] Conventional Suspend to RAM works by stopping the clocks to the system, while leaving the entire system power on. Because the power used by the system depends on the system clock speeds, removing the clock signals significantly lowers the system power. Suspend to RAM often is referred to as “Power on Suspend.” When the system resumes operation from Suspend to RAM, the clocks may simply be started to restore system operation. Another form of Suspend to RAM stores the context of certain system devices to system memory. Examples of the device contexts that may be saved include peripherals such as audio controllers, the state of the processor, the contents of the processor cache, and the like. Once the context of these devices is stored to system memory, the clocks to those devices are stopped and power is removed. The system memory, however, remains powered to maintain its contents. To resume operation, the system BIOS or operating system restores the context of the peripherals from system memory, and then system operation is resumed.
[0014] The hibernation mode has been preferred because little or no power is consumed while the system is in this state. Recent improvements in the circuitry used for Suspend to RAM, however, have minimized the power drain that occurs in suspend mode. However, Hibernation to Disk still has a key integrity advantage over Suspend to RAM, because Suspend to RAM relies on the use of volatile DRAM memory. If power is lost to the DRAM during suspend mode, the system context is lost, and the user may lose work or data. Also, DRAM is inherently subject to data corruption because the DRAM cells must be periodically refreshed to maintain a charge on very small capacitors that represent each data bit. A leaky cell, high temperature, or electromagnetic interference can invalidate the contents of the DRAM. These or other conditions may cause the DRAM contents to become corrupted while the system is in suspend mode.
[0015] Traditionally, the use of either Suspend to RAM or Hibernation to Disk have been exclusive, so that only one of these techniques is implemented as the low power state in a computer system. Recently, the IBM 600 portable computer advanced an idea marketed as “Redisafe,” in which Suspend to RAM was used, but the system contents also were stored redundantly to the hard drive. In the event that the system loses power while in suspend mode, the system BIOS restores the system contents from the hard drive. If power is not lost, the system resumes operation from system memory. Thus, the Redisafe system provided a redundant backup copy of the system memory, thereby protecting the user from a power loss, while still preserving the lower latency of the Suspend to RAM mode if power was not lost.
[0016] While this approach has some advantages over the previous low power modes, it still does not protect the user from the potential of hardware problems that may result during a Suspend to RAM. The IBM system relies solely on detecting a loss of power during suspend mode, and does not gauge the integrity of the DRAM contents after the resume is completed. Thus, while the IBM system takes measures to insure the integrity of system memory in the event of a power failure, it does not consider the validity of the data itself.
[0017] It would be desirable if a system could be developed that would minimize latency to the extent possible for a low power of a computer system. It would also be advantageous if a computer system provided a low power mode which could be resumed quickly in the event that the contents of system memory were valid, but which used a copy of data that had been saved to non-volatile memory in the event that the data in system memory was not valid. Despite the apparent advantages such a system would offer, to date no such system has been developed.
BRIEF SUMMARY OF THE INVENTION
[0018] The present invention solves the deficiencies of the prior art by implementing a low power mode in a computer system that stores a copy of the data in system memory to the hard drive prior to entering the suspend mode. The system supports a quick resume from suspend if the data in system memory is valid. If the data in system memory is not valid, then the system causes the data to be restored from the hard drive. Thus, the system supports a quick resume, while also supporting a system that insures data integrity in the suspend mode. To minimize the amount of data that must be reloaded in the event the data is corrupted, the system memory may be partitioned into smaller blocks or pages that can be validated independently.
[0019] According to one exemplary embodiment of the present invention, error checking and correction memory is used as the system memory. Prior to entering a Suspend to RAM state, the system stores a backup copy of the system memory and other context information to the hard drive. When the system resumes from the suspended state, the CPU reads system memory. If error checking and correction memory is implemented, appropriate ECC logic will examine the data read from memory, and if errors are detected, the ECC logic will generate a non-maskable interrupt (NMI). An algorithm executing on the CPU acknowledges the NMI, and identifies the memory address being read which caused generation of the NMI. The CPU then reads the backup copy of that address range from the hard drive, and restores that memory range to the system memory, as a substitute for the invalid data in system memory. This operation is repeated until all data in system memory is examined.
[0020] As an alternative embodiment, the present invention may be used in systems that do not implement ECC memory, by having the CPU or some other programmable device perform the error checking of system memory. In this embodiment, the CPU detects initiation of a low power state, and reads each page of memory. For each page of memory, the CPU calculates a signature for that page. The signature may represent a checksum value, a cycle redundancy check (CRC) value, or any other appropriate signature that can be used to later verify the validity of the data upon exiting from a low power mode. After the signature is calculated, that page of memory is saved to the hard drive. The signature value also is saved to either non-volatile memory or to volatile memory. Thus, the signature may be saved to static RAM, the hard drive, or to system memory. This process is repeated until a signature is calculated for each memory page, and the memory page and signature have been saved. When the system resumes from suspend mode, the CPU reads a page of system memory and calculates the signature. The calculated signature is then compared with the saved signature value. If the signatures match, the data for that page is assumed valid. If the signatures do not match, the data in that page is assumed to be invalid, and the CPU then restores the backup copy for that page from the hard drive. This process is repeated until all pages are validated or replaced.
[0021] The present invention also may be configured to run in the background after operation is resumed from a low power mode. In that event, the page translation tables are programmed to respond with a Page Fault interrupt if an access is directed to a section of memory that has not yet been validated. In response to the Page Fault Interrupt, an algorithm executing on the CPU determines if the Page Fault interrupt was generated because data had not been validated, or because the application software had not yet utilized the memory. If the algorithm determines that this memory address has not been validated, then the algorithm proceeds to validate that page of memory, and preferably all other pages in that Page Directory.
[0022] These and other aspects of the present invention will become apparent upon analyzing the drawings, detailed description and claims, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0024] [0024]FIG. 1 is a block diagram illustrating an exemplary computer system constructed according to the preferred embodiment;
[0025] [0025]FIG. 2 is a flow chart depicting an exemplary operation of the Redundant Suspend to RAM technique in the system of FIG. 1, with which error checking memory is implemented;
[0026] [0026]FIG. 3 is a flow chart depicting another exemplary alternative of the Redundant Suspend to RAM technique in system of FIG. 1, with which standard memory components are used that do not include error checking capabilities;
[0027] [0027]FIG. 4 is a diagram illustrating the manner in which a logical address is translated to a physical memory address;
[0028] [0028]FIG. 5 is a diagram illustrating a Page Entry Register and an associated Hibernation Data file that are saved to non-volatile memory prior to entering a Suspend state; and
[0029] [0029]FIG. 6 is an exemplary diagram of a Page Directory Entry register.
NOTATION AND NOMENCLATURE
[0030] Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “couple” or “couples” is intended to mean either an indirect or direct electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections. The term “system memory” refers to the working memory of a computer system. The term “DRAM” is intended to refer to system memory that is implemented with dynamic random access memory components. To the extent that any term is not specially defined in this specification, the intent is that the term is to be given its plain and ordinary meaning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring initially to FIG. 1, a computer system 50 may comprise a personal computer, a web computer, a server, or a workstation, without limitation. Although not shown, the computer system 50 preferably couples via a suitable network connection to a local area network (LAN). As shown in FIG. 1, the computer system 50 preferably implements a standard computer architecture, including a CPU (or processor) 130 , system memory 125 , a memory controller 100 , AGP video controller 140 , and I/O controller 150 . The processor 130 preferably couples to the memory controller 100 through host bus 135 . It should be understood that other embodiments of the invention may include more than one processor or CPU coupled to the host bus. The processor may comprise any suitable microprocessor such as the Pentium II®), Pentium III®, or Celeron® processor by Intel®, the Athlon® processor by AMD, the Alpha processor by Compaq, or other microprocessors from these or other manufacturers that may be used or configured for use in a computer system. The system memory 125 preferably comprises one or more memory devices such as any suitable type of random access memory (RAM). System memory may comprise, for example, synchronous dynamic random access memory (SDRAM), or other memory designs suitable for use in a computer. According to the preferred embodiment, the system memory 125 comprises banks of dynamic random access memory that are volatile in nature. Thus, when power is removed from the system memory, the memory cells lose the data stored therein. As will be discussed in reference to FIGS. 2 and 3, the system memory 125 may comprise error checking memory, such as error checking and correction (ECC) memory, or Parity memory, both of which are well known in the computer industry. Alternatively, the present invention may be implemented without error checking memory, as will be described below. Also, the system memory may be partitioned into memory pages of any arbitrary size. Although not required, partitioning the memory into smaller pages may enable the system to validate pages in a parallel or pipelined fashion, thus reducing the amount of time it takes to validate the contents of system memory when resuming from a low power mode of operation. Partitioning also potentially limits the amount of data that may need to be restored from non-volatile memory, since corrupt data can be identified more precisely.
[0032] The memory controller 100 permits the processor 130 and other devices in computer system 50 to read data from or write data to system memory 125 . Thus, the memory controller formats data cycles from other components in the computer system 50 in a manner that is compatible with the memory devices used in the system memory 125 . The memory controller 100 performs necessary precharge charge, refresh, and other cycles as required by the memory devices. In addition, the memory controller issues appropriate commands such as row address strobe commands and column address strobe commands as necessary to access the memory. If error checking memory is used, error checking logic may be included as part of the memory controller, or may be included as part of the memory devices themselves. The error checking logic performs certain integrity checks on the contents of memory as it is read from memory according to techniques that are well known in the industry.
[0033] As shown in FIG. 1, the memory controller 100 preferably includes an interface to an advanced graphics port (AGP) to support a graphics video controller 140 or other graphics device. According to normal convention, an AGP bus 145 couples the video controller 140 to the memory controller 100 . As one skilled in the art will understand, graphics processors or accelerators implementing other protocols also may be used instead of an AGP controller. Typically, a monitor (not shown) couples to the video controller 140 . The memory controller 100 also preferably functions as an interface to a system or peripheral bus 155 . In the preferred embodiment, the system bus 155 comprises a high-speed data bus to the I/O controller hub 150 .
[0034] The I/O controller hub 150 bridges the system bus 155 to a variety of peripheral busses, including a USB bus 165 , an IDE bus 175 , and a PCI bus 185 . Coupled to each of these busses are ports or slots that enable compatible devices to be connected to the computer system 50 . Thus, for example, a PCI peripheral device, such as a PCI-compatible network interface card (or NIC) may be inserted into one of the PCI slots 180 , for coupling to the I/O controller 150 via the PCI bus 185 . In similar fashion, USB devices may be connected to the computer system through one or more USB ports 160 , and IDE devices may be connected to the system by inserting the IDE device in any available IDE slot 170 . Thus, in accordance with the preferred embodiment, one or more hard drive devices 172 may be inserted in the IDE slots 170 , as shown in FIG. 1. To support legacy ISA devices, a PCI-to-ISA bridge 190 preferably couples to the PCI bus 185 . A conventional ISA bus 195 couples ISA slots 197 to the PCI-to-ISA bridge 190 . Other devices, such as a modem, audio amplifier, or LAN connection may connect directly to the I/O controller hub 150 , or may couple via the conventional peripheral busses.
[0035] As shown in FIG. 1, the I/O controller hub 150 preferably couples to a Super I/O controller 210 through an I/O bus 215 . The Super I/O device 210 preferably includes conventional ports for coupling to floppy disk drives, a keyboard, and a mouse. Thus, the Super I/O device 210 preferably includes conventional keyboard and mouse controllers for converting user inputs to a traditional format for relaying to the CPU 130 . The Super I/O 210 also preferably includes standard parallel and serial ports to permit other peripheral devices to be added to the computer system 50 , as desired by the user.
[0036] It should be understood that although a preferred architecture is shown for a computer system, that various other architectures are possible. Thus, for example, conventional North bridge and South bridge topology may be used, if desired. The system architecture of the system is not critical, and thus the invention should not be construed as limited to a particular architecture.
[0037] The present invention may be used in any computer system that includes a volatile memory and a non-volatile memory, and which may be placed in a low power mode. In addition, the present invention may be used in any system in which corrupted data can not be tolerated. The present invention preferably comprises a portable computer system, or other computer system that supports a low power mode of operation. Preferably, the low power mode comprises a Reliable Suspend to RAM mode that operates by making a back-up copy of the system memory 125 to the non-volatile hard drive 172 prior to entering the suspend mode. As will be apparent to one skilled in the art, other non-volatile memory devices may be used instead of the hard drive. Examples include CR-ROMs, DVD-ROMs, zip drives, tape drives, and the like. When the system is ready to resume operation, the system checks the contents of the system memory 125 for errors. If an error is found in the system memory 125 , the system substitutes the invalid data in memory with reliable data from the hard drive 172 or other non-volatile memory device.
[0038] The present invention may be implemented with an error checking and correction (ECC) DRAM or Parity memory, or in a system without error checking DRAM. ECC DRAM is tolerant of the failure of a few bits in any byte, and may even mend itself using correction algorithms that are known in the industry. If multiple bits are corrupted, or if a single bit failure occurs for parity memory, the address for a faulty memory section may be identified so that the invalid memory section is isolated within a few bytes.
[0039] Referring now to FIG. 2, one embodiment of the present invention is shown for implementation with error checking memory, such as ECC DRAM or Parity memory. The flow chart of FIG. 2 may be implemented as a state machine, or as a separately executing program or algorithm. The flow logic shown in FIG. 2 may be implemented by the CPU, or by other programmable logic located elsewhere, such as in the memory or memory controller.
[0040] The sequence for performing a reliable resume from Suspend to RAM begins when the system initiates a low power mode (step 200 ). When the suspend event is initiated in step 202 , the system BIOS or operating system running on the CPU 130 preferably initiates the saving of context information and data in system memory 125 to the hard drive 172 . The algorithm used to perform this operation is similar to that conventionally used for Hibernation to Disk, and makes an exact association of the system memory address to the location on the hard drive. Thus, the algorithm executing in the CPU tracks the association of DRAM contents to locations on the hard drive. After this backup occurs, the computer system enters the Suspend to RAM state in step 204 , where the system memory 125 remains powered to preserve the data in the DRAM cells. As part of step 204 , the clocks to the peripheral devices in the computer system 125 are stopped, and power is removed from the peripheral devices.
[0041] When resume is initiated (step 206 ), error checking and memory substitution are performed as part of the resume process. Thus, in step 208 , the system clocks are started, and all peripheral devices are powered on. At this point in a normal resume of a Suspend to RAM, control passes to the user. According to the preferred embodiment of the present invention, several other steps are taken before control is passed to the user to verify the validity of the data in RAM. Thus, in step 210 , the algorithm executing on the CPU performs a read of the system memory 125 . If a data error is detected in the system memory by the ECC logic (step 212 ), an NMI (non-maskable interrupt) will be generated as part of the read process (step 214 ). According to the preferred embodiment, the Redundant Suspend algorithm executing on the CPU acknowledges the NMI in step 216 . The algorithm inherently is cognizant of the current address where the memory error was generated as part of the read process, and thus the algorithm, in response to receipt of the NMI, issues a read request to the associated backup copy of that address in the hard drive (step 218 ). The data read from the hard drive is then written to the system memory to replace the invalid data in the system memory. Once the system memory contents have been substituted with the hard drive backup copy, the Redundant Suspend algorithm continues to read the remaining portions of the system memory in step 220 . As shown in step 222 , once the entire system memory has been read and validated, operation is restored to the user. Thus, using the flow logic of FIG. 2, the system examines the integrity of data stored in system memory when resuming from a suspend mode.
[0042] The operation of an exemplary system that does not implement ECC DRAM will now be described with reference to FIG. 3. It should be noted that most personal computer systems currently do not include ECC or Parity memory devices because of the cost associated with these types of memory devices. In systems that do not include error checking capabilities, there is no simple way to detect errors on a per-byte or word level. To compensate for this, the present invention preferably includes logic that supports a high level error checking capability that may be implemented in software or hardware, as desired by the manufacturer. Thus, in accordance with the embodiment of FIG. 3, the present invention preferably makes a signature of the system memory contents before suspend mode is entered, and saves that signature value. During the resume sequence, the system memory contents are checked for discrepancies with the saved signature value. To increase the resolution of the signature technique, the memory preferably is partitioned into smaller pages. The size of these pages is arbitrary.
[0043] Referring now to FIG. 3, when the suspend event is initiated in step 300 , the system BIOS or operating system initially performs an operation similar to a Hibernation to Disk, except that the system memory contents are not treated as a single contiguous block. Instead, the preferred method is to store the memory contents to the hard drive in several pages, with each page having a direct association with particular memory addresses. Thus, for example, a system with 64 MB of DRAM memory may be divided by the algorithm into 4 pages of memory, each with 16 MB. Other page divisions are possible, and pages of much smaller size may be used, if desired. As an example, a page size consistent with page sizes used by the Intel Pentium processor may be used, which typically are 4 KB. Thus, the page size is completely arbitrary with the system designer, and not a limitation of the present invention. Regardless of the page size, an associated signature of each page is calculated and kept in either non-volatile or volatile system memory.
[0044] Referring still to FIG. 3, the system memory preferably is read 32 bits at a time and is stored with a known association onto the hard drive. In this example, the Hibernation file (the file that is backed up to non-volatile memory) contains 4 pages of memory, each 16 MB long. As the algorithm reads the data off the system memory (step 302 ), it develops a signature (step 304 ), such as a checksum value or a CRC (Cyclical Redundancy Check) value. A CRC value represents a more unique signature than a simple checksum, but requires more processing power to generate. After the page of memory is stored onto the hard drive (step 306 ), the signature value calculated by the algorithm is stored in either volatile (such as DRAM) or non-volatile (such as the hard drive or static RAM) memory, as shown in step 308 . Each of the subsequent pages is read in similar fashion, and a signature is calculated for each of these sections and stored in memory for each page of system memory, as shown by step 310 . At that time, the system enters the Suspend to RAM state, in which the clocks are turned off and power is removed from the peripheral devices (step 312 ).
[0045] When a resume operation occurs (step 314 ), error checking and memory substitution is performed on a page-by-page basis. Initially, the clocks are started and power is turned on to the peripherals to initiate the resume process (step 316 ). Next, the algorithm performs a read of the system memory. In accordance with this embodiment, the algorithm reads a page of system memory and calculates the signature for that page (step 318 ). The algorithm then retrieves the stored signature and compares that signature to the signature calculated during the resume operation, as shown in step 320 . If the signatures match, that page or section of memory is assumed to be valid. If the signatures do not match, the contents of that section of system memory are assumed to be invalid, and thus that page is restored from the hard drive to the system memory (step 322 ). Once each page of system memory has been validated or substituted with the hard drive backup copy (step 324 ), the Redundant suspend Algorithm hands the operation of the system back to the user (step 326 ).
[0046] [0046]FIGS. 2 and 3 thus show exemplary flow logic for implementing a Redundant Suspend to RAM operation. It should be understood, however, that many other variations are possible based on the principles advanced above. For example, it is possible to alter the resume sequence to minimize the time it takes to resume normal operation from a Suspend to RAM. Resume time can be an important consideration to certain users, and thus it is advantageous to minimize resume time. The method described in conjunction with FIGS. 2 and 3 contemplate a serial process of checking the memory before handing control to the user. The delay associated with such a serial process in large memory systems may be deemed unacceptable in some situations.
[0047] As an alternative to this serial approach, the validation algorithm may work in the background after system operation is restored. In this approach, the operating system must monitor accesses to any memory pages or sections that have not been validated. At least two techniques may be used by the operating system. The first technique is to have the algorithm disallow accesses to memory address ranges that have not been validated. If an access is made to a memory range that has not been validated by the Redundant Suspend Algorithm, the Algorithm may intervene by first checking that memory address range before allowing the application or the operating system to use that memory address range. The second technique is for the Algorithm to let accesses occur to address ranges that have not been validated. If, however, a write operation occurs to an uncheck address range, the hard drive image will become incoherent and the algorithm will relinquish the opportunity to validate the memory.
[0048] An exemplary method to check the integrity of system memory as a background operation after a system has resumed normal operation uses the Page Translation hardware in the Intel Pentium processor to intercept an access to system memory. When an access is made to a part of system memory that has not yet been validated, an algorithm is called by the CPU to examine the integrity of each page of system memory targeted by the access. If the page of system memory is not valid, then the copy of the page stored in non-volatile memory is written to system memory to replace the invalid data.
[0049] The following discussion describes one exemplary implementation for a Redundant Suspend to RAM technique in which the algorithm works in the background after the system has resumed operation. This technique uses page translation hardware in the CPU, and thus some background on page translation is provided. Referring now to FIG. 4, the Intel Pentium processor is capable of 4 GB of virtual memory space ( 2 32 ) divided into 4 KB size pages. These pages of memory are mapped into 1024 Page Directories, with each Page Directory including 1024 page tables. As shown in FIG. 4, the logical CPU address 400 includes 32 bits, that are broken into three hierarchical blocks 405 , 410 , 415 . The first block 405 includes address bits 22 - 31 , which select one of the 1024 Page Directories (one of which is shown at 425 ). Each page Directory will index 1024 Page Tables. The second block 410 of the logical address includes address bits 12 - 21 that select which one of the 1024 Page Tables will be used. One such page table 450 of Directory 425 is shown. Each Page Table points to a 4 KB block of physical memory space, called a Page Frame 475 . Address bits 0 - 11 of block 415 are used to index within the 4 KB Page Frame.
[0050] The Page Directory and Page Table entries comprise 32-bit registers that contain re-mapping and control fields. As shown in FIG. 6, bit 0 of both the Page Directory and the Page Table entries indicates if the entry is valid. Thus, a zero value in bit 0 of the Page Directory entry 600 indicates that none of the Page Tables which it indexes hold valid data. Similarly, a zero value in bit 0 of a Page Table entry indicates that Page Table is not associated with a valid Page Frame. Bits 1 - 8 of each Page Directory entry and each Page Table entry hold information relating to the characteristics of the Page Frame, such as whether it is cacheable, writeable, etc. Bits 9 - 11 have no designated function, and may be used by the operating system or by other algorithms. According to the embodiment disclosed herein, bit 9 is used in the present invention to indicate if the data has been validated after a resume operation. Bits 12 - 31 of the Page Directory and Page Table registers form the address to the Page Frame that will be used. This is the actual physical address used to select which of the one million 4 KB pages in memory is being accessed.
[0051] Thus, according to the preferred embodiment, the system memory 125 (FIG. 1) preferably is organized as 1024 page directories, each with 1024 page tables that map to 4 KB of system memory. Prior to entering suspend mode, a copy and a description of the system memory is calculated and stored onto the hard drive by the algorithm. Referring to FIG. 5, preferably, the algorithm stores 1024 doublewords in a Page Entry Backup Register 500 , with one doubleword (32 bits) associated with one Page Directory. The doubleword for each Page Directory describes the memory associated with each Page Directory. This description preferably includes a 22 bit signature value that will be created for all the memory that is accessible under each Page Directory. The signature value may represent a CRC value or checksum of all the 4 KB blocks beneath each Page Directory. The description also preferably includes a 10 bit size value (representing up to 1024 pages of memory) that indicates the number of 4 KB blocks that are stored to the hard drive and associated with that Page Directory. The maximum amount of memory under any Page Directory is 4 MB, which equate to 1024 pages of 4 KB memory. If there is no valid memory stored in the Page Tables behind the Page Directory, the signature and size values are represented “0” for all 32 bits.
[0052] In addition to the signature value and size value stored in the Page Entry Backup Register 500 , the algorithm also preferably generates a Hibernation Data file 550 that contains a copy of the system memory contents, and each page address. For each active Page Table, a DRAM Image is stored in the Hibernation Data file that includes the Page Table number that is copied, and the contents of the 4 KB memory pointed to by that Page Table. Thus, according to the preferred embodiment, the DRAM Image includes 2 bytes that identify the Page Table number, which ranges from 0 to 1023. The DRAM Image also includes 4096 bytes of information copied from the 4 KB memory frame pointed to by the associated Page Table. Thus, each DRAM Image preferably is 4098 bytes long, which includes two bytes of overhead for identifying the active Page Frame.
[0053] Referring now to FIGS. 4, 5 and 6 , when suspend is initiated, the Page Directory and Page Table entries are tested to determine if they reference a valid section of system memory. Each 4 KB Page Frame of valid memory is stored to the hard drive in the Hibernation Data file 550 , along with a signature of the valid memory in each Page Directory, as identified in the Page Entry Backup Register 500 . Whether valid data is present is determined by reading bit 0 (the present bit) of each Page Directory entry. If this bit is not set, then there is no valid memory pointed to by this Page Directory, or any of the Page Tables underneath this Page Directory. The algorithm zeroes the signature and the size bits in the Page Entry Backup Register 500 , and also preferably sets bit 9 of the Page Directory Entry 600 to a “0” if no data is valid in the Page Directory.
[0054] If, conversely, the present bit is set in the Page Directory entry 600 , then there is a valid Page Frame pointed to by the Page Directory. The algorithm then tests each of the 1024 Page Table entries under that Page Directory. Each Page Table includes its own present bit (bit 0 ) indicating validity of the memory frame pointed to by that table. The algorithm stores each valid 4 KB page of memory to the hard drive in Hibernation Data file 550 , together with the number of each table. Pages with no valid memory are not saved into the hibernation file. Once all the Page Frames associated with a Page Directory are stored, the algorithm calculates a signature of all the cumulative 4 KB Page Frames stored that are associated with that Page Directory. The algorithm then writes to the Page Entry Backup Register 500 the number of valid pages stored in the hibernation file for that directory, and the signature accumulated for all of the valid pages of memory associated with that Page Directory. The present bit (bit 0 ) then is cleared in that Page Directory Entry. Bit 9 of each Page Directory entry then is set to a “1”, which will then be used by the algorithm during the resume process. Once this process is repeated for each Page Directory, the entire contents of system memory will have been saved to the hard drive or other non-volatile memory. The system then may enter the Suspend to RAM state. It should be noted that the signature value may be calculated for each Page Table that is stored, instead of obtaining a cumulative signature for the Page Directory. This would provide greater resolution so that validation and substitution of a section of memory can be performed faster.
[0055] According to this embodiment of the invention, the system performs a fast resume, without requiring that all of the system memory be validated prior to resuming operation. The validation operation preferably executes in the background until completed. In the event, however, that a data cycle targets any memory address that has not been validated, the algorithm intercepts that access. Because the Present bits of the Page Directory entries (bit 0 ) have been cleared, a Page fault interrupt will be generated when an access targets a memory address that has not been validated. In response to the Page Fault interrupt, the algorithm will be called. The algorithm then checks to see if bit 9 of the Page Directory Entry 600 has been set to “1” to determine if the Page Fault was generated because the DRAM address has not yet been validated, or because the application program was not copied from the hard drive or removable media. If bit 9 is clear (set to “0”), that, coupled with the “0” value in bit 0 , indicates that this page of memory did not contain valid data before the suspend operation. The algorithm will then hand control to the Operating System, which will fetch the software application from the hard drive and load it to memory, as usual.
[0056] If conversely, bit 9 of the Page Directory Entry 600 is set, then that page was valid before the Suspend operation, and its memory integrity has not yet been checked. The algorithm will then check the validity of that page. This is done by calculating a signature of the valid memory in every page underneath the Page Directory. The calculated signature value than is compared against the signature value stored in the Page Entry Backup Register 500 . If the signature does not validate, that section of the DRAM is assumed to be corrupt. Consequently, the algorithm will substitute the non-volatile hard drive data for the corrupted system memory section. This is done by locating the associated page of memory in the Hibernation Data file. A starting address is created for the first page, by adding up the size entries for every previous Page Entry Backup Register entry. For example, if the memory error is associated with Page Directory 980 , then the size data for Page Entry Backups 0 - 979 are added together to find the start address for the data page associated with Page Directory 980 . The number of 4 KB blocks to substitute is read in the size information for the present Page Entry Backup (which is the size information for Page Directory 980 in this example). The maximum size is 1024 pages. An index then is formed and the first relevant Page Table address is located inside the Hibernation file. The remaining 4096 bytes of information from that block are copied from the hard drive into system memory. The algorithm repeats this process, copying all the pages associated with that Page Directory to system memory to restore the entire Page Directory (because the signature indicates that there is an error in at least one bit in the Page directory contents). Once all the pages have been validated for a Page Directory, the algorithm will set the present bit (bit 0 ) in the Page Directory Entry register 600 , and clear bit 9 . This will indicate that the Page Frames under that Page Directory have been validated since the last resume. At that point, the algorithm returns to the background, and the execution of the application software will start at the address where the Page Fault interrupt was generated.
[0057] Preferably, the algorithm is called and validates system memory during idle or slow periods of the CPU and hard drive. The algorithm will validate each page of memory by starting with the first page entry backup. The algorithm will check the size entry for a non-zero value. The algorithm then will validate the DRAM contents for each Page that is indicated to hold valid data. The algorithm will index to the next Page Directory entry until the entire system memory has been validated.
[0058] There are a number of variations and modifications that may be made to the present invention. For example, the algorithm may be programmed to distinguish the source of the resume operation. If the resume operation is caused by an electrical wakeup, then any resume latency maybe intolerable. In this instance, the integrity algorithm may ignore the integrity check and assume that the system memory is valid. Thus, a wakeup caused by a modem ring may be handled differently than a manual wakeup caused by the user depressing a key. To detect a critical wakeup, hardware must be capable of identifying the source of the wake up. Typically, each individual wake up source has an associated flag that is set when the wake up condition is detected. The algorithm then can read each flag, and determine if the resume might require a time-critical response. The integrity algorithm may also be designed to spot check the system memory, without checking every single DRAM byte. Thus, the algorithm may be configured to check specific rows or devices as part of the validation process. As yet another alternative, the system can be configured to store a substantial image of the system memory to non-volatile memory, instead of copying on a bit-by-bit basis. Thus, for example, a compressed image of the system memory, or a Hamming code signature of the system memory, may be written to the hard drive in lieu of copying each bit. The term “substantial image” is intended to cover a complete image of the system memory, or a partial or compressed image of the system memory that is sufficient to repair or restore damaged system memory. Moreover, the present invention may also be used to provide a fast resume from a hibernation state, instead of a Suspend to RAM state, by resuming operation before the saved memory pages have been restored to system memory. Additional details regarding the fast resume operation are discussed in co-pending and commonly-assigned U.S. patent application Ser. No. _____, entitled, “Fast Suspend to Disk,” the teachings of which are incorporated by reference herein.
[0059] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A computer system supports suspend operations to save power. The suspend operation maintains power to the system memory to enable a quick recovery from the suspend mode. To insure the accuracy of the data in system memory, a copy of the data is backed up to non-volatile memory, such as a hard disk drive, prior to entering the suspend mode. In addition, a signature value representing blocks or pages of memory also is saved with the data. When normal operation resumes, data in system memory is validated by calculating a new signature for each data block or page, and comparing it with the save signature values. If the signatures match, the data is assumed to be valid. If the values do not match, a restore operation proceeds to load the back up copy to that block of system memory. The algorithm may be run immediately upon resuming operation, or may run in the background when the CPU is idle. In the event a transaction occurs prior to validation of a particular memory location, the access is interrupted and the data is validated or restored. In addition, the error checking and restoration operations may be used during normal system operations to insure the integrity of data in the system memory or other volatile memory components.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is related to pneumatic valves and in particular to a microminiature valve compatible in size and materials with current integrated circuit technology.
2. Prior Art
The need for small pneumatic valves for use in conjunction with integrated circuits is exemplified by Terry et al in their publication "A Chromatographic Air Analyzer Fabricated on a Silicon Wafer" IEEE Transactions on Electronic Devices, Vol. ED 26, No. 12, December 1979. In this publication Terry et al discloses a miniature valve made on a silicon wafer having a nickel diaphragm actuatd by a solenoid plunger. In contrast to the metal diaphragm taught by Terry et al, Greenwood, U.S. Pat. No. 4,293,373, and Guckel et al, U.S. Pat. No. 4,203,128, disclose techniques for forming flexible diaphragms from silicon wafers by diffusing boron into the surface of the silicon wafer in the region where the flexible diaphragm is to be formed. The undoped silicon is then preferentially etched away leaving a flexible diaphragm in the boron diffused region. Guckel et al additionally discloses a two part valve using a boron doped flexible diaphragm. Alternatively, K. E. Peterson in his article "Dynamic Micromechanics on Silicon: Techniques and Devices" IEEE Transactions on Electron Devices, Vol. ED-25, No. 10, October 1978, discloses a method for making miniature cantilever beam devices using silicon dioxide layers on a silicon substrate. In these devices, the silicon underlying the silicon dioxide layer is etched away to form a well under the unetched silicon dioxide beam. Petersen also teaches electrostatic deflection of the cantilever beams using a metal electrode deposited over the top surface of the silicon dioxide beam. In contrast to the solenoid plunger deflection of the membrane as taught by Terry et al, Brandt in U.S. Pat. No. 3,936,029, teaches a pneumatic amplifier in which the diaphragm is disposed between an operating chamber and a signal chamber. The pressure in the signal chamber displaces the membrane which varies the fluid conduction through the operating chamber.
The invention is a multi-layered integral microminiature valve which is compatible with current silicon wafer processing technology and eliminates the nickel diaphragm and solenoid actuator in the microminiature valve taught by Terry et al.
SUMMARY OF THE INVENTION
The invention is a single piece microminiature valve compatible with existing silicon wafer processing techniques common in the electronics industry having fast response and small dead volumes. The micorminiature valve is of the type as taught by Terry et al formed on a semiconductor substrate having an inlet and outlet port passing through the substrate, a raised valve seat circumscribing the inlet port, a spacer circumscribing said inlet and outlet ports, a flexible diaphragm supported by said spacer and means responsive to an input signal for deflecting the flexible diaphragm to engage said valve seat occluding fluid flow between said inlet and outlet ports, characterized in that said microminiature valve is a multilayer integral structure comprising said semiconductor substrate having said inlet and outlet ports and said raised valve seat, a nonporous top layer and an intermediate layer preferentially etched to form an annular spacer between said substrate and said top layer, circumscribing said inlet and outlet ports and peripherally supporting said top layer above said raised valve seat, wherein the unsupported central portion of said top layer constitutes said flexible diaphragm. In the preferred embodiment a thin metal electrode is disposed over the top layer permitting the central portion thereof to be electrostatically deflected to engage the valve seat in response to an applied electrical potential.
The advantage of the microminiature valve is that it is a single piece integral structure eliminating the requirement of precise mating of multiple components. Another advantage is that the microminiature valve can be made using existing semiconductor processes. Still another advantage is that it has a low profile on the order of the thickness of a silicon wafer. A final advantage is that the valve can be made from only silicon and silicon dioxide materials eliminating possible sources of contamination.
These and other advantages will become more apparent from reading the Specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional side view of the microminiature valve in the open state.
FIG. 2 is a cross-sectional side view of the microminiature valve in the closed state.
FIG. 3 is a cross-sectional top view of the microminiature valve.
FIGS. 4 through 8 are cross-sectional side views of the microminiature valve used to explain the fabrication steps for making the valve.
FIG. 9 is a cross-sectional side view of an alternate embodiment of the microminiature valve actuated by a pressure signal.
DETAILED DESCRIPTION OF THE INVENTION
The details of the microminiature valve are shown on FIGS. 1 through 3. Referring to FIGS. 1 and 3 the microminiature valve 10 is a multi-layered structure comprising a p type silicon substrate 12 having a centrally disposed inlet port 14, an offset outlet port 16 passing therethrough and a raised annular valve seat 18 circumscribing the inlet port 14 on the top or internal surface of the substrate 12. An annular spacer 20 is formed on the top surface of the substrate 12 circumscribing the inlet port 14 and outlet port 16. The spacer 20 supports a thin nonporous layer 22, such as a silicon dioxide layer, a small distance above the top of the annular valve seat 18 enclosing the volume 24 defined by the spacer 20 between the substrate 12 and layer 22. The unsupported central portion of layer 22 constitutes a flexible diaphragm. A thin conductive metal electrode 26 is provided on the top surface of layer 22.
A source of electrical power illustrated by battery 28 and switch 30 is connected between the substrate 12 and electrode 26.
In operation, when the switch 30 is open, as shown on FIG. 1, the nonporous layer 22 is supported by the spacer 20 above the top surface of the valve seat 18 providing a fluid flow path between the inlet port 14 and the outlet port 16. However closing switch 30 applies the electrical potential from the source of electrical power 28 between the substrate 12 and the electrode 26 generating an electrostatic static field therebetween. This electrostatic field generates a force deflecting the central portion of layer 22 towards the substrate as shown in FIG. 2. The potential of the source of electrical power is selected to generate an electrostatic force on layer 22 greater than the force exerted in the reverse direction by the pressure of the fluid received at the inlet port 14. Therefore when switch 30 is closed, the electrostatic force will deflect the central portion of layer 22 sufficiently to seat on annular valve seat 18 occluding the inlet port 14 and inhibiting the fluid flow between the inlet port 14 and outlet port 16. Removal of the electrical potential between the substrate 12 and electrode 22 will terminate the electrostatic force, and layer 22 will return to the position shown in FIG. 1 opening the fluid connection between the inlet and outlet ports. The opening of the valve 10 upon termination of the electrostatic field will also be assisted by the pressure of the fluid applied to the inlet port 14 enhancing the response time of the valve.
The fabrication of the microminature valve will be discussed relative to FIGS. 4 through 8. Referring first to FIG. 4, the nnular valve seat 18 is formed on the top surface of a (100) oriented p type silicon susbstrate 32 using photolithography and an isotropic silicon etchant such as HF--HNO 3 . Next a thick layer 34 of n+ type silicon is deposited or grown on the top surface of the silicon wafer as shown in FIG. 5. The n+ type silicon layer 34 must be etchable by chemicals which do not attack the p type silicon substrate 32 or silicon dioxide layer 22. Preferably the n+ type silicon layer 34 is a polysilicon layer grown on the surface of the substrate 32 using any of the conventional techniques known in the semiconductor field. This layer is preferably in the range from 10 to 20 micrometers thick determined by height of the raised valve seat 18 and other operational parameters of the valve.
The top surface of the n+ type silicon layer is then polished to remove surface irregularities. Silicon dioxide layers 36 and 38, about 10 micrometers thick, are then formed on opposite sides of the coated substrate as shown in FIG. 6. The silicon dioxide layer 36 will become the flexible diaphragm of the completed valve while silicon dioxide layer 38 is patterned and used as a mask for the formation of the inlet port 14 and outlet port 16.
The inlet port 14 and outlet port 16 are then formed by an anisotropic etch through the p type silicon substrate 32 using a first etchant such as KOH-isoproponol-water stopping at the top silicon dioxide layer 36 as shown in FIG. 7. The silicon dioxide layer 38 is then removed. Finally the n+ type polysilicon layer 34 is preferentially etched to form the internal volume 24 of the valve by introducing a second etchant, such as HF--HNO 3 --CH 3 COOH solution through the input port 14. The second etchant will preferentially etch the n+ type polysilicon 34 layer from between the silicon substrate 32 and the silicon dioxide layer 36 forming a silicon dioxide flexible diaphragm, spacer 20, and internal volume 24 as shown in FIG. 8. The valve is completed by adding an electrically conductive metal electrode 26 over the silicon dioxide layer 36 as shown in FIG. 1. Although silicon dioxide is the preferred material for nonporous layer 22, it is recognized that other oxides compatible with the etching steps may be used as well as forming layer 22 from a p type polysilicon.
An alternate pressure actuated configuration of the microminiature valve is illustrated on FIG. 9. In the configuration, the substrate 12, including inlet and exit ports 14 and 16, spacer 20 and flexible diaphragm 22 are fabricated as discussed relative to FIGS. 4 through 8. Above nonporous layer 22 there is attached a cup shaped housing 40 having a signal input port 44. Housing 40 defines an internal chamber 42 enclosed on one side by the central portion of layer 22. The cup shaped housing 40 may be bonded to the top of the layer 22 or the substrate 12 using any of the standard techniques known in the art.
The operation of the pressure actuated configuration of the microminiature valve is straightforward. The opening and closing of the valve is controlled by the pressure P2 at the signal input port. When the pressure P2 is less than the pressure P1 of the fluid received at the inlet port 14, central portion of layer 22 deflects upward away from the valve seat 18 providing a fluid flow path between the inlet port 14 and outlet port 16. However when the pressure P2 applied to the signal input port 44 exceeds the pressure P1 applied to the inlet port 14 by an amount sufficient to deflect the central portion of layer 22 downwardly to engage the valve seat 18, the fluid flow path between the inlet port 14 and outlet port is occluded by the nonporous layer 22 closing the valve.
As will be appreciated by those skilled in the art, the disclosed microminiature valve is not limited to the configuration shown in the drawing or the materials and processes discussed in the specification. It is recognized that inlet port and valve seat may be offset with respect to the center of the enclosed volume 24, that the outlet port may also have a valve seat corresponding to valve seat 18, and that different materials for the substrate 12, spacer 20 and flexible diaphragm 22 may be substituted for the materials discussed in the Specification without departing from the spirit of the invention.
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A microminiature valve having a multilayer integral structure formed on a semiconductor substrate. The valve comprises a semiconductor substrate having inlet and outlet apertures and a raised valve seat. The substrate is overlayed with a nonporous top layer and an intermediate layer. The central portion of the intermediate layer is preferentially etched away to form an enclosed chamber connecting said inlet and outlet ports. The unetched portion of said intermediate layer peripherally supports said top layer above the valve seat. An electrically conductive electrode disposed on the unsupported portion of the top layer permits it to be electrostatically deflected to engage the valve seat and close the valve.
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RELATED APPLICATIONS
The present application is a continuation-in-part of prior U.S. patent application Ser. No. 11/392,976, entitled: “COLD START SATELLITE SEARCH METHOD”, filed on Mar. 28, 2006, and U.S. patent application Ser. No. 11/566,009, entitled “SATELLITE SEARCH METHOD”, filed on Dec. 1, 2006. The entirety of each application is hereby incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a satellite searching, more particularly, to a method for dynamically and rapidly searching satellites and a receiver implementing such a method.
BACKGROUND OF THE INVENTION
Nowadays, multiple Global Navigation Satellite System (GNSS) are available, including GPS (Global Positioning System) of US, which is designed to have 32 operational satellites, Galileo of Europe, which is designed to have 27 operational satellites, GLONASS (Global Navigation Satellite System) of USSR, which is designed to have 24 operational satellites, and Compass of China, which is designed to have 35 operational satellites. The constellation composed of these systems is called a super GNSS constellation. In addition, Regional Navigation Satellite Systems (RNSS) such as QZSS (Quasi-Zenith Satellite System) of Japan and GAGAN (GPS Aided Augmented Navigation System) of India are also planed to be operable in the near future.
Further, various SBAS (Satellite Based Augmentation Systems) have been developed to augment GNSS, such as WAAS (Wide Area Augmentation System) of US, EGNOS (European Geostationary Navigation Overlay Service) of Europe, MSAS (MTSAT Satellite Based Augmentation System) of Japan, and GAGAN of India.
As can been seen, the current constellation of satellites has been quite dense. As can be easily expected, the sky will be crowded with more and more satellites in the coming future. Therefore, how to search all the satellites quickly becomes more and more challenging for a receiver. As known in this field, searching for a satellite is to determine its satellite ID, Doppler frequency and PRN (Pseudo Random Number) code phase. The hardware speedup for the receiver is usually performed to reduce searching time in acquisition of Doppler frequency and PRN code phase. Little attention has been given to deal with the unknown satellite IDs. As mentioned, there are more and more satellite IDs to try in the satellite search as the constellation becomes larger and larger. It will take a very long period of time to acquire all the visible satellites by using the conventional sequential search method. In such a conventional method, the satellites are searched one by one and in a fixed order. The present invention provides a solution to overcome this problem.
SUMMARY OF THE INVENTION
The present invention provides a satellite time dynamic search method, by which the satellite ID uncertainty can be significantly reduced so that a predetermined or required number of satellites can be rapidly acquired. The present invention also provides a receiver implementing such a method. The method comprises (a) providing a candidate satellite list containing a plurality of satellites; (b) calculating mean visibility of each satellite listed in the candidate satellite list for possible time samples in view of an observation location; (c) selecting a satellite from the candidate satellite list according to the mean visibility of each satellite listed in the candidate satellite list; (d) searching the selected satellite to obtain a search result; (e) eliminating at least one time sample from the possible time samples according to the search result; and (f) repeating steps (b) to (e), so as to rapidly and efficiently acquire satellites.
The present invention further provides a receiver for receiving and processing satellite signals to conduct a satellite search. The receiver comprises: a correlation block for correlating the satellite signals with a code of a satellite so as to search the satellite; and a navigation processor for controlling the correlation block. The navigation processor provides a candidate satellite list containing a plurality of satellites, calculates mean visibility of each satellite listed in the candidate satellite list for possible time samples in view of an observation location, instructs the correlation block to search a satellite which is selected according to the mean visibility of each satellite to obtain a search result, and eliminates at least one time sample from the possible time samples according to the search result.
According to the present invention, a satellite with the maximum mean visibility is selected from the candidate satellite list to be searched. The search result of the currently searched satellite is used to eliminate impossible time samples from the possible time samples so as to reduce the uncertainty range.
In an embodiment of the present invention, each time sample that the searched satellite is not visible is eliminated if the search result indicates that the searched satellite is acquired, while each time sample that the searched satellite is visible is eliminated if the search result indicates that the searched satellite is unacquired.
The candidate satellite list can be updated in various manners. In one case, one satellite is removed from the candidate satellite list once it has been searched to update the candidate satellite list, no matter the satellite has been acquired or not. In another case, one satellite is removed from the candidate satellite list once it has been acquired to update the candidate satellite list.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further described in details in conjunction with the accompanying drawings.
FIG. 1 is a block diagram showing a receiver in accordance with the present invention;
FIG. 2 is a flow chart showing a method in accordance with the present invention;
FIG. 3 to FIG. 13 respectively show visible time samples and mean visibilities of the respective candidate satellites in eleven searches using the method in accordance with the present invention;
FIG. 14 is a chart showing calculated mean visibilities of the respective satellites for the first six searches using the method in accordance with the present invention; and
FIG. 15 is a chart showing a search time comparison between results obtained by the conventional sequential search method and the method in accordance with the embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
When a receiver starts, the first task is to search all the visible satellites in the sky. Satellite visibility relates to a user's position, system time (e.g. GPS time) and satellite orbital information. The satellite orbital information is from data collected in the last fixing of the receiver or from a remote aiding data server. The receiver can determine the satellite visibility by checking an elevation angle of a satellite with respect to the receiver, for example. A specific satellite is deemed as visible when the elevation angle is greater than 5 degrees. Otherwise, this satellite is deemed as invisible. However, in addition to the elevation angle of the satellite with respect to the receiver's position, the visibility of each satellite can be determined by any other proper method. The satellite visibility can be expressed as a function of the user's position, the system time and the satellite orbit information. If the user's rough position, the rough time (e.g. time provided by RTC (real time clock) unit of the receiver) and rough satellite orbit information (e.g. the six Kepler orbit parameters or an almanac) are known, it is possible to derive which satellites are visible under such a condition. Reversely, the current system time (e.g. current GPS time) is an inverse function of the user's position, the satellite orbit information and the satellite visibilities. That is, if the rough user's position and satellite orbital information are known, the current time can be approached by using the fact that a satellite is visible or not. The present invention is developed based on this concept.
In the following descriptions, GPS with 32 satellites (SV 1 , SV 2 , . . . , SV 32 ) is taken as an example. However, the present invention is not limited thereto.
FIG. 1 is a block diagram showing a receiver 100 in accordance with the present invention. The receiver 100 receives and processes satellite signals such GPS signals or other satellite system signals to position a user's location. For example, GPS signals, which are radio frequency (RF) signals, of all satellites are received by an antenna 101 . The RF signals are amplified by a preamplifier 103 . The amplified signals are then down converted by a down-converter 116 into intermediate frequency (IF) or baseband signals, using signal mixing frequencies provided by a frequency synthesizer 114 , which uses a reference clock provided by a reference oscillator 112 to generate the required frequencies. The IF or baseband signals are converted into digital signals by an analog-to-digital converter (ADC) 120 . In general, the preamplifier 103 , down-converter 116 , frequency synthesizer 114 , oscillator 112 and ADC 120 can be considered as a whole and referred to as an RF block 110 for dealing with RF signal processing. The digital signals are then passed to a correlation block 130 to be correlated with codes of satellites to obtain correlation results. This is known as satellite search. The correlation results from the correlation block 130 are provided to a navigation processor 140 to judge acquisition of the satellites. The correlation block 130 is controlled by the navigation processor 140 to execute satellite search and/or tracking. The details will be further described later.
A predetermined time period of 24 hours is chosen in the present embodiment since the revolution period of the GPS satellite is about 24 hours. The period of 24 hours (i.e. 86400 seconds) is sampled every 600 seconds, and therefore there are 144 time samples.
FIG. 2 is a flow chart showing a method in accordance with the present invention. The method starts at step S 210 . In step S 220 , an initial candidate satellite list “candList” including all the 32 satellites of GPS is set in the navigation processor 140 . That is, candList={1, 2, . . . , 32}. In step S 230 , an initial GPS time list “gpstList” including all the time samples is set in the navigation processor 140 . That is, gpstList={0, 600, 1200, . . . , 85800}. It is noted that the sequence of the steps 220 and 230 is arbitrary. These two steps can also be executed in parallel.
In step S 240 , a visibility “vis(SV, t)” of each satellite in view of a specific position is calculated for each time sample. As mentioned, the visibility can be derived from the position, time and satellite orbital information. If a specific satellite (e.g. SV 1 ) is visible at a specific time (e.g. t=0), the visibility thereof is 1, that is, vis(SV 1 , 0)=1. If the satellite SV 1 is invisible at time 0, the visibility thereof is 0, that is, vis(SV 1 , 0)=0.
In step S 250 , a mean visibility of each satellite “meanVis(SV)” of the candidate satellite list for the possible time samples is calculated as:
meanVis ( SV ) = 1 gpstList ∑ t ∈ gpstList vis ( SV , t ) ( 1 )
where |gpstList| is the number of samples in gpstList.
In the beginning, the meanVis(SV) is calculated for each satellite SV 1 to SV 32 with respect to the whole time period of 24 hours in this example. That is, all time samples are possible to be the true system time. It is found that the mean visibility of SV 29 is the highest. That is, the satellite SV 29 is most probably visible during the whole 24-hour time period. Accordingly, the navigation processor 140 chooses SV 29 as the candidate satellite “candSV” to be searched (step S 260 ) and instructs the correlation block 130 to execute correlation for searching SV 29 (step S 270 ). In step S 280 , the navigation processor 140 determines SV 29 is hit or not. If SV 29 is hit (i.e. acquired), then the time samples during which SV 29 is not visible are all removed from the GPS time list gpstList. That is, the navigation processor 140 removes each t for vis(candSV, t)=0 from gpstList (step S 292 ). If SV 29 is not hit (i.e. missed, unacquired), then the time samples during which SV 29 is visible are removed from the GPS time list gpstList. That is, the navigation processor 140 removes t for vis(candSV, t)=1 from gpstList (step S 295 ). No matter what the search result is, the amount of the possible time samples is significantly decreased. It is noted that the search result of “a missed satellite” should be carefully verified to make sure that the searched satellite is indeed unacquired. For example, an integration interval for correlation may be extended and then the extended interval is used in correlation to search the satellite again.
In step S 300 , the navigation processor 140 determines whether a predetermined number of satellites have been acquired. If so, the process can be ended at step S 310 . Otherwise, the process goes to step S 320 , in which the candidate satellite list candList is updated. In the present embodiment, once a satellite has been searched, it is removed from candList no matter it is hit or not. In another embodiment, only if a satellite is hit, then it is removed from candList. After updating candList, the navigation processor 140 determines whether the candidate satellite list candList is empty in step S 330 . If the candidate satellite list candList is not empty (i.e. candList≠{ }), it means that the current round of search has not been finished yet. The process goes back to step S 250 , the navigation processor 140 calculates the mean visibility for each candidate satellite of the updated candList based on the updated gpstList. In the present embodiment, if the candidate satellite list candList is empty (i.e. candList={ }), the navigation processor 140 puts all the unacquired satellites into the list to form a new initial candidate satellite list for the next round of search in step S 340 , and the process goes back to step S 250 to run the next round of search.
An experimental example will be given as follows to reveal the effects of the present invention. FIG. 3 to FIG. 13 respectively show visible time samples and mean visibilities of candidate satellites in eleven searches of this example. In each drawing of FIG. 3 to FIG. 13 , the upper chart shows that candidate satellites are visible at which time samples; and the lower chart shows the mean visibility of each candidate satellite. In this example, GPS satellites visible at time t 0 are to be acquired. As can be seen, satellites SV 2 , 4 , 5 , 10 , 12 , 13 , 17 and 26 should be acquired. The predetermined time period is selected to be 24 hours. The period of 24 hours (i.e. 86400 seconds) is divided into 144 time samples, each of which has 600 seconds.
In the beginning, all of the 32 GPS satellites are candidate satellites. That is, the candidate satellite list, candList, includes the 32 GPS satellites. The time t 0 is unknown. At an observation location (e.g. an observation station) where the user is, the time that each of the 32 GPS satellites is visible is recorded in the upper chart of FIG. 3 . As mentioned, at time t 0 , satellites SV 2 , 4 , 5 , 10 , 12 , 13 , 17 and 26 should be visible in this assumed example.
As described, the visibility vis(SV, t) of each satellite SV 1 to SV 32 can be determined to be 0 or 1 according to the position of the observation station, the satellite orbital information and the GPS system time. The mean visibilities of the respective 32 GPS satellites for the period of 24 hours are calculated. The result is shown in the lower chart in FIG. 3 . In this example, the satellite SV 29 has the maximum mean visibility for the whole period of 24 hours. Therefore, SV 29 is selected as the first satellite to be searched.
As shown in the upper chart of FIG. 3 , at time t 0 , the satellite SV 29 is not visible. Therefore, the search result for SV 29 should be “missed” (i.e. unacquired). Based on the search result of SV 29 , we eliminate those time samples at which SV 29 is visible from the possible time samples. The resultant time sample chart is shown in the upper chart of FIG. 4 .
The possible time samples are reduced after searching of SV 29 . The mean visibilities of all the satellites for the remaining possible time samples are re-calculated. The result is shown in the lower chart of FIG. 4 . As can be seen, the satellite SV 13 has the maximum mean visibility at this stage. Accordingly, SV 13 is selected as the second satellite to be searched.
It is noted that each satellite is only searched once in one round of search no matter it is hit or not in this example. Therefore, in the second search, SV 29 is removed from the candidate satellite list.
At time t 0 , the satellite SV 13 is visible. Therefore, the search result for SV 13 should be “hit” (i.e. acquired). The time samples that SV 13 is not visible are then eliminated. The result is shown in the upper chart of FIG. 5 . The possible time samples are further reduced. The mean visibilities of all the satellites for the remaining possible time samples are re-calculated again. The result is shown in the lower chart of FIG. 5 . Since SV 13 has been searched, it is removed from the candidate satellite list. That is, the candidate satellite list is again updated. The satellite SV 23 has the maximum visibility in the updated candidate satellite list. Accordingly, SV 23 is selected as the third satellite to be searched.
As can be seen, the satellite SV 23 is invisible at time t 0 . Therefore, the search result for SV 23 should be “missed” (i.e. unacquired). The time samples that SV 23 is visible are then eliminated. The result is shown in the upper chart of FIG. 6 . The possible time samples are further reduced. The mean visibilities of all the satellites for the remaining possible time samples are re-calculated again. The result is shown in the lower chart of FIG. 6 . In the present example, since SV 23 has been searched, it is removed from the candidate satellite list even it is not acquired. That is, the candidate satellite list is again updated. The satellite SV 27 has the maximum visibility in the updated candidate satellite list. Accordingly, SV 27 is selected as the fourth satellite to be searched.
At time t 0 , the satellite SV 27 is invisible. Therefore, the search result for SV 27 should be “missed” (i.e. unacquired). The time samples that SV 27 is visible are then eliminated. The result is shown in the upper chart of FIG. 6 . The possible time samples are further reduced again. The mean visibilities of all the satellites for the remaining possible time samples are re-calculated again. The result is shown in the lower chart of FIG. 7 . As can be seen, the mean visibilities of the satellites SV 2 , 4 , 5 , 10 , 12 , 13 , 17 , 26 are significantly higher than the other satellites. That is, the true visibilities have been obtained at this stage.
In additional to executing the method of the present invention to the end, since several satellites have significantly high mean visibilities (e.g. approaching 1), these sieved satellites can also be searched in sequence at this stage. In this example, SV 2 is selected to be the fifth satellite to be searched, and the process described above is repeated. The time samples are sieved again and again, and finally the remaining time sample approaches the true time t 0 . The mean visibilities of the satellites will approach the true condition very soon by using the method of the present invention. FIG. 14 is a chart showing calculated mean visibilities of the respective satellites for the first six searches. In this chart, each mean visibility is converted to a weight ranged from 0 to 2. The vertical axis is the weight, while the horizontal axis is the satellite ID. As a result, the satellites SV 4 , 5 , 10 , 12 , 17 , 26 are acquired in sequence in the following searches (i.e. the fifth search to the eleventh search) by executing the method of the present invention to the end.
By using the method of the present invention to dynamically schedule the candidate satellites to be searched, all the eight visible satellites SV 2 , 4 , 5 , 10 , 12 , 13 , 17 and 26 are acquired in 11 searches even there is one erroneous judgment occurred. In comparison, if the conventional sequential search method is used, 26 searches are required to acquire the eight satellites. FIG. 15 is a chart showing a search time comparison between results obtained by the conventional sequential search method and the method in accordance with the present invention. To fix a position, at least four satellites are necessary to be acquired. If the conventional sequential search method is used, 10 searches are necessary to hit four satellites. By using the present invention, the first four satellites can be hit in 7 searches.
While the preferred embodiment of the present invention has been illustrated and described in details, various modifications and alterations can be made by persons skilled in this art. The embodiment of the present invention is therefore described in an illustrative but not in a restrictive sense. It is intended that the present invention should not be limited to the particular forms as illustrated, and that all modifications and alterations which maintain the spirit and realm of the present invention are within the scope as defined in the appended claims.
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A satellite time dynamic search method and a receiver implementing such a method are disclosed. In the present invention, a predetermined period of time is sampled into multiple time samples. The time samples are sieved according to a search result of a satellite selected from candidate satellites each time. By repeatedly doing so, the finally remaining time sample will approach a true satellite system time, and accordingly the candidate satellites converge to the most possible ones as to facilitate satellite search.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Continuation of copending PCT International Application No. PCT/EP2009/066348 filed on Dec. 3, 2009, which designated the United States, and on which priority is claimed under 35 U.S.C. §120. This application also claims priority under 35 U.S.C. §119(e) on U.S. Provisional Application No. 61/119,591, filed on Dec. 3, 2008. The entire contents of each of the above documents is hereby incorporated by reference into the present application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a reprographic system comprising at least one sensor, providing a sensor signal, at least one actuator, responsive to an actuator signal, and a control unit for generating the actuator signal for the at least one actuator in dependence on the sensor signal of the at least one sensor
2. Description of Background Art
In many cases, complex systems such as reprographic systems are required to make trade-offs between important characteristics of the system such as warm-up time, speed, and power consumption. Most of the time these characteristics, further to be indicated as “system characteristics,” are established when the system is designed. However such trade-offs heavily depend on the environment where the reprographic system eventually will be used. Therefore, it is desirable that the control of the system should adapt the system dynamically. Failure to respond adequately to changing environments might result in the occurrence of faults.
Nowadays, current controllers for reprographic machines are not able to adapt to various circumstances. Most of the time, another controller for that circumstance is needed to cope with other circumstances.
Adaptive control as such is known in the art. In this respect, adaptability is defined as a dynamic in-product trade-off between characteristics of the system at system level.
Several approaches to realize adaptive control exist. According to a first approach, Model Reference Adaptive Control (MRAC) uses a reference model that reflects the desired behavior of the system. On the basis of the output of the reference model and the observations, the controller is tuned. A second approach considers a type of adaptive controllers, so called self-tuning controllers (STC), which estimate the correct parameters of the system based on observations and tunes the control accordingly. In the last few decades, techniques from the area of artificial intelligence (AI), such as rule-based systems, fuzzy logic, neural networks, evolutionary algorithms, etc. have been used in order to predict the right control parameters. A drawback of some of these techniques, such as neural networks, is that such techniques do not provide any insight in why the machine changes its behavior. This is because such models are ‘black-box’ models, which make the diagnostics and explanation of the behavior of a machine cumbersome. Furthermore, rules of fuzzy logic sentences are difficult to obtain and require extensive testing in order to handle all the relevant situations.
It is desirable to be able to realize a controller for a reprographic machine that is adaptive.
SUMMARY OF THE INVENTION
In order to overcome the problems of the background art, a reprographic system according to the present invention is improved in that the control unit comprises a signal processing module for generating the actuator signal based on at least one sensor signal with involvement of a probabilistic network.
In the case of printing, system-wide qualities include the distribution of power over various parts of the printer, the speed of printing, the energy usage, etc. The inventors found out that there are two characteristics of such problems. First, decisions are typically required at a low frequency, i.e., it is not necessary and even undesirable to change the speed or energy usage many times per second. Second, there is a lot of uncertainty involved when making decisions, in particular about the environment and the state of the machine, but also about the exact dynamics of the system. Probabilistic reasoning approaches such as Bayesian networks seem therefore appropriate.
The behavior of system components and their relationships can be expressed using graphical probabilistic models that succinctly represent joint probability distributions. With relatively simple and understandable models, it becomes possible to reason about component observations, actions and their relations.
The present invention is related to the use of probabilistic estimators for machine control, in particular for engine control for a printer. This is done by setting up a probabilistic model, training the model with realistic data and using the model for control.
Usage of these kind of models is advantageous, since it allows to derive control rules in a probabilistic manner: control as close to a certain value as possible, or control such that the control value crosses in less than x % a certain threshold. It provides a control that by its nature is able to adapt to various circumstances.
In a next embodiment, the probabilistic network is a Bayesian network.
Bayesian networks have been around for a while, and have seen a remarkable rise in their popularity within the scientific community during the past decade. Researchers from various application areas such as psychology, biomedicine and finance have applied these techniques successfully. In the area of control engineering, little research has been done in order to apply these techniques. We believe that these techniques may be useful when system-wide decisions have to be made during runtime, e.g., when the system has to dynamically adapt itself to the environment. Often, it is not feasible to explicitly model the underlying physical model of the complete system, but a model might be learned from data. Controllers based on Bayesian networks have not been investigated extensively.
According to the present invention, Bayesian networks are used to tune parameters of controllers of the system, which is applied to an adaptive control of a part of a printing system.
One advantage of Bayesian networks is that it contains a qualitative part, which can be constructed using expert knowledge, i.e. it is understandable. Moreover, the quantitative part of a Bayesian network can be learned from data, which makes it possible to calculate the desired control signal. Also, the availability of probabilities makes it possible to control the system in such a way that truly undesired states can be avoided with high probability. Productivity improves compared to rule-based systems. Finally, the logic of the controller you get for free.
Applications demonstrated here are in the field of controller stability and robustness, but it can also be used for environment and state recognizers.
Difference with previous stochastic approaches is that there is an underlying domain model, which is understandable. This is particularly important if we would like to use or re-use these models for, for example, diagnostic purposes.
In a next particular embodiment of a reprographic system according to the present invention, the sensor is a temperature sensor for sensing the temperature of a copy sheet and the actuator is a heating component.
For the types of printing systems under consideration, various temperatures during the printing process play an important role. Low-level controllers make sure that the temperature of measurable components can be kept on setpoint. However, due to design and financial considerations, it is not possible to place sensors at all places of interest. According to an aspect of the present invention, by making use of a probabilistic network, it is possible to estimate the right control parameters for a heating component when only one or a few sensors for measuring the temperature of media (paper) that has passed this heating component are available. Clearly, this cannot be done without taking into account uncertainty, such as the environmental temperature, the speed, and the type of paper. In this case, we focus on the latter aspect.
An example of an application for the present invention is the control of paper temperature. When a model is trained with different paper weights and situations, you can derive rules such that your paper will always (e.g. 99% of the cases) be warmer than, e.g. 80° C. Because the behavior of the system is learned, the controller will adapt itself: when the paper is very light weight, it will make sure that the paper temperature is higher such that it can cope with a certain switch to heavy paper, while, when the paper is heavy, it will use less margin. This feature is very effective in minimizing the needed latitude.
In another embodiment of the reprographic system according to the invention, where the system is a printing system, having a printing speed, the sensor is a sensor for determining the power available and the actuator is an actuator for controlling the requested power by controlling the printing speed.
The productivity of printers is limited to the amount of power available, in particular in environments which depend on weak mains. If there is insufficient power available, then setpoints cannot be reached, which causes bad print quality. To overcome this problem, it is either possible to decide to print at lower speeds or to adapt to the available power dynamically. In the section, we explore the latter option by a dynamic speed adjustment using a Bayesian network.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be explained further with reference to the accompanying drawings, wherein:
FIG. 1 shows a reprographic system;
FIG. 2 shows the control unit of the reprographic system;
FIG. 3 shows the topology of a first Bayesian network for control of Temperature;
FIG. 4 shows the operating environment for control of Temperature;
FIG. 5 shows results of the Bayesian controller;
FIG. 6 shows results of an improved Bayesian controller;
FIG. 7 shows the operating environment for optimizing productivity;
FIG. 8 shows the topology of a second Bayesian network for optimizing productivity;
FIG. 9 shows a graph showing distribution of available power; and
FIG. 10 shows a graph showing curves of three Bayesian networks.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic diagram of an environment in which the present invention may be used. The reprographic system 1 as presented here comprises a scanning unit 2 , a printing unit 3 and a control unit 4 .
The scanning unit 2 is provided for scanning an original color document supported on a support material. The scanning unit is provided with a CCD type color image sensor (i.e. a photoelectric conversion device), which converts the reflected light into electric signals corresponding to the primary colors red (R), green (G) and blue (B). A local user interface panel 5 is provided for starting scan and copy operations.
The printing unit 3 is provided for printing digital images on image supports. The printing unit may use any number of printing techniques. It may be a thermal or piezoelectric inkjet printer, a pen plotter, or a press system based on organic photoconductor technology, for instance. In the example shown in FIG. 1 , printing is achieved using an electrophotographic printing process with a transfer belt and a fuse roll. An image is projected on a photosensitive drum, which will be charged accordingly. The image on the drum is provided with toner, and next the image is transferred to a transfer belt and subsequently fused on a paper sheet in a fuse pinch. A local user interface panel 6 is provided with an input mechanism, such as buttons, for selecting a user, a job and for starting a printing operation, etc.
The scanning unit 2 and the printing unit 3 are both connected to the control unit 4 . The control unit 4 executes various tasks such as receiving input data from the scanning unit 2 , handling and scheduling the submitted data files, controlling the scanning unit 2 and the printing unit 3 , and converting image data into printable data, etc. The control unit is provided with a user interface panel 7 for offering the operator an extensive menu of commands for executing tasks and making settings.
Moreover, the control unit is connected to a network 8 so that a number of client computers 9 , also connected to the network, may make use of the reprographic system 1 .
The reprographic system is depicted in FIG. 1 as three distinct apparatuses: scanner, printer and control unit, however, it is equally possible to combine these three components into one reprographic apparatus.
The control unit is in more detail presented in FIG. 2 . As shown in FIG. 2 , the control unit 4 of the reprographic system 1 comprises a Central Processing Unit (CPU) 40 , a Random Access Memory (RAM) 48 , a Read Only Memory (ROM) 60 , a network card 46 , an interface card 47 , a hard disk (HD) 50 , an image processing unit 54 (such as a Raster Image Processor or RIP) and a signal processing unit 55 . The aforementioned units are interconnected through a bus system 42 .
The CPU 40 controls the respective units of the control unit 4 , the local user interface 7 , scanning unit 2 and the printing unit engine 3 , in accordance with control programs stored on the ROM 60 or on the HD 50 .
The ROM 60 stores programs and data such as a boot program, a set-up program, various set-up data or the like, which are to be read out and executed by the CPU 40 .
The hard disk 50 is an example of a storage unit for storing and saving programs and data, which make the CPU 40 execute a print process to be described later. The hard disk 50 also comprises an area for saving the data of externally submitted print jobs. The programs and data on the HD 50 are read out onto the RAM 48 by the CPU 40 as needed. The RAM 48 has an area for temporarily storing the programs and data read out from the ROM 60 and HD 50 by the CPU 40 , and a work area, which is used by the CPU 40 to execute various processes.
Interface card 47 connects the control unit to scanning unit 2 and printing unit 3 .
Network card 46 connects the control unit 4 to the network 8 and is designed to provide communication with the workstations 9 , and with other devices reachable via the network.
The signal processing unit 55 may be implemented either as a software component of an operating system running on the control unit 52 or as a firmware program executed on the CPU 40 .
The internals of the signal processing module will be elaborated in relationship to the description of the embodiments.
Basic modes of operation for the reprographic system are scanning, copying and printing.
With the electric signals corresponding to the primary colors red (R), green (G) and blue (B) obtained during scanning, a digital image is assembled in the form of a raster image file. A raster image file is generally defined to be a rectangular array of regularly sampled values, known as pixels. Each pixel (picture element) has one or more numbers associated with it, generally specifying a color, which the pixel should be displayed in. The representation of an image may have each pixel specified by three 8 bit (24 bits total) colorimetric values (ranging from 0-255) defining the amount of R, G, and B, respectively, in each pixel. In the right proportions, R, G, and B can be combined to form black, white, 254 shades of grey, and a vast array of colors (about 16 million). The digital image obtained by the scanning unit 2 may be stored on a memory of the controller 6 and be handled according to a copy path, wherein the image is printed by the print engine 4 .
Alternatively, the digital image may be transferred from the controller to a client computer 9 (scan-to-file path).
Finally a user of the client computer 9 may decide to print a digital image, which reflects the printing mode of operation of the system.
According to an aspect of the present invention, the signal processing unit that controls system characteristics of the reprographic system uses a Bayesian network to determine actuator signals based on incoming sensor signals.
A Bayesian network B=(X,G, P) consists of a directed acyclic graph G=(V,E) where Visa set of vertices {v 1 , . . . , vn} and E ⊂ V×V is a set of directed arcs; the set X is a set of (discrete) random variables that correspond one-to-one with the vertices of G, i.e., each vertex v corresponds exactly with one random variable Xv; P is a set of conditional probability distributions containing one distribution, P(Xv|Xπc(v)), for each random variable Xε2 X, where π (v) is the set of parents of v in the graph G.
A Bayesian network encodes a joint probability distribution over the set of random variables X, which can be calculated by multiplying the conditional probabilities, i.e.,:
P
(
X
)
=
∏
v
∈
V
P
(
X
v
|
X
π
(
v
)
)
Bayesian networks can encode various probability distributions. Most often the variables are either all discrete or all continuous. Hybrid Bayesian networks, however, contain both discrete and continuous conditional probability distributions. A commonly used type of hybrid Bayesian network is the conditional linear Gaussian model. Efficient exact and approximate algorithms have been developed to infer probabilities from such networks.
A Bayesian network can be constructed with the help of one or more domain experts. However, building Bayesian networks using expert knowledge, although by now known to be feasible for some domains, can be very tedious and time consuming. Learning a Bayesian network from data is also possible, a task which can be separated into two subtasks: (1) structure learning, i.e., identifying the topology of the network, and (2) parameter learning, i.e., determining the associated joint probability distribution for a given network topology. According to the present invention, we employ parameter learning. This is typically done by computing the maximum likelihood estimates of the parameters, i.e., the conditional probability distributions, associated with the networks structure given data.
A dynamic Bayesian network is a Bayesian network where the vertices of the graph are indexed with (discrete) time slices. Each time slice consists of a static Bayesian network, and the time slices are linked to represent the relationships between states in time.
According to the present invention, the topology of a Bayesian network is established a priori during the design phase of the reprographic apparatus for each characteristic of the apparatus where adaptability is required.
In a next step according to the present invention, parameter learning takes place. For the embodiments presented here, this is also carried out during the design of the apparatus. Heretofore, the targeted hardware is modeled, and this model is used to infer the associated joint probability distribution for the given network topology. It is remarked, however, that this latter step is carried out at runtime when the reprographic system is actually in use.
The topology and the probability distribution data obtained are stored on the hard disk of the control unit, and will be invoked at the moment the signal processing unit is required to act according to the invention.
Next, a first particular embodiment is presented where an optimal setpoint for a heater is generated.
In a probabilistic model, the available power for heating the paper, the temporal properties of heating components, different paper weights, minimum temperature requirements for high quality prints, and the basic process speed, have been related.
Subsequently, this model is applied to construct a controller that regulates setpoints (e.g. of a heater component) on the basis of some observables (e.g. temperatures) and other properties which are unknown (e.g. paper glossiness) but probabilistically related.
This simple approach leads to controllers with some surprising characteristics and features.
As an example, a controller target can be either stated as “keep the temperature as close as possible to a certain value” or as “regulate the temperature such that its probability to decrease to a certain value is less than x %.” The second option leads to a kind of smart buffer behavior: for light paper, the temperature is regulated at a higher set point in order to account for the possibility that heavier paper will arrive.
Such behavior can be built into a rule-based controller as well, after the designer has become aware of this fact. In the probabilistic model-based controller, this behavior follows automatically from the system knowledge that is captured in the model itself.
The qualitative structure of the domain, and the topology of the network, has been elicited from the domain experts. For the purpose of clarity, we focus on certain relevant parts of the complete network dealing with the specific problem of determining the correct setpoint of the heater. The structure of the domain consisting of two time slices is presented in FIG. 3 . FIG. 4 shows the operative environment for this control. The associated random variables for this network have been modeled as discrete variables by discretizing the values to typical values that can be found during simulation. The setpoint variables have a domain size of 12; media (e.g. paper) temperature has a domain size of 16, and we consider three paper types: 80, 120 or 160 grams paper. In order to acquire data and to test the system, a physical model of the system will be created, e.g. by using Simulink. The data that will be generated in this way is used to learn the conditional distributions of the model by calculating the parameters associated to the qualitative structure of the Bayesian network. In the operating environment depicted in FIG. 4 , the signal processing unit controls the setpoint for the heater. As input, it uses the temperature of the heater obtained from a sensor at the heater, and paper weight obtained from the job definition of the print job that is actually carried out. The signal processing unit according to the present invention, making use of a Bayesian network, is used to control the setpoint of this controller. For this we consider 2 time slices, one describing the current situation and the next used to reason about the next situation, i.e., we take a joint probability distribution:
P(Setpoint 0 ,HeaterTemp 0 ,PaperTemp 0 ,PaperWeight 0 ,SetPoint 1 ,HeaterTemp 1 ,PaperTemp 1 ,PaperWeight 1 )
The objective is to keep the paper temperature on setpoint. The goal is then to decide the next setpoint, such that the temperature of the paper will be at a setpoint of 66° C., based on the measurement of the temperature T and the current setpoint SP. Specifically, we calculate:
SP
*
=
arg
max
︸
SP
′
∈
dom
(
Setpoint
1
)
P
(
PaperTemp
=
66
|
Setpoint
1
=
SP
′
,
Setpoint
0
=
SP
,
PaperTemp
0
=
T
)
Due to the fact that we take a simplified Bayesian network, i.e., variables are independent of their history given the immediate history, this may lead to undesired effects. For example, increasing the setpoint of the heater controller will lead to a higher setpoint, but low temperature, as it takes some time for the heater to become effective. The conclusion may be that the setpoint needs to be increased even further for the desired temperature to be reached, i.e., the interpretation of the situation is wrong. There are several solutions for this problem. Thus in an improved embodiment, the probablisitic network is extended to incorporate additional evidence of earlier states. In the alternative, it is possible to sample less, i.e., by waiting for the system to return to a steady state. One simple heuristic that proved to be very successful in this situation is to avoid making decisions when the interpretation is uncertain, i.e., by:
max ︸ W ∈ dom ( PaperWeight 0 ) P ( PaperWeight 0 = W | Setpoint 0 = SP , PaperTemp 0 = T ) < k
where k is some tuning constant less than 1.
The results of a Bayesian controller are presented in FIG. 5 (with k=0.9). Note that there is some amount of noise of the temperature of the paper, since this noise is not controlled in the adaptive control setting. This noise was added to the model to account for various uncertainties such as measurement errors. Clearly, such noise has no impact on the actual paper temperature.
The embodiment shown is rather straightforward. It is noted that the invention is in particular suited for more complex controllers, where traditional control theory starts to become more difficult. One example we discuss in the next section.
The embodiment presented so far is still limited in that if we try to keep the paper at the minimum temperature, temperatures may drop below this value in certain situations, e.g. when the media changes. As mentioned before, in order to get high quality prints, it is of importance to have a certain amount of heat at any time. This could lead to a system fault. One solution is to put the setpoint at a higher temperature which provides a buffer for the media changes; however, if it is unnecessarily high, energy is lost and may cause problems at other parts of the printing process.
To cater for the above in a further improved embodiment also a lowest temperature is put as a probability constraint on the control signal. In this case, we are interested in the lowest temperature that ensures that we avoid dropping below 66° C. Formally, to decide on the next setpoint, we calculate the minimum SP′ such that:
∑
T
∈
{
50
,
…
,
64
}
P
(
PaperTemp
1
=
T
|
Setpoint
1
=
SP
′
,
Setpoint
0
=
SP
,
PaperTemp
0
=
T
)
<
0.01
The result can be found in FIG. 6 . What is interesting here is that the heater temperature is relatively high when the paper weight is lower. This is because the system anticipates on paper that might arrive with a high paper weight, as this high paper weight causes a sudden large drop in temperature. This type of logic could be modeled by any system; however, it is interesting to see here that this is implicit in the probability distribution that has been learned from data.
The effect is that in order to get high quality prints, a certain amount of heat is available at any time.
A next particular embodiment is presented now that aims at optimizing productivity in environments with weak mains.
The productivity of printers is limited to the amount of power available, in particular in environments which depend on weak mains. If there is insufficient power available, then setpoints cannot be reached, which causes bad print quality. To overcome this problem, the embodiment presented implements dynamic speed adjustment using a Bayesian network.
The operating environment for this embodiment is shown in FIG. 7 . Shown is a sensor for available power and a sensor for velocity. Motor M drives the photosensitive drum with a velocity v, being the printing speed. The available power is by means of a sensor communicated to the signal processing unit. The requested power is known. This may result in an error. Velocity is controlled to minimize the error. The signal processing unit generates the setpoint for velocity based on the inputs and by making use of a Bayesian network. In this way the requested power is controlled by controlling the printing speed.
The topology of the Bayesian network on each time slice for this embodiment is shown in FIG. 8 . The requested power available is an observable variable that depends on lower-level controllers that aim at maintaining the right setpoint for reaching a good print quality. The error variable is only observable in laboratory situations, and models the deviation of the actual temperature from the ideal temperature. If this error variable exceeds a certain threshold, then the print quality will be below a certain norm. Both velocity and available power influence the power that is or can be requested by the low-level controllers. Furthermore, the combination of the available power and the requested power is a good predictor of the error according to the domain experts. In the embodiment presented, two time slices are used with the interconnections between the available power, which models that the power supply on different time slices is not independent, and requested power, which models the state of the machine that influences the requested power. In order to choose the family of distributions, the variables are modeled as Gaussian variables. This is reasonable as most variables are normally distributed, except for the available power (see FIG. 9 ). Fitting a Gaussian random variable to such a distribution will typically lead to insufficient performance. However, it can be seen as a sum of two Gaussian distributions, one around 400 W and a second around 1500 W with a small variance. Such a distribution can be modeled using a hybrid network. One of the main reasoning tasks of the network is to estimate the error given a certain velocity and certain observations. We could consider this a classification performance, i.e., the print quality is bad or good. This provides means to compare different models and see how well it performs at distinguishing between these two possibilities. A standard way to visualize and quantify this is by means of an ROC curve, which shows the relation between the false positive ratio and the true positive ratio (sensitivity). The area under the curve is a measure for its classification performance. We have compared three models, i.e., a discrete model, a fully continuous model and a hybrid model for modeling the distribution of the requested power with two Gaussians. The classification performance is then outlined in FIG. 10 . As expected, the fully continuous model performs worse, whereas the hybrid and discrete shows a similar trend. The advantage of the discrete version is that the probability distribution can easily be inspected and it has no underlying assumptions about the distribution, which makes it easier to use in practice. The hybrid version however allows for more efficient computation as we need a large number of discrete to describe the conditional distributions. For this reason, we used the latter in experiments.
In the simulation, the available power is modeled as a random variable with a mean of 600 W and a standard deviation of 200 W. The available power given to the system is sampled from this variable every 100 seconds. Given the information about the power available and requested, i.e., the error information is not available during runtime, the marginal probability distribution of the error in the next time slice is computed. This error is a Gaussian random variable with mean μ and standard deviation σ. For Gaussian variables, more than 99.7% of the real value of the error will be within three standard deviations of the mean. Given a maximum error that we allow τ—in this case we chose 5° C.—we compute the highest velocity v such that the marginal probability distribution of P(Error — 1) is such that μ+3σ<τ, which implies that, P(Error — 1<τ)>99.7%.
It is advantageous that the logic underlying the controller does not have to be designed. Which would be a cumbersome task when adaptability is needed. According to an aspect of the present invention, what is required is a qualitative model, data and a probabilistic criterion that can be inferred.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A probabilistic network, in particular a Bayesion network, is used for control of a printing system in order to realize an adaptable printing system. A reprographic system, includes at least one sensor, providing a sensor signal; at least one actuator, responsive to an actuator signal; and a control unit for generating the actuator signal for the at least one actuator in dependence on the sensor signal of the at least one sensor. The control unit includes a signal processing module configured to generate the actuator signal based on at least one sensor signal with involvement of a probabilistic network.
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CROSS REFERENCE TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to measuring a tire's thickness from within the tire, including thickness of aircraft tires, commercial trucking tires, and tires used in the consumer automotive industry as well as racing. More specifically, the invention relates to an apparatus that is securable to the inside of a tire and a corresponding method for measuring tire thickness, thus allowing for the operator of a vehicle to be alerted about an eminent failure of or the need to replace a failing or failed tire.
2. Description of Related Art
A tire's tread serves to improve contact between the tire and road in wet conditions. Without the grooves of the tread, water on the road surface would be trapped under the tire and cause a loss of friction resulting in hydroplaning. This is an extremely dangerous occurrence wherein braking, cornering, or abruptedly accelerating the vehicle can result in loss of control with potentially fatal results. The tread provides a route for the water to escape from under the tire and allows the tire to more effectively grip the road.
For those applications where treaded tires are used, proper tread depth is important to safely operating the vehicle, but over time the tread wears with increased usage and the tire must eventually be replaced. Failure to timely replace a worn tire can result in a tire blowout, which at high speeds may lead to significant loss of control. Most modern road tires have built-in tread wear indicators in the form of small blocks of rubber molded into the bottoms of the grooves of the tread. When the tread has worn down to where the tops of these blocks are level with the top of the tread, the tire needs to be replaced. Alternatively, a tire tread depth gauge could be used to measure the depth of the remaining tread. Both of these methods require the operator to visually inspect the tire, which is a duty that may be neglected.
But because tire tread reduces the grip on the road by reducing the contact area between the rubber and driving surface, motor racing vehicles such as stock racing cars, open-wheeled racing cars, and dragsters frequently use treadless tires, or “slicks,” to create the greatest amount of friction between the tire and the track. This allows the driver to maintain greater control at high speeds.
For those applications that use treadless tires, such as racing, the thickness of the tire material is equally important as it is for treaded tires. If the tire abnormally wears, or wears regularly but more quickly than expected, the life of the vehicle operator as well as other participants and spectators could be placed in jeopardy due to a tire failure. Accordingly, an apparatus that can measure tire thickness in various applications would aid in preventing blowouts and other tire failures, as well as increase the efficiency and reliability of performing timely maintenance on the tires.
Numerous patents and applications have addressed devices and methods for measuring tread depth. For example, U.S. Published Application 2005/0242935 (the '935 application) presents a detection and warning system wherein a conductive element is embedded in the tire tread at a predetermined level. When the tire is worn to the predetermined level of the conductive element, the conductive element breaks, and the open circuit is detected by a logic element electrically connected to the conductive element. The driver is then alerted to the need for replacing the tire.
Similarly, U.S. Pat. No. 7,095,311 (the '311 patent) presents a coding apparatus that uses a modulated reflectance technology to measure tire tread depth. By placing a thin wire loop into the tire tread at a predetermined level, the loop will be broken when the tread is worn to that level. The broken loop changes the electromagnetic response of the loop, and appropriate circuitry detects the change in frequency response and interprets that change as a certain amount of tread wear.
U.S. Pat. No. 7,119,896 (the '896 patent) also provides a method and system for measuring wear on a tire. The '896 patent discloses a system wherein electromagnetic energy is transmitted into the tire's internal space through a transmission element disposed in the tread. The length of the transmission element changes as the tire tread wears. The amount of energy transmitted into the tire's internal space is a function of the length of the transmission element. The tire tread thickness can then be determined by analyzing the amount of energy that has propagated into the tire's internal space.
U.S. Published Application 2006/0208902 (the '902 application) presents a system wherein at least one radio frequency identification (RF ID) tag is embedded in the tread of a tire. So long as the RF ID tag remains embedded within the tread, an associated RF tag reader located within the tire's inner space detects its presence and can determine that the tread is at least not worn to the known level of the RF ID tag. As the tread wears to the level of the RF ID tag, the RF ID tag is exposed and discarded from the tire and moves outside of the range of the RF tag reader. If the RF tag reader fails to detect an RF ID tag, the system knows that the tire has worn to at least the level of the missing RF ID tag.
Among other disadvantages, each of the aforementioned systems is destroyed or otherwise modified during normal operation such that it cannot be reused. For example, the conductive element of the '935 application cannot be “unbroken”; the wire loop of the '311 patent is permanently broken and cannot be reused. Similarly, the embedded transmission element of the '896 patent cannot be lengthened and reinstalled in another tire, nor can the RF ID tag of the '902 application be recovered and reinserted into a different tire. Moreover, each of the systems disclosed by these applications and patents would have limited use in treadless applications, such as tires used in motor racing, because they are specifically contemplated for use in the tire's tread. Accordingly, a need exists for a reusable apparatus for measuring tire thickness that can be removed from a worn tire and re-installed on a new tire, regardless of whether the tire is treaded or slick.
SUMMARY OF THE INVENTION
The present invention discloses an apparatus and method for measuring tire thickness, and is applicable to all tires, including those used in aircrafts, automobiles, commercial trucking, and racing. The invention comprises a patch securable to a tire inner wall. At least one sensor is disposed within the patch for generating a signal directed radially outwardly from the tire and then sensing a reflection of the signal. Circuitry means electrically connected to the sensor receives a representation of the reflected signal and generates data representative of a distance measurement between the sensor and the reflection point; thus, the data represents the distance between the sensor and the outer surface of the tire. Communication means then accepts the data from the circuitry means and communicates the data to a predetermined location, which is preferably inside the passenger cabin of a corresponding vehicle.
In the preferred embodiment of the present invention, the patch is reusable and programmable/adjustable for the appropriate thickness of the tire to be gauged. Other aspects of the invention include indication means for receiving the data from the communication means and presenting the data in a form from which the amount of current tire thickness may be determined. By comparing the measured tire thickness to the original tire thickness, the amount of wear on the tire and tire material remaining may be calculated, and tire safety characteristics determined.
Yet another aspect of the invention is a tab positioned at the perimeter of the patch for aiding with the removal of the patch from the tire inner wall. After removal, the patch may be re-installed on another tire for use. Moreover, multiple patches may be installed within a single tire to provide additional measurements of the thickness of the tire. The invention further provides for audible as well as visual indication of a potential tire failure.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The present invention, as well as further objects and features thereof, is more clearly and fully set forth in the following description of the preferred embodiment, which should be read with reference to the accompanying drawings, wherein:
FIG. 1 is an elevation of the patch of the present invention;
FIG. 2 discloses a side elevation of the patch along section line 2 - 2 of FIG. 1 ;
FIG. 3 shows the apparatus disposed within the inner space of a tire;
FIG. 4 is a block diagram of the preferred embodiment of present invention;
FIG. 5 and FIG. 6 illustrate the present invention installed in the inner space of a new tire and a worn tire, respectively; and
FIG. 7 is a representation of four preferred indicators of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1 and FIG. 2 , the present invention comprises a patch 20 securable to the inner wall of a tire and that is preferably rubber or a combination of different rubbers that facilitate bonding to the inner wall, but in any event the patch 20 is bondable to an inner wall of a tire with an adhesive. Within the patch 20 is disposed a plurality of sensors 22 a - 22 g , each of which has an emitting side 24 a - 24 g oriented toward a bonding surface 26 of the patch 20 . The emitting side 24 a - 24 g of each sensor 22 a - 22 g is preferably flush with the bonding surface 26 such that the emitting sides 24 a - 24 g contact the inner wall of the tire. Each of the sensors 22 a - 22 g is electrically connected to a wiring harness 29 that allows for further electrical connection to other components of the invention. The bonding surface 26 of the patch 20 is coatable with the adhesive (not shown), which is distributed over the bonding surface 26 so as not to interfere with the emitting sides 24 a - 24 g of the sensors 22 a - 22 g and disrupt distance measurements. A tab 28 positioned at the perimeter of the patch 20 provides an easily grippable location by which one may remove the patch 20 from the inside wall of the tire by gently peeling the patch 20 away from the adhesive.
The sensors 22 a - 22 g described herein are known in the prior art, such as those used for ultrasonic nondestructive testing (NDT). Ultrasonic testing, wherein materials are characterized by means of high-frequency sound waves, is extensively used for quality control applications. In thickness gauging, ultrasonic techniques permit quick and reliable measurement of thickness without requiring access to both sides of a part, which is in this case a tire. Ultrasonic thickness gauges usually operate at frequencies between 500 kHz and 100 MHz using piezoelectric transducers to generate bursts of sound waves when excited by electrical pulses. A pulse-echo ultrasonic thickness gauge determines the thickness of a part or structure by accurately measuring the time required for a short ultrasonic pulse generated by a sensor to travel through the thickness of the material, reflect from the back surface, and be returned to the sensor. In most applications this time interval is only a few microseconds or less. The result is expressed in the relationship:
d=Vt/ 2,
where
d=the thickness of the tire,
V=the velocity of sound waves in the tire, and
t=the measured round-trip transit time.
Thus, because V is known (or measurable for a tire), d is readily calculable. See Kenneth A. Fowler, et al., Theory and Application of Precision Ultrasonic Thickness Gaging, which is incorporated herein by reference.
FIG. 3 is a partial sectional view of a wheel assembly 31 having a rim 30 , a tire 32 , and a tube (not shown for simplicity). The tire 32 comprises a tread area 34 and a tread base 36 . A valve stem 38 connected to the tube protrudes through the rim 30 to provide a path for tube inflation. Prior to affixing the tire 32 to the rim, the patch 20 is secured to the tire 32 by removing a protective film (not shown) from the bonding surface 26 to expose the pre-applied adhesive (not shown), and then pressing the patch 20 firmly onto the inside inner wall 40 of the tire 32 . Appropriate adhesives, or rubber bonding agents, are known and readily available. Alternatively, the adhesive may be first applied to the inside inner wall 40 of the tire and the patch 20 then directly pressed thereon. The wiring harness 29 is electrically connected to circuitry means 42 for receiving a representation of the time difference between the generated signal and the reflected signal from the sensors 22 a - 22 g and providing the resulting distance data to a transmitter 44 , which uses the valve stem 38 as an antenna to transmit data to the passenger compartment of the vehicle. U.S. Published Application 2005/0237170 teaches alternative methodologies wherein an antenna is mounted to a tire sidewall, and the present invention may be similarly configured. Alternatively, the antenna may be any variety of suitable antennas such as a wire, a bar, a plate, or the like.
FIG. 4 depicts a block diagram showing the functional operation of the preferred embodiment. The plurality of sensors 22 a - 22 g is electrically connected to circuitry means 42 comprising a first microcontroller 45 , which analyses the representations transmitted from the sensors 22 a - 22 g according to a predefined program. The predefined program selects the minimum distance measurement during any given tire rotation and calculates the tire thickness based on that measurement as described hereinbelow. The tire thickness information is then provided to communication means 46 comprising a wireless transmitter 44 and wireless receiver 50 located remotely and preferably within the passenger compartment of the vehicle. After the tire thickness information is received, the data is transmitted to indication means 52 comprising a second microcontroller 54 and an indicator 56 . While the preferred embodiment utilizes wireless technology to convey the data to the indication means 52 , hardwired technology may also be used wherein a transmitter is coupled to a receiver using a conductive element.
It should further be noted that a number of combinations of these same components may perform the same tasks, which is evident to one having ordinary skill in the electronic arts. For example, the first microcontroller 45 might not perform any analysis of the sensor representations to determine tire thickness, but might simply transmit (and manage the transmission of) the sensor representations to the indication means 52 via the communication means 46 , which may perform the required analysis. Similarly, the indicator 56 of the preferred embodiment is visual (see FIG. 8 ), although an auditory indicator may also be used.
Moreover, while a first microcontroller 45 is used in the preferred embodiment, many alternatives exist, such as programmable logic chips or microprocessors, that may also be used depending on specific application needs. For example, while a single microcontroller may be sufficient to handle data from a single patch 20 comprising of a plurality of sensors 22 a - 22 g , a microprocessor may be used for the increased processing requirements of a plurality of patches secured to a single tire.
As shown in FIG. 5 and FIG. 6 , each of the sensors 22 a - 22 g continuously generates a signal directed radially outwardly from the tire 32 and senses a reflection of the signal to determine a distance D x to the outer surface of the tire 32 . As used herein, D x represents a distance measurement from sensors 22 a - 22 g . Thus, D a corresponds to a distance measurement to the outer surface of the tire 32 —the surface that normally contacts the road—from one sensor 22 a . Similarly, D g represents a distance measurement from a sensor 22 g . Each of the sensors 22 a - 22 g generates a signal and senses a reflected signal from which the distance to the tire 32 outer surface may be determined. Each of the sensors 22 a - 22 g then provides representations of a distance measurement (D a through D g ) to the circuitry means 42 , which in the preferred embodiment includes a first microcontroller 45 (see FIG. 4 ) that analyzes the data as it is received from the sensors 22 a - 22 g . “Continuously” as used herein means without interruption or at some predetermined interval. For example, the data provision may occur once every millisecond, once every ten milliseconds, or at some other predetermined interval sufficient to accurately measure the distance between the emitting sides 24 a - 24 g (see FIG. 2 ) of the sensors 22 a - 22 g and the outer surface of the tire 32 .
More specifically, FIG. 5 particularly illustrates the present invention in operation on a new tire 32 having a tire base 36 of thickness B and an initial tread area 34 of thickness TR new . Similarly, FIG. 6 illustrates the present invention in operation with the same tire base 36 of thickness B and a worn tread area 34 of thickness TR worn . Each of the sensors 22 a - 22 g will determine a corresponding distance D a through D g approximately equal to TR worn plus B. In some applications, greater emphasis may be placed on distance measurements from the two sensors 22 a , 22 g positioned closest to the sidewalls of the tire 32 , which may be more vulnerable to blowouts.
While the sensors 22 a - 22 g may be spaced across the width of the inner wall 40 of the tire 32 (see FIG. 5 and FIG. 6 ), the microprocessor, power supply, transmitter and all other components composing the system may be situated anywhere within the tire, including on the sensor patch 20 or on a separate patch adhering to the sidewall of the tire 32 .
It should further be noted that only a certain percentage of the tire's 32 thickness may be worn prior to needing to replace the tire 32 . For example, in FIG. 5 and FIG. 6 above, the simplest model would be to assume that the usable portion of the tire's thickness is equal to the tread thickness. In that case, when the tread thickness TR equals zero, the tire 32 has no more usable thickness—because the tire 32 has no more tread—and the tire 32 must be replaced as the remaining tire material would compose only the base B of the tire 32 . In reality, however, not even the entire tread thickness may be worn before the tire 32 needs replacing, but only a portion of the tread may be worn.
When considering treadless or “slick” tires, again only a portion of the tire thickness is usable. For example, if a new tire's thickness is one inch, perhaps only a half inch may be worn before the tire needs replacing. Thus, a tire thickness of three quarters of an inch represents a tire with fifty percent of its usable thickness depleted. These numbers are exemplary and highly dependent on individual tire characteristics and applications needs. For example, a commercial trucking tire will be much larger (and thicker) than a tire designed for a compact consumer automobile. Similarly, the characteristics (and safety parameters) of an aircraft tire will be much different than those of a stock racing car or a dragster.
FIG. 7 depicts an exemplary dashboard display configuration 64 comprising a first indicator 66 , second indicator 68 , third indicator 70 , and fourth indicator 72 , each of which corresponds to a tire on a typical four-wheeled vehicle. The first indicator 66 , designated “FL” (meaning “front left”), and the second indicator 68 , designated “FR” (meaning “front right”) represent that the corresponding tires have fifty percent of their usable thickness remaining. The first indicator 66 and second indicator 68 further advise that the tire should be replaced by illuminating the word “Replace,” and flashing to draw the driver's attention to the indicators 66 , 68 . The third indicator 70 and fourth indicator 72 correspond to the rear left and rear right tires of the vehicle respectively. The third indicator 70 indicates that seventy-five percent of the tire's usable thickness remains, and that the tire condition is “Good.” Similarly, the fourth indicator 72 indicates that one-hundred percent of the tire's usable thickness remains—in other words, the corresponding tire is for all intents and purposes new—and that the tire condition is “Good.”
It should be noted that the indicator of the present invention is not limited to any particular form or increment of measure. The apparatus is capable of measuring very small increments of tire thickness, and the usable thickness remaining could be represented in any form sufficient to convey the information to the vehicle operator. For example, in racing applications, the vehicle operator or maintainer may desire to monitor the tires' usable thickness to a degree of one percentage point, thus allowing more accurate measurement not only of usable thickness but of the rate of change of usable thickness. Moreover, in alternative embodiments, these indicators 66 , 68 , 70 , 72 could also comprise an audible warning chime to alert the driver or maintainer that a tire needs repair or replacement. The indicators 66 , 68 , 70 , 72 may be made from any of the standard types of dashboard display technologies, including LEDs, liquid crystal displays, dials, and gauges. In alternative embodiments, the indicators 66 , 68 , 70 , 72 may be auditory, or some combination of an auditory indicator with a visual indicator.
It should further be noted that, prior to operation, the apparatus must either be calibrated for the specific tire characteristics (i.e., tire thickness, tire base, tread depth, etc.) or the known tire characteristics programmed into the circuitry means 42 (see FIGS. 4 , 5 , and 6 ). This may be done by performing a calibration procedure that is part of the predefined program when the apparatus is installed or by altering the predefined program to account for the values of these characteristics.
The present invention is described above in terms of a preferred illustrative embodiment of a specifically described apparatus and method for measuring tire thickness, as well as alternative embodiments of the present invention. Those skilled in the art will recognize that alternative constructions of such an apparatus can be used in carrying out the present invention. For example, while the present invention is described specifically in FIG. 5 and FIG. 6 with regard to a preferred embodiment that measures tire thickness of a treaded tire, the invention is equally adept at measuring tire thickness of racing, or “slick,” tires, as described herein. Other aspects, features, and advantages of the present invention may be obtained from a study of this disclosure and the drawings, along with the appended claims.
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A reusable patch adhesively bondable to the inside of a tire. Disposed within the patch is at least one sensor that generates a radially outwardly directed signal and senses a reflection thereof from the tire's outer surface. Circuitry means is connected to the receiver for receiving data representative of the original and reflected signal and calculating a distance measurement representative of the distance between the sensor and the reflection point. Communication means then transmits the appropriate data to indication means, which triggers an indicator to alert the driver of a tire failure or potential tire failure.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of copending application Ser. No. 825,259 filed Feb. 3, 1986, now Pat. No. 4,676,956 which in turn is a continuation-in-part of Paul J. The et al U.S. patent application Ser. No. 816,242, filed Jan. 6, 1986 now U.S. Pat. No. 4,678,477.
FIELD OF THE INVENTION
This invention relates to an improved process for lowering impurities in Bayer liquor. More particularly, it relates to production of higher quality aluminum hydroxide with improved color characteristics.
BACKGROUND OF THE INVENTION
The recovery of aluminum hydroxide from bauxite and similar alumina-bearing materials according to the Bayer process is achieved by digesting the ore with caustic liquor. The major portion of the alumina values are dissolved by the liquor, and the major portion of the unwanted ore constituents remain undissolved, making it separable from the liquor. The undissolved constituent is often referred to as "red mud". After pressure digestion of bauxite with caustic liquor, the red mud is removed from the sodium aluminate liquor by decantation and filtration, and the aluminum hydroxide is separated from the supersaturated sodium aluminate liquor, known as "green" or "pregnant" liquor, by precipitation. During the precipitation process, the supersaturated sodium aluminate liquor is cooled and mixed with a slurry of fine aluminum hydroxide which acts as seed to induce formation of its own species. Following the precipitation period, the slurry is pumped through a classification system. The coarse fraction of the crystallized aluminum hydroxide is separated from the sodium aluminate liquor and the resulting spent sodium aluminate liquor is recycled to be mixed with incoming bauxite in the digester.
High levels of impurities are undesirable in the "green" liquor used to produce aluminum hydroxide. Impurities decrease the whiteness or color purity of the aluminum hydroxide and, therefore, it is desirable to minimize those impurities in green sodium aluminate liquor before crystallization of aluminum hydroxide takes place. Typically, the impurities result in an aluminum hydroxide product having a whiteness of lower than 70% which greatly affects its use in commercial products where a high level of whiteness is required. The present invention solves the problem of poor whiteness and is capable of producing an aluminum oxide product having levels of whiteness powder of 90% or more. The whiteness level is relative to TiO 2 which is considered to have a whiteness of 100%.
It is also well known that the presence of organic and inorganic impurities in a caustic sodium aluminate liquor causes process problems, lowers liquor productivity, and reduces the purity of the produced alumina. Difficulties caused by the organic impurities include lowered alumina yield, generation of excessive fine aluminum hydroxide particles, a higher impurity content in the alumina, colored liquor and aluminum hydroxide, lower red mud settling rate, loss of caustic due to formation of sodium organic compounds, increased liquor density, higher viscosity, raising of the boiling point, and foaming of the liquor.
Numerous methods are known for controlling and/or removing the organic material in Bayer process liquor. These include the treatment of the process liquor with sodium hypochlorite or other oxidizing agents such as oxygen or air. For example, German patent document Off. No. 2,945,152 describes a process for removing organic compounds from Bayer liquor by heating the liquor to 120° to 350° C. and introducing oxygen containing gas until a partial pressure of 3 to 30 atmospheres is reached. Inao et al U.S. Pat. No. 4,215,094 discloses a process for removing organic substances by contacting the aluminate solution with molecular oxygen containing gas in the presence of copper ions as a catalyst at an elevated temperature, e.g. 180° to 300° C.
It is also known to remove some impurities in a Bayer liquor by treatment with alkaline earth compounds. Schepers et al U.S. Pat. No. 4,046,855 teaches the treatment of aluminate liquor with a magnesium compound to remove organic materials. Mercier et al U.S. Pat. No. 4,101,629 treats a solution from the Bayer process with a barium compound to remove impurities. German patent document Off. No. 2,415,872 involves the addition of a calcium compound to the process liquor to remove the humic matter as insoluble calcium compounds.
Impurity levels of organic materials such as sodium oxalate have also been removed from sodium aluminate solutions as taught by Lever U.S. Pat. No. 4,275,042 by the use of cationic sequestrants comprising quaternary nitrogen compounds possessing medium and long chain alkyl groups and a single cationic charge. DeLaBretique U.S. Pat. No. 3,457,032 also discloses purification of a strongly alkaline solution such as sodium aluminate solution by treating the solutions with anion exchange resins of strongly basic and macroreticular type which are said to widely eliminate iron, silica, titanium, zinc, and organic acid impurities.
The removal of sodium oxalate from a sodium aluminate spent liquor solution by spraying the concentrated liquor onto a packing material is disclosed by Carruthers et al U.S. Pat. No. 4,038,039. Bush et al U.S. Pat. No. 4,496,524 teaches the removal of sodium oxalate from a sodium aluminate spent liquor by treatment with ethanol to cause the sodium oxalate to precipitate.
Yamada et al U.S. Pat. No. 4,280,987 removes carbon compounds from Bayer liquor by adjusting the molar ratio of the aluminum component to the sodium component and then heating the liquor to form sodium aluminate and drive off the carbon compounds as carbon dioxide.
Bird et al U.S. Pat. No. 4,282,191 describes the removal of zinc impurities from a caustic sodium aluminate solution using zinc sulfide seed to cause precipitation of the zinc in the liquor. Columbo et al U.S. Pat. No. 3,295,961 discloses a process for removal of iron impurities from the red mud slurry from a Bayer process by first drying the mud and then heating it to reduce the iron compound to metallic iron which is then separated from the dried mud using magnetic separation. Goheen U.S. Pat. No. 3,729,542 teaches the removal of iron impurities in a sodium aluminate solution by filtering the solution through a bed of iron particulate.
Conventional filtration is also, of course, known in the separation of sodium aluminate solutions from the red mud residue of a Bayer process digestion. For example, Corona U.S. Pat. No. 2,653,716 describes the cleaning of filter cloths used to separate sodium aluminate solutions from red mud.
The use of osmotic type filtration is known in the purification, for example, of water using reverse osmosis. Typical of such apparatus and associated processing are the disclosures in McLain U.S. Pat. Nos. 3,422,008; Coillet 4,161,446; Davis 4,367,132; and Klein et al 4,495,067. However, the purification of a highly caustic solution presents problems not normally encountered when purifying water. By highly caustic solution is meant solution from the Bayer process such as a sodium aluminate solution or caustic solutions having 1 wt. % or greater NaOH concentration or caustic solutions having a pH higher than 10.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a system for purifying caustic solutions such as sodium aluminate solutions by filtration.
It is another object of this invention to provide a system for purifying caustic solutions such as sodium aluminate solutions by membrane ultrafiltration using porous hollow fibers coated with a semipermeable membrane.
It is yet another object of this invention to provide a system for purifying caustic solutions such as sodium aluminate solutions by reverse osmosis using porous hollow fibers coated with a semipermeable membrane wherein both the hollow fibers and the semipermeable membrane are capable of withstanding exposure to a caustic environment.
It is a further object of this invention to provide a system for purifying caustic solutions such as sodium aluminate solutions by reverse osmosis using porous polysulfone hollow fibers coated with a semipermeable sulfonated polysulfone membrane capable of withstanding exposure to a caustic environment.
And yet it is a further object of this invention to provide an aluminum hydroxide having a level of brightness of at least 90% and having lower levels of organic matter.
These and other objects of the invention will become apparent from the following description and accompanying drawings.
In accordance with the invention, there is disclosed a process for producing an improved aluminum hydroxide product having an improved level of whiteness. The process comprises the steps of subjecting a caustic solution containing dissolved aluminum hydroxide to a purification step to remove dissolved impurities including color producing humate material therefrom, the purification including passing the solution through a semi-permeable membrane capable of separating the humate material from the solution. After separation, the purified solution is treated to precipitate aluminum hydroxide therefrom. The aluminum hydroxide has an improved level of whiteness. Other impurities which can be removed include iron, silicon and sodium compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing one embodiment of the invention.
FIG. 2 is a diagram illustrating another embodiment of the invention.
FIG. 3 is a graph showing the effect of pressure on filtration.
FIG. 4 is a flow sheet illustrating the system of the invention.
FIG. 5 is a flow diagram illustrating steps for producing whiter aluminum hydroxide.
DETAILED DESCRIPTION OF THE INVENTION
As illustrated in the flow sheet in FIG. 4, in accordance with the invention, a caustic solution such as a solution of Bayer liquor which comprises sodium aluminate dissolved in caustic, may be purified by bringing the solution into contact, under pressure, with a filtration medium comprising a semipermeable membrane to separate the impurities from the solution. For purposes of the present invention, the membrane must be inert with respect to highly caustic solutions.
Referring now to FIG. 1, Bayer spent liquor, i.e., a caustic sodium aluminate liquor from a Bayer process after initial precipitation, is shown at 2 inside a pressure vessel 10 which is maintained under pressure from a source of pressurized gas 4 such as a nitrogen source. The liquor is preferably maintained at a temperature above room temperature and is kept agitated by stirrer means 12. The heated and pressurized liquor is fed to an entrance port 22 in a filter module 20 through flow meter 15, valve 16 and pressure gauge 18 via line 14. The liquor is filtered in filter module 20 to provide a purified permeate which exits filter module 20 via permeate exit port 28 to line 30 and is collected in vessel 32. The unfiltered concentrate exits module 20 via concentrate exit port 24 to line 36 where it passes into reservoir 40 through valve 38.
The filter medium in filter module 20 comprises a plurality of porous hollow polysulfone fibers or tubes which have been coated with a sulfonated polysulfone coating to form a semipermeable membrane. The coated fibers within filter module 20 may comprise an annulus of helically wound porous hollow fibers. At least one end of all or most of the hollow fibers is open and these open ends are directed toward a portion of filter module 20 spaced apart from entrance port 22 and concentrate exit port 24. The purified liquid is then collected from these open ends of the porous fibers adjacent permeate exit port 28.
Construction details for filter modules of this type are generally described in U.S. Pat. Nos. 4,045,85: 4,207,192; 4,210,536; 4,220,489; 4,267,630; and 4,351,092; cross-reference to which is hereby made. Sulfonated polysulfone materials which may be used in forming the semipermeable membrane coating on the porous hollow fibers are described in U.S. Pat. Nos. 4,413,106 and 4,508,852; cross-reference to which is hereby made. While reference has been made herein to sulfonated polysulfone materials for forming semi-permeable membranes, it will be understood that other membranes may be used which are inert to the highly caustic solutions and which provide satisfactory separation.
The pressure under which the liquor should be maintained during the filtration step preferably ranges from about 34 to 1380 kPa (5 to 200 psig), although higher pressures may be used and should be deemed to be within the scope of the practice of the invention. The temperature at which the liquor is maintained during filtration should preferably range from around 35° to 100° C. (95° to 212° F.), preferably about 72° C. (162° F.).
While the process diagram of FIG. 1 illustrates the system of the invention as operated on a batch basis, the system advantageously, may be operated continuously as shown in FIG. 2. In FIG. 2, the Bayer spent liquor 2 in vessel 10 is pumped to filter module 20 by a pump 44 through line 62 while the flow is monitored by flow meter 15. The permeate discharged from module 20 via exit port 28 flows via line 58 through valve 52 to vessel 32 while the pressure of the flow is monitored by pressure gauge 50. The permeate may be returned to the Bayer process or otherwise utilized by removing the permeate from vessel 32 via line 68 through valve 72.
In this embodiment, pump 44 maintains the desired pressure on the filter membranes in filter module 20. The concentrate leaves module 20 via exit port 24 and line 64 to pass through flow meter 56 and valve 48. Pressure in line 64 is monitored by pressure gauge 18. Line 64 joins with liquor input line 66 to feed liquor back to vessel 10 via line 60. Additional liquor from a liquor precipitation stage or the like may thus be fed in via line 66 and valve 70, if desired, to be blended with the recycle stream of liquor concentrate in line 64. The temperature of the liquor is maintained in vessel 10 via heating means 80.
To illustrate the effectiveness of the system of the invention, several types of Bayer liquor were purified by the system shown in FIG. 3 using, respectively three different filter membranes of varying permeability. The results of the tests are shown in Tables 1 and 2. Filtration rate data with respect to pressure is shown in the graph of FIG. 3. In each test, feed and permeate liquor sample were collected and analyzed for alumina, total caustic soda (TC), total alkali (TA), organic carbon, sodium oxalate, iron, silica, and liquor color.
The organic carbon and sodium oxalate concentrations of the liquor were analyzed using an Astro organic carbon analyzer Model 1850 and an ion chromatograph, respectively. Liquor color was measured by light transmission of 1:10 diluted samples at a wavelength of 435 nm. A reference of 100% for distilled water was used for comparison. Liquor color measurement was also conducted on undiluted samples at 691 nm. The decrease of the humate concentration in the liquor can be observed by the change in the color of the permeate. Equivalent humate concentration was measured by the liquor color at 691 nm and was directly correlated to the color of a standard humate solution in caustic liquor.
As shown in Table 1, it was discovered that for liquor type "A", depending upon the permeability of the membrane, a decrease of the humate concentration of the permeate was observed as can be shown by the increase of the percentage of light transmission, measured at 691 nm, of from 82.6 up to 99.1%. This decrease was also measured by the increase in light transmission at 435 nm, of from 27.6 up to 80.3% with reference to 100% of distilled water. This translates to a decrease in humate concentration of 0.12 down to 0.01 gram/liter (g/l). In addition, organic carbon concentration was also lowered from 14.4 down to 9.1 g/l and sodium oxalate from 3.4 down to 1.1 g/l. For the less permeable membrane, it was observed that sodium carbonate and silicon dioxide were lowered, respectively, from 53 and 0.61 g/l to 49.9 and 0.33 g/l. Iron oxide was also slightly reduced from 0.005 to 0.004 g/l.
TABLE I__________________________________________________________________________Membrane Ultrafiltration of Bayer Liquor "A" at 72° C. Start Membrane I Membrane II Membrane III Liquor Permeate Corr..sup.1 Permeate Corr..sup.1 Permeate Corr..sup.1__________________________________________________________________________Al.sub.2 O.sub.3 g/l 80.7 82.3 76.2 82.4 76.3 82.7 79.7TC g/l 189.7 204.8 189.7 202.4 189.7 196.6 189.7TA g/l 242.7 254.4 235.6 255.7 239.6 253.1 244.2SiO.sub.2 g/l 0.61 0.37 0.34 0.35 0.33 0.52 0.50Fe.sub.2 O.sub.3 g/l 0.005 0.004 0.004 0.004 0.004 0.004 0.004Org. Carb. 14.4 9.8 9.1 10.4 9.7 13.6 13.1g/lNa.sub.2 CO.sub.3 g/l 53.0 49.6 45.9 53.3 49.9 56.5 54.5Na.sub.2 C.sub.2 O.sub.4 g/l 3.4 1.2 1.1 1.5 1.4 3.1 3.0Humate g/l 0.12 0.01 -- 0.01 -- 0.02 --A/TC 0.425 0.402 0.402 0.407 0.402 0.421 0.420% Transmission435 nm 27.6 80.3 -- 76.3 -- 52.1 --691 nm 82.6 98.2 -- 99.1 -- 97.0 --Press. psig -- 200 -- 200 -- 150 --Filt. Rate -- 4.9 × 10.sup.-2 -- 12.2 × 10.sup.-2 -- 44.1 × 10.sup.-2 --gal/sq ft/hr__________________________________________________________________________ .sup.1 corrected value to the same caustic concentration of starting liquor
The results obtained when filtering liquor type "B" are shown in Table 2. The humate concentration of the permeate in this instance was lowered as measured by the light transmission at 691 nm to provide an increase in light transmission of from 42.3 up to 98.4% and from 7.0 to 79.5% of the 1:10 diluted liquor samples measured at 435 nm. This corresponds to a drop in the humate concentration from 0.64 down to 0.01 g/l. Organic carbon concentration was lowered from 5.2 down to 2.1 g/l.
TABLE II__________________________________________________________________________Membrane Ultrafiltration of Bayer Liquor "B" at 72° C. Start Membrane I Membrane II Membrane III Liquor Permeate Corr..sup.1 Permeate Corr..sup.1 Permeate Corr..sup.1__________________________________________________________________________Al.sub.2 O.sub.3 g/l 42.7 42.1 40.2 42.1 40.2 42.9 42.1TC g/l 141.0 147.7 141.0 147.7 141.0 143.8 141.0TA g/l 203.8 201.5 192.3 207.1 197.7 207.1 203.1SiO.sub.2 g/l 0.29 0.31 0.29 0.29 0.29 0.29 0.28Fe.sub.2 O.sub.3 g/l 0.004 0.004 0.004 0.004 0.004 0.004 0.004Org. Carb. 5.2 2.2 2.1 2.4 2.3 3.6 3.5g/lNa.sub.2 CO.sub.3 g/l 62.8 53.8 51.3 59.4 56.7 63.3 62.1Na.sub.2 C.sub.2 O.sub.4 g/l 2.9 2.6 2.5 2.9 2.8 3.0 2.9Humate g/l 0.64 0.01 -- 0.03 -- 0.05 --A/TC 0.302 0.285 0.285 0.285 0.285 0.298 0.298% Transmission435 nm 7.0 79.5 -- 77.0 -- 43.8 --691 nm 42.3 98.4 -- 95.3 -- 91.5 --Press. psig -- 200 -- 200 -- 200 --Filt. Rate -- 15.9 × 10.sup.-2 -- 28.1 × 10.sup.-2 -- 122.5 × 10.sup.-2 --gal/sq ft/hr__________________________________________________________________________ .sup.1 corrected value to the same caustic concentration of starting liquor
The effect of pressure on the filtration rate is shown for both Membrane II and Membrane III in FIG. 3. It will be noted that the filtration rate goes up for both membranes but rises more rapidly with pressure for the more porous Membrane III than Membrane II.
Reference is now made to FIG. 5 for purposes of illustrating a method for producing aluminum hydroxide having improved whiteness.
In FIG. 5, Bayer spent liquor with the composition shown in Table III was fed to a digester to digest bauxite which had the analysis shown in Table IV. The bauxite used is characterized with low silica and iron contents with total sulfur of 0.32%, total carbon and total organic carbon of respectively 0.57 and 0.35%. It contained also siderite, and iron carbonate compound. This type of bauxite produces aluminum hydroxide with high iron content as a result of siderite and sulfur compounds. It has been reported in the literature that during digestion, the siderite reacts with caustic soda to form finely colloidal ferrous hydroxide particles which are very difficult to remove by the conventional Bayer filtration technique.
Digestion was conducted at 143° C. for 30 minutes. After digestion, the slurry was discharged to a blow-off tank. Sufficient amount of starch or synthetic flocculant was added to the blow-off slurry to promote the settling of red mud. Overflow liquor was then separated from the settled mud. Calcium filter aid in the amount of 1 g/L as CaO was added to the overflow liquor. The slurry was then filtered using No. 4 Whatman paper. The resulting filtered green liquor was adjusted to precipitation temperature, seeded with sufficient amount of dry aluminum hydroxide seed, and precipitated in a Bayer precipitator tank for 24 hours at a constant temperature of 74° C. Aluminum hydroxide was filtered using No. 42 Whatman paper, washed with sufficient amount of distilled water, dried, weighed and submitted for Inductively Coupled Plasma, microtrac and hydrate brightness analyses. To demonstrate the benefit of the membrane filtration technique, a portion of the filtered green liquor from the overflow liquor tank was fed to the membrane module at a pressure of 1380 kPa (200 psig). The membrane module comprised of porous hollow polysulfone fibers coated with semipermeable sulfonated polysulfone membrane. Liquor temperature was maintained at about 75° C. The permeate green liquor from the membrane module was treated for precipitation in the white precipitator tank with the same precipitation conditions as described above.
Organic carbon concentration in the filtered green liquors was analyzed using Astro organic carbon analyzer. Liquor color was measured using Bausch & Lomb Spectronic-2000 spectrophotometer. Measurement was conducted by the light absorbance at a wave length of 691 nm. The change of the equivalent humate concentration of the liquor can be observed by the change in liquor color and was directly correlated to the color of a standard humate solution in caustic liquor. The results of the experiments are tabulated in Table V.
As shown in Table V, membrane filtration of green liquor produced a permeate with low color as indicated by the light absorbance at 691 nm of 0.010 compared to 0.46 of the control run. This translates to a decrease in equivalent humate concentration from 0.67 to 0.01 g/L. The purified green liquor produced aluminum hydroxide with a brightness of 91.6% compared to 72.4% of the control. In addition, the corresponding Fe 2 O 3 , SiO 2 , CaO and Na 2 O contents were significantly lowered from 0.060, 0.008, 0.018 and 0.36% to respectively, 0.026, 0.001, 0.012 and 0.17% on calcined basis. Particle size of the product aluminum hydroxide, shown by the particles finer than 38 micrometers, were not significantly different. Alumina yield produced by the permeate was slightly lower due to the slight decrease in alumina to caustic soda weight ratio in the green liquor. It seems that a small amount of alumina was rejected during the membrane filtration.
The results of membrane filtration of green liquor obtained by digesting either bauxite or impure aluminum hydroxide in organic free synthetic sodium aluminate liquor are presented in Table VI. The experiments were performed with the objective to determine the effect of recycling the purified spent liquor, which was simulated by an organic free synthetic sodium aluminate liquor. In this case, the overflow liquors were treated with additional 2 g/L MgO, in an attempt to further lower the iron in liquor.
In the first set of experiments, the green liquor was prepared by digesting bauxite with the composition shown in Table IV. The color of the permeate was improved from a light absorbance at 691 nm of 0.059 to 0.001, which translates to a drop in equivalent humate concentration from 0.1 g/L to almost neglibible. The permeate produced brighter aluminum hydroxide of 93.5% brightness compared to 85.2% of the control run. Fe 2 O 3 , SiO 2 , CaO and Na 2 O were correspondingly decreased to respectively, 0.021, 0.003, 0.011 and 0.26% on calcined basis. For the second set of expermiments, the green liquor was obtained by digesting impure aluminum hydroxide with impurities shown in Table VII and organic free synthetic liquor. In this case, liquor color measurement at 691 nm show no difference between permeate and control liquor. For both liquors, they measured at 0.001, which corresponds to negligible humate concentration. However, liquor absorbance determined at 435 nm indicated low color of permeate of 0.007 compared to 0.045 of the control. This low color permeate produced aluminum hydroxide of 94.1% brightness compared to 93.0% of the control run. Product particle size, shown by the particles finer than 38 micrometers, were not significantly different. They registered respectively, 3.5 and 5.5%.
Significantly, this technique has demonstrated the capability of membrane filtration to effectively lower the impurities in Bayer green liquor, especially, the humate materials, the color imparting organic matter, thereby producing a better uality aluminum hydroxide with brighter color and lower impurities.
TABLE III______________________________________Composition of Start Liquor g/l______________________________________Al.sub.2 O.sub.3 62.1Total Caustic Soda (TC) 178.2Total Alkali (TA) 250.4Total Organic Carbon (TOC) 4.5Na.sub.2 C.sub.2 O.sub.4 3.1Absorbance (691 nm) 0.346______________________________________
TABLE IV______________________________________ % Composition______________________________________Bauxite AnalysisAl.sub.2 O.sub.3 56.5SiO.sub.2 3.96Fe.sub.2 O.sub.3 3.66TiO.sub.2 2.43CaO 0.10LOF 31.7Total S 0.32Sulfate S 0.08Total C 0.57TOC 0.35XRD AnalysisMajor Phase GibbsiteMinor Phase SideriteMinor Phase KaoliniteVery Small Boehmite______________________________________
TABLE V______________________________________Green Liquor Purification by Membrane Filtration(Bauxite and Plant Spent Liquor) Control Permeate______________________________________Liq. anal. g/LAl.sub.2 O.sub.3 108.9 99.5TC 169.1 164.3TA 245.4 231.8Al.sub.2 O.sub.3 /TC 0.644 0.605TC/TA 0.689 0.709TOC 4.4 3.3Na.sub.2 C.sub.2 O.sub.4 3.4 2.2SiO.sub.2 0.39 0.07Fe.sub.2 O.sub.3 0.033 0.012Humate 0.67 0.01Abs. (691 nm) 0.460 0.010Abs. (435 nm) 9.79 0.36Al.sub.2 O.sub.3 yield, g/L 39.2 34.1Prod. anal. % (2)Fe.sub.2 O.sub.3 0.060 0.026SiO.sub.2 0.008 0.001CaO 0.018 0.012Na.sub.2 O 0.36 0.17Brightness, % (1) 72.4 91.6-38 micrometers, Part. 8.5 8.5______________________________________ (1) Reference: 100% for TiO.sub.2 standard. (2) On calcined basis and adjusted to net 45 g/L yield basis.
TABLE VI______________________________________Green Liquor Purification by Membrane Filtration(Bauxite or Hydrate and Synthetic Liquor) Bauxite and Hydrate and Synthetic Liquor Synthetic Liquor Start Con- Per- Con- Per- Liquor trol meate trol meate______________________________________Liquor analysis g/LAl.sub.2 O.sub.3 61.8 109.5 101.3 110.5 103.4TC 183.4 175.7 168.3 177.1 175.6TA 254.1 243.4 226.6 242.6 229.6Al.sub.2 O.sub.3 /TC 0.337 0.623 0.602 0.624 0.589TC/TA 0.721 0.721 0.743 0.730 0.765TOC 0.2 0.2 0.2 0.2Na.sub.2 C.sub.2 O.sub.4 0.08 0.06 0.02 0.02SiO.sub.2 -- 0.29 0.06 0.08 0.06Fe.sub.2 O.sub.3 -- 0.020 0.020 0.030 0.020CaO -- 0.010 0.010 0.010 0.010Humate -- 0.10 0 0 0Absorbance (691 nm) 0.001 0.059 0.001 0.001 0.001Absorbance (435 nm) 0.232 0.741 0.047 0.045 0.007Al.sub.2 O.sub.3 yield, g/L 43.0 39.0 43.5 37.5Product analysis % (1)Fe.sub.2 O.sub.3 0.030 0.021 0.033 0.023SiO.sub.2 0.013 0.003 0.003 0.001CaO 0.012 0.011 0.025 0.015Na.sub.2 O 0.37 0.26 0.32 0.23Brightness, % (2) 85.2 93.5 93.0 94.1-38 micrometer, part. 4.1 5.2 3.5 5.5______________________________________ (1) On calcined basis and adjusted to net 45 g/L Al.sub.2 O.sub.3 yield basis. (2) Reference: 100% for TiO.sub.2 standard.
TABLE VII______________________________________Impurity Contents of the Impure Aluminum Hydroxide:Inductively Coupled Plasma Analysis % Composition______________________________________SiO.sub.2 0.011Fe.sub.2 O.sub.3 0.025TiO.sub.2 0.001Na.sub.2 O 0.36CaO 0.021% Brightness 67.8% -38 micrometer part. 6.9Median particle size 82.8 micrometers______________________________________
Thus, the invention provides an improved method for the purification of a caustic solution such as a sodium aluminate solution from a Bayer process wherein both organic and inorganic impurity levels may be reduced.
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A process for producing aluminum hydroxide product having an improved level of whiteness is disclosed. In the process, a caustic solution having dissolved aluminum hydroxide is subjected to purification to remove color producing humate material. Purification includes passing the caustic solution through a semi-permeable membrane. The solution purified of humate material is treated to precipitate aluminum hydroxide therefrom.
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CLAIM OF PRIORITY
[0001] This application claims priority to Great Britain Patent Application No. 0202032.9 filed Jan. 29, 2002.
FIELD OF THE INVENTION
[0002] This invention is related to methods of measuring and changing the level of stress or relaxation level in mammals. More particularly, the invention is related to methods of measuring and changing the activity of the sympathetic nervous system of a mammal.
BACKGROUND OF THE INVENTION
[0003] Advances in technology in the last century have brought benefits to society but have resulted in a greater prevalence of stress in the daily lives of people at all levels of society. Our stress response mechanisms have not adapted at the same pace as advancing technology. The effect of stress on health and well being is well documented. See, for example, Robert M. Sapolsky, Why Zebra's Don't Get Ulcers - An Updated Guide to Stress, Stress Related Diseases and Coping, ISBN 0-7167-3210-6, Chapter 1, (5 th Edition 2000), and George P. Chrousos and Philip W. Gold, “The Concepts of Stress and Stress System Disorders-Overview of Physical and Behavioral Homeostasis,” JAMA, Mar. 4, 1992, Vol. 267, No. 9. It is known that stress, particularly chronic stress, may cause or aggravate many conditions, including immunosuppression and susceptibility to infectious diseases, gastric conditions, sleep problems, depression, premature birth in expectant mothers, low birth weight, degeneration of brain neurons leading to memory and learning problems, elevated blood pressure, heart complications and stroke due to elevated blood lipid levels and other health complications.
[0004] Repeated exposure to acute stressors may lead to chronic stress. The acute stress response is commonly known as the “fight or flight” response. Acute stress is any stimulus or experience that is perceived as causing conflict or danger. In modern life, there exists a multitude of sources of acute stress, some examples of which include stress associated with interviews, public speaking, examinations, a dispute within a relationship, a traffic jam, being told some unpleasant news, or witnessing an unpleasant or disturbing scene. The “fight or flight” response promotes survival by protecting from bodily harm through providing the physical resources required either for conflict with the danger (fight) or to escape from the danger (flight). The response originates in the hypothalamus, which responds to a stressor by activating the sympathetic nerve endings in the adrenal medulla to produce epinephrine (adrenaline) as a part of the sympathetic-adrenal-medulla (SAM) system. Epinephrine (adrenaline) is secreted by the nerve endings in the adrenal medulla and norepinephrine (noradrenaline) is secreted by all other sympathetic nerve endings in the body that control relatively unconscious functions, including heart rate, digestion and salivary flow. It is epinephrine and norepinephrine that produce the “fight or flight” response in the organs of the body, preparing the mammal to respond to a stressor by increasing heart rate, increasing blood flow to muscles, diverting blood flow from the digestive system and inhibiting digestion, inhibiting saliva flow and dilating pupils, which are all desirable physiological responses in a survival threatening situation.
[0005] One method of measuring the response to an acute stressor in a mammal is to monitor the hypothalamus-pituitary-adrenal (HPA) system, and, in particular, the release of cortisol, corticotropin releasing hormone (CRH) and adrenocorticotrophic hormone (ACTH). Cortisol may be detected in saliva as a measure of response to a stressor. However, where cortisol is secreted in response to an acute stressor, it takes approximately twenty minutes after the onset of the stressor before the change in cortisol is detectable in saliva. Furthermore, additional time is required for the quantitative analysis of cortisol in saliva.
[0006] Given that the rapid onset of an acute stress response, or conversely the immediate physiological response to relaxation, occurs over a short time frame (generally on the order of seconds), measurement of changes of bodily functions controlled by the sympathetic nervous system would be useful in measuring stress or relaxation response. Accordingly, there remains a need for a time-independent measure of the acute stress or acute relaxation response of a mammal.
[0007] Another method of measuring the response to stress or relaxation is to quantify or observe physiological changes driven by the sympathetic nervous system. For example, some devices like mood rings and thumb press stress indicators, which rely on skin temperature changes, are simple however they only measure qualitative temperature differences. Other techniques, including lie detector type tests, such as those described in Japanese Kokai 11-034688, which rely on skin impedance changes, and thermal imaging techniques, such as those described in U.S. Pat. No. 5,771,261, which rely on skin temperature changes, may be used to supply quantitative information on the response to stress or relaxation, but these techniques are complicated and cumbersome.
[0008] Given the shortcomings of known methodology, there exists a need for a non-invasive, easy-to-use, time-independent and non-cumbersome method of measuring the state of the sympathetic nervous system as a means of measuring acute stress or relaxation response in a mammal.
[0009] The present invention addresses the problem of quantitatively measuring the immediate physiological response to acute stress or relaxation in a non-invasive, time-independent and easy-to-use method. We have surprisingly found that comparisons of the levels of oxyhemoglobin and deoxyhemoglobin in cutaneous blood supply provide a quantitative measure and a means of monitoring the acute stress or relaxation level of a mammal.
SUMMARY OF THE INVENTION
[0010] In one embodiment, the invention is directed to a method of measuring the stress or relaxation level of a mammal, including the step of:
[0011] measuring the ratio of the level of deoxyhemoglobin to the level of oxyhemoglobin of the mammal [Hb/HbO 2 ]; or
[0012] measuring the ratio of the level of deoxyhemoglobin to the sum of the level of deoxyhemoglobin and the level of oxyhemoglobin of the mammal [Hb/(Hb+HbO 2 )].
[0013] In another embodiment, the invention is directed to a method of measuring the activity of the sympathetic nervous system of a mammal, including the step of:
[0014] measuring the ratio of the level of deoxyhemoglobin to the level of oxyhemoglobin of the mammal [Hb/HbO 2 ]; or
[0015] measuring the ratio of the level of deoxyhemoglobin to the sum of the level of deoxyhemoglobin and the level of oxyhemoglobin of the mammal [Hb/(Hb+HbO 2 )].
[0016] In another embodiment, the invention is directed to a method of measuring the activity of the sympathetic nervous system of a mammal, including the steps of:
[0017] a. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal prior to exposing said mammal to an acute stressor or relaxor;
[0018] b. exposing the mammal to the acute stressor or relaxor;
[0019] c. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal during or after the exposing step; and
[0020] d. for step a and step c, calculating and comparing at least one ratio selected from the group consisting of:
[0021] i. the ratio of the level of deoxyhemoglobin to the level of oxyhemoglobin of said mammal; and
[0022] ii. the ratio of the level of deoxyhemoglobin to the sum of the level of deoxyhemoglobin and the level of oxyhemoglobin of said mammal.
[0023] Preferably, the level of deoxyhemoglobin and oxyhemoglobin are measured by at least one noninvasive technique, including spectroscopic techniques, such as diffuse reflectance spectroscopy, near infrared spectroscopy or ultraviolet-visible spectroscopy.
[0024] In yet another embodiment, the invention is directed to a method of changing the activity of the sympathetic nervous system of a mammal, including the steps of:
[0025] a. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal prior to exposing the mammal to an acute stressor or relaxor;
[0026] b. exposing the mammal to the acute stressor or relaxor;
[0027] c. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal during or after the exposing step;
[0028] d. for step a and step c, calculating and comparing at least one ratio selected from the group consisting of:
[0029] i. the ratio of the level of deoxyhemoglobin to the level of oxyhemoglobin of the mammal; and
[0030] ii. the ratio of the level of deoxyhemoglobin to the sum of the level of deoxyhemoglobin and the level of oxyhemoglobin of the mammal; and
[0031] e. changing at least one of the ratios before and after step b by at least 1%, preferably at least 5% and most preferably at least 10%.
[0032] Preferably, the changing step e includes the step of administering an effective amount of sensory regimen to the mammal. Examples of a suitable sensory regimen include the administration of sensory stimuli selected from auditory stimuli, visual stimuli, tactile stimuli, gustatory stimuli and olfactory stimuli and combinations thereof.
[0033] In one particularly preferred embodiment, the mammal is a human operator of a vehicle or a machine and the method preferably includes the step of alerting the human operator of impaired ability to operate the vehicle or the machine, caused by stress, agitation, exhaustion, sleepiness, inattentiveness, boredom, illness and distraction. Most preferably, the method further includes the step of administering an effective amount of sensory regimen.
[0034] In a particularly preferred embodiment, the mammal is a human operator of a vehicle or a machine and the method preferably includes the step of alerting the mammal of a detrimental level of stress, such as the stress caused by heavy traffic or dangerous situations leading so-called “road rage.” Most preferably, the method further includes the step of administering an effective amount of sensory regimen.
[0035] In another particularly preferred embodiment, the mammal suffers from cardiovascular disease or related complications and the method preferably includes the step of alerting the mammal of a detrimental level of stress. Most preferably, the method further includes the step of administering an effective amount of sensory regimen.
[0036] In yet another particularly preferred embodiment, the mammal is pregnant and the method preferably includes the step of alerting the pregnant mammal of a detrimental level of stress. Most preferably, the method further includes the step of administering an effective amount of sensory regimen.
[0037] In another particularly preferred embodiment, the mammal is preparing for sleep and the method preferably includes the step of alerting the mammal of a detrimental level of stress. Most preferably, the method further includes the step of administering an effective amount of sensory regimen.
[0038] The mammal may alerted to a detrimental level of stress in any of a number of ways that includes feedback to the mammal when such level is approached or exceeding, such as a visual indication (for example, flashing or colored lights), audio indication (for example, voice message, beeping sound or alarm), tactile indication (for example, vibration or mild shock) or combinations thereof.
[0039] In a particularly preferred embodiment, the invention is directed to a method of improving the complexion of the skin of a mammal, including the steps of:
[0040] a. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal prior to exposing the mammal to an acute relaxor;
[0041] b. exposing the mammal to the acute relaxor;
[0042] c. measuring the level of oxyhemoglobin and the level of deoxyhemoglobin in the cutaneous blood supply of the mammal during or after the exposing step;
[0043] d. for step a and step c, calculating and comparing at least one ratio selected from the group consisting of:
[0044] i. the ratio of the level of deoxyhemoglobin to the level of oxyhemoglobin of the mammal; and
[0045] ii. the ratio of the level of deoxyhemoglobin to the sum of the level of deoxyhemoglobin and the level of oxyhemoglobin of the mammal; and
[0046] e. reducing at least one of the ratios before and after step b by at least 1%, preferably at least 5% and most preferably at least 10%.
[0047] Preferably, the changing step e includes the step of administering an effective amount of sensory regimen to the mammal.
DETAILED DESCRIPTION OF THE INVENTION
[0048] As discussed above, the techniques according to the invention provide methods in which the level of acute stress or acute relaxation of a mammal may be non-invasively and easily measured quantitatively during or immediately following a stressful or relaxing experience.
[0049] As used herein, the term “mammals” includes any of a class of warm-blooded higher vertebrates that nourish their young with milk secreted by mammary glands and have skin usually more or less covered with hair, and non-exclusively includes humans, dogs and cats.
[0050] As used herein, the term “acute stressor” or “acute stress” is any stimulus or experience that is perceived by the mammal as either a source of conflict or danger.
[0051] As used herein, the term “acute relaxor” or “acute relaxation” is any stimulus or experience that is perceived by the mammal as a source of relaxation.
[0052] Techniques that quantify the level of saturation of oxygen in the blood and that may be used to compare the levels of oxyhemoglobin (HbO 2 ) to deoxyhemoglobin (Hb) in cutaneous blood supply are useful in the practice of the invention. Specifically, the techniques that may be used in the practice of the methods of the invention are techniques that measure the intensity of transmitted or reflected electromagnetic waves respectively through or from the cutaneous tissue of a mammal, including diffuse reflectance spectroscopy (DRS), near infrared spectroscopy (NIR) and ultraviolet-visible (UV-vis) spectroscopy. Use of these techniques gives values of oxyhemoglobin and deoxyhemoglobin in arbitrary units that may subsequently be used in the calculation of the ratios [Hb/(Hb+HbO 2 ) and Hb/HbO 2 ].
[0053] Since cutaneous blood flow will vary from individual to individual, one must first select an appropriate baseline measurement. As an example, an occasion could be chosen, because the individual is “stress” free, such as, for example, after a restful experience. In this case, one is using this invention to measure any increases in stress in the individual. On the other hand, the initial occasion could be representative of a time where the individual has some level of detrimental stress. In this case, subsequent measures can be used to determine the amount and effectiveness of a stress management or intervention technique.
[0054] Once the ratio(s) has been calculated, a comparison may be done between the ratio(s) after exposure to the stressor or relaxor and the baseline ratio(s) prior to the exposure to the stressor or relaxor, to determine the change, if any, in stress or relaxation level of the mammal from the baseline measurement to the current testing interval. A comparison of all of these values is necessary to help determine the magnitude of the effect.
[0055] The level of HbO 2 and Hb are measured during or after the exposing the mammal to the stressor or relaxor. If analysis of the current state of the sympathetic nervous system of the mammal is desired, it is preferable to measure the levels of HbO 2 and Hb either during the exposure of the stressor or relaxor or immediately following the exposure, generally within 15 minutes, preferably 5 minutes and more preferably 1 minute. However, long periods of time are contemplated within the scope of this invention.
[0056] The methods of the invention may be used to monitor the stress or relaxation level of a mammal, and where appropriate administer a treatment to either reduce or increase the activity of the sympathetic nervous system of the mammal to effect relaxation or stimulation. In cases where it is desired to change the activity of the sympathetic nervous system of a mammal, a step of administering a sensory regimen is included. For example, when a difference between the subsequent measure of activity of the sympathetic nervous system (after exposure to the stressor or relaxor) and the baseline stress value (prior to the exposure to the stressor or relaxor) of at least 1%, at least 5%, and at least 10% different is desired, the method of the invention may preferably include an additional step wherein the activity of the sympathetic nervous system system is changed to at least original baseline level or lower in the case where a reduction in stress level is desired, or, alternatively, to at least some set goal level in the case where an increase in the stimulation level is desired.
[0057] Examples of a suitable sensory regimen include the administration of sensory stimuli selected from auditory stimuli, visual stimuli, tactile stimuli, gustatory stimuli and olfactory stimuli and combinations thereof.
[0058] As used herein, “effective amount” refers to the frequency, level and duration of the regime of sensory experience sufficient to significantly induce a positive modification in the condition to be treated, but low enough to avoid serious side effects (at a reasonable benefit/risk ratio), within the scope of sound medical judgment. The effective amount of the compound or composition will vary with the particular condition being treated, the age and physical condition of the patient being treated, the severity of the condition, the frequency, level and duration of the treatment, the nature of concurrent therapy, the specific compound or composition employed, the particular pharmaceutically-acceptable carrier utilized, and like factors within the knowledge and expertise of the attending physician. Use of a multiple sensory regimen can affect the duration that would be needed to create the desired response.
[0059] Examples of desired responses when relaxation is sought include:
[0060] (i) a reduction in the ratio of deoxyhemoglobin to the sum of deoxyhemoglobin and oxyhemoglobin (Hb/(Hb+HbO 2 )) in the cutaneous blood supply of the mammal;
[0061] (ii) a reduction in the ratio of deoxyhemoglobin to oxyhemoglobin (Hb/HbO 2 ) in the cutaneous blood supply of the mammal; or
[0062] (iii) both (i) and (ii).
[0063] Examples of desired responses when stimulation is sought include:
[0064] (i) an increase in the ratio of deoxyhemoglobin to the sum of deoxyhemoglobin and oxyhemoglobin (Hb/(Hb+HbO 2 )) in the cutaneous blood supply of said mammal;
[0065] (ii) an increase in the ratio of deoxyhemoglobin to oxyhemoglobin (Hb/HbO 2 ) in the cutaneous blood supply of the mammal; or
[0066] (iii) both (i) and (ii).
[0067] A preferred means of delivering sensory stimuli is in the form of a personal care composition. Personal care compositions are particularly useful in delivering olfactory stimuli. For example, the sensory fragrance may be produced by mixing the selected essential oils and odoriferous components under ambient conditions until the final mixture is homogenous using equipment and methodology commonly known in the art of fragrance compounding. It is preferable to store the final sensory fragrance mixture under ambient conditions for a few hours after mixing before using it as a component of a personal care composition.
[0068] The personal care compositions useful in the methods of the present invention may then be produced by blending the desired components with the sensory fragrance using equipment and methodology commonly known in the art of personal care product manufacture. To improve the solubilization of the sensory fragrance in aqueous personal care compositions, the sensory fragrance may be pre-blended with one or more of the nonionic surfactants.
[0069] “Personal care compositions” refers to personal cosmetic, toiletry, and healthcare products such as dry and wet wipes, washes, baths, shampoos, gels, soaps, sticks, balms, sachets, pillows, mousses, sprays, lotions, creams, cleansing compositions, powders, oils, bath oils and other bath compositions which may be added to a bath. Personal care compositions may also include, but are not limited to, aerosols, candles, and substances that may be used with vaporizers. The aforementioned wipes, washes, baths, shampoos, gels, soaps, sticks, balms, sachets, pillows, mousses, sprays, lotions, creams, cleansing compositions, oils, and bath oils, are commercially known to those who have knowledge of preparing personal care compositions. Suitable personal care compositions, include but are not limited to Johnson's Bedtime Bath® product available from Johnson & Johnson Consumer Companies, Inc.
[0070] To achieve the desired response in a mammal, the personal care composition may be used in a dosing amount that is in accordance with the prescribed directions of the personal care composition. Although a greater effect is generally achieved when multiple stimuli are used together, a single stimulus may also be effective so are included in the invention.
[0071] Practice of a sensory regimen using the aforementioned stimuli may lead to acute relaxation and increased levels of oxygenated hemoglobin cutaneous blood supply. Accordingly, another embodiment of the invention is a method of increasing the supply of blood-borne nutrients, including oxygen, to cutaneous tissue of a mammal by administering to the mammal an effective amount of a sensory regimen. When the supply to cutaneous tissue of blood-borne nutrients, including oxygen, is enhanced, good health of the tissue is promoted. There are several technical methods of measuring the state of health of the skin, including transepidermal water loss, pH, and type and count of microflora. A visual indicator that would be meaningful to the consumer is a healthy complexion. By the term “healthy complexion” is meant skin that has even skin tone, is free of blemishes and is glowing and radiant. Accordingly, the methods of the invention may be used to improve the complexion of the skin of a mammal.
[0072] To illustrate the methods of the invention, the following examples are included. These examples do not limit the invention. They are meant only to describe a method of practicing the invention.
EXAMPLES
Example 1
[0073] One Time Exposure to Audio Stimuli and Short Term Effect on Sympathetic Nervous System Activity As Measured By HbO 2 and Hb Levels in Cutaneous Blood Supply Using Diffuse Reflectance Spectroscopy
[0074] A group of males and females aged 20 to 55 in good general health were invited to participate in a paid study in which over the course of 10 minutes they would listen to soothing sounds. The purpose of this study was to measure the effect of the experience on sympathetic nervous system activity as measured by deoxyhemoglobin (Hb) and oxyhemoglobin (HbO 2 ) levels in cutaneous blood supply using diffuse reflectance spectroscopy (DRS) in the time period following the application of a positive stressor (relaxing music).
[0075] The diffuse reflectance spectroscopic technique used to quantify and analyze spectra for Hb and HbO 2 levels is described in detail by N. Kollias et al. in “A Single Parameter, Oxygenated Hemoglobin, Can Be Used to Quantify Experimental Irritant-Induced Inflammation,” The Journal of Investigative Dermatology, Vol. 104, No 103, March 1995, and is incorporated herein by reference.
[0076] Upon arriving at the study site, the panelist was asked to sit quietly for 10 minutes and relax. Three baseline DRS measurements were performed on the volar forearm of the panelist. The panelist then listened to 10 minutes of relaxing music from the music CD entitled “Relax with Ocean Relaxing Surf” by Eclipse Music Group Ocean Wave Music through personal headphones. During or immediately following this 10-minute session, three DRS measurements were performed on the same area of the volar forearm as was used for the baseline measurements. The data was then transferred into a program that presented the DRS data in an ASCII file format. The results of the spectroscopic analyses are presented in Table 1 below.
TABLE 1 HbO 2 Before HbO 2 After Hb Before Hb After (Arbitrary (Arbitrary (Arbitrary (Arbitrary Panelist Units) Units) Units) Units) 1 0.30 0.31 0.61 0.31 2 0.25 0.25 0.57 0.46 3 0.14 0.18 0.39 0.31 4 0.26 0.34 0.81 0.32 5 0.14 0.17 0.49 0.39 6 0.22 0.23 0.49 0.28 7 0.20 0.25 0.50 0.44 8 0.28 0.32 0.78 0.32 9 0.18 0.10 0.67 0.26 10 0.26 0.27 0.66 0.09 11 0.22 0.24 0.54 0.46 12 0.33 0.51 0.87 0.09 Average 0.23 0.26 0.62 0.31
[0077] The ratio of Hb/(Hb+HbO 2 ) and the ratio of Hb/HbO 2 were subsequently calculated from the average values of Hb and HbO 2 presented in Table 1. The result of these calculations are shown in Table 2 below:
TABLE 2 Hb/(Hb + HbO 2 ) Hb/HbO 2 Before Stressor 0.73 2.70 After Stressor 0.54 1.19
[0078] The ratio of Hb/(Hb+HbO 2 ) and the ratio of Hb/HbO 2 decreased following the application of the positive stressor. A decrease in these ratios indicates increased cutaneous supply of oxygenated blood, which would be consistent with an acute relaxation response.
Example 2
[0079] One Time Exposure to Arithmetic Challenge and Short Term Effect on Sympathetic Nervous System Activity As Measured By HbO 2 and Hb levels in Cutaneous Blood Supply Using Diffuse Reflectance Spectroscopy
[0080] A group of males and females aged 20 to 55 in good general health were invited to participate in a paid study in which over the course of 10 minutes they were given a series of arithmetic problems to solve, the experience of which was subjectively perceived to be stressful. The purpose of this study was to measure the effect of the experience on sympathetic nervous system activity as measured by deoxyhemoglobin (Hb) and oxyhemoglobin (HbO 2 ) levels in cutaneous blood supply using diffuse reflectance spectroscopy in the time period following the application of the negative stressor.
[0081] Baseline measures of Hb and HbO 2 were made using diffuse reflectance spectroscopy as set forth in Example 1. Each adult was then asked to provide the correct answers to a series of arithmetic questions within a period of 10 minutes. Immediately following this arithmetic challenge a second measurement of Hb and HbO 2 was made for each panelist as set forth in Example 1. The results of the spectroscopic analyses are presented in Table 3 below.
TABLE 3 HbO 2 Before HbO 2 After Hb Before Hb After (Arbitrary (Arbitrary (Arbitrary (Arbitrary Panelist Units) Units) Units) Units) 1 0.17 0.20 0.43 0.51 2 0.24 0.29 0.58 0.62 3 0.13 0.10 0.46 0.48 4 0.32 0.20 0.64 0.92 5 0.12 0.15 0.49 0.52 6 0.15 0.19 0.61 0.47 7 0.22 0.18 0.58 0.42 8 0.21 0.25 0.75 0.82 9 0.22 0.19 0.83 0.93 10 0.19 0.17 0.63 0.56 11 0.16 0.16 0.54 0.57 12 0.25 0.39 0.66 0.93 Average 0.20 0.20 0.60 0.65
[0082] The ratio of Hb/(Hb+HbO 2 ) and ratio of Hb/HbO 2 were subsequently calculated from the average values of Hb and HbO 2 presented in Table 3. The result of this calculation is shown in Table 4 below:
TABLE 4 Hb/(Hb + HbO 2 ) Hb/HbO 2 Before 0.75 3.0 After 0.76 3.25
[0083] The ratio of Hb/(Hb+HbO 2 ) and ratio of Hb/HbO 2 increased following the arithmetic challenge. An increase in these ratios indicates decreased cutaneous supply of oxygenated blood that would be indicative of redirection of oxygen away from cutaneous tissue and towards tissues and organs that would be involved in a flight or flight response to a challenge. The magnitude of the increase here is somewhat limited, but it would be expected that in the face of a real, rather than an artificial challenge, that the magnitude of the increase would be greater. In a laboratory setting ethics necessarily prohibits the nature of the stressor, thus the usefulness of this method in the measurement of an acute stress response is not best demonstrated under the conditions described in this example.
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A method of measuring the stress or relaxation level of a mammal and a method of measuring the activity of the sympathetic nervous system of a mammal by measuring quantititative levels of deoxyhemoglobin and oxyhemoglobin are disclosed. Preferably, the levels of deoxyhemoglobin and hemoglobin are measured by a noninvasive technique, such as spectroscopy. A method of changing the activity of the sympathetic nervous system of a mammal is also disclosed, wherein the method includes a step of administering an effective amount of sensory regimen to the mammal. The method is useful for humans who are operating vehicles or machinery, who are suffering from cardiovascular disease or related complications, who are pregnant, or who are preparing for sleep. In addition, a method of improving the complexion of the skin of a mammal is disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to earthmoving equipment and, more particularly, to a self-loading earthmoving scraper with an ejector bottom.
2. Description of the Prior Art
Earthmoving equipment of the scraper type has been known for some time and has been used extensively on every conceivable type of project. After the bowl on the scraper has been filled with soil, the scraper is moved to a location where the soil is to be dumped and spread. Many different mechanisms have been devised for dumping the load where and when desired.
One of the principal difficulties faced by designers of the dumping mechanisms is the fact that a heavy load of soil is stacked on top of the floor or platform of the bowl which floor or platform must be moved in some way to permit the soil to drop from the bowl. In the Simmons et al. U.S. Pat. No. 3,564,737, a pair of floor plates are hinged together and at the same time a slidable third floor plate is located adjacent thereto. To dump the load, the hinge ends of the pair of plates are forced up into the load in the bowl as the third plate slides into a position beneath the upwardly hinged plates. Since the hinged ends of the plates meet the full resistance of the load, considerable force is required to operate the dumping mechanism.
Another solution to the problem is shown in the Campbell et al. U.S. Pat. No. 3,452,458 wherein the floor of the bowl is pivoted up along one wall of the bowl as the load spills down out of the bowl when the floor moves out of supporting relationship. Although this mechanism operates satisfactorily, the dumping mechanism must again overcome a considerable downwardly directed force to initiate dumping of the load.
SUMMARY OF THE INVENTION
A scraper is provided with a two-part dump mechanism which facilitates starting and completing the dumping process. The mechanism has a hinged platform and a pivoted platform which platforms combine to form the support bottom for the contents of the bowl. Actuators are connected to each platform and are pivoted to each other with a linear power source drivingly connected to one of said actuators. Linear movement from the power source aided by the weight of the load on the hinged platform will drop the one end of the hinged platform and, along with it the soil piled immediately thereon. Simultaneously, the pivoted platform will pivot about its mounting and out from beneath the soil thereby dumping the soil from the bowl.
The hinged platform, upon dropping partially under the weight of the load in the bowl and partially from the movement of the power source, commences dumping the center of the load which loosens the packing in the load making the continued movement of the hinged and pivoted platforms easier. Since the whole bottom of the bowl is open, once the two platforms are moved out of supporting position, the likelihood of material hanging up or staying in the bowl is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of construction and operation of the invention are more fully described with reference to the accompanying drawings which form a part hereof and in which like reference numerals refer to like parts throughout.
In the drawings:
FIG. 1 is a side elevation view, partially in section, of a self-loading scraper having the load ejector or dumping structure of the present invention in load supporting position; and
FIG. 2 is a side elevation view of the scraper of FIG. 1 only with the load ejector or dumping structure in load dumping position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, and in particular to FIG. 1 thereof, a self-loading elevator scraper 10 is provided with a bowl assembly 12 mounted on a draft frame 14 which in turn is supported on an axle 16 upon which a pair of rear wheels 18 is rotatably mounted. The scraper 10 may be propelled over the terrain by any one of the well known means and, as shown, is drawn by a tractor (not shown) through a gooseneck 20 which is connected to the draft arms 22 pivotally mounted on the side walls 21,23 of the bowl. The forward ends of the draft arms 22 are attached together by a spreader bar 24 with the gooseneck 20 being connected to the midportion of said spreader bar 24. Jacks 28 extend between the outer ends of extension plates 30 carried by the bowl 12 and links 32 fastened to the spreader bar 24 thereby providing vertical control for the forward part of the scraper. A support bar 29 extends between the extension plates 30 to add rigidity to said plates. A chain and flight elevator 26 is operatively mounted at the front of the bowl 12 for loading soil into the bowl.
Fastened between the side walls 21,23 of the bowl 12, slightly rearward of the elevator 26, is the cutting blade support 34 to which is fastened a cutting blade 36 along the lower forward edge thereof. The blade 36 projects forwardly and downwardly from the bowl to cut away a layer of soil and together with the support 34 guides the soil into the bowl 12.
Improved means and mechanisms are provided for supporting the soil in the bowl and to facilitate dumping the soil from the bowl when desired. Specifically, the rear wall 38 of the bowl is formed in a slightly concave or curved shape which concavity or curvature lies generally along a surface generated by a radius about a point 40 which point lies on the axis of a pair of sidewardly projecting pins 42. The base or bottom of the bowl is comprised of two separate sections or platforms, one being a pivoted platform 44 and the other being a hinged platform 46. The platforms 44 and 46, when in closed position, mate with each other in such a way as to form the floor or bottom for the bowl 12 and lie in a common, substantially horizontal plane having a longitudinal axis extending perpendicular to the cutting blade support 34. The pivoted platform 44 has a pair of generally triangularly-shaped side walls 47,48 which walls are secured to the pivot pins 42 at the apex of said triangularly shaped walls. The bases of the triangular side walls 47,48 are interconnected side-to-side by a floor portion 50, which throughout a front portion 51 of its longitudinal length is substantially flat and which has an angled rear portion 52 projecting rearwardly and upwardly therefrom. The rear portion 52 tapers in thickness from its juncture with portion 51 to an outer edge 53 which faces and somewhat mates with the lower segment of the arcuately curved rear wall 38 of the bowl. With the pivoted platform 44 in closed position, the rear portion 52 overlaps with the wall 38 and the front portion 51 spans the width of the bowl to hold the contents of the bowl therewithin. The pair of pivot pins 42 project through openings in the side walls 21,23, respectively, of the bowl and are fixedly attached to the links 54 which are positioned parallel to the outer surfaces of the side walls.
The hinged platform 46 consists of a flat, straight portion extending substantially between the inside of the side walls 21,23 and has a forward edge 55 lying in close proximity to the rear edge of the cutting blade support 34 with the rearward edge 57 lying parallel to and close to the forward edge of the pivoted platform 44. The hinged platform 46 has a pair of spaced apart lugs 56 secured to the top surface thereof. The lugs 56 are pivotally connected by means of a pair of short arcuately shaped links 58 to a pair of spaced apart lugs 60 carried on the rearward face of the support 34. The axis passing through the pivots between the lugs 56 and links 58 is located forward of the side-to-side center line of said hinged platform 46 so that the weight of soil on the platform 46 tends to pivot the platform counterclockwise, as viewed in FIG. 1, which tends to bring link 64 down with it. A plane containing the pivots 42 for the platform 44 lies parallel to the horizontal plane of the platforms 44,46, when in the closed position, and is spaced from said horizontal plane a distance several orders of magnitude greater than the distance between said horizontal plane and the plane containing the pivot axis passing through the pivots between the lugs 60 and the lower end portions of links 58. A pair of projections 62 extend downwardly from the bottom rear portion of said hinged platform 46 with the outer surface of said projections 62 extending beyond the plane of the outer surface of the side walls of the bowl 12. The link 64 is pivotally connected at 63 to the projections 62 exteriorly of the side walls of the bowl 12. The other ends of the links 64 are pivotally connected to the forward ends of the links 54 so that the two links 64,54 on each side of the bowl are capable of moving relative to each other about a pivot pin 66 passing through both of said links.
A power source, such as a hydraulic cylinder 68, is connected to each side of the bowl 12 exteriorly of the side walls thereof with the one end of each hydraulic cylinder being connected by a pivot pin 70 to the frame 14 and with the extendable end 69 of the cylinder being pivotally connected by means of a pivot pin 72 to the intermediate portion of the link 54. Each pivot pin 72 is spaced from the pivot pin 66 an amount less than the spacing of the pivot pin 72 from the pivot pin 42. As shown, the distance from pin 72 to pin 66 is approximately one-half the distance from the pin 72 to the pin 42. The ratio of these distances can vary depending upon the amount of relative movement intended between the pivoted platform 44 and the hinged platform 46.
Upon actuation of the hydraulic cylinders 68, the links 54 will be pivoted about the axis of the pins 42 passing through the side walls 21,23 whereupon the pivoted platform 44 will be rotated clockwise from the closed position of FIG. 1 to the open position of FIG. 2. Simultaneously, the links 64 will be lowered moving the hinged platform 46 about the end of the link 58 so as to hinge the platform 46 about the pivots at each end of the link 58 so as to drop the platform 46 and pivot it out of the way of the falling material in the bowl. The hinged platform 46 moves to a vertical orientation lying parallel to and immediately behind the support 34. In this way, all of the material originally supported by the pivoted platform 44 and the hinged platform 46 will be dumped or dropped out the bottom of the bowl of the scraper. Upon reactivation of the cylinder 68, the pivoted platform 44 and the hinged platform 46 will be returned to the bottom-forming position shown in FIG. 1 whereupon continued forward movement of the scraper with the forward end portion of the bowl lowered, another layer of soil will be scraped up by the cutter blades 36 which soil will be elevated by the elevator 26 into the bowl 12 and onto the supporting surfaces 51,52 of the pivoted platform 44 and onto the supporting surface of the hinged platform 46.
The pivoted platform 44 is pivoted about the pins 42 and subscribes a substantially arcuate path in conformance with the arcuate shape of the rear wall 38 of the bowl. Since it is a pure pivoting motion and since material is being dumped as it begins to move, the resistance to pivoting of the platform is reduced. The rear leading edge 53 of the angled floor portion 52, is narrow and acts almost as a scraper in cutting through the material that lies in its path along the arcuate curved wall 38 of the bowl 12. In this way, resistance to the pivoting of the pivoted platform 44 is reduced. The hinged platform 46, since it is dropped down and pivoted out of the way of the falling material, has the weight of the dirt or soil as a helping influence in dropping down out of the way of the falling material. Once again, since the weight of the material on the platform 46 acts through the link 64 to the link 54, the weight of the material on the platform 46 will also assist in pivoting the pivoted platform 44 out of the supporting position shown in FIG. 1. In this way, the weight of the material, instead of resisting opening the platforms for dumping of the materials, serves to assist said dumping function.
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A self-loading elevating scraper is provided with a dumping or ejector mechanism for quickly and efficiently expelling the entire contents of the scraper bowl. The bowl is provided with a pivoted floor or platform and a hinged floor or platform which platforms are interconnected by links. A power source, such as a hydraulic cylinder, is mounted on the scraper and engages with one of said links such that actuation of the cylinder pivots both the pivoted floor or platform and the hinged floor or platform out of soil supporting relationship thereby permitting the soil to drop from the bowl.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/776,773, filed on May 10, 2010, which claims the benefit of U.S. Provisional Application No. 61/178,720, filed on May 15, 2009. The entire disclosures of the above applications are incorporated herein by reference.
FIELD
[0002] The present disclosure relates generally to compressor machines. More particularly, the present disclosure relates to a compressor and an oil-cooling system that cools the lubricating oil that flows through the compressor.
BACKGROUND
[0003] Compressor machines in general, and particularly scroll compressors, are often disposed in a hermetic or semi-hermetic shell which defines a chamber within which is disposed a working fluid. A partition within the shell often divides the chamber into a discharge-pressure zone and a suction-pressure zone. In a low-side arrangement, a scroll assembly is located within the suction-pressure zone for compressing the working fluid. Generally, these scroll assemblies incorporate a pair of intermeshed spiral wraps, one or both of which are caused to orbit relative to the other so as to define one or more moving chambers which progressively decrease in size as they travel from an outer suction port towards a center discharge port. An electric motor is normally provided which operates to cause this relative orbital movement.
[0004] The partition within the shell allows compressed fluid exiting the center discharge port of the scroll assembly to enter the discharge-pressure zone within the shell while simultaneously maintaining the integrity between the discharge-pressure zone and the suction-pressure zone. This function of the partition is normally accomplished by a seal which interacts with the partition and with the scroll member defining the center discharge port.
[0005] The discharge-pressure zone of the shell is normally provided with a discharge-fluid port which communicates with a refrigeration circuit or some other type of fluid circuit. In a closed system, the opposite end of the fluid circuit is connected with the suction-pressure zone of the shell using a suction-fluid port extending through the shell into the suction-pressure zone. Thus, the scroll machine receives the working fluid from the suction-pressure zone of the shell, compresses the working fluid in the one or more moving chambers defined by the scroll assembly, and then discharges the compressed working fluid into the discharge-pressure zone of the compressor. The compressed working fluid is directed through the discharge port through the fluid circuit and returns to the suction-pressure zone of the shell through the suction port.
[0006] A lubricant (e.g., oil) sump can be employed in the shell of the compressor to store the lubricant charge. The sump can be placed in either the low-pressure zone or the high-pressure zone. The lubricant serves to lubricate the moving components of the compressor and can flow with the working fluid through the scroll assemblies and be discharged along with the working fluid into the discharge-pressure zone of the compressor. The temperature of the lubricant being discharged, along with that of the working fluid, is elevated. Cooling the lubricant prior to flowing back through the compressor and lubricating the components therein can reduce suction-gas superheat, thereby improving compressor volumetric efficiency and providing better performance. The reduced lubricant temperature may also improve compressor reliability by cooling the suction gas and the motor. Cooling the lubricant can also keep the viscosity of the lubricant at a desirable level for maintaining oil film thickness between moving parts.
[0007] Within the compressor, the lubricant is provided to the various moving components. Improving the distribution of the lubricant throughout the compressor can advantageously improve the performance and/or longevity of the compressor.
[0008] Within the compressor, the proper alignment of the various components relative to one another can improve the performance of the compressor and/or reduce the sound generated by the compressor. Improving the alignment between the various components, such as the non-orbiting scroll member, the bearings, and the motor, can improve the performance and/or reduce the sound generated by the compressor. The compressors typically use numerous discrete components that are assembled together within the shell to provide the alignment. The use of these numerous separate and discrete components, however, increases the potential for inaccuracy in the alignment of the components and, further, can be more expensive or time consuming to manufacture as tighter tolerances for the various components are required to produce the desired alignment.
SUMMARY
[0009] In one form, the present disclosure provides a system that may include a compressor, a lubricant, a condenser, an expansion device, and a heat exchanger. The compressor may compress a working fluid from a suction pressure to a discharge pressure greater than the suction pressure. The lubricant may lubricate the compressor. The condenser may condense working fluid discharged by the compressor. The expansion device may expand working fluid condensed by the condenser. The heat exchanger may transfer heat from the lubricant to expanded working fluid.
[0010] In another form, the present disclosure provides a compressor that may include a shell, a compression mechanism, a crankshaft, a bearing, and a lubricant sump. The compression mechanism may be disposed in the shell and compressing a working fluid. The crankshaft may be disposed at least partially in the shell and drivingly engaged with the compression mechanism. The bearing support may rotatably support the crankshaft. The lubricant sump may retain a volume of lubricant and disposed between the bearing support and the compression mechanism.
[0011] In yet another form, the present disclosure provides a compressor that may include a unitary body including a shell unitarily formed with a main bearing support. The main bearing support may include a bore for supporting a portion of a crankshaft. The shell may include a continuous annular surface on an interior of the shell adjacent a first end of the shell and a plurality of axially extending arcuate surfaces adjacent a second end of the shell. The plurality of arcuate surfaces being spaced apart along the interior of the shell.
[0012] The compressor may also include a scroll member having a peripheral exterior surface dimensioned to fit inside of the first end of the shell and engage the annular surface. The annular surface may center the scroll member in the shell.
[0013] The compressor may also include a partition plate having a rim dimensioned to fit inside of the first end of the shell and engage the annular surface. The annular surface may center the partition plate relative to the shell.
[0014] The compressor may also include an end cap having a rim dimensioned to fit inside of the second end of the shell and engage the arcuate surfaces. The end cap may have a bore for supporting an end portion of the crankshaft. The arcuate surfaces centering the end cap relative to the shell and axially aligning the bore in the end cap with the bore in the main bearing support.
[0015] The compressor may also include a stator having an exterior surface dimensioned to be received in the shell. The exterior surface may engage the arcuate surfaces. The arcuate surface may center the stator in the shell.
[0016] In yet another form, the present disclosure provides a compressor that may include a shell, a compression mechanism, a crankshaft, a bearing support, and a lubricant sump. The compression mechanism may be disposed in the shell and may compress a working fluid. The crankshaft may be disposed at least partially in the shell and may drivingly engage the compression mechanism. The bearing support may rotatably support the crankshaft. The lubricant sump may retain a volume of lubricant and may be disposed between the bearing support and the compression mechanism.
[0017] In some embodiments, the compressor may include a thrust plate disposed between the bearing support and the compression mechanism. The thrust plate may include an engaging surface that is engaged with the compression mechanism. The lubricant sump may be defined by the thrust plate, the bearing support, and the shell.
[0018] In some embodiments, the bearing support and the thrust plate may both include a plurality of openings allowing the working fluid and the lubricant to flow throughout the shell.
[0019] In some embodiments, the compressor may include a counterweight attached to the crankshaft and rotating with rotation of the crankshaft. The counterweight may travel through lubricant in the lubricant sump during rotation of the crankshaft and may splash the lubricant therein to transmit the lubricant to the compression mechanism.
[0020] In some embodiments, an eccentric portion of the counterweight may travel through lubricant in the lubricant sump during less than one-hundred-eighty degrees of rotation of the crankshaft.
[0021] In some embodiments, the compressor may include an end cap connected to the shell and defining a high-side lubricant sump.
[0022] In some embodiments, the compressor may include a lubricant discharge fitting in fluid communication with the high-side lubricant sump and a heat exchanger.
[0023] In some embodiments, the heat exchanger may include a first fluid passageway receiving lubricant from the high-side lubricant sump and a second fluid passageway receiving a working fluid from the compression mechanism. The first and second fluid passageways may be fluidly isolated from each other.
[0024] In some embodiments, the compression mechanism may include an intermediate-pressure location receiving expanded working fluid from the heat exchanger.
[0025] In some embodiments, the compressor may be in fluid communication with a condenser, an expansion device, and a heat exchanger. The condenser may condense working fluid discharged by the compressor. The expansion device may expand working fluid condensed by the condenser. The heat exchanger may transfer heat from the lubricant to expanded working fluid.
[0026] In some embodiments, the shell may define a first lubricant passageway that is fluidly separated from the lubricant sump and in communication with an inlet of the compressor that is distinct from a working fluid inlet of the compressor.
[0027] In some embodiments, the crankshaft may include a second lubricant passageway providing communication between the lubricant sump and the inlet.
[0028] In another form, the present disclosure provides a compressor that may include a shell, a compression mechanism, a first lubricant sump, and a second lubricant sump. The shell may define a suction-pressure region and a discharge-pressure region. The compression mechanism may be disposed between the suction-pressure region and the discharge-pressure region. The first lubricant sump may be disposed in the suction-pressure region. The second lubricant sump may be disposed in the discharge-pressure region.
[0029] In some embodiments, the compressor may include a crankshaft, a bearing support, and a thrust plate. The crankshaft may drivingly engage the compression mechanism. The bearing support may rotatably supporting the crankshaft. The thrust plate may engage the compression mechanism and may be disposed between the compression mechanism and the bearing support. The first lubricant sump may be defined by the thrust plate, the bearing support, and the shell. The bearing support and the thrust plate may both include a plurality of openings allowing the working fluid and the lubricant to flow throughout the shell.
[0030] In some embodiments, a lubricant level within the first lubricant sumps may be defined by a location of a vertically lowest of one the plurality of openings.
[0031] In some embodiments, the first lubricant sump may be defined by an inner diametrical surface of the shell.
[0032] In some embodiments, the compressor may include a crankshaft, a bearing support, a thrust plate, and a counterweight. The crankshaft may drivingly engage the compression mechanism. The bearing support may rotatably support the crankshaft. The thrust plate may engage the compression mechanism and may be disposed between the compression mechanism and the bearing support. The first lubricant sump may be defined by the thrust plate, the bearing support, and the shell. The counterweight may be attached to the crankshaft and may rotate with the crankshaft. The counterweight may travel through lubricant in the first lubricant sump during rotation of the crankshaft and may splash the lubricant therein to transmit the lubricant to the compression mechanism.
[0033] In some embodiments, an eccentric portion of the counterweight may travel through lubricant in the first lubricant sump during less than one-hundred-eighty degrees of rotation of the crankshaft.
[0034] In some embodiments, the shell may define a lubricant passageway that is separated from the first and second lubricant sumps and in communication with an inlet of the compressor that is distinct from a working fluid inlet of the compressor.
[0035] In some embodiments, the lubricant passageway may extend longitudinally in a direction parallel to a rotational axis of a crankshaft driving the compression mechanism.
[0036] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood however that the detailed description and specific examples, while indicating preferred embodiments of the invention, are intended for purposes of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
[0038] FIGS. 1A-C are perspective views of a compressor according to the present teachings;
[0039] FIG. 2 is a cross-sectional view along line 2 - 2 of FIG. 1C ;
[0040] FIGS. 3A and 3B are perspective views of the shell of the compressor of FIG. 1 ;
[0041] FIG. 3C is an end view of the housing of FIG. 3A ;
[0042] FIG. 4 is an end view of another embodiment of the housing of FIG. 3C ;
[0043] FIG. 5 is a perspective view of the low-side cover of the compressor of FIG. 1 ;
[0044] FIG. 6 is a perspective view of the partition of the compressor of FIG. 1 ;
[0045] FIGS. 7 and 8 are perspective views of the non-orbiting scroll of the compressor of FIG. 1 ;
[0046] FIG. 9 is a cross-section view along line 9 - 9 of FIG. 8 ;
[0047] FIG. 10 is an enlarged fragmented cross-sectional view of a portion of the compressor of FIG. 1 showing features of the non-orbiting scroll and partition;
[0048] FIG. 11 is a cross-sectional view along line 11 - 11 of FIG. 3A ;
[0049] FIG. 12 is a perspective view of the thrust plate of the compressor of FIG. 1 ;
[0050] FIG. 13 is a perspective view of another embodiment of the thrust plate of the compressor;
[0051] FIG. 14 is a schematic view of the cooling system utilized with the compressor of FIG. 1 within a refrigeration system according to the present teachings; and
[0052] FIG. 15 is a schematic view of another cooling system for the lubricant utilized in a compressor and within a refrigeration system according to the present teachings.
DETAILED DESCRIPTION
[0053] The following description is merely exemplary in nature and is in no way intended to limit the present disclosure, its application, or uses.
[0054] Referring to FIGS. 1-3 and 10 , a compressor 20 according to the present teachings is shown. Compressor 20 is a semi-hermetic compressor having a housing or shell 22 with opposite ends 23 , 25 . A low-side (LS) end cap 24 is attached to end 23 and a partition member 26 and a high-side (HS) end cap 28 are attached to end 25 . LS end cap 24 , partition 26 , and HS end cap 28 can be attached to shell 22 with bolts or other types of fasteners, as known in the art. Other major elements affixed to shell 22 can include a working fluid inlet fitting 30 , a heat exchanger 32 , and an electronics box 31 that can communicate with sensors and other components within or outside compressor 20 . LS end cap 24 includes a lubricant inlet fitting 34 . HS end cap 28 may define a high-side lubricant sump and includes a lubricant outlet fitting 36 . HS end cap 28 can also include a working fluid discharge fitting 38 and a sight gauge 40 . Partition 26 can include a fluid injection inlet fitting 42 that communicates with an intermediate-pressure location in the compression members of the compressor, as described below. HS end cap 28 and partition 26 define a discharge chamber 46 , while LS end cap 24 , shell 22 , and partition 26 define a suction or intake chamber 48 .
[0055] Referring to FIGS. 2-4 and 11 , shell 22 is a single integral component or piece that can have various features machined therein. By way of non-limiting example, shell 22 can be a cast component. Various features are machined into shell 22 to provide precise alignment for the internal components to be assembled therein. Shell 22 includes a main bearing support 50 with a precision machined central opening 52 therein. Opening 52 is configured to receive a main bearing or bushing 54 to support an intermediate portion of a crankshaft 56 . Bearing 54 can be press fit into opening 52 .
[0056] Main bearing support 50 also includes a plurality of upper peripheral openings 58 that facilitate the flow of the working fluid and lubricant throughout shell 22 and compressor 20 . A lower portion 59 of main bearing support 50 is solid to prevent fluid flow therethrough and defines a portion of an intermediate lubricant sump, as described below. While FIG. 3C depicts the main bearing support 50 including three openings 58 , the main bearing support 50 may include four openings 58 , as shown in FIG. 4 . The four openings 58 shown in FIG. 4 may be arranged in a pattern that is both vertically and horizontally symmetrical (relative to the view shown in FIG. 4 ). Such an arrangement of the openings 58 maintains a relatively uniform stiffness across the main bearing support 50 , thereby providing evenly distributed support for the bearing 54 and crankshaft 56 . In still other embodiments not shown in the figures, the main bearing support 50 may include other numbers and arrangements of the openings 58 . For example, three apertures 58 , or any other number of apertures 58 , may be arranged to provide relatively uniform support for the bearing 54 and crankshaft 56 .
[0057] Shell 22 also includes a precision machined surface 60 adjacent end 25 . Surface 60 is cylindrical and acts as the pilot ring for compressor 20 . Surface 60 provides a precision surface for the mounting of a fixed or non-orbiting scroll 62 of a scroll assembly 64 . Surface 60 also provides a precision surface for the mounting of partition 26 . A precision machined shoulder 65 is adjacent surface 60 and provides a precision surface for mounting a thrust plate 112 in shell 22 . Shell 22 also includes a plurality of precision machined surfaces 66 adjacent first end 23 . Each surface 66 forms a part of a cylinder and collectively provide a precision surface for the precise alignment and centering of a stator 68 of a motor 70 within shell 22 . Surfaces 66 also provide a precision surface for the precise alignment and centering of LS end cap 24 . Ends 23 , 25 are also machined surfaces for the attachment of LS end cap 24 and partition 26 and HS end cap 28 to shell 22 .
[0058] Referring now to FIGS. 2 and 5 , LS end cap 24 includes a central recessed bore 72 and an outwardly projecting annular rim 74 circumscribing bore 72 and spaced radially inwardly from a periphery 76 of LS end cap 24 . An engaging surface 78 extends between rim 74 and periphery 76 . Engaging surface 78 is configured to engage against end 23 of shell 22 . A gasket or other sealing means can be disposed between surface 78 and end 23 to provide a fluid-tight seal therebetween, by way of non-limiting example. Bore 72 and rim 74 are precision machined surfaces in LS end cap 24 and provide precise centering of LS end cap 24 and crankshaft 56 within compressor 20 . Specifically, a bearing or bushing 82 is press fit into bore 72 and an end 96 of crankshaft 56 is disposed in bearing 82 . Rim 74 engages with multiple surfaces 66 to provide a precise centering of LS end cap 24 relative to shell 22 such that bore 72 is aligned with central opening 52 and crankshaft 56 is precisely located within compressor 20 .
[0059] Motor 70 includes stator 68 and a rotor 84 press fit onto crankshaft 56 . Stator 68 is press fit into shell 22 with the exterior surface of stator 68 engaging with multiple surfaces 66 . As such, surfaces 66 can provide a precise centering of stator 68 within shell 22 . The precision machined surfaces of opening 52 , surfaces 66 , bore 72 , and rim 74 facilitate precise alignment of crankshaft 56 and motor 70 within compressor 20 such that a precise gap exists between rotor 84 and stator 68 along with the proper alignment to the other components of compressor 20 .
[0060] Referring to FIG. 2 , crankshaft 56 has an eccentric crankpin 86 at one end 88 thereof. Crankpin 86 is rotatably journaled in a generally D-shaped inner bore of a drive bushing 90 disposed in a drive bearing 91 press fit into an orbiting scroll 92 of scroll assembly 64 , as described in more detail below. Drive bushing 90 has a circular outer diameter. An intermediate portion 94 of crankshaft 56 is rotatably journaled in bearing 54 of opening 52 in main bearing support 50 . The other end 96 of crankshaft 56 is rotatably journaled in bearing 82 in bore 72 of LS end cap 24 .
[0061] Crankshaft 56 has, at end 96 , a relatively large diameter, concentric bore 98 , which communicates with a radially outwardly smaller diameter bore 100 extending therefrom to end 88 . Bores 98 , 100 form an internal lubricant passageway 102 in crankshaft 56 . Lubricant is supplied to bore 98 through a lubricant passageway 104 in LS end cap 24 that communicates with inlet fitting 34 .
[0062] Crankshaft 56 is rotatably driven by electric motor 70 including rotor 84 and stator 68 . A first counterweight 106 is coupled to rotor 84 adjacent end 96 of crankshaft 56 . A second counterweight 108 is attached to crankshaft 56 between end 88 and intermediate portion 94 .
[0063] Referring now to FIGS. 2 and 11 - 12 , a thrust plate 112 is disposed in compressor 20 against machined shoulder 65 between end 25 and main bearing support 50 . Thrust plate 112 may be secured within shell 22 with a plurality of fasteners that engage with complementing bores 116 in shell 22 , by way of non-limiting example. Thrust plate 112 can thereby be fixedly secured within shell 22 with the surface of thrust plate 112 against shoulder 65 . The opposite side of thrust plate 112 includes an annular thrust-bearing surface 114 which axially supports orbiting scroll 92 . Thrust plate 112 includes a central opening 120 and a plurality of upper peripheral openings 122 . Openings 122 are arranged on thrust plate 112 such that thrust plate 112 has a lower solid section 124 below central opening 120 . Solid section 124 defines a portion of an intermediate lubricant sump, as described below. Openings 122 allow fluids, such as lubricant and working fluid, to flow throughout compressor 20 .
[0064] While FIG. 12 depicts the thrust plate 112 including three openings 122 , the thrust plate 112 having four openings 122 , as shown in FIG. 13 . The four openings 122 shown in FIG. 13 may be arranged in a pattern that may provide a relatively uniform stiffness across the thrust plate 112 , thereby providing relatively evenly distributed support for the orbiting scroll 92 and reduces uneven deflection of the thrust plate 112 caused by axial forces exerted on the thrust plate 112 by the orbiting scroll 92 . In still other embodiments not shown in the figures, the thrust plate 112 may include other numbers and arrangements of the openings 122 . For example, three apertures 112 (or any other number of apertures 112 ) may be arranged to provide relatively uniform stiffness across the thrust plate 112 and evenly distributed support for the orbiting scroll 92 .
[0065] Orbiting scroll 92 includes a first spiral wrap 128 on a first surface thereof. The opposite or second surface of orbiting scroll 92 engages with thrust-bearing surface 114 of thrust plate 112 and includes a cylindrical hub 130 that projects therefrom and extends into central opening 120 of thrust plate 112 . Rotatably disposed within hub 130 is bushing 90 in which crankpin 86 is drivingly disposed. Crankpin 86 has a flat on one surface which drivingly engages the flat surface of the inner bore to provide a radially compliant driving arrangement, such as shown in Assignee's U.S. Pat. No. 4,877,382, the disclosure of which is hereby incorporated by reference.
[0066] An Oldham coupling 136 is disposed between orbiting scroll 92 and thrust plate 112 . Oldham coupling 136 is keyed to orbiting scroll 92 and non-orbiting scroll 62 to prevent rotational movement of orbiting scroll 92 . Oldham coupling 136 is preferably of the type disclosed in Assignee's U.S. Pat. No. 5,320,506, the disclosure of which is hereby incorporated by reference. A seal assembly 138 is supported by non-orbiting scroll 62 and engages a seat portion 140 of partition 26 for sealingly dividing suction chamber 48 from discharge chamber 46 . Seal assembly 138 can be the same as that disclosed in Assignee's U.S. patent application Ser. No. 12/207,051, the disclosure of which is incorporated herein by reference.
[0067] Referring now to FIGS. 2 and 7 - 10 , non-orbiting scroll 62 includes a second spiral wrap 142 positioned in meshing engagement with first spiral wrap 128 of orbiting scroll 92 . Non-orbiting scroll 62 has a centrally disposed discharge passage or port 144 defined by a base-plate portion 146 . Non-orbiting scroll 62 also includes an annular hub portion 148 , which surrounds discharge passage 144 . A unitary shutdown device or discharge valve 150 can be provided in discharge passage 144 . Discharge valve 150 is shown as a normally closed valve. During operation of compressor 20 , the valve may be in an open position or a closed position depending on pressure differentials between discharge passage 144 and discharge chamber 46 as well as the design of discharge valve 150 . When operation of compressor 20 ceases, discharge valve 150 closes.
[0068] Non-orbiting scroll 62 includes a machined peripheral surface 154 that is dimensioned for a clearance fit with surface 60 of shell 22 . As a result of the precision machining of surface 60 and peripheral surface 154 , non-orbiting scroll 62 is precisely centered within compressor 20 . Non-orbiting scroll 62 includes an opening 156 adjacent to peripheral surface 154 and extends through base plate portion 146 . Opening 156 is configured to receive an anti-rotation pin 157 which extends from partition 26 to prevent rotation of non-orbiting scroll 62 within compressor 20 . A bleed opening 158 extends through base-plate portion 146 and allows compressed fluid between first and second wraps 128 , 142 to bleed into an intermediate cavity 160 between non-orbiting scroll 62 and partition 26 . The bleed opening 158 allows pressurized fluid to enter cavity 160 and bias non-orbiting scroll 62 toward orbiting scroll 92 .
[0069] Non-orbiting scroll 62 includes a first radially extending passageway 162 that can receive a temperature probe 164 measuring non-orbiting scroll 62 temperature near the discharge pressure region. By way of non-limiting example, temperature probe 164 could be a positive temperature coefficient thermistor, a negative temperature coefficient thermistor or a thermocouple. Non-orbiting scroll 62 can include a second radial passage 166 that communicates with two branches 168 , 170 . Passage 166 communicates with inlet fitting 42 that extends through partition 26 . At the end portions of each branch 168 , 170 are a pair of axially extending openings 172 that extends into the compression cavities formed between first and second wraps 128 , 142 . Passage 166 , branches 168 , 170 , and openings 172 allow a fluid to be injected into the compression cavities between first and second wraps 128 , 142 at intermediate pressure locations.
[0070] Referring now to FIGS. 2 , 6 , and 10 , partition 26 includes a machined engaging surface 176 that extends adjacent the periphery and a machined-raised annular rim 178 extending from engaging surface 176 . Engaging surface 176 engages with end 25 of shell 22 . A gasket or other sealing means can be disposed between surface 176 and end 25 to provide a fluid-tight seal therebetween, by way of non-limiting example. Rim 178 engages with precision machined surface 60 of shell 22 to provide precise centering of partition 26 relative to shell 22 . Rim 178 is dimensioned to form a clearance fit against surface 60 of shell 22 . Rim 178 may axially engage with an engaging surface 192 on non-orbiting scroll 62 adjacent its periphery. Engagement of rim 178 with engaging surface 192 limits the axial positioning of non-orbiting scroll 62 within shell 22 . Partition 26 includes a central seat portion 140 that faces non-orbiting scroll 62 and forms a portion of the intermediate cavity 160 that allows pressurized fluid to bias non-orbiting scroll 62 toward orbiting scroll 92 . Partition 26 includes a plurality of openings 182 adjacent the periphery for fastening to shell 22 in conjunction with HS end cap 28 with fasteners. Partition 26 includes an opening 184 in rim 178 that is configured to receive anti-rotation pin 157 that engages with opening 156 in non-orbiting scroll 62 to prevent rotation of non-orbiting scroll 62 within compressor 20 . A pair of radial passages 186 , 188 is provided in the periphery of partition 26 to receive temperature probe 164 and inlet fitting 42 coupled to an internal fluid injection tube 187 , respectively. Partition 26 includes a second engaging surface 190 on an opposite side from engaging surface 176 . Engaging surface 190 is machined and is configured to engage with a complementary machined engaging surface 194 of HS end cap 28 . A gasket or other sealing means can be disposed between engaging surfaces 190 , 194 to provide a fluid-tight seal therebetween, by way of non-limiting example.
[0071] Partition 26 includes a central opening 198 that communicates with discharge passage 144 and discharge valve 150 on one side thereof and with a fluid filter/separator 200 on an opposite side thereof. Partition 26 separates the suction chamber 48 from discharge chamber 46 .
[0072] During operation of compressor 20 , working fluid and lubricant flow from suction chamber 48 through lower scroll intake 202 and into the chambers formed between first and second wraps 128 , 142 and are subsequently discharged through discharge passage 144 , discharge valve 150 and through opening 198 in partition 26 and into separator 200 in discharge chamber 46 . Within separator 200 , the lubricant is separated from the working fluid and the lubricant falls, via gravity, to the lower portion of discharge chamber 46 while the working fluid is discharged from discharge chamber 46 through discharge fitting 38 in HS end cap 28 .
[0073] Referring to FIGS. 1-2 , outlet fitting 36 in HS end cap 28 communicates with discharge chamber 46 and the lubricant therein. A lubricant line 210 extends from outlet fitting 36 and into a top portion of heat exchanger 32 through a fitting 212 . A lubricant return line 214 extends from a fitting 216 on a lower portion of heat exchanger 32 to inlet fitting 34 on LS end cap 24 . Discharge chamber 46 is at a discharge pressure while suction chamber 48 is at a suction pressure, typically less than the discharge pressure. The pressure differential causes the lubricant to flow from discharge chamber 46 to suction chamber 48 through heat exchanger 32 . Specifically, the lubricant flows through lubricant line 210 , through heat exchanger 32 , through return line 214 , and passageway 104 in LS end cap 24 . From passageway 104 , the lubricant flows into bearing 82 to lubricate bearing 82 along with end 96 of crankshaft 56 . The lubricant also flows into the large bore 98 and then through small bore 100 as it travels to end 88 of crankshaft 56 . When crankshaft 56 is rotating, the centrifugal force causes the lubricant to flow from large bore 98 to small bore 100 and onto end 88 . The lubricant exits end 88 and flows into and around drive bushing 90 in the hub 130 of orbiting scroll 92 .
[0074] The lubricant flowing out of end 88 falls by gravity into an intermediate sump 222 . Intermediate sump 222 is defined by solid section 124 of thrust plate 112 and solid lower portion 59 of main bearing support 50 . Lubricant may accumulate in intermediate sump 222 during operation of compressor 20 . During rotation of crankshaft 56 , counterweight 108 travels through the lubricant in intermediate sump 222 and splashes or sloshes the lubricant therein throughout the space between main bearing support 50 and thrust plate 112 such that Oldham coupling 136 and the interface between thrust plate 112 and orbiting scroll 92 receive lubrication. The lubricant flow provides lubrication and a cooling effect.
[0075] Lubricant within bore 72 of LS end cap 24 can flow downward via gravity and some lubricant may accumulate in a motor area 220 around the lower portion of stator 68 and rotor 84 . Motor area 220 is defined by the opposite side of solid lower portion 59 of main bearing support 50 , shell 22 , and LS end cap 24 . The lubricant exiting bore 72 drops to the bottom of shell 22 and flows to the scroll side of shell 22 through a passageway 226 , as described below.
[0076] Passageway 226 extends between motor area 220 and the far side of thrust plate 112 adjacent lower scroll intake 202 . Passageway 226 can be machined through main bearing support 50 of shell 22 . The separation of passageway 226 from intermediate sump 222 advantageously allows some lubricant to collect or pool in intermediate sump 222 for lubrication of the components therein and adjacent or approximate thereto via the rotation of crankshaft 56 and of counterweight 108 . The engagement of thrust plate 112 with shoulder 65 of shell 22 may provide a semi-fluid-tight engagement wherein lubricant in intermediate sump 222 can pool while still allowing some lubricant to flow out as it is being replaced by incoming lubricant exiting end 88 of crankshaft 56 , thereby providing continuous flow into and out of intermediate sump 222 . The solid section 124 and solid section 59 thereby form an intermediate sump 222 that can pool lubricant therein during operation of compressor 20 . These features may be cast into thrust plate 112 and shell 22 . As shown in FIG. 2 , the nominal operational lubricant level in intermediate sump 222 is significantly higher than in motor area 220 . The nominal operational lubricant level in discharge chamber 46 is also shown.
[0077] In operation, motor 70 is energized causing crankshaft 56 to begin rotating about its axis, thereby causing orbiting scroll 92 to move relative to non-orbiting scroll 62 . This rotation pulls working fluid into suction chamber 48 . Within suction chamber 48 , working fluid and lubricant mix together and are pulled into lower scroll intake 202 and between first and second wraps 128 , 142 of orbiting and non-orbiting scrolls 92 , 62 . The working fluid and lubricant are compressed therein and discharged through discharge passage 144 and discharge valve 150 to discharge pressure. The discharged working fluid and lubricant flow into lubricant separator 200 wherein the working fluid passes therethrough and the lubricant therein is entrapped and flows, via gravity, into the bottom portion of discharge chamber 46 . The working fluid flows out of discharge chamber 46 through discharge fitting 38 and into the system within which compressor 20 is utilized. If the system is a closed system, the working fluid, after passing through the system, flows back into suction chamber 48 of compressor 20 via inlet fitting 30 .
[0078] Referring now to FIGS. 1 and 14 , cooling of the lubricant when compressor 20 is utilized in conjunction with an exemplary refrigeration system 250 is shown. Refrigeration system 250 includes compressor 20 that compresses the working fluid (e.g., refrigerant) flowing therethrough from a suction pressure to a discharge pressure greater than the suction pressure. Inlet fitting 30 is in fluid communication with a suction line 254 and with suction chamber 48 . Discharge fitting 38 is in fluid communication with a discharge line 256 that receives compressed working fluid from discharge chamber 46 of compressor 20 . Inlet fitting 42 forms an intermediate-pressure port that communicates with the compression cavities of scroll assembly 64 in compressor 20 at a location that corresponds to an intermediate pressure between the discharge pressure and the suction pressure. Inlet fitting 42 can thereby supplies a fluid to the compression cavities of compressor 20 at an intermediate-pressure location.
[0079] Discharge working fluid flowing through discharge line 256 flows into a condenser 258 wherein heat Q 1 is removed from the working fluid flowing therethrough. Heat Q 1 can be discharged to another fluid flowing across condenser 258 . By way of non-limiting example, heat Q 1 can be transferred to an airflow 261 flowing across condenser 258 induced by a fan 260 . Working fluid flowing through condenser 258 can be condensed from a high-temperature, high-pressure vapor-phase working fluid into a reduced-temperature, high-pressure condensed liquid working fluid.
[0080] The condensed working fluid flows from condenser 258 into heat exchanger 32 via a condensed working fluid line 262 . The condensed working fluid can enter a top portion of heat exchanger 32 through a fitting 264 . The working fluid exits heat exchanger 32 through another line 266 . Line 266 can be coupled to a lower portion of heat exchanger 32 and communicate therewith via a fitting 268 . Within heat exchanger 32 , heat Q 2 is removed from the condensed working fluid flowing therethrough, as described below. As a result, the condensed working fluid is sub-cooled and exits heat exchanger 32 at a lower temperature then when entering heat exchanger 32 .
[0081] The sub-cooled condensed working fluid in line 266 flows through a main throttle or expansion device 270 . The working fluid flowing through expansion device 270 expands and a further reduction in temperature occurs along with a reduction in pressure. Expansion device 270 can be dynamically controlled to compensate for a varying load placed on refrigeration system 250 . Alternatively, expansion device 270 can be static.
[0082] The expanded working fluid downstream of expansion device 270 flows through line 272 into an evaporator 274 . Within evaporator 274 , the working fluid absorbs heat Q 3 and may transform from a low-temperature, low-pressure liquid working fluid into an increased-temperature, low-pressure vapor working fluid. The heat Q 3 absorbed by the working fluid can be extracted from an airflow 276 that is induced to flow across evaporator 274 by a fan 278 , by way of non-limiting example.
[0083] Suction line 254 is coupled to evaporator 274 such that working fluid exiting evaporator 274 flows through suction line 254 and back into suction chamber 48 of compressor 20 , thereby forming a closed-system.
[0084] The lubricant from compressor 20 can also flow through heat exchanger 32 , as described above with reference to compressor 20 . Specifically, lubricant can flow, via the pressure difference between discharge chamber 46 and suction chamber 48 , from discharge chamber 46 , through heat exchanger 32 , and back into suction chamber 48 . Within heat exchanger 32 , heat Q 4 can be removed from the lubricant flowing therethrough. As a result, the temperature of the lubricant exiting heat exchanger 32 is less than the temperature of the lubricant entering heat exchanger 32 .
[0085] Compressor 20 and refrigeration system 250 utilize expanded condensed working fluid to absorb heat Q 2 and Q 4 in heat exchanger 32 . Specifically, an economizer circuit can be used to sub-cool the condensed working fluid in heat exchanger 32 . Sub-cooling the condensed working fluid prior to the working fluid flowing through expansion device 270 can increase the capacity of the working fluid to absorb heat Q 3 in evaporator 274 and thereby increase the cooling capacity of refrigeration system 250 .
[0086] To provide the sub-cooling, a portion of the working fluid flowing through line 266 downstream of heat exchanger 32 may be routed through an economizer line 280 , expanded in an economizer expansion device 282 (thereby reducing the temperature and pressure), and directed into heat exchanger 32 through line 284 . Specifically, the economizing working fluid can be routed into a lower portion of heat exchanger 32 through a fitting 286 . The expanded economizing working fluid in line 284 may be in a liquid state, a vapor state, or in a two-phase liquid and vapor state. The economizing working fluid can flow upwardly through heat exchanger 32 and exit into an injection line 288 which is connected to inlet fitting 42 of partition 26 . Specifically, the economizing working fluid can exit an upper portion of heat exchanger 32 through a fitting 290 coupled to injection line 288 .
[0087] Within heat exchanger 32 , the economizing working fluid absorbs heat Q 2 from the condensed working fluid entering heat exchanger 32 through line 262 such that the temperature of the condensed working fluid is reduced (i.e., sub-cooled). The economizing working fluid exiting heat exchanger 32 through injection line 288 is injected into an intermediate-pressure location of scroll assembly 64 through inlet fitting 42 and radial passage 166 , branches 168 , 170 , and openings 172 in non-orbiting scroll 62 .
[0088] Compressor 20 and refrigeration system 250 advantageously utilize the economizer circuit to cool the lubricant flowing through compressor 20 . Specifically, within heat exchanger 32 , heat Q 4 is transferred from the lubricant into the economizing working fluid. As a result, the temperature of the lubricant exiting heat exchanger 32 , via line 214 , is reduced. Heat exchanger 32 thereby functions as a dual-system heat exchanger.
[0089] Expansion device 282 may be a dynamic device or a static device, as desired, to provide a desired economizer effect and cooling of the lubricant. Expansion device 282 can maintain the pressure in injection line 288 above the pressure at the intermediate-pressure location of the compression cavities that communicate with inlet fitting 42 . The working fluid injected into the intermediate-pressure locations may be in a vapor state, a liquid state, or a two-phase, liquid-vapor state. The injection of the economizing working fluid into an intermediate-pressure location of the scroll assembly 64 may advantageously cool the scrolls and reduce the discharge temperature.
[0090] The use of heat exchanger 32 to extract both heat flows Q 2 and Q 4 can provide a lower complexity and/or less expensive refrigeration system wherein a single heat exchanger can provide both the sub-cooling of the condensed working fluid and the cooling of the lubricant. Additionally, the use of the economizing working fluid to cool the lubricant eliminates the need for a separate or different cooling system for the lubricant along with the use of possibly a different medium to cool the lubricant, such as chilled water. Moreover, the integration of these features into a single heat exchanger 32 allows the heat exchanger to be easily integrated onto compressor 20 such that a more compact design can be achieved, along with reducing the system footprint.
[0091] Optionally, the economizer circuit can utilize condensed refrigerant downstream of condenser 258 and upstream of heat exchanger 32 . Specifically, as shown in phantom in FIG. 14 , economizer line 280 ′ can extend from line 262 to expansion device 282 . When this is the case, economizer line 280 is not utilized. As a result, a portion of the condensed working fluid flowing through line 262 is routed to expansion device 282 through economizer line 280 ′ and expanded thereacross to form the economizing working fluid flow through heat exchanger 32 . The remaining operation of refrigeration system 250 is the same as that discussed above.
[0092] Referring now to FIG. 15 , an alternate configuration for cooling the lubricant is schematically illustrated in a refrigeration system 300 . Refrigeration system 300 is similar to refrigeration system 250 , discussed above, and the same reference numerals are utilized to indicate the same or similar components, lines, features, etc. As such, only the main differences between refrigeration system 300 and refrigeration system 250 are discussed in detail.
[0093] A difference in refrigeration system 300 is that a single dual-system heat exchanger 32 is not utilized. Rather, in refrigeration system 300 , two separate heat exchangers 302 , 304 are utilized. In refrigeration system 300 , heat exchanger 302 functions as an economizer heat exchanger to sub-cool the condensed working fluid flowing therethrough while heat exchanger 304 functions to reduce the temperature of the lubricant flowing therethrough. Specifically, a line 305 extends from expansion device 282 to heat exchanger 302 and directs the expanded working fluid into heat exchanger 302 . Within heat exchanger 302 , heat Q 2 is absorbed by the expanded working fluid from the condensed working fluid entering in heat exchanger 302 through line 262 . As a result, the condensed working fluid is sub-cooled in heat exchanger 302 by the expanded working fluid.
[0094] The expanded working fluid exits heat exchanger 302 through a line 306 and flows into heat exchanger 304 . Heat exchanger 304 operates as a lubricant heat exchanger. Lubricant line 210 extends from compressor 20 into heat exchanger 304 and lubricant return line 214 extends from heat exchanger 304 back to compressor 20 . Within heat exchanger 304 , heat Q 4 is removed from the lubricant flowing therethrough and transferred into the expanded working fluid flowing through heat exchanger 304 . As a result, the temperature of the lubricant flowing through heat exchanger 304 is reduced.
[0095] The expanded working fluid exits heat exchanger 304 and is injected into an intermediate-pressure location within scroll assembly 64 in compressor 20 through injection line 288 , as discussed above. The expanded working fluid flowing through heat exchangers 302 , 304 can enter therein and exit therefrom in a liquid state, a vapor state, or a two-phase, liquid-vapor state.
[0096] Optionally, in refrigeration system 300 , the sub-cooling of the condensed working fluid can be eliminated. In such an arrangement, heat exchanger 302 and lines 266 and 306 would not be present. Rather, condensed working fluid is extracted from line 262 prior to flowing through expansion device 270 , expanded through expansion device 282 , and provided to heat exchanger 304 through expanded working fluid line 305 ′ (shown in phantom). In this configuration, the working fluid expanded by expansion device 282 is utilized to absorb a single heat flow Q 4 from the lubricant flowing through heat exchanger 304 . As a result, the temperature of lubricant from heat exchanger 304 is reduced. The expanded working fluid exiting heat exchanger 304 is injected into an intermediate-pressure location of compressor 20 through injection line 288 , as discussed above.
[0097] Thus, in refrigeration system 300 , condensed working fluid can be expanded and utilized to sub-cool the condensed working fluid and/or cool the lubricant that flows through compressor 20 . The use of the expanded working fluid can advantageously reduce system complexity and cost by avoiding the necessity of a different external cooling media for cooling the lubricant. Additionally, the use of the expanded working fluid can allow for a space-saving configuration, wherein heat exchanger(s) 302 and/or 304 can be attached to compressor 20 . As a result, a space-saving system can be realized with a reduced system footprint.
[0098] Thus, a compressor and refrigeration system according to the present teachings can advantageously utilize condensed working fluid that is subsequently expanded to reduce the temperature of the lubricant that flows through the compressor. The cooling of the lubricant can be coordinated with an economizer circuit that sub-cools the condensed working fluid. As a result, external cooling media or sources to cool the lubricant are not required. Additionally, a more compact design can be utilized by attaching the one or more heat exchanger(s) to the compressor. In some embodiments, a dual-system heat exchanger can be utilized to both sub-cool the condensed working fluid and cool the lubricant. In other embodiments, separate heat exchangers can be utilized. In some embodiments, expanded working fluid can be utilized without sub-cooling the condensed liquid working fluid line, wherein only the lubricant is cooled with the expanded working fluid. In all of these embodiments, the expanded working fluid that absorbs heat is injected into an intermediate-pressure location of the compressor. The reduction in the temperature of the lubricant can result in a lower injected lubricant temperature, which can reduce suction gas superheat, thereby improving compressor volumetric efficiency and improving performance. Additionally, the reduced lubricant temperature can improve compressor reliability due to the cooling of the suction gas and the motor, and maintain a desirable level of viscosity to achieve proper film thickness between moving parts of the compressor.
[0099] The incorporation of various machined surfaces into the shell of the compressor advantageously facilitates the precise alignment, both centering and axially, of various components within the compressor. The machining of the shell can be accomplished with a single setup thereby providing efficient manufacturing. Additionally, the machined surfaces are all round features that facilitate easy of machining. The components engaging with the machined surfaces of the shell may also be efficiently manufactured. Thus, the compressor may provide superior alignment and/or efficient manufacturing of the compressor.
[0100] The forming of an intermediate sump in the compressor between the main bearing support and the thrust plate can advantageously facilitate the lubricating of the orbiting scroll and related components. The thrust plate, the shell, and the main bearing support can define the intermediate sump. The inclusion of the counter weight on the crankshaft between the main bearing support and the orbiting scroll can advantageously travel through lubricant in the intermediate sump and splash and slosh the lubricant on the components in the area of the intermediate sump. A bypass groove can be machined into the shell to bypass the intermediate sump to allow lubricant to flow from the area of the motor (low side) to the lower scroll intake.
[0101] While the present invention is shown on a horizontal compressor with the motor within the shell, the invention can also be utilized in an open-drive compressor wherein the motor is external to the shell and drives a shaft that extends through the shell.
[0102] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A compressor may include a shell, a compression mechanism, a crankshaft, a bearing support, and a lubricant sump. The compression mechanism may be disposed in the shell and may compress a working fluid. The crankshaft may be disposed at least partially in the shell and may drivingly engage the compression mechanism. The bearing support may rotatably support the crankshaft. The lubricant sump may retain a volume of lubricant and may be disposed between the bearing support and the compression mechanism.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to Christmas light apparatus, and more particularly pertains to a new and improved Christmas light mounting apparatus wherein the same is arranged for permanent mounting to an exterior surface of a building or dwelling.
2. Description of the Prior Art
Various Christmas light mounting structure is available in the prior art and exemplified by U.S. Pat. Nos. 4,821,158; 5,024,406; 4,714,219; 4,769,749; and 3,883,926.
The instant invention attempts to overcome deficiencies of the prior art by the employment of a housing structure arranged to afford protection to Christmas tree lights during periods of non-use, wherein the housing is arranged for opening to permit viewing of the light members during the Christmas season.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of Christmas light mounting structure now present in the prior art, the present invention provides a Christmas light mounting apparatus wherein the same is directed for the selective viewing of Christmas lights contained within a housing. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved Christmas light mounting apparatus which has all the advantages of the prior art Christmas light mounting structure and none of the disadvantages.
To attain this, the present invention provides an elongate housing structure having a base plate, a first planar cover plate, and a second V-shaped cover plate hingedly mounted to the first planar cover plate, provided to selectively provide viewing of Christmas tree sockets and bulbs contained within the housing structure for permanent mounting relative to an exterior surface of a dwelling.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved Christmas light mounting apparatus which has all the advantages of the prior art Christmas light mounting structure and none of the disadvantages.
It is another object of the present invention to provide a new and improved Christmas light mounting apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved Christmas light mounting apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved Christmas light mounting apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such Christmas light mounting apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved Christmas light mounting apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is an isometric illustration of the invention mounted to an exterior surface of a dwelling.
FIG. 2 is an enlarged isometric illustration of section 2 as set forth in FIG. 1.
FIG. 3 is an orthographic view, taken along the lines 3--3 of FIG. 2 in the direction indicated by the arrows.
FIG. 4 is an enlarged orthographic view of section 4 as set forth in FIG. 3.
FIG. 5 is an orthographic view, taken along the lines 5--5 of FIG. 3 in the direction indicated by the arrows.
FIG. 6 is an orthographic view, taken along the lines 6--6 of FIG. 3 in the direction indicated by the arrows.
FIG. 7 is an enlarged orthographic cross-sectional illustration, taken along the lines 7--7 of FIG. 6 in the direction indicated by the arrows.
FIG. 8 is an enlarged orthographic view of section 8 as set forth in FIG. 7.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 8 thereof, a new and improved Christmas light mounting apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, the Christmas light mounting apparatus 10 of the instant invention essentially comprises a base plate 11 arranged for mounting to an eave or other suitable exterior surfaces of an associated dwelling, as indicated in FIG. 1. The base plate is formed with a rear wall 12 and a front wall 13 (see FIGS. 2 and 3 for example), with a row of spaced bulb sockets 14 mounted to the front wall 13, with each of the bulb sockets having a bulb member 15 therewithin for selective illumination in a manner known in the prior art. A first planar cover plate 16 is mounted from an uppermost edge of the base plate 11 defining an acute first angle 17 between the front wall 13 and the first cover plate 16. Spaced ferrous metallic plates 18 are mounted to an exterior surface of the first planar cover plate 16. A second V-shaped cover plate 19 is pivotally mounted to the first cover plate 16 about a hinge 22. The second cover plate 19 includes a second plate first web 20 mounted to the hinge 22, having a row of first magnets 21 mounted to an exterior surface of the second plate first web 20 for selective engagement with the first ferrous metallic plates 18 to secure the second V-shaped cover plate 19 in a raised orientation relative to the first cover plate 16 to provide for visual viewing of the bulb members 15 during use during the Christmas season and the like. The second cover plate first web 20 mounted to the second cover plate second web 23 defines a second acute angle 24 therebetween. The second web is formed with a second web end 25 arranged for selective communication with the front wall 13, with a first end of the second web 23 mounted to the first web 20. The second web second end 25 includes a sealing strip 26 and a second magnet 27. A plurality of such second magnets may be provided if desired, with at least one of second magnets 27 provided for securement to a second ferrous metallic plate 28 mounted to the front wall 13 to secure the second V-shaped cover plate 19 into engagement selectively with the base plate 11, in a manner as indicated in FIGS. 1-4. An electrical conductive cable 29 is illustrated in the FIG. 5 to provide for electrical communication between the various bulbs 15 and secured to the front wall 13 by securement flanges 30.
FIG. 6 indicates the use of a plurality of base plate apertures, having base plate apertures first bores 31 (see FIG. 7 and FIG. 8), with the first bores 31 coaxially aligned with second bores 32. The first bores have a first diameter greater than a second diameter of the second bore to provide for an abutment wall 36 intermediate the rear and front walls 12 and 13 extending from each first bore 31 to each respective second bore 32 to receive a fastener 37 into the first and second bores, with the fastener having a fastener head received within the first bore, and the fastener having a fastener shank received through the second bore. An annular piercing blade 33 is mounted within the second bore in contiguous communication into the first bore and in contiguous communication with a torroidal frangible ring 34 mounted onto the abutment wall 36, whereupon projection of the fastener into the first and second bores effects destruction of the torroidal frangible ring 34 releasing a fluid adhesive 35 to insure engagement and bonding of the fastener, as well as the base plate 11 to the associated dwelling in a mounted configuration. The first and second bores, as illustrated, are mounted within a projecting boss 38 that projects rearwardly of the rear wall 12 to space the base plate 11 from the dwelling to minimize accumulation of mold and mildew between the base plate 11 and the associated dwelling and thereby eliminate associated accelerated deterioration of paint and the like positioned between the base plate 11 and the exterior surface of the dwelling.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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An elongate housing structure having a base plate, a first planar cover plate, and a second V-shaped cover plate hingedly mounted to the first planar cover plate is provided to selectively provide viewing of Christmas tree sockets and bulbs contained within the housing structure for permanent mounting relative to an exterior surface of a dwelling.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of partially or fully implantable hearing aids comprising a transducer which provides direct mechanical excitation of the middle or inner ear. More specifically, this invention relates to such transducers including a housing which can be fixed at the implantation site and a coupling element which can move with respect to the housing, the housing accommodating a piezoelectric element by which the coupling element can transmit vibrations from the piezoelectric element to the middle ear ossicle or directly to the inner ear.
2. Description of Related Art
A transducer of this general type is illustrated in U.S. Pat. No. 5,277,694. In this patent, it is proposed that one wall of the housing be made as a vibrating membrane with an electromechanically active heteromorphic composite element with a piezoelectric ceramic disk attached to the side of the membrane inside the housing. Generally good results have been obtained with a hearing aid transducer built in this manner. However, it has been found that at low frequencies, the coupling element driven by the piezoelectric ceramic disk does not create sufficient deflections to provide adequate loudness level for patients with medium and more serious hearing loss. This insufficient deflection has been attributed, in part, to be caused by the low electrical voltages required for such implants.
U.S. Pat. No. 5,624,376 discloses a transducer for partially or fully implantable hearing aids based on the electromagnetic principle in which a permanent magnet is permanently joined to hermetic housing. An induction coil which interacts with the magnet is permanently joined to the housing wall which is made as a vibratory membrane. On the side of the vibratory membrane outside the housing, the vibratory membrane is provided with a clip element which attaches the transducer to the incus. As AC voltage is applied to the induction coil, the magnet within the housing is displaced thereby causing vibrational excitation of the incus.
The disadvantage of hearing aids provided with these electromagnetic transducers is that the transducer deflection at high frequencies can be too small to achieve a sufficient loudness level for the user. It has been found that in such electromagnetic systems, the electrical impedance increases simultaneously at higher frequencies because of the inductive component. Therefore, broadband electromagnetic systems, for example, those which allow transmission up to 10 kHz, have a high power consumption when compared to piezoelectric systems.
Therefore, there exists an unfulfilled need for partially or fully implantable hearing aids comprising transducers which provide direct mechanical excitation of the middle or inner ear at a sufficient loudness levels at a wide range of frequencies. There also exists an unfulfilled need for such hearing aids which use relatively little amount energy.
SUMMARY OF THE INVENTION
In view of the forgoing, the primary object of the present invention is to devise a hearing aid comprising a transducer which is mechanically coupled to a middle ear ossicle or directly to the inner ear for transmission of vibration.
A second object of the present invention is to devise a hearing aid comprising a transducer of the initially mentioned type which can generate sufficient deflection to achieve sufficient loudness level at a wide range of frequencies.
Yet another object of the present invention is to devise a hearing aid comprising a transducer which accomplishes the above objectives and at the same time, uses relatively little energy.
These objects are achieved by providing a hearing aid which comprises a transducer including a housing accommodating a piezoelectric element and an electromagnet arrangement. The electromagnet arrangement includes an electromagnetic component which is fixed relative to the housing and a vibratory component which is connected to the coupling element such that the vibrations of the vibratory component are transferred to the coupling element.
The present invention has advantages over the prior art hearing aids in that the frequency response of the transducer can be improved as compared to purely piezoelectric and also purely electromagnetic systems so that sufficient loudness level is attained. Additionally, the present invention provides flat frequency response with respect to the deflection of the coupling element over a wide frequency band, even when the stimulation levels are high while at the same time, maintaining low power consumption.
More specifically, in one preferred embodiment, one wall of the transducer housing may be made to vibrate and thus, may be formed as a vibratory membrane. The vibratory membrane may be provided with a piezoelectric element attached to the side of the membrane inside the housing, and a coupling element connected to the side of the membrane outside the housing. The combination of the passive vibratory membrane and the active piezoelectric element which may be disk-shaped, forms a heteromorphic, piezoelectric bending oscillator. In the oscillator, the theoretical change in the radius of the disk-shaped piezoelectric element, which would occur upon application of an electrical voltage to the piezoelectric element, is transformed into bending of the composite element perpendicularly to the plane of the plate thereby allowing large deflections at small voltages at the higher frequencies.
Furthermore, in a transducer of a hearing aid in accordance with the present invention, an electromagnet arrangement is provided in conjunction with the piezoelectric element. A vibratory component of the electromagnet arrangement is connected to the side of the piezoelectric element inside the housing and may be made as a permanent magnet. In addition, the electromagnet arrangement includes an electromagnetic component fixedly attached in the housing. The electromagnetic component may be an electromagnetic coil thereby causing the vibratory component such as a permanent magnet to vibrate when voltage is applied to the electromagnetic component. This represents especially feasible coupling of the electromagnet arrangement and the piezoelectric element.
According to one modified embodiment, the permanent magnet may be directly connected to the vibratory membrane through a center opening in the piezoelectric element.
In other embodiments, the transducer of the hearing aid of the present invention may have associated thereto a control arrangement which selectively causes the piezoelectric element and/or the electromagnet arrangement to vibrate. This allows optimization of the frequency response of the transducer such that only the piezotransducer or the electromagnetic transducer is operated or both may be operated simultaneously.
Preferred embodiments of this invention are described below with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a sectional view of a transducer for a hearing aid in accordance with one embodiment of the present invention.
FIG. 2 shows an electrical schematic of a hearing aid comprising the transducer of FIG. 1.
FIG. 3A shows, in schematic form, the wiring of a hearing aid comprising a transducer in accordance with another embodiment of the present invention.
FIG. 3B shows an alternative wiring of a hearing aid having a transducer in accordance with yet another embodiment of the present invention.
FIG. 4 illustrates a sectional view of another embodiment of a transducer for a hearing aid in accordance with the present invention.
FIG. 5 illustrates a sectional view of yet another embodiment of a transducer for a hearing aid in accordance with the present invention.
FIG. 6 shows a sectional view of a human ear with an implanted hearing aid in accordance with the present invention including a transducer such as those illustrated in FIGS. 1, 4, and 5.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates an implantable transducer 10 for a hearing aid for direct mechanical excitation of the middle or inner ear in accordance with one embodiment of the present invention. A detector such as a microphone 12 (as shown in FIG. 2) may be provided and is preferably, implanted to receive sound. As FIG. 1 illustrates, the transducer 10 includes a hermetically sealed, biocompatible cylindrical housing 14 which is made of an electrically conductive material. The housing 14 may be filled with an inert gas 16. One end wall of the housing 14 is made as an electrically conductive vibratory membrane 18 which is provided with a coupling element 20 on the side of the vibratory membrane 18 outside of the housing 14 for mechanical vibrational coupling to a middle ear ossicle or to an inner ear. The vibratory membrane 18 is also provided with a piezoelectric element 22 such as a thin piezodisk made from a piezoelectric material, for example, lead zirconate titanate (PZT) on the side inside of the housing 14. The piezoelectric element 22 is attached to the membrane 18 by means of an electrically conductive adhesive connection and is electrically connected to terminal 28 by a thin flexible wire 24. The terminal 28 is positioned outside of the housing 14 through a hermetic feed-through means 26. The Around pole 29 is also routed via the feed-through means 26 to the inside of the housing 14. Application of an electrical voltage to the terminal 28 causes the hetero-composite of the vibratory membrane 18 and the piezoelectric element 22 to flex and thus, leads to deflection of the vibratory membrane 18. This deflection is transmitted via the coupling element 20 to a middle ear ossicle or directly to the inner ear (not shown). The coupling element 20 may be made as a coupling rod and may be connected to the ossicular chain, for example, by a thin wire, hollow wire clip, or a clip of carbon-fiber reinforced composite (not shown). Housing 14, suitably, has a diameter in the range of 6 to 13 mm, preferably about 9 mm. The thickness of membrane 18 and piezoelectric element 22 are advantageously each in the range of 0.05 to 0.15 mm. Membrane 18 and piezoelectric element 22 are advantageously each of circular design, with the radius of membrane 18 preferably being greater than the radius of piezoelectric element 22 by a factor of 1.2 to 2.0. A factor of about 1.4 has proven especially advantageous. The transducer housing 14, including membrane 18, is made of a biocompatible material, preferably titanium, niobium, tantalum or their alloys, or of another biocompatible metal. Suitable arrangements of this type are described in commonly owned, co-pending U.S. patent application Ser. No. 09/042.805 which is hereby incorporated by reference.
The aspects of the present invention described thus far in the above discussion are generally known from U.S. Pat. No. 5,277,694 assigned to the assignee of the present invention and likewise incorporated herein by reference. However, as discussed previously, the deflection which can be achieved with a piezoelectric system can be too small for a proper hearing impression at low and middle frequencies. To improve the frequency response in this range, the transducer in accordance with the present invention is provided with both the piezotransducer and an electromagnetic transducer. In this regard, an electromagnet arrangement which includes an electromagnetic component 32 and a vibratory component 30 is provided in conjunction with the piezoelectric element 22 as will be discussed in further detail below.
In accordance with the present invention, the piezoelectric element 22 is permanently joined by means of adhesive, welding or solder to the vibratory component 30 of the electromagnet arrangement on the side facing away from the membrane 18 as illustrated in FIG. 1. The vibratory component 30 may be formed from a permanent magnet and be positioned within the electromagnetic component 32. The electromagnetic component 32 may be made as an electromagnetic coil or an electrical coil. In the preferred embodiment, the vibratory component 30 may be positioned to be movable within the electromagnetic component 32. The electromagnetic component 32 is permanently mounted within the housing 14 and is connected to terminals 36 by wires 34 which are guided to the outside the housing 14 through feed-through means 26. Excitation of the electromagnetic component 32 by application of an AC voltage to terminals 36 causes displacement of the vibratory component 30 relative to the housing-mounted electromagnetic component 32 thereby resulting in deflection of the vibratory membrane 18. The deflection caused by the vibratory component 30 may optionally be superimposed with the membrane deflection caused by the simultaneous application of voltage to the piezoelectric element 22 thereby increasing the deflection of the vibratory membrane 18. In this manner, the frequency response of the transducer 10 in accordance with the present invention can be improved by single or additional application of a corresponding signal-voltage to the electromagnetic component 32 via the terminals 36, especially in the low frequency range.
In order to more specifically explain the operation of the hearing aid provided with transducer 10, an electrical schematic is shown in FIG. 2 in accordance with one embodiment of the present invention which may be used in operating the transducer 10. The sound to be transmitted is converted by a microphone 12 into an electrical signal which is filtered and amplified in a signal processor 38. The output signal from the signal processing means 38 is sent to two parallel filters 40 and 42, each of which are connected in series to output amplifiers 44 and 46 respectively. The output amplifiers 44 and 46 are connected to the terminals 36 of the electromagnetic component 32 and terminals 28 of the piezoelectric element 22 respectively. A microcontroller 48 may be used to control the signal processor 38 and the parallel filters 40 and 42. In this regard, the microcontroller 48 receives information from the signal processor 38 regarding the composition of the signal being processed in the signal processor 38. All of these components including the microphone 12, the signal processor 38, the parallel filters 40 and 42, the microcontroller 48 and the output amplifiers 44 and 46 may be powered by a power supply which, in the preferred embodiment, is an implantable battery unit 50. In addition, all of these components and methods of signal processing are generally known in the electrical and electronic arts. Thus, their specific structures or the details as to their function need not be discussed in further detail.
The microcontroller 48 may control the parallel filters 40 and 42 such that, depending on the frequency or frequency focus of the signal being instantaneously processed in the signal processor 38, the piezoelectric element 22 and/or the electromagnetic component 32 may be selectively operated by excitation with the signal to be transmitted. In the preferred embodiment illustrated in FIGS. 1 and 2 microcontroller 48, filters 40 and 42 and output amplifiers 44 and 46 are disposed outside of the transducer housing 14; however some or all of these components also could be incorporated into the housing of transducer 10.
In the present embodiment, the microcontroller 48 can be designed such that in a first frequency band which extends from a first frequency f 1 to a cutoff frequency f T , the electromagnetic component 32 may be operated to produce the vibrations to be transmitted to the coupling element 20. In a similar manner, the microcontroller 48 can be designed such that in a second frequency band which extends from the cutoff frequency f T to a second frequency f 2 , the piezoelectric element 22 is operated to produce the vibrations to be transmitted to the coupling element 20. Of course, the microcontroller 48 can be programmed with respect to the cutoff frequency f T value according to the specific application and the patient's condition. Again, because all of the above discussed control methods and signal processing are generally known in the electrical and electronic arts, they need not be discussed in further detail.
In the above discussed embodiment which is shown in FIGS. 1 and 2, the electromagnetic component 32 such as an electromagnetic coil and the piezoelectric element 22, are conductively decoupled from one another. This allows the use of double bridge amplifiers for triggering the electromagnetic component 32 and the piezoelectric element 22. However, in an alternative embodiment, triggering of the electromagnetic component 32 and the piezoelectric element 22 can also be achieved by providing only one common ground terminal 52 for the electromagnetic component 32 and the piezoelectric element 22. This alternative modification is illustrated in FIG. 2 by broken lines which would replace the separate around terminals shown as solid lines. In this modified embodiment, a terminal wire 34 of the electromagnetic component 32 would then be connected on the inside to the housing 14 rather than being guided to the outside of the housing 14. This embodiment has the advantage in that there would only be three terminals on the transducer 10 and would also simplify the hermetic feed-through means 26. As will be appreciated, the above discussed embodiments of the transducer 10 which separately trigger the electromagnetic component 32 and the piezoelectric element 22 have the distinct advantage of being highly flexible with respect to optimization of the transducer's 10 frequency response.
FIGS. 3A and 3B show two embodiments in which separate triggering of the electromagnetic component 32 and the piezoelectric element 22 is eliminated in favor of simplification of the overall transducer 10. In these embodiments, only two terminals 160 and 161 must be routed out of the transducer 10, i.e. the housing 14. The electromagnetic component 32 and the piezoelectic element 22 can be connected in a parallel circuit as illustrated in FIG. 3A or alternatively, in a series circuit as illustrated in FIG. 3B. As in the embodiments shown in FIG. 2, the electrical signal generated by the microphone 12 is filtered and amplified in the signal processor 38 which is controlled by the microcontroller 48. At this point, the output signal can be supplied directly to an output amplifier 162 which is connected to the terminals 160 without additional filtering. Therefore, parallel filters 40 and 42 and an amplifier of the previous embodiment can be eliminated. It has been found that generally, parallel or series electrical connection yields an electrical resonant circuit which can adversely affect the transducer's 10 frequency response. This negative aspect, however, can be minimized and offset by proper selection of the mechanical components of the system. Thus, in either of these embodiments (parallel connection of FIG. 3A or series connection of FIG. 3B), both the electromagnetic component 32, and also the piezoelectric element 22, are operated so that the deflections of the membrane 18 and correspondingly, the coupling element 20, are produced by superimposing the vibrations of both the electromagnetic component 32 and the piezoelectric element 22. The frequency response of the transducer 10 thus follows from superposition of the frequency responses of the electromagnetic component 32 and the piezoelectric element 22 thereby allowing the generation of sufficient deflection to achieve sufficient loudness level at a wide range of frequencies. And by careful selection of the transducer's 10 mechanical components, strong deflection of the membrane 18 at both low frequencies and also high frequencies can be achieved.
FIG. 4 illustrates a sectional view of another embodiment of a transducer with an alternative mechanical coupling of the electromagnetic transducer and piezotransducer. Parallel to a first membrane 218 which forms one end wall of the housing 214, there is provided a second membrane 270 within the housing 214. On the bottom of the second membrane 270 on the side facing away from the first membrane 218, a piezoelectric element 222 is attached in order to excite the second membrane 270. On the top of the second membrane 270, one end of a vibratory component 230, such as a permanent magnet, is attached. The other end of the vibratory component 230 is attached to the first membrane 218 so that the vibratory component 230 provides for mechanical coupling of the first membrane 218 and the second membrane 270. The vibratory component 230 is arranged in a maimer similar to the prior embodiments allowing it to move and vibrate within an electromagnetic component 232 in response to operation of the electromagnetic component 232. Again, the electromagnetic component 232 may be an electromagnetic coil or an electrical coil. Thus, in this embodiment, the vibratory component 230 deflects both the first membrane 218 and the second membrane 270. When the piezoelectric element 222 is operated by applying a voltage to it, this causes deflection of the second membrane 270. This deflection in the second membrane 270 is transmitted through the mechanically coupled vibratory component 230 to the first membrane 218 which is deflected accordingly. Correspondingly, this deflection of the first membrane 218 causes vibrational displacement of the coupling element 20. The electrical operation and circuitry of the piezoelectric element 222 and the electromagnetic component 232 can be accomplished in the same maimer as described with respect to FIGS. 2, 3A and 3B, i.e. frequency-dependent separate triggering in isolation or with a common ground or common triggering in a parallel or series connection.
The alternative embodiment illustrated in FIG. 5 differs from the embodiment illustrated in FIG. 1 only in that the vibratory component 30, such as a permanent magnet extends through a middle opening 23 of the piezoelectric element 22 and is securely connected to the vibratory membrane 18.
FIG. 6 shows a hearing aid 51 which is equipped with a transducer 10 of the above described type as implanted in a human ear 100. The hearing aid 51 includes a battery unit 53, a charging reception coil 54, and all electronic module 55. These components are accommodated in a hermetically sealed housing 56 which can be implanted in the mastoid region 57. The transducer 10 and a microphone 58 are connected via wires 59 and 60 to the electronic module 55. The coupling element 20 (illustrated penetrating through an opening on the incus) is coupled to the ossicular chain 62. The portable charging unit 63 includes a charging transmission coil 64 which can be inductively coupled to the charging reception coil 54 for transcutaneous charging of the battery unit 53. A remote control unit 65 may also be provided. A hearing aid of this general type is exemplified in U.S. Pat. No. 5,277,694 and therefore, need not be discussed in further detail here
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto, and is susceptible to numerous changes and modifications as known to those skilled in the art. Therefore, this invention is not limited to the details shown and described herein, and includes all such changes and modifications as are encompassed by the scope of the appended claims.
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The invention relates to a transducer for partially or fully implantable hearing aids for direct mechanical excitation of the middle or inner ear. The transducer is provided with a housing fixedly mounted at the implantation site and a coupling element moveable with respect to the housing for transmitting vibration to the middle ear ossicle or directly to the inner ear. The housing accommodates a piezoelectric element with which the coupling element can be vibrated and an electromagnet arrangement including an electromagnetic component, such as an electromagnetic coil, fixedly mounted relative to the housing and a vibratory component, such as a permanent magnet, mechanically connected to the coupling element such that the vibration of the vibratory component is transferred to the coupling element.
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BACKGROUND OF THE INVENTION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/478,043, filed Jun. 7, 2004, which claims priority of PCT Patent Application No. PCT/AU02/00602, filed May 17, 2002.
[0002] The present invention relates to a spiral separator and to a method of spiral separation, and in particular, to a deflector to use in a spiral separator and method of spiral separation. In particular, the present invention relates to the use of such a deflector for the improved separation of particles of different densities.
DESCRIPTION OF THE PRIOR ART
[0003] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in Australia.
[0004] Spiral separators are extensively used for the wet gravity separation of solids 15 according to their specific gravity, for example, for separating various kinds of mineral sands from silica sands.
[0005] Separators of the kind under discussion are shown, for example, in the Applicant's Australian Patent No. 552425 (82717/82). Such separators commonly include a vertical column about which there are supported one or more helical troughs. ill operation, a “pulp” or slurry of the materials to be separated and water is introduced to the upper end of a trough and, as the pulp descends the helix, centrifugal forces act on the dense particles in a radially outwards direction while the more dense particles segregate to the bottom of the flow, and after slowing, through close approach to the working surface of the trough, gravitate towards the vertical column.
[0006] During operation of a spiral separator there is a general migration of water from the inner portion or smaller radius of the flow to the outer portion of the flow. However, particularly when there are high proportions of high specific gravity particles present in the pulp, the total water supply at the inner portion can be used up before segregation is completed. As this takes place there is an accumulation of particles at the inner portion which, while it does not prevent the stream from continuing to move, changes the effective shape of the volute cross section and separation proceeds no further.
[0007] To improve on the operation of such spiral separators, a deflector has been previously developed by the Applicants of the present invention, as described in Australian Patent Serial No. 575046 (27077/84). In that specification, there is described a spiral separator characterized by the inclusion of at least one deflector located adjacent an outer edge of the spiral separator, the deflector having a contoured upper surface to receive and deflect a portion of the low solids, high velocity, stream component in a fan like spray from the outer edge of the pulp stream back across the stream towards the inner edge. In particular, that device interrupts a portion of low density, high water content, stream from the ‘tailing zone’ and sprays or redeposits it into the high density, low water content, ‘middling zone’.
[0008] Whilst the deflector of Australian Patent Serial No. 575046 improved the recovery of minerals, due to the inability for the device to be readily adjusted, and due to its somewhat inflexible design, the deflector device has been found to be somewhat limited, identifying a need for an improved product thereto.
SUMMARY OF THE INVENTION
[0009] The present invention seeks to provide a deflector device which seeks to overcome at least some of the disadvantages of the prior art deflector devices, including that described in Australian Patent Serial No. 575046 (27077/84).
[0010] The present invention seeks to provide a deflector device which has a more refined action and has much greater scope for influencing the stream in a spiral separation, to enhance separation.
[0011] In one broad form, the present invention provides a deflector adapted to be attached to a spiral separator for capturing and redirecting a controlled portion of a flowing stream 25 of material flowing through said spiral separator, said deflector including:
[0012] attachment means, for attachment of said deflector to said spiral separator;
[0013] a capturing portion, shaped to substantially ride atop and capture a portion of said flowing stream of material; and,
[0014] a redirecting portion, integrally formed with said capturing portion, shaped to emit 30 said portion of said stream of material captured by said capturing portion.
[0015] Preferably, said attachment means includes an arm member, to permit substantially resilient and/or pivotal movement of said deflector connected to said spiral separator.
[0016] Also preferably, said arm member includes anyone or combination of a pivoting arm, a flexible arm, a string, line, flap, magnetic field or any other mechanical means.
[0017] Most preferably, said capturing portion captures the ‘tailing’ portion of said flowing stream of material from an outer region of the trough of the spiral separator.
[0018] Also most preferably; said redirecting portion redirects said captured material into the ‘middlings’ portion of the flowing stream.
[0019] Also preferably, said redirecting portion redirects said captured material into said flow stream in a patterned spray.
[0020] In a preferred form, said patterned spray is in a ‘fan-like’ shape, a substantially hemispherical shape, or other thin broad canopy of spray that re-enters the main stream substantially in an arc about the head of the reflector.
[0021] Alternatively, but also preferably, said redirecting portion redirects said captured material to another device such as, but not limited to, a gallery or distributor to administer the water in a controlled manner.
[0022] Preferably, said deflector is formed to function in a substantially buoyant manner. Also preferably, said deflector is at least partly formed from substantially buoyant material.
[0023] Also preferably, said device substantially rides on or aquaplanes on the surface of said stream.
[0024] Also preferably, said device is weighted or tensioned for heavier action (heavier fan) or unweighted for lighter action by adjusting the flexibility, weight, tension and/or tightness of the arm member or the like.
[0025] Preferably also, said device may be twisted or pivotally adjusted to enable adjustment of the rate and/or other characteristics of the emission of the captured material.
[0026] Also preferably, said arm member is lengthened or shortened to change the angle and/or weighting with which the capturing portion penetrates the stream.
[0027] In a further broad form, the present invention provides a spiral separator adapted to receive a flowing stream of water and particulate material at an upper end thereof, to separate particles of different densities as the stream moves downwardly therethrough, said separator including at least one deflector therein to capture and redirect a portion of said material flowing adjacent to an outer edge of said separator, said deflector including:
[0028] attachment means, for attachment of said deflector to said spiral separator;
[0029] a capturing portion, shaped to substantially ride atop and capture a portion of said flowing stream of material; and, a redirecting portion, integrally formed with said capturing portion, shaped to emit said portion of said stream of material captured by said capturing portion.
[0030] In yet a further broad form, the present invention provides a method of separating particles of different densities using a spiral separator including a deflector, substantially as herein described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The present invention will become more fully understood from the following detailed description of preferred but non-limiting embodiments thereof, described in connection with the accompanying drawings, wherein:
[0032] FIG. 1 illustrates sketches of a deflector device in accordance with the present invention, showing front, plan and side views in FIGS. 1 ( a ), 1 ( b ) and 1 ( c ), respectively;
[0033] FIG. 2 illustrates the deflector device attached to a spiral separator in accordance with the present invention; and,
[0034] FIG. 3 illustrates top, sectional and end views of the deflector shown attached to the spiral separator, in FIGS. 3 ( a ), 3 ( b ) and 3 ( c ), respectively.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] Throughout the drawings, like numerals will be used to identify similar features, except where expressly otherwise indicated.
[0036] As shown in the drawings, the deflector, generally designated by the numeral I, is adapted to be attached to a spiral separator, generally designated by the numeral 2 . The deflector 1 is designed to capture and redirect a controlled portion of the flowing stream of material flowing through the spiral separator. The deflector 1 , generally includes an attachment means 3 , for attachment of the deflector 1 to the spiral separator 2 , a capturing portion 4 shaped to substantially ride atop and capture a portion of the flowing stream of material 5 , and a redirecting portion 6 , which is integrally formed with the capturing portion 4 , and which is shaped to spray or otherwise emit the captured material, as illustrated by reference numeral 7 . The spray 7 may be patterned to be of any desired shape, depending upon the desired pattern of the spray as it re-enters the main stream. For example, the spray may be fan-shaped, substantially hemispherical in shape, or any other thin broad canopy of spray such that it re-enters the main stream-substantially in an arc about the head of the reflector.
[0037] Other than the attachment means 3 being used to affix the deflector 1 to the side of the spiral separator 2 , the attachment means 3 may incorporate an arm member 12 , to permit substantially resilient and/or pivotal movement of the deflector 1 when connected to the spiral separator 2 . The arm member 12 may include anyone or combination of a pivoting arm, a flexible arm, a string, line, flap, magnetic field, or any other mechanical means. Other forms of arm member may alternatively become apparent to persons skilled in the art and should be considered to be encompassed within the scope of this invention.
[0038] The capturing portion 4 of the deflector 1 , is shown in the drawings as capturing the “tailings” portion of the flowing stream of material 5 from an outer region ill of the trough 11 of the spiral separator 2 .
[0039] As will be understood by persons skilled in the art, and as shown in FIG. 3 ( b ), spiral separators are generally used to recover minerals, and function by separating materials in to three generally known streams, including the ‘concentrate’ 8 found at the inner edge of the trough 11 of a spiral separator 2 and which is formed of particles of higher specific gravity, a ‘tailing’ stream 10 which is found towards the outer part of the trough 11 being the particles of lower specific gravity, and the ‘middlings’ stream 9 which is found intermediate the concentrate and tailings in the central transition zone.
[0040] As such, it will be appreciated that the deflector 1 shown in the drawings, redirects the portion of the material from the ‘tailings’ stream 10 in to the ‘middlings’ 9 portion of the flowing stream 5 . It is also shown in the drawings that this is redirected in a fan like spray manner.
[0041] By redirecting the material in this manner, the ‘middlings’ 9 stream is exposed to two gentle influences, firstly as it enters the fan upstream, and again when it emerges downstream. Such an effect provides a significant performance enhancement of the spiral separator.
[0042] In an alternative arrangement, the redirecting portion, could redirect the captured material to another device (not shown), such as, but not limited to, a gallery or distributor to administer the water in a controlled manner.
[0043] The deflector device 2 of the present invention may either be at least partly formed from substantially buoyant material and/or, can be shaped to function in a substantially buoyant manner, then being formed of any desirable material. The device may be weighted or tensioned for heavier action (heavier fan), or unweighted for lighter action by adjusting the flexibility, weight, tension or tightness of the arm member portion of the device, or by other means. Depending on the particular amount of capture desired, these attributes can be selectively varied such that it either substantially ‘rides’ or ‘aquaplanes’ the surface of the stream due to the pressure, velocity of the liquid, or, it can be submerged to a greater or lesser extent.
[0044] The device may also be twisted or pivotally adjusted to enable adjustment of the rate and/or format of the emission of the captured material.
[0045] The arm member may also be lengthened or shortened to change the angle and/or the weighting in which the capturing portion penetrates the stream.
[0046] It will be appreciated that the present invention therefore provides a deflector device which is novel and inventive over the known prior art, including the Applicant's prior Australian Patent No. 575046 (27077/84). The differences and advantages of the device of the present invention is at least partially due to the freedom of movement of the device, whereby the head of the device floats or “rides” on top of the ‘tailing’ stream where it captures and redirects a controlled quantity of the flow in to another region of the trough. As described, usually, the redirected flow would typically take the form of a gentle fan or other patterned spray, and the fan or spray is usually directed in to the ‘middlings’ stream.
[0047] The head of the device is buoyant, created either by the material and/or by hydraulic pressure, to remain skimming the surface of the stream regardless of the flow rate of the spiral feed. The deflector therefore always remains in position for optimal performance. When the flow rate on a spiral increased, the stream at the outer wall rises. This causes conventional deflectors with fixed position, such as described in the
[0048] Applicant's earlier Australian Patent No. 575046 (27077/84) to become more violent in its action, causing excessive disruption of the flow. When the flow rate on a spiral decreased, the level of the stream falls. This reduces the influence of prior art deflectors, and in some cases, the stream may fall completely below the point where the deflector is attached.
[0049] It will be appreciated that numerous variations and modifications may be envisaged by persons skilled in the art to the device hereinbefore described. All such variations and modifications should be considered to fall within the scope of the invention as broadly herein described and as hereinafter claimed.
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A deflector ( 1 ) for attachment to a spiral separator ( 2 ), for capturing and redirecting a portion of a flowing stream of material ( 5 ). The deflector ( 1 ) includes an attachment means ( 3 ), to attach the deflector ( 1 ) to the spiral separator ( 2 ), a capturing portion ( 4 ) to capture a portion of the flowing stream ( 5 ), and, a redirecting portion ( 6 ) to emit a portion ( 7 ) of the stream. A method of separating particles of different densities using the deflector device ( 1 ) in conjunction with a spiral separator ( 2 ) is also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2006-011459, filed Jan. 19, 2006, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a printing rubber blanket used in lithography, and more specifically to a printing rubber blanket with which sinking down of the rubber blanket, which occurs while using the blanket, can be reduced, and the reduction of thickness of the rubber blanket is less, thereby achieving an excellent durability.
[0004] 2. Description of the Related Art
[0005] The lithographic offset press printing operates in the following manner. First, the printing rubber blanket rotates while being brought into tight contact with the plate cylinder on which characters and images are formed and printing ink is provided, and thus the ink of the characters and images on the plate cylinder is transferred onto the rubber blanket. Then, the characters and images on the rubber blanket are (transferred and) set on a print medium such as paper sheet, which is conveyed as being brought into tight contact with the rubber blanket, thereby carrying out printing.
[0006] The rubber blanket, which is conventionally employed, includes a smooth surface rubber layer having a thickness of about 0.4 mm, a fabric layer underlying the rubber layer to integrally adhered to the surface rubber layer, a compression layer underlying the fabric layer to integrally adhered to the fabric layer, and two to four fabric layers that are stacked one on another via adhesive layers alternately under the compression layer. The total thickness of the printing rubber blanket is in a range of 1.16 to 3 mm.
[0007] As shown in FIG. 3 , the printing rubber blanket is wound around the cylinder at a high tension. FIG. 3 illustrates a rubber blanket 1 , a blanket cylinder 2 , which is a cylinder around which the rubber blanket is wound, and a bar member 3 mounted on an end portion of the rubber blanket 1 .
[0008] The lithographic offset press that uses such a rubber blanket as described above, applies a very high printing pressure between the plate cylinder and the rubber blanket and also a very high transferring pressure between the rubber blanket and the impression cylinder in order to obtain a print that has no uneven density on its printed surface but has an excellent reappearance of halftone.
[0009] Therefore, in actual printing, the rubber blanket used here undergoes severe dynamic shock repeatedly. As a result, the rubber blanket, as it is used, loses its thickness, which is the phenomenon called “sink down”. As the rubber blanket sinks down and the thickness of the rubber blanket reduces, the printing pressure acting between the plate cylinder and the rubber blanket naturally reduces.
[0010] As the reduction in the printing pressure between the plate cylinder and the rubber blanket occurs, the transfer of the ink from the plate cylinder is not properly performed, and the transfer of the ink is not sufficiently carried out. Especially, in the case where the rubber blanket is used under severe conditions such as in high-speed printing, the sink-down of the rubber blanket is further promoted, and therefore it is likely that the reduction in the thickness of the rubber blanket occurs in an early stage. Under these circumference, the life of the rubber blanket is significantly shortened in the case of high-speed printing, at present.
[0011] It is well known that one of the main factors of the sink-down of a rubber blanket is the reduction in thickness of the woven fabric of the fabric layer of the blanket. In order to suppress the sink-down of the rubber blanket, thereby decreasing the reduction in the thickness of the rubber blanket, the following technique is conventionally known. That is, the woven fabric of the fabric layer used for the rubber blanket is in advance subjected to calendaring, in which fabric are allowed to pass between calender rolls to be crimped, and thus the thickness of the woven fabric is reduced in advance.
[0012] FIG. 7 shows the calendaring of woven fabric 4 , which serves as the fabric. FIG. 7 illustrates a pair of calender rolls 5 and 6 . The pair of calender rolls 5 and 6 may be a pair of a metal roll and a metal roll, or a metal roll and a resin roll. The woven fabric 4 is passed through the gap between the calender rolls 5 and 6 , thereby compressing by pressing the woven fabric 4 in advance. A rubber blanket that uses a highly dense woven fabric prepared by the compression, as its fabric layer, can reduce the sink-down.
[0013] In rubber blankets, there is a close relationship between the degree of the sink-down of the fabric and the density of the woven fabric of the fabric layer.
[0014] It is known that the woven fabric applied to a rubber blanket exhibits a larger sink-down degree as the density of the woven fabric is lower, after repetitious compression when the rubber blanket that uses the fabric is actually used. Therefore, the calendaring of the woven fabric carried out in advance before it is used for the rubber blanket, to increase its density, brings a remarkable effect in the reduction of the sink-down of the rubber blanket. Thus, the technique of calendaring the woven fabric used in a rubber blanket to make it highly dense, thereby suppressing the sink-down of the rubber blanket, has been widely employed.
[0015] However, rubber blankets that include a fabric layer that uses a calendered woven fabric have such properties that as the time passes, the woven fabric recovers its thickness before it was calendered. Thus, a rubber blanket that uses a calendered woven fabric cannot maintain its thickness stably for a long period of time, but the woven fabric recovers its original thickness. In this manner, it becomes easy for the rubber blanket to have the sink-down, which creates a problem.
[0016] Rubber blankets that employ a calendered woven fabric of, particularly, cotton fiber, polynosic fiber, rayon or mixture of these fibers, are sensitive to temperature and moisture and tend to recover their thickness to the thickness before the calendaring. Thus, there are possibilities that rubber blankets which easily create sink-down are formed, which is a serious drawback.
[0017] The lithographic offset press uses dampening water during printing at all times. The damping water easily permeates inside the rubber blanket from the edge portion thereof during printing, and the water eventually will reach the fabric layer of the rubber blanket. When a portion of the damping water reaches the fabric layer of the rubber blanket, the fabric layer easily swells as it absorbs the water portion, and the portion of the fabric layer easily recovers the thickness before being calendered.
[0018] In the state described above, the rubber blanket regionally creates a difference in thickness between its edge portion and the other section. When such a difference is created, the printing pressure and transferring pressure are not constantly applied by the rubber blanket, but a difference is created between the edge portion and the other portion. Due to this drawback, there is conventionally a possibility of occurrence of printing troubles including uneven printing. Under these circumstances, there has been a demand for an invention of rubber blanket which rarely reduces its thickness by sink-down or rarely creates a regional difference in thickness, even after it is used in operation for a long period.
BRIEF SUMMARY OF THE INVENTION
[0019] The object of the present invention is to provide a durable rubber blanket designed to be used in lithography offset printing, which does not significantly reduce its thickness or regionally create a difference in thickness by the sink-down of the blanket, thereby making it possible to perform excellent printing for a long time.
[0020] In order to achieve the above-described object, there is provided according to an aspect of the present invention, a printing rubber blanket comprising a surface rubber layer and a compression layer provided on a lower surface of the surface rubber layer via an adhesive layer. Further, two or more fabric layers are provided on a lower surface of the compression layer via adhesive layers. Furthermore, the rubber blanket of the present invention employs a thick yarn of No. 10 count or less but No. 6 count or more for warps of woven fabric, and a slender yarn of No. 30 count or less but No. 20 count or more for wefts of the woven fabric in at least one of fabric layers, and the woven fabric is subjected to a stretching process in which the fabric is expanded in the warp direction.
[0021] In the rubber blanket of the present invention, which uses a particular woven fabric as described above in a fabric layer, the sink-down of the rubber blanket can be lessen and the reduction in the thickness of the rubber blanket can be suppressed. Further, it is possible to avoid the creation of a difference in thickness from one region to another. Consequently, the life of the blanket can be prolonged, and the gap between the plate cylinder and the rubber blanket can be maintained constantly at a predetermined distance for a long time, thereby making it possible to assure an appropriate printing pressure. Further, the gap between the rubber blanket and the impression cylinder can be set appropriately, and therefore the application of the pressure can be well adjusted, thereby making it possible to carry out excellent printing.
[0022] Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be leaned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0023] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
[0024] FIG. 1 is a diagram showing a cross section of a part of a rubber blanket according to an embodiment of the present invention;
[0025] FIG. 2 is a diagram showing a cross section of a part of a rubber blanket according to the present invention, when it is placed on a cylinder;
[0026] FIG. 3 is a diagram showing a cross section of a part of a rubber blanket according to the conventional technique, when it is placed on a cylinder;
[0027] FIG. 4 is a diagram showing a cross section, in a woof direction, of a textile stuff of woven fabric used in a fabric layer of a rubber blanket according to the conventional technique;
[0028] FIG. 5 is a diagram showing a cross section, in a woof direction, of a textile stuff of woven fabric used in a fabric layer of the rubber blanket of the present invention;
[0029] FIG. 6 is a diagram showing a cross section, in a woof direction, of woven fabric used in the fabric layer of the rubber blanket of the present invention, which was stretched in its warp direction;
[0030] FIG. 7 is an explanatory diagram showing the woven fabric of the fabric layer of the rubber blanket while it is being calendered; and
[0031] FIG. 8 is a chart illustrating the relationship between the residual ductility (%) after the woven fabric is subjected to stretching and the tensile strength (kg) of the rubber blanket that employs the fabric layer of this woven fabric.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 illustrates a cross section of a part of a printing rubber blanket-according to the present invention. FIG. 2 is a partially enlarged view of the rubber blanket shown in FIG. 1 when it is mounted on a cylinder. FIG. 2 shows a cylinder 10 and a rubber blanket 20 .
[0033] As shown in FIGS. 1 and 2 , the rubber blanket 20 includes a surface rubber layer 22 on a surface of which ink is received and transferred, and a first fabric layer 1 a adhered onto a lower surface of the surface rubber layer 22 with adhesive rubber glue. A thick compression layer 2 b is adhered via an adhesive layer onto a lower surface of the first fabric layer 1 a . Further, a second fabric layer 1 b , a third fabric layer 1 c and fourth fabric layer 1 d are stacked via respective adhesive rubber layers 2 c and 3 c on a lower surface of the compression layer 2 b . Apart from the above-described case, it is alternatively possible that the first fabric layer is adhered onto the lower surface of the compression layer 2 b via an adhesive layer, and the second and third fabric layers are stacked underneath via respective adhesive layers. It is further alternatively possible that there is only one fabric layer provided in the blanket. The total thickness of the resultant rubber blanket is about 1.9 mm.
[0034] According to the present invention, the above-described rubber blanket 20 employs a yarn of No. 10 count or less but No. 6 count or more for warps of woven fabric, and a yarn of No. 30 count or less but No. 20 count or more for wefts of the woven fabric in at least one of fabric layers other than that adjacent to the surface rubber layer 22 , and the woven fabric is subjected to stretching.
[0035] In other words, a thick yarn of No. 10 count or less but No. 6 count or more is used for the warps, whereas a slender yarn of No. 30 count or less but No. 20 count or more is used for the wefts to make the woven fabric, and the fabric is expanded in the warp direction for stretch process. In this manner, the woven fabric is set in such a state where the thick warps creates less difference in height between top and bottom it's the fabric's thickness direction and are aligned substantially linearly in its weaving direction of the fabric, and slender wefts are woven between the warps.
[0036] As compared to the conventional case, the conventional woven fabric uses warps and wefts, which have the same thickness or a little difference, which make the weft threads run up and down greatly in the fabric's thickness direction of the textile stuff. Therefore, the cross section of the conventional woven fabric shows that thick wefts are woven between warps to run up and down greatly. On the other hand, according to the present invention, thick warps and slender wefts are used and therefore the cross section of the woven fabric of its textile stuff shows such a state that there is a small difference between top and bottom of each weft. FIGS. 4 and 5 show an enlarged view of such states. FIG. 4 is a cross section of the textile stuff of the conventional woven fabric, whereas FIG. 5 is a cross section of the textile stuff of the woven fabric of the present invention. In FIG. 4 , reference numeral 30 denotes a warp and reference numeral 31 denotes a weft 31 , whereas in FIG. 5 , reference numeral 40 denotes a warp and reference numeral 41 denotes a weft.
[0037] As is clear from FIG. 5 , the textile stuff of the woven fabric of the present invention has such an arrangement that slender wefts 41 are woven between warps 40 . With this arrangement, the cross section of the woven fabric shows the wefts 40 which have a difference smaller than that of the case of the conventional technique, between their tops and bottoms. Further, the woven fabric used in the present invention is subjected to stretching, where the fabric is further expanded in the warp direction (the longitudinal direction of the warps). With the stretching process, the swell of the warps 40 is stretched and further the gaps between adjacent ones of the warps 40 are narrowed to be dense, thereby making a woven fabric with a higher strength. FIG. 6 shows an enlarged cross section view of the above-described state of the woven fabric. In the woven fabric of the present invention, the warps 40 are each substantially linearly arranged side by side to be dense, and the slender wefts 41 are woven between the warps. With this texture, the woven fabric of the fabric layer of the blanket according to the present invention exhibits a sufficient strength and less sink-down even without being subjected to calender process in advance.
[0038] By contrast, in the woven fabric used in the conventional blanket, the wefts are not sufficiently slender as compared to the warps and therefore the wefts that are woven between the warps run significantly up and down as can be seen in FIG. 4 . Further, conventionally, such woven fabric is subjected to stretching, which makes the wefts arranged to run even more up and down, thereby increasing the thickness of the fabric. Therefore, in order to reduce the thickness, the woven fabric is subjected to calendering to press and squash it, before it is used. For this reason, a blanket that uses such woven textile is easily influenced by water depending on how it is used, and therefore it easily recovers its original thickness for sink-down to occur.
[0039] According to the present invention, the warps used for the woven fabric are yarns of No. 10 count or less but No. 6 count or more, and more specifically, those of No. 9 count or less but No. 7 count or more. When an excessively slender yarn is used for the warps, it is not possible to produce such a great difference of the thickness between the warps and wefts, and therefore a yarn of No. 10 count or less is used for the warps. On the other hand, when an excessively thick yarn is used for the warps, the texture becomes coarse, and therefore a yarn of No. 6 count or more is used for the warps.
[0040] With regard to the wefts, if an excessively slender yarn, which is more slender than those defined by the present invention, is used, a sufficient strength cannot be obtained in the texture. Therefore, a yarn of No. 30 count or less but No. 20 count or more, and more specifically, that of No. 30 count or less but No. 25 count or more is used. On the contrary to the above, when an excessively thick yarn is used for the wefts, the warps cannot be arranged each linearly and dense if the woven fabric is subjected to the stretching. Therefore, a yarn of No. 20 count or less is used for the wefts.
[0041] In the present invention, the maximum difference and minimum difference between the warps and wefts in thickness are as follows. That is, the maximum difference can be obtained when a yarn of No. 6 count is used for the warps and a yarn of No. 30 count is used for the wefts, whereas the minimum difference can be obtained when a yarn of No. 10 count is used for the warps and a yarn of No. 20 count is used for the wefts. In the conventional cases, it is usual to use a yarn of No. 10 to 15 count is used for the warps and a yarn of No. 10 to 20 count is used for the wefts. From the comparison, it can be understood that the ratio in thickness of the warps to the wefts in the present invention is larger than that of the conventional cases. It should be noted that there are the cotton yarn count number, hemp count number and wool count number, and in the present invention, the cotton yarn count is used.
[0042] According to the present invention, at least one of the fabric layers other than that adjacent to the surface rubber layer of the rubber blanket is made to have the above-described texture. Rubber blankets usually include a surface rubber layer, the first fabric layer adhered to the surface rubber layer, and a plurality of layers underlying these, such as the second fabric layer and the third fabric layer. According to the present invention, at least one of these plurality of underlying fabric layers is made to the have the above-described textile. Naturally, it is fine that the woven fabric of two or more fabric layers or even all of the fabric layers are formed to have the above-described texture. The first fabric layer is adhered to the surface rubber layer such as to be integrated therewith, and with this textile, there is a low possibility that the thickness thereof is reduced after a long period of use. However, in the present invention, the woven fabric of the fabric layer as well may be formed to have the above-described textile.
[0043] In the present invention, the woven fabric having the above-described textile is subjected to stretching. The stretching process applied here is the same as the one carried out in the process of manufacturing of the conventional blanket fabric. For example, in the stretching process, the woven fabric made of the warps and wefts of the above-described textile is held by its edges and it is expanded in the warp direction. In the case where the present invention is employed for woven fabric of a plurality of layers, the stretching process is carried out for each one by one, and then these layers are stacked and adhered to each other.
[0044] In the stretching process, the residual ductility of the woven fabric is set within a range of 3.5 to 6.5%. When the residual ductility is less than 3.5%, it indicates that an excessive stretching force has been applied, which results in the lowering of the tensile strength of the warps. On the other hand, when the residual ductility exceeds 6.5%, there is no problem in terms of strength; however, the stretching is not sufficient so that a large difference is created in the warps between top and bottom in the thickness direction of the fabric, and the warps cannot be arranged linearly in the longitudinal direction of the warps. Thus, it is not possible to obtain an excellent blanket having less sink-down in the fabric layers and less variation in thickness.
[0045] The invention recited in claim 2 is based on the invention of claim 1 and a further limitation is provided, in which the number of warps in the textile stuff of the woven fabric is set to 55 to 57 per 1 inch, and the ratio of the number of warps to that of wefts is set 1.1 times or more. In other words, a yarn thicker than that used for the wefts is used for the warps and further, the number of warps per 1 inch is set in the above-described range and the number of warps is set to be 1.1 times or more than the number of wefts. When the ratio is set to 1.1 times or more, the density of thick warps is increased in the woven fabric, and the difference between top and bottom of the warps can be further reduced in the thickness direction. Thus, the warps are each aligned linearly side by side in the weaving direction of the fibers, and the slender wefts are arranged to weave between the warps, respectively.
[0046] The residual ductile set by the stretching process, recited in claim 3 , is as described above. The invention of claim 4 specifies the materials for the warps and wefts, and it defines that either one of or both of warp and weft is of cotton fiber, polynosic fiber, nylon fiber, polyester fiber, polyvinylalcohol fiber, polyolefin fiber, acryl fiber, rayon fiber, or cotton cloth fiber or a blended yarn of these fibers.
[0047] The present invention is similar to that of the conventional technique except for the above-described structure in which the woven fabric of at least one of the fabric layers of the blanket is made to have the above-described texture. That is, as shown in FIG. 1 , 2 or more, usually, 3 or 4 fabric layers are adhered together with adhesive to form a stack layer, and a compression layer 2 b having a predetermined thickness is adhered onto the stacked layer. Further, a surface rubber layer 22 on a bottom surface of which a fabric layer 1 a is adhered, is formed on the resultant stacked layer.
EXAMPLES 1 TO 9, COMPARATIVE EXAMPLES 1 TO 8
[0048] Sulfur, a vulcanization stabilizer, an antioxidant, a reinforcing agent and a plasticizer were mixed into 100 parts by weight of nitrile rubber (NBR), and the mixture was dissolved into methylethylketone to prepare mucilage (to be called as “adhesive mucilage”). Apart from this adhesive mucilage, 20 parts by weight of microballoon of a copolymer of methacrylonitryl and acrylonitryl (tradename: Expansel 091DE of Novel Industry Co., Inc.) was added to mucilage obtained in the same manner as described above and uniformly mixed to prepare mucilage containing microballoon as well. In both mucilage materials, dibenzothiazol was used as vulcanization accelerator.
[0049] The microballoon-free adhesive mucilage was applied uniformly on the second fabric layer 1 b having a thickness of about 0.4 mm as shown in FIG. 1 . Then, the microballoon-containing adhesive mucilage was applied as a coating having a thickness of 0.35 mm thereon in order to form a compression layer 2 b . The layer of the microballoon-containing adhesive mucilage is formed into the compression layer 2 b which has a cushion property by further vulcanizing it. Further, the adhesive mucilage was uniformly applied onto the surface of the first fabric layer, and the first fabric layer 1 a was adhered on the compression layer 2 b.
[0050] The third fabric layer 1 c and the fourth fabric layer 1 d were adhered to each other via the adhesive layers 2 c and 3 c , respectively, on an opposite side of the second fabric layer 1 b . Lastly, a sheet-like member of a nitrile rubber mixture was stacked on the first fabric layer 1 a via adhesive mucilage applied thereon, thereby forming the surface rubber layer 22 .
[0051] An unvulcanized compressed rubber blanket prepared as above was wrapped around a metal-made drum, and the resultant was placed in an inner container of a double can in which vapor of 150° C. was introduced in an outer container. Then, the can was heated for 6 hours and thus the vulcanization was completed. After that, the blanket-wrapped drum was unloaded from the can and cooled. Subsequently, the surface rubber layer 22 was polished with sand paper of 240 mesh and thus a blanket having a thickness of 1.9 mm was obtained.
[0052] In a similar manner to that of the above-described example, Examples 1 to 9 were prepared to present the following variations. That is, in each case, a yarn of No. 10 count or less but No. 6 or more was used for the warps of the woven fabric and a yarn of No. 30 count or less but No. 20 or more was used for the wefts, and the ratio between the number of warps to that of wefts per 1 inch was changed from 1.1 to 1.4. The woven fabric of each of the first to fourth fabric layers was subjected to the stretching process in which the woven fabric was stretched in the warp direction. The residual ductility of the woven fabric subjected to the stretching process was indicated in TABLE 1 each case. In each case, the number of warps per in inch in the woven fabric was set to 55 to 75. Whether or not the sink-down (reduction in thickness) takes places in the woven fabric of the rubber blanket was examined in the following manner.
[0053] A blanket cylinder having a diameter of 343.7 mm and a length of 480 mm and an impression cylinder having a diameter of 347.8 mm and a length of 480 mm were used.
[0054] In each test, a respective one of the above-described various types of blankets was wound around the blanket cylinder, and the cylinder was rotated 200,000 times at a revolution of 500 ppm at an applied pressure (squeeze) of 0.2 mm before the variation amount was measured. The variation amount was expressed in terms of the ratio (%) of the reduced thickness to the thickness of the blanket immediately after it was wrapped around the blanket cylinder.
[0055] If the reduction of the thickness that is expressed by the variation ratio to the thickness of the blanket after the above examination was less than 10%, the example was evaluated as ◯, whereas the reduction of the thickness exceeds 10%, the example was evaluated as X. The woven fabric having a variation ratio of less than 10% has less reduction in the thickness of the fabric layer, and therefore it exhibits not significant adverse effect on the printing performance. When the ratio exceeds 10%, such woven fabric cause a significant effect on the printing performance. The results obtained in the tests were as indicated in TABLE 1.
[0056] Comparative Examples each are the cases where at least one of the count number of warps, count number of wefts, ratio between the number of warps to that of wefts fell out of the range defined by the present invention. Further, in each comparative example, the residual ductility was excessive, and the stretching process was slightly insufficient or insufficient. The results of Comparative Examples were shown in TABLE 1.
[0000]
TABLE 1
Examples and
Comparative Examples
EXAMPLES
COMPARATIVE EXAMPLES
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
Count number for Warps
6
7
7
8
8
9
9
10
10
5
6
7
7
10
11
11
11
Count number for Wefts
20
20
23
23
25
25
28
28
30
19
18
19
21
31
31
19
31
Ratio between the number
1.1
1.1
1.1
1.2
1.2
1.2
1.3
1.3
1.4
1.1
1.1
1.1
1.2
1.3
1.5
1.1
1.3
of warps and that of wefts
Residual ductility (%)
3.5
4.0
4.3
4.3
4.5
4.5
5.0
5.5
6.5
3.5
3.5
6.7
7.1
7.2
4.0
3.5
7.1
Sink-down of Fabric
◯
◯
◯
◯
◯
◯
◯
◯
◯
X
X
X
X
X
Δ*
X
X
Occurred
*Comparative Example 6 had a nearly good condition in terms of sink-down, but was insufficient in terms of tensile strength.
[0057] As shown in TABLE 1, all of Examples 1 to 9 exhibited less sink-down in the woven fabric and were evaluated as ◯, which means a good result. As compared to these, Comparative Example 1 exhibited large sink-down, in which a yarn of the No. 5 count was used for the warps, which was thicker and fell out of the range of No. 6 count or more defined by the present invention, and a yarn of the No. 19 count was used for the wefts, which was thicker and fell out of the range of No. 20 count or more defined by the present invention. Comparative Example 2 exhibited large sink-down, in which a yarn of the No. 18 count was used for the wefts, which was thicker and fell out of the range of No. 20 count or more defined by the present invention. In Comparative Example 3, a yarn of the No. 19 count was used for the wefts, which was thicker and fell out of the range of No. 20 count or more defined by the present invention and the residual ductility was 6.7%, which indicated insufficient stretching, and this comparative example exhibited a large variation ratio in the fabric layer and an adverse effect in the printing performance.
[0058] In Comparative Example 4, a yarn of the No. 7 count was used for the warps, and a yarn of the No. 21 count was used for the wefts, both of which fell within the range defined by the present invention, but the residual ductility was 7.1%, which indicated insufficient stretching. The results indicate that this comparative example exhibited a large variation ratio in the fabric layer. In Comparative Example 5, a yarn of the No. 10 count was used for the warps, and a yarn of the No. 30 count was used for the wefts, both of which fell out of the range defined by the present invention, and the residual ductility was 7.2%, which indicated insufficient stretching. The results indicate that this comparative example exhibited a large variation ratio in the fabric layer. In Comparative Examples 6 to 8, yarns used for the warps and/or wefts fell out of the range defined by the present invention. The results indicate that these comparative examples each exhibited a large variation ratio in the fabric layer.
EXAMPLE 10
[0059] The blanket obtained in Example 1 was subjected to tensile strength test while the residual ductility of the woven fabric was varied 1%, 3%, 3.5%, 5%, 6.5% and 7%. The results were as shown in FIG. 8 .
[0060] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A printing blanket is designed to have less sink-down, less variation in thickness along with time, less susceptible to temperature or moisture, and which employs woven fabric having excellent measurement stability, thereby having a sufficient durability against variation in thickness in high-speed printing. The printing rubber blanket includes a surface rubber layer, and at least two fabric layers, in which at least one of the fabric layers other than that located adjacent to the surface rubber layer is woven fabric made of a yarn of No. 10 count or less but No. 6 count or more used for warps of the woven fabric, and a yarn of No. 30 count or less but No. 20 count or more used for wefts of the woven fabric, and the woven fabric is subjected to a stretching process in which the woven fabric is expanded in the warp direction.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation in part of my prior application on this subject matter filed Jul. 2, 1997, Ser. No. 08/886,905 now U.S. Pat. No. 5,988,984 issued on Nov. 23, 1999 which was a continuation in part of my application filed Apr. 24, 1995, Ser. No. 08/427,448 (now abandoned) which was a continuation in part of my application filed Aug. 6, 1993, Ser. No. 08/103,340 (now abandoned). Specific reference is made to the above documents.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to liquid pumps and liquid systems and more particularly to a valve and system to prevent a motor driving a liquid pump from cycling, that is quickly and repeatedly turning off and on. Owners and operators of water systems have ordinary skill in the art of this invention.
(2) Description of the Related Art
Many water pumps supply water to a system having irregular, intermediate use. Often these water pumps supply water into a small reservoir such as a pressure tank. Water systems normally have a range of operating pressures. For example, the range of water of pressures is set between 40 and 60 p.s.i. This pressure range is normally achieved with a pressure switch which cuts off the motor to the pump at 60 p.s.i., which is a second preset condition and then turns it on at a pressure of 40 p.s.i., which is a first preset condition. If the use is such that the small pressure tank is quickly drained, the motor is switched on, the pump fills the pressure tank quickly, the pump switches off, and then as the tank is quickly drained, the pump switches on again. Most of the wear and damage to the motors and the pumps is caused by the numerous repeated starts and stops of the system.
Such a system as described is common on residential water supplies having a separate water supply for every residence, as often occurs in rural areas. Also the problem arises in systems that have irregular irrigation, for example, golf courses, and municipal water systems where different flow rates are required. Some systems with cycling problems have multiple pump stations which are activated according to the different amounts of water needed. Also a system with cycling problems exists in tall buildings where, because of the building height, it is necessary to have controls for different levels of the building, and different flow rates. The problem also exists in liquid systems other than water. For example, the ordinary gasoline fuel dispenser at an auto service station has an electric motor driven pump which delivers fuel to a small pressure tank, then to a metering device, and then to the manually controlled nozzle. When the auto tank is nearly full the customer will often reduce the flow to a dribble to "top off" the tank. This will cause the motor to cycle on and off.
Constant outlet pressure valves are well known to the art. Such valves are designed to reduce the flow if the outlet pressure is above the optimum range and to completely stop the flow when it exceeds the preset pressure.
Before this invention, attempted solutions to alleviate the cycling problem included installing a small bypass around a constant outlet pressure valve. The valve is installed downstream of the pump and upstream of the reservoir and pressure switch. As an example, if the normal flow is fifteen gallons per minute, the bypass provides a flow of one gallon per minute. Therefore when there is a withdrawal from the reservoir, the liquid will continue to dribble through the bypass and slowly refill the reservoir. When the reservoir is sufficiently full, the pressure switch will shut the motor off. The reservoir will supply the need until the water pressure drops to a level at which the pressure switch closes, starting the pump motor to fill the reservoir. However these bypasses exhibited certain problems. One of which is often the bypass will be noisy because of the pressure of the liquid flowing through a small opening. Also the small opening is susceptible to being clogged by debris.
The constant outlet pressure valves (called the valve device herein) often have a plane (or flat) valve seat seating the surface and a valve seating surface that moves normal to the valve seating surface.
SUMMARY OF THE INVENTION
(1) Progressive Contribution to the Art
This invention solves the problem by cutting a notch or groove in one of the seating surfaces, either the valve seat or the movable valve member of the constant pressure outlet valve. Therefore when the valve is closed, the dribble flow is through this notch or groove. Experience has shown that this will not be a noisy flow. Also experience has shown that it will not clog because each time the valve opens any debris which might otherwise collect in the restricted flow device (the notch or groove) is flushed out by the opening of the valve and the flow of liquid across the notch or groove surface.
If the notch or groove is directed to a side of the valve, the water through the notch or groove will erode the side of the valve. This problem is solved by placing the notch or groove so it directs the flow of water through the notch or groove to the outlet of the valve where no damage results.
(2) Objects of this Invention
An object of this invention is to provide a valve device with a modified controlled outlet pressure.
Another object of this invention is to prevent cycling of motors on liquid pumps feeding small reservoirs.
A further object of this invention is to prevent the cycling with a non-clogging dribble flow through a constant outlet pressure valve.
Yet, another object of this invention is to prevent the flow of water through a notch or groove in the valve surface from damaging a housing of the valve.
Further objects are to achieve the above with devices that are sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, operate, and maintain.
Other objects are to achieve the above with a method that is versatile, ecologically compatible, energy conserving, efficient, and inexpensive, and does not require highly skilled people to install, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawings, the different views of which are not necessarily scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a liquid system using a valve device according to this invention.
FIG. 2 is a sectional representation somewhat schematic of a valve device according to this invention.
FIG. 3 is a representation similar to FIG. 2 showing a second embodiment.
FIG. 4 is an enlarged detail taken substantially on line 4--4 of FIG. 2 of the valve seat and valve element of the valve device shown in FIG. 2.
FIG. 5 is an enlarged detail similar to FIG. 4 taken substantially on line 5--5 of FIG. 3.
CATALOGUE OF ELEMENTS
As an aid to correlating the terms of the claims to the exemplary drawing(s), the following catalog of elements and steps is provided:
______________________________________ 10 pump12 motor14 water supply16 pipe20 valve device22 pressure switch24 reservoir26 distribution system28 reservoir entrance pipe29 distribution pipe30 housing32 inlet34 outlet36 valve seat38 seat seating surface40 movable valve member42 valve seating surface44 diaphragm46 opening48 valve closure section50 intermediate flexible section52 cylindrical guiding section54 cylindrical guiding surface56 cover58 control chamber60 spring64 pilot or supplemental control valve65 notch or groove66 tube68 tube69 notch or groove70 tube______________________________________
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the valve device according to this invention is designed to work with motor driven pumps which are non-positive displacement. The valves would also work with a positive displacement pump if the pump were powered by a motor which would reduce its speed with increased back pressure on the pump. However usually the valves are used on pumps wherein with the pump's constant velocity, the flow rate of the pump decreases with increased pressure. The most common of pumps of this type are centrifugal pumps. Some of this type are either axial flow pumps (the water flows parallel to the axis of the rotating pump) or at least combined partially centrifugal.
The valve devices of this invention will always include a valve seat and a valve element which moves relative to the valve seat. Often the valve seat and the valve each have a plane surface and the surfaces are always parallel in their relationship. However in some cases the valve surfaces are conical. Also some valves have a toothed surface to cause a spray pattern from the partially opened valve to be a zigzag pattern instead of a flat spray pattern. Also in some cases a butterfly or gate valve is used and the opening and closing of the valve control by a servo motor.
The valve device is basically a constant outlet pressure valve. Upon increase of the downstream pressure, the valve opening is reduced to reduce the flow so that downstream maximum pressure is maintained; and upon reduced downstream pressure the valve opening increases. Normally the flow will be adjusted by having a spring bias the valve element away from the valve seat and the valve element will have a diaphragm wherein the fluid pressure on one side of the diaphragm will force the valve element toward the valve seat. However, as stated before for the butterfly valve, the motor controlling the valve opening can be responsive to a downstream pressure measurement which would control the positioning of the valve through the servo motor. Such valves are known to the valve arts and are commercially available. The programming of the valve to close with additional downstream pressure is within the skill of persons skilled in such art.
Referring to FIG. 1 there may be seen a schematic representation of a water system according to this invention.
Pump 10 connected to motor 12 pumps liquid from a liquid supply which is usually a water supply 14 into pipe 16. With increased pressure in the pipe 16, the pump 10 pumps less water through pipe 16. Centrifugal pumps have this as a inherent characteristic. Also vane pumps with axial flow would have this inherent characteristic. Constant displacement pumps would not have this characteristic; however if the power supply from motor 12 were such that increased load by the pump would reduce the motor speed; this would have the required result. The required result as stated before is that the increased pressure upon pump outlet pipe 16 reduces the volume of flow from the pump.
The motor could be of various types. The water supply could be of any type. It might be an underground well. It might be a low pressure reservoir and the pump was pumping from the reservoir to have the desired outlet pressure of the system.
The outlet of the pipe 16 is connected to valve device 20 that will be described in detail later. The outlet from the valve device is connected to pressure switch 22 and reservoir 24 by reservoir pipe 28. The reservoir is connected to the distribution system 26 by distribution pipe 29. According to this invention, the reservoir is a pressure reservoir. In an elevated tank the water pressure of the reservoir pipe 28 will vary with the height of water in the reservoir. More commonly, according to the use of this invention, the reservoir would be a pressure tank having a compressed air cap which under normal practice would be separated from the water by a flexible bladder. Increase water in the tank compresses the air and increases the pressure on the pipe 28. Such tanks are well known and commercially available on the market.
The distribution system might be any distribution system: a single rural residence; the complete system for a golf course with a club house including showers, kitchens, etc.; a small village; subdivision of a city; the upper floors of a tall building; or for other liquids such as gasoline pumps.
The pressure switch 22 for an electric motor 12 would be a simple switch which at a first preset condition, namely low pressure provides electrical power to the motor 12 and at a second preset condition, namely high pressure would cut off the electric power to the motor 12. Such switches are well known and commercially available on the market. If the motor 12 were an internal combustion engine, the pressure switch 22 might remain the same but the control for the motor would be required to have automatic starting control at the low pressure output from the pressure switch 22 and also have a shut-off control responsive to the high pressure output from the pressure switch 22. Such motor controls are also well known and commercially available. A check valve (not shown) in pipe 16 prevents liquid from flowing back into the water supply 14 when the pump is not operating.
FIG. 2 illustrates a valve device 20 with housing 30. The housing 30 has an inlet 32 and an outlet 34 divided by valve seat 36. The inlet 32 is connected to the pump outlet pipe 16. The outlet 34 is connected to the reservoir pipe 28. The valve seat 36 has a seat seating surface 38. The seat seating surface lies in a plane. The valve has a movable valve member 40 which has a valve member seating surface 42. The valve seating surface 42 lies in a plane which plane is parallel to the seat seating surface 38. The valve member 40 is movable or displaceable.
In the valve illustrated in FIG. 2 the valve member includes a diaphragm 44 within the housing 30. The diaphragm includes an open peripheral section secured to an opening 46 in the housing in alignment with the valve seat. The diaphragm 44 also has a valve closure section 48. The valve closure section is also displaceable with respect to the valve seat for controlling the flow of fluid through the passageway surrounded by the valve seat. An intermediate flexible section 50 of the diaphragm permits the displacement of the valve closure section 48. The diaphragm also includes a cylindrical guiding section 52 between the valve closure section 48 and the intermediate flexible section 50.
The valve closure section 48 includes the valve seating surface. The valve seating surface 42 contacts the seat seating surface 38 when the valve member is fully closed.
The housing 30 includes a cylindrical guiding surface 54 for guiding the movement of said valve closure section of the diaphragm. Said housing also includes a cover 56 defining a control chamber 58. The control chamber 58 is between the cover 56 and the diaphragm 44. Spring 60 extends between the cover 56 and the diaphragm 44. The valve described is a slight modification of the valve shown in U.S. Pat. No. 5,464,064.
Referring again to FIG. 1, pilot or supplemental control valve 64 is fluidly connected by tube 66 to the control chamber 58 of the control valve 20. The pilot valve 64 is also connected by a tube 68 to the pipe 16. The pilot valve 64 controls the flow of water according to the pressure upon the reservoir pipe 28 which is sensed through tube 70. When the pressure in pipe 28 increases beyond the preset pressure it will cause the pilot valve 64 to direct the pressure from pipe 16 to increase the pressure in the control chamber 58. This increase pressure in the control chamber 58 will move the valve member 40 into a fully closed position. Reduction of pressure in the pipe 28 will cause the pilot valve 64 to reduce the pressure in the control chamber 58 so that the control valve 20 opens and remains open until the pressure in pipe 28 again reaches the preset pressure. This modulating maintains a constant pressure in pipe 28.
The other characteristics of closing the valve 40 will be determined by the design of elements of the valve device 20. Such design elements as changing the strength of the spring 60 and the design of the pilot valve 64 will govern the characteristics of the system. The valve member 40 may be designed to go from a fully closed position to a fully open position within a 5 lb. range. That is, it could be designed so that at a pressure of 50 p.s.i. at outlet 34 would fully close the valve member 40 but at a pressure of 45 p.s.i. at the outlet 34 would fully open the valve member 40. A different design could result in a one pound range for example.
Those skilled in the art will understand that the structure described to this point is old and well known. All parts and elements thereof are commercially available on the market. Also it will be understood that valve device 20 as described at this point is commonly known as a pressure reducing valve or a constant outlet pressure valve.
According to this invention a notch or groove is cut into one of the valve seating surfaces. As illustrated in FIGS. 2 and 4, the notch or groove 65 is cut into the valve seating surface 42 of the valve element 40. However notch or groove 69 could also be cut into the seating surface 38 of the valve seat as illustrated in FIGS. 3 and 5.
The size of the notch or groove would normally be controlled by many factors. For example, if the pump motor were a submergible motor attached to a submergible pump located in the bottom of a well, it would be necessary that the flow of the water through the notch or groove be sufficient to adequately cool the motor over an extended period of time. Also the relative size of the reservoir to the pump capacity would enter into the design factors. If the system were designed so that the distribution system would operate at a pressure from 50 p.s.i. to 30 p.s.i. then the pressure switch would be set to turn on at 30 p.s.i. and off at 50 p.s.i. If the pump had a capacity of 15 gallons per minute at 50 p.s.i., the reservoir could have a capacity of 5 gallons. The term the "capacity of the reservoir" is meant to indicate in such a case that at 30 p.s.i. it would have a minimum amount of water and at 50 p.s.i. it would have a maximum amount of water. That is to say that the reservoir system would be such that if it was full at 50 p.s.i. that the reservoir could deliver at least 5 gallons before the pressure switch would start the pump motor at 30 p.s.i. If no valve device 20 were present, it will be seen that when the motor turned on, and if the flow from the reservoir was 5 gallons per minute, that the motor would run for less than a minute. In less than a minute, the pump would deliver about 5 gallons to the reservoir, and deliver 5 gallons to the distribution system. The 5 gallons forced into the reservoir would cause it to reach its 50 p.s.i. and shut down the pump. Then within a minutes time, the reservoir would be empty and it would turn on again. That is to say if there were a continual flow of water from the distributing system of 5 gallons per minute, that the motor would go through a complete cycle of turning on and turning off and turning on again in less than two minutes without a valve device.
However it may be seen that if the notch or groove in the valve were set to flow one gallon a minute (about 7% of full capacity) and the fully closed position of the valve device is 30 p.s.i. that the pump would continue to operate if there were water usage of one gallon a minute or greater. If the water usage were below one gallon per minute, it could be calculated the length of time that the motor would run and be off. If the distribution system had a very small leak, for example, a rate of a half a gallon a minute and the notch or groove was cut to flow one gallon a minute, the pump would run for at least ten minutes to refill the tank and be off for at least ten minutes while the tank again drained. This would result in the pump going through a complete cycle in twenty minutes. Analysis shows that if the water usage was more or less than one half the notch or groove size that the cycle would not be shorter.
FIGS. 3 and 5 show a second embodiment of this device. The second embodiment is strikingly similar to FIGS. 2 and 4 except that in this embodiment the notch or groove 69 is cut in the valve housing 30 seating surface 36 rather than the moveable valve member 40. FIG. 5 shows the notch 69 cut in the valve seat 36 which can then be easily contrasted with FIG. 4 showing the notch 65 cut in the valve member 40. This second embodiment shows that if over time the notch or groove 69 is washed out, becomes larger because of erosion caused by the water and entrained particles therein, repair may only be had by replacing the valve housing 30. Contrasted to the embodiment of FIGS. 2 and 4, if the notch 65 washes out, repair may be had by replacing the valve member 40.
The embodiments shown and described above is only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention.
The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to enable one skilled in the art to make and use the invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims.
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A water system uses a pressure reservoir of extremely small size. A valve device is placed between a water pump and the pressure reservoir. The valve device has a constant outlet pressure function to limit the flow from the pump at high pressures. The pump is turned on and off responsive to a pressure on/off switch located down stream of the valve device. The valve device maintains the pressure to the reservoir below the off switch pressure except for a dribble flow. The dribble flow fills the reservoir when there is little or no water usage from the reservoir. The dribble flow is achieved by a notch or groove in the valve surfaces of the valve device. Each time the valve opens any debris in the notch or groove is washed from the notch or groove thereby keeping the notch or groove free of debris.
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TECHNICAL FIELD OF THE INVENTION
This invention relates to swath printing systems, and more particularly to techniques for high accuracy swath advance media positioning.
BACKGROUND OF THE INVENTION
Accurately advancing paper between print swaths is becoming a greater and greater challenge. In early inkjet printers, the swath advances were short and the allowable error large. With the push to improve print quality and speed, the swath advances are getting larger and at the same time the accuracy needs to be greater. This invention provides accurate pen/paper positioning regardless of the length of swath advance.
Early inkjet printers relied on stepper motor position through a gear train to a drive shaft with rubber wheels to position the paper. This was adequate for the small advances and the coarse large dots. Subsequent improvements in swath advances have been accomplished using higher precision gears, micro-stepping, and drive rollers with lower run-out.
More recently an encoder has been added to the drive roller shaft to get direct feedback of drive shaft and reduce the requirement for precision gears. A second encoder is typically needed to compensate for eccentricity of the encoder disk. In addition, the manufacturing variation in the drive tire diameter may require a calibration routine to measure the drive tire circumference. This information is stored in non-volatile RAM and used to further improve the swath advance accuracy.
All these improvements have helped to meet the requirements for each new generation of printer. With the precision required for the next generation products, the existing technologies are again exceeded.
The swath advance distances can be expected to increase substantially. At the same time the number of dots per inch is increasing, e.g. from 600 dpi to 1200 dpi. In the past, system paper swath advance accuracies on the order of ½ to ¼ dot row have been required. To position paper to +/− 0.0002 inches for paper advances greater than one inch would be difficult to achieve using conventional techniques.
SUMMARY OF THE INVENTION
Techniques are described for high accuracy media positioning in a swath printer. According to one aspect of the invention a high accuracy media positioning method includes mounting a computer-controlled printing element for movement along a swath axis for swath printing of an image on a print medium, moving the printing element along the swath axis and printing at least a portion of a swath of the image on the print medium, sensing the position of an edge of the just printed portion of the image which is nominally aligned with the scan axis; providing relative motion between the print medium and the printing element to accurately position the printing element in dependence on the sensed position of the edge of the just printed portion of the image.
The fine compensation needed to compensate positioning errors can be performed prior to printing a swath, or even “on the fly” during the printing of a swath. Coarse positioning errors can be measured by the sensor and compensated by use of the printer media advance system, by increasing or decreasing as appropriate the nominal commanded swath-to-swath advance distance.
BRIEF DESCRIPTION OF THE DRAWING
These and other features and advantages of the present invention will become more apparent from the following detailed description of an exemplary embodiment thereof, as illustrated in the accompanying drawings, in which:
FIG. 1 is a diagrammatic view showing a printer carriage with sensors for detecting the edge of the prior swath.
FIGS. 2A–2C illustrate respective image examples with low to high swath alignment accuracy requirements.
FIG. 3 is a diagrammatic view illustrating how the carriage sensor detects the swath edge.
FIGS. 4A–4C illustrate different types of swath errors.
FIGS. 5A–5C illustrate types of swath printing compensation techniques for addressing swath errors.
FIG. 6 illustrates the partial image fill areas in which high swath accuracy is necessary.
FIG. 7 is a simplified diagrammatic side view of the media path and media advance elements of a printer embodying this invention.
FIG. 8 is a schematic block diagram of the printer of FIG. 7 .
FIGS. 9A–9B and 10 illustrate an exemplary process flow diagram of an exemplary swath position correction technique in accordance with this invention.
FIG. 11 illustrates an exemplary sensor calibration mode for the printer.
FIG. 12 is a diagrammatic side view of an apparatus for effecting position correction by moving the printer pens in relation to the printer carriage.
FIG. 13 is a diagrammatic side view of an apparatus for effecting position correction by moving the carriage in relation to the carriage rod.
FIG. 14 is a diagrammatic side isometric view of an apparatus for effecting position correction by moving the carriage rod in relation to the printer frame.
FIG. 15 is a diagrammatic side view of an apparatus for effecting position correction by moving the printer platen in relation to the printer frame.
FIG. 16 is a diagrammatic side view of an apparatus for effecting position correction by moving the print medium in relation to the printer platen.
FIG. 17 is a diagrammatic side view of an apparatus as in FIG. 16 , but allowing movement of the platen during position correction.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention involves a major paradigm shift in the way a print medium is positioned for each swath. This invention recognizes that a critical task in high accuracy alignment is not in moving the paper accurately, but rather in lining up the bottom of the last swath with the top of the next swath. Existing media advance technologies can readily position the print medium to within +/− 0.001 inch. Higher positioning accuracies would be desirable, e.g., to align the bottom of the last swath to the top of the current swath to within +/− 0.0001 inch.
In accordance with aspects of this invention, high positioning accuracy can be achieved by measuring the bottom of the last swath with a sensor located on the carriage. In order to have bi-directional printing, a sensor is placed on both sides of the carriage. This arrangement is illustrated in FIG. 1 , which illustrates a carriage 20 mounted for sliding movement along a carriage rod 22 . The carriage supports a plurality of ink jet pens 24 A– 24 D having nozzles arrays for ejecting droplets of ink as the carriage is moved along the swath axis 30 . Mounted at each side of the carriage are respective sensors 26 , 28 . As the carriage is traveling across the page, i.e., along the X axis, the carriage location along the Y axis can be adjusted on the fly to compensate for positioning errors of the media advance system, e.g. +/− 0.001 inch positioning errors, to a much smaller range, e.g. to within +/− 0.0001 inches. Of course, it is to be understood that the magnitudes of the particular positioning errors will be dependent on the particular system design.
Since the correction required in many applications is less than a few thousandths of an inch, it can be accomplished, e.g., with a servo controlled piezoelectric apparatus, pneumatic cylinder, motor with cam-actuator or linear actuator, or a solenoid wedge actuator. This final correction move can be done by moving the carriage, the individual pens, the carriage rod, the carriage plate, the drive roller shaft, the paper path module, or at other locations that affect pen to paper relative positions.
The advantages of making a final adjustment of pen to paper alignment on the fly are several fold. The error for “final positioning on the fly” is independent of the length of swath advance, whereas for all previous techniques, for swath advance, the error is directly proportional to the length of swath advance. Consider the example of a printer with a 0.5 inch swath advance, and a typical tolerance of +/− 0.001 inch for a 0.5 inch move. The maximum error is 0.2% of a 0.5 inch move. Now consider a printer having a 2 inch swath advance and a positioning requirement of +/− 0.0001 inch. The required maximum error is only 0.005% of a full swath move. For a 2 inch move, a 0.2% error would position the paper within +/− 0.004 inch, and this could be achieved by known media advance systems. The final 0.004 inch error can be compensated by the “final positioning on the fly” technique. This requires a final positioning accuracy of only +/− 2.5%. For longer swath advances, there are not only errors in Y position but also in Theta-Z. The “final positioning on the fly”technique can also compensate for this paper skew by adjusting for the swaths not being parallel.
In zones where there is white space between swaths, i.e. in which there are blank, unprinted space between swaths, the positioning accuracy requirements are substantially reduced. Since the image to be printed is known, it is also known where it is critical to match top and bottom edge of swaths. It is only critical to align where there is a match and thus a signal is available to do the match. This is illustrated in FIGS. 2A–2C . FIG. 2A illustrated diagrammatically the case in which the swath boundary 40 falls between two blocks or lines of text, indicated as text 42 and 44 , with space between the boundary and adjacent portions of the text. For this case, the alignment of one swath to the next swath is not critical. FIG. 2B illustrates the case in which the swath boundary 40 passes through a block or line of text 46 . Here, the alignment between successive swaths is somewhat critical. FIG. 2C illustrates the case in which the swath boundary 40 passes through a graphical or solid image 48 . For this case, the alignment between the adjacent swaths is very critical for high image quality.
In accordance with an aspect of the invention, the edge of the last swath is sensed, and compensation is achieved by moving either the paper or the pens, using the position information regarding the edge of the last swath. The preferred embodiment is to move the pens by either moving the carriage with respect to the carriage rod or the carriage rod with respect to the printing platen.
Gross or accumulated errors can be compensated during paper advances, i.e. by use of the media advance system, by commanding larger or smaller advances in comparison to the nominal advance distance. Minor errors can be compensated via carriage/pen servoing. The range of “on the fly” compensation is limited to some relatively small range, say for the sake of example +/− 0.01 inch. If there is an error of say 2 mils in each swath advance, it would only take 5 advances to take up all of the “on the fly” range of compensation. Therefore, by knowing an average error for each advance, which can be measured “on the fly” by the sensor, the next media advance could be commanded to be larger/smaller than the nominal advance distance to compensate.
FIG. 3 illustrates the location on the image at which the sensor 28 carried by the carriage 20 will be activated to sense the edge, as the carriage transports the sensor in the direction indicated by arrow 40 A. The sensor 28 will be deactivated after the sensor reaches location 40 B, where the previously printed image ends. Since the printer controller knows the location of the edges (along the Y axis) of the just printed edges, the locations at which the sensor needs to be activated and deactivated are known. Of course, the sensor could alternatively be activated continuously during a swath.
FIGS. 4A–4C illustrate three types of swath errors. FIG. 4A illustrates a linear swath error, wherein the second swath is offset from its nominal position relative to the first swath by an error ΔY 1 =ΔY 2 across the width of the swath. Linear swath errors can be compensated down the page with a combination of pen servo and subsequent compensation during media advances.
Skew or rotational error, illustrated in FIG. 4B , wherein ΔY 1 does not equal ΔY 2 , can accumulate down the page and compensation would be limited to the range of the pen/carriage servo. This type of error has been common with previous inkjet printers using a drive tire arrangement. Use of a belt drive would reduce this type of error.
Any remaining nonlinearities across the page, such as those illustrated in FIG. 4C , can be “straightened out” over several swaths. Since the swath should be straight, the tracking algorithm can aim to minimize deviations gradually enough to handle or minimize print defects.
One pass straightening, depicted in FIG. 5A , would produce print defects. Tracking from one swath to the next, as shown in FIG. 5B , could emphasize defects further down the page. Hybrid compensation, melding the techniques of FIGS. 5A and 5B , minimizes print defects and will tend to straighten swaths after several passes.
Swath tracking works well where there is continuous fill on the previous swath. Swath tracking works also on non-continuous previous swaths. Since it is known where the filled areas of the previous swath are, the tracking is turned on in those areas only. FIG. 6 illustrates the case in which the image includes non-continuous areas 1 and 2 of solid fill. Since the critical alignment areas are those of the solid fill areas, the tracking to detect the edge of the previous swath can be turned on or activated only for these areas.
There are several possible techniques for tracking. The preferred embodiment involves a pair of CCD arrays, one on each side of the carriage for bi-directional printing, as generally illustrated in FIG. 1 . Consider the example in which the media positioning system without tracking can position the media within approximately 0.001 inch for a one half inch swath, and can position the media within approximately 0.004 inch on a 2 inch swath. For this example, the CCD array need only be about 0.010 inch tall and at a minimum one pixel wide. An array as small as one by one hundred pixels would provide adequate resolution for tracking. Arrays wider than one pixel could provide better resolution and accuracy. The size of the array is therefore determined by the required resolution and accuracy of a particular application.
Since the compensation for position is small, on the order of 0.004 inch for this example, the “servo”or actuating element could be as simple and lightweight as a piezoelectric driver on the carriage, or as simple as a DC motor driving a cam mounted to a carriage rod. Individual pen datums could also incorporate a piezoelectric element. In general, the actuating element could be a piezoelectric element, a pneumatic or hydraulic cylinder, a motor with a linear actuator or a cam actuator, a solenoid, a wedge actuated by any of these active devices, or other actuation structure.
FIG. 7 is a simplified diagrammatic side view of an exemplary printer 50 with one possible form of media advance apparatus. The printer includes a frame 66 which supports the carriage drive and the carriage 20 . A motor driven pick roller 52 is activated to pick a sheet of the print media from an input source 54 , and pass it into the nip between drive roller set 56 . The print media may be any type of suitable material, such as paper, cardstock, transparencies, photographic paper, fabric, mylar, metalized media, and the like, but for convenience, the illustrated embodiment is described using paper as the print medium. The invention is also applicable to roll-fed media as well. The sheet is advanced onto an endless perforated belt 58 , mounted for rotation on belt pulleys 60 , 62 . The pulleys are driven to advance the sheet to the print zone 25 under the pens 24 A– 24 D. A vacuum plenum 62 holds the sheet tightly against the belt surface at the print zone. The exiting sheet is passed through the nip formed by output roller set 64 to an output tray (not shown in FIG. 7 ). Of course, the invention is not limited to the specific form of media advance apparatus. Other media advance systems could be employed, e.g. friction roller drives.
FIG. 8 is a schematic block diagram of the control system for the printer of FIG. 7 . A controller 70 such as a microcomputer or ASIC receives print job commands and data from a print job source 72 , which can be a personal computer, digital camera or other known source of print jobs. The controller acts on the received commands to activate the pick roller motor 74 to pick a sheet from the input tray 54 , advance the sheet to the nip between the drive roller and pinch roller set 56 , and activate the drive motor system 76 to advance the sheet onto the belt, and move the belt to advance the sheet to the print zone. The carriage drive 78 is driven by the controller to position the carriage 20 for commencement of a print job, and to scan the carriage along the slider rod 28 . As this is done firing pulses are sent to the printheads comprising the pens 26 A– 26 D. The controller receives encoder signals from the carriage encoder 80 to provide position data for the carriage. The controller is programmed to advance incrementally the sheet to position the sheet for successive swaths using the media advance belt drive, and to finely position the print media and pen in relation to one another using an error compensation positioning system 90 . The controller ejects the completed sheet into the output tray upon completion of printing.
Exemplary techniques for effecting the fine position compensation will be discussed further below.
FIGS. 9A–9B illustrate steps of a flow diagram of an exemplary process 100 for high accuracy swath advances in a swath printer. The first swath is printed ( 102 ), and the media is advanced for the second swath using the media advance system ( 104 ). At 106 , the zones that need high accuracy swath alignment are determined, based on the type of image and the print quality requested (e.g., draft mode, high resolution, etc.). At 108 , printing of the next swath is commenced. During the printing of the swath, if in a zone needing high accuracy swath alignment ( 110 ), the error compensation needed is determined and applied to effect the compensation ( 112 ), and the compensation values are stored in memory ( 114 ). The process continues until the swath printing is completed ( 116 ). Referring now to FIG. 9B , If the just completed swath is the last swath for the page ( 118 ), operation proceeds to print the next page (if any), which involves ejecting the sheet just printed to an output location, loading a fresh sheet, and positioning the new sheet to commence printing the first swath, at which time the process 100 is repeated.
FIG. 10 illustrates in further detail the process step 112 of FIG. 9A . At 112 A, the sensor is read to determine the position of the edge of the last swath. The error is determined at 112 B, and at 112 C, the appropriate compensation drive signal is generated and applied to the compensation apparatus.
Preferably, the printer will include a calibration mode for calibrating the swath edge sensors. An exemplary calibration process 150 is shown in FIG. 11 . A blank sheet is fed to the print zone for use in the calibration process at 152 . A “blackout” swath is printed across the sheet, from left to right, at 154 ; the blackout swath has only a dark strip along the top of the swath, say 0.01 inch thick. At step 156 , the position of the trailing (left) sensor is recorded to calibrate the top of the swath with the left sensor. The sheet is advanced at 158 , and second blackout swath is then printed, from right to left, at 160 . The position of the trailing (right) sensor is then recorded at 162 , calibrating the top of the swath with the right sensor. Thus, the calibration process employs the trailing sensor. During printing the leading sensor is typically used to align the bottom of the last swath printed with the top of the current swath. For a multiple-pen printer, each pen could be calibrated relative to the sensor, thus repeating the calibration steps ( 154 – 162 ) for each pen.
Several alternate means for effecting relative movement between the pens and the print media to provide fine position compensation are illustrated in FIGS. 12–17 . FIG. 12 illustrates a technique for providing pen-to-carriage position compensation. Shown in cross-section is a carriage structure 102 holding one or more ink jet pens 104 , and mounted for sliding movement along slider rod 106 . The pen position in the carriage is registered by pen datum surfaces 104 A and 104 B, and by piezoelectric device 104 C which also acts as a datum. Spring contacts 108 bias the position of the pen away from the rod, bringing the device 104 C against the carriage shoulder surface 102 A. The device 104 C is driven by the printer controller to modify the pen position along the Y axis. Typically, for a color printer there will be a plurality of pens held in the carriage, and each will have a piezoelectric element to modify its position within the carriage. Alternatively, the element 104 C could include another type of positioning element or apparatus, such as a solenoid, a pneumatic or hydraulic actuator, a cam, or other commonly used positioning apparatus. Piezoelectric actuators suitable for the purpose are known in the art; by way of example only, piezoelectric actuators and translators are marketed by Micro Pulse Systems, Inc., Santa Barbara, Calif., and by PiezoMech Incorporated.
FIG. 13 illustrates a technique for providing carriage-to-carriage-rod fine position compensation. This will effect movement for all pens mounted in the carriage 110 , shown in cross-section, with exemplary pen 112 visible in FIG. 13 . The carriage is mounted on rod 116 for sliding movement. The carriage includes a carriage stall portion 110 A which is cantilevered from carriage rod portion 110 B; a gap 110 C is formed between the two portions. The pens include datums 112 A, 112 B and 112 C. Spring contacts 118 urge the pen in registered position within the carriage as determined by the datums against corresponding carriage surfaces. To achieve fine position compensation between the rod 116 and the carriage portion 110 A, a position control device 114 such as a piezoelectric device is placed in the gap 110 C. Driving the device will cause movement of the carriage portion 110 A relative to the rod 116 . FIG. 14 is a diagrammatic illustration of a fine position compensation technique which achieves pen to media position control by providing relative movement of the carriage rod in relation to the printer frame 66 . The slider rod 124 is mounted at each rod end on a rod mount, one of which is shown in FIG. 14 as rod mount 122 . The rod mount is secured to frame portion 66 A, and includes thin flexible beam members 122 A, 122 B. A spring structure 126 exerts a bias force pushing the rod mount against an actuator element 128 .
The rod 124 can be moved in the Y axis by actuating element 128 , to cause the beams to flex, moving the mount against the bias force. The actuating element could be a piezoelectric element, a pneumatic or hydraulic cylinder, a motor with a linear actuator or a cam actuator, a solenoid, a wedge actuated by any of these active devices, or other actuation structure.
Another technique for providing fine position compensation in accordance with the invention is to position the printer platen relative to the printer frame. This technique is illustrated in FIG. 15 , a simplified diagrammatic side view showing the media advance system 130 including a drive belt 58 as in the system of FIG. 7 , mounted on a slidable support table 132 which slides on bearings 136 relative to frame 134 along the Y axis. The position of the table is controlled by actuator 140 , which can be a piezoelectric actuator, or another actuator type as described above with respect to the embodiment of FIG. 14 . The print medium is located on the media advance system at the print zone 142 under the printer pens. In this embodiment, the printer platen 144 , and its position and that of the print medium 146 held thereon, is movable in response to actuation of the element 140 .
FIG. 16 shows an exemplary technique for providing relative movement between the print medium and the printer platen by moving the print medium relative to the platen. The media advance system includes a belt 58 and belt drive as described with respect to FIG. 7 . With the print media held against the platen 154 at the print zone 152 by a vacuum hold-down, the media drive is actuated to provide incremental rotation of the drive belt, thus moving the print medium relative to the platen. For this embodiment, the fine compensation movement can be accomplished via a second drive motor system that has a very high, but precise gear reduction. Another technique is to mount the main drive motor to a plate that rotates coaxially relative the motor shaft. The main motor moves a commanded position (say +/− 5 mils) and then its position is locked relative to the plate using a brake. The second motor then rotates the plate to achieve fine compensation.
In the embodiment of FIG. 16 , the platen is stationary. Alternatively, the platen can be mounted on a slide arrangement. This is illustrated in FIG. 17 , with the platen 162 moving with the belt 58 and the print medium when the media advance system is incrementally advanced with the vacuum hold-down actuated, effecting the fine position compensation. The media advance system has a main motor which coarsely positions the belt with the platen in a locked position. The platen is then unlocked, the main motor is disengaged, and the platen is incrementally moved to achieve fine compensation, with a vacuum holding the belt to the platen.
It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope and spirit of the invention.
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Techniques for high accuracy media positioning in a swath printer. A high accuracy media positioning method includes mounting a computer-controlled printing element for movement along a swath axis for swath printing of an image on a print medium, moving the printing element along the swath axis and printing at least a portion of a swath of the image on the print medium, sensing the position of an edge of the just printed portion of the image which is nominally aligned with the scan axis; providing relative motion between the print medium and the printing element to accurately position the printing element in dependence on the sensed position of the edge of the just printed portion of the image. The fine compensation needed to compensate positioning errors can be performed prior to printing a swath, or even “on the fly” during the printing of a swath. Coarse positioning errors can be measured by the sensor and compensated by use of the printer media advance system, by increasing or decreasing as appropriate the nominal commanded swath-to-swath advance distance.
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BACKGROUND OF THE INVENTION
In the field of body exercise and strength training, there is a need to exercise the posterior deltoid rotator cuff, rhomboideus, latissimus dorsi, and trapezius muscles under a resistive load. Various exercisers have been devised to strengthen these muscles of the body through pulling movements, including pulling weight-bearing cables over pulleys or using a complicated lever apparatus with each arm bearing a separate load. However, the use of available exercise machinery does not vary the resistance presented to the muscles as the body's ability to overcome resistance increases. The known devices fail to vary the load between stages in the exercise when the body is weaker such as when the elbows are fully flexed and they fail to promote proper joint alignment as the exercise is performed. A need exists for an exercise machine which can be safely used to effectively resist the action of the back muscles and which provides variable loading and proper joint alignment as the device is used.
SUMMARY OF THE INVENTION
The present invention relates to apparatus useful to an athlete to increase upper body strength, and in particular for strengthening latissimus dorsi and trapezius muscles and the rotator cuff. The invention allows the user to perform strengthening exercises while maintaining proper shoulder, elbow, and wrist joint alignment throughout the movements made with reduction in effective load as the muscles reach relatively weaker positions. A supporting base is provided with a foot plate on which the user stands. A cushion on an adjustable height stand is positioned on the base. The cushion member is adjustable in height above the base and is positioned beside the foot plate on which the user stands. The foot plate on which the user stands is tilted downward toward the cushion stand and the user leans against the cushion to restrain the user from pulling himself or herself forward as the exercise apparatus is used.
A weight rest member stands above the second end of the frame opposite the foot plate and serves as a rest for a weight carrying member. The weight carrying member is pivotally mounted to a horizontal bar fixed between the cushion stand and the weight rest member. The weight carrying member is pivotable toward the user in a vertical plane which is aligned with the centerline of the user. The weight carrying member includes a bar which extends upward and away from the user when the weight carrying member rests on the weight rest member. A transverse handlebar is mounted at or near the upper end of the upwardly extending bar and has a handle member mounted at each of its ends by a multiple axis pivotable joint. The handle members are curved to allow each handle grip to be easily grasped by the user with his or her arms outstretched in a natural position for the wrists. Each handle member is freely rotatable as the user pulls the pivotable member towards himself or herself. In addition, each multiple axis pivotable joint allows the handle to be pivotable over a lateral range about its end of the handlebar. Further, each handle member is rotatable about and over the axis of the transverse arm through an approximate sixty-degree range. By allowing the handle members to be freely moveable about several axes, the apparatus prevents the user from having to constrain the wrists, elbows, or hands as the pivotable member is drawn toward the user. The wide range of motion of the handle members on the ends of the handlebar allows the user to bring his or her elbows backward past his or her sides and to shrug, thereby increasing the flexion of the trapezius muscles.
A weight displacement arm depends from the bar of the weight carrying member in the plane of movement of the bar. A weight support rod is transversely mounted at the free end of the weight displacement arm and is sized so that Olympic barbell weights can be mounted on the weight support rod in such weights and numbers as are chosen by the user.
In order to allow the apparatus to be used by differing sizes of persons, the handlebar is adjustable relative to the point of pivot of the pivotable member so that the height of the handle members may be set at a comfortable height for the user, especially to allow the forearms and wrists of the user to remain generally horizontal as the pivotable member is drawn close to the user and the elbows move past the user's sides. The height adjustment is provided by mounting the handlebar to a telescoping bar which is received by a hollow box tube, the telescoping bar and the box tube being part of the upwardly extending bar of the weight carrying member. The selected height adjustment is maintained by use of a telescoping bar maintained in selected extension by a pop pin assembly.
It is an object of the invention to provide an exercise apparatus which decreases the resistance to the muscles of the user as the muscles decrease in effective strength.
It is a further object of the invention to provide an exercise apparatus for strengthening trapezius and latissimus dorsi muscles of a user.
It is a further object of the invention to provide an exercise apparatus which allows the shoulders of the user to travel over a full range of motion.
It is a further object of the invention to provide an exercise apparatus which may be conveniently loaded with existing Olympic sized or other barbell weights.
It is a further object of the invention to provide an exercise apparatus which allows the user to strengthen latissimus dorsi and trapezius muscles at minimal risk of injury to the ligaments, tendons and joints of the user.
It is a further object of the invention to provide an exercise apparatus which may be adjusted for varying strength and size of users.
These and other objects of the invention will become apparent from examination of the description and claims which follow.
DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a front left perspective view of the rowing exercise apparatus invention shown at rest.
FIG. 2 is a front elevation of the invention being operated by a user. The user and barbell weights mounted to the invention are shown in phantom.
FIG. 3 is a front expanded view of the movable member of the exercise apparatus shown with the handles thereof omitted.
FIG. 4 is a top plan view of the handle bar and handles of the invention.
FIG. 5 is an exploded perspective view of the handle bar and one handle member and the multiple axis hinge interconnecting them.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, the exercise apparatus for arm and back muscles is illustrated. The invention 2 includes a base 4 which is generally rectangular. At a first end 6 of base 4 is disposed a foot plate 8 extending from side 13 to side 14 of base 4. Foot plate 8 is preferably tilted downward from its higher edge 10 which is adjacent first end 6. User 5, shown in phantom, is stationed standing on foot plate 8. Foot plate 8 extends to cross member 12 mounted between sides 13, 14 of base 4. Cushion stand 16 stands above cross member 12. Cushion stand 16 includes a lower elongate box tube 18 into which is telescopingly slidable an upper cushion mounting shaft 20 which is held in a selected vertical position by means of adjustment knob 22 which may be manipulated by the user to loosen cushion mounting shaft 20 within box tube 18 to allow cushion 24 to be selectively vertically adjusted to comfortably engage the abdomen of user 5. Other means to restrain forward motion of user 5 may be employed as an alternative to cushion 24.
Forward of cushion stand 16 at the second end of base 4 is an upstanding post 26. A horizontal bar 30 is disposed between cushion stand 16 and upstanding post 26 which serves as a support for movable member 32. In the preferred embodiment, movable member 32 is pivotable upon horizontal bar 30 such that movable member 32 pivots in the plane defined by cushion stand 16 and upstanding post 26. It is to be understood that the precise structure illustrated in the drawings is but one arrangement whereby the pivot pin 34 of movable member 32 is maintained at a height slightly below the height of the user's patella, or in the range of 12-24 inches above the base 4, preferably about eighteen inches above the frame 4 when an adult of average height is the intended user of the device. Pivot pin 34 is preferably disposed a small distance horizontally removed and forward of the user.
Movable member 32 comprises a first telescoping elongate bar 36 having a lower end 38 to which is mounted a generally perpendicular lever 40. Lever 40 is pivotable about pivot pin 34 such that movable member 32 pivots about pivot point 34. A resilient stop 39 is disposed on horizontal bar 30 to engage lever 40 and limit travel of moveable member 32 as it is pulled by user 5 toward himself or herself. First telescoping bar 36 includes inner shaft 42 which is selectively slidable within the outer housing 48 of telescoping bar 36. At or near upper end 44 of inner shaft 42 is transversely mounted a handlebar 46 having opposing ends to which are mounted a pair of handle members 50, 51. Handle members 50, 51 are spaced apart a typical spacing of an average adult person's shoulders.
Midway along elongate bar 32 is fixed a weight displacement arm 52 which depends at an angle, preferably perpendicularly, from elongate bar 32 on the side thereof directed away from cushion stand 16. Weight displacement arm 52 is preferably disposed in the plane of travel of moveable member 32. Disposed at or near the free end 54 of weight displacement arm 52 is a horizontally oriented weight support bar 56 on which typical barbell weights 55 may be placed. In the preferred embodiment, weight support bar 56 is a two-inch diameter rod to accommodate Olympic weights and is centered on free end 54 of weight displacement arm 52. Depending from free end 54 of weight displacement arm 52 is stub arm 58 which is angularly disposed upon free arm 52 such that it will abut horizontal bar 30 at or near its mounting to upstanding post 26. A resilient bumper 28 is fixed at free 60 of stub arm 58 to cushion abutment of stub arm 58 on horizontal bar 30. The length and angular disposition of stub arm 58 are designed to allow moveable member 32 to come to rest with stub arm 58 abutted to the top of horizontal bar 30. When so at rest, weights 55 may be safely added or removed from weight support bar 56 and the length of moveable member 32 may be adjusted to fit the user's needs.
Referring now to FIG. 3, moveable member 32 is illustrated with handlebar 46 and handles 50, 51 omitted. Inner shaft 42 of movable member 32 is slidable within the housing 48 of telescoping bar 36. The length of telescoping bar 36 is adjustable by extension or retraction of inner shaft 42 within housing 48 of telescoping bar 36. Holes 43 along inner shaft 42 are provided to receive plunger pin 45 which is topped by knob 47 such that the user may easily adjust the height at rest of the handlebar 46 to be comfortable for use. Knob 47 is drawn away from housing 48 such that plunger pin 45 will be drawn from one of holes 43 of inner shaft 42 and inner shaft 42 may be slid from or into housing 48 to the desired extension and plunger pin 45 allowed to drop into one of holes 43.
Referring now to FIGS. 4 and 5, the details of handle bar 46 and handle members 50, 51 may be observed. A handle member 50, 51 is mounted to each of the opposing ends of handlebar 46. Each of handle members 50, 51 includes a shaft 70 fixed at one end to handle bar 46 and terminating on the opposing end in a curved handle 72 covered with a cushioned grip 74. The length of shaft 70 is selected such that the user may extend his or her hands forward to grasp the handles while resting against cushion 24. Each handle member 50, 51 is freely rotatable about the axis of shaft 70 and also each handle member 50, 51 may pivot laterally over a limited range (±30 degrees from perpendicular) upon the end of handlebar 46. Further, each handle member 50, 51 may independently rotate about the axis of handlebar 46 in a range of approximately 60 degrees with the lower extreme of the rotation being a position in which shafts 70 are generally horizontal when weight displacement arm 52 rests atop upstanding support 26.
Referring now to FIG. 5, the structure utilized to allow the unique movements of handle members 50, 51 upon handlebar 46 is illustrated in an exploded view. Handlebar 46 is preferably a hollow tube having equivalent structures on each end. End 66 of handlebar 46 is provided with paired annular slots 68, 69 of which upper slot 68 extends from the top of handlebar 46 away from first end 6 about 60 degrees when moveable member 32 rests on bumper 28, while lower slot 69 diametrically opposes upper slot 68. A nylon cylindrical insert 76 is received within bushing 78 and the bushing 78 with nylon insert 76 overlies end 66 of handlebar 46. An end cap 82 overlies the bushing 78 and a capscrew 80 is passed through an opening in end cap 82 which is in registration with an opening through bushing 78, insert 76, and with slots 68, 69. Handle shaft 70 is fixed to end cap 82 such that shaft 70 may rotate about its own axis.
Operation of the Invention
A user choosing to exercise his or her arm and back muscles may adjust the height of cushion 24 to a comfortable engagement with the user's abdomen and may also adjust the height of handle bar 46 by extending or retracting inner shaft 42 within telescoping elongate bar 36 and securing it in place by operation of plunger pin 45. The user then may place selected weights on the weight support bar 56 of moveable member 32. Then while standing on foot plate 8 and leaning the abdomen against cushion 24, the user may grasp each of handle members 50, 51 in the hands and turn them to a comfortable position and begin to draw the moveable member 32 toward himself or herself. As this is done, barbell weights 55 describe a curved path as the user brings the hands closer to the user's sides, with the weights 55 drawn closer to the fulcrum provided by the pivot pin 34, thereby reducing the moment arm of the barbell weights 55 and reducing the resistive force provided by the weights 55 as the user draws the hands further back and shrugs the shoulders, thereby exercising the trapezius muscles while simultaneously working the latissimus dorsi muscles and encountering lessening resistance as the muscles reach positions of reduced leverage. The variability of the angular relationships of the handle members 50, 51 to handlebar 46 permits proper joint alignment throughout the movements made while using the invention.
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An improved exercise apparatus for muscles of the upper extremities, mid-back, and posterior shoulder girdle provides negative variable resistance as the muscles are contracted over a wide range of motion while maintaining proper joint alignment in the shoulders, elbows, and wrists. A movable weight carrying assembly has a transverse handlebar from the ends of which extend handle members which the user grasps to pivot the weight carrying assembly toward himself or herself while moving the arms from an outstretched position to a position with the elbows flexed, scapulae adducted, and the trapezius muscles contracted in a shrugging action. The weight carrying assembly is adjustable for varying heights of user.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to improvements in apparatus for accumulating successive sheets of short or long series of sheets into piles or stacks of overlapping sheets at a stacking station, and for removing stacks from a sheet-gathering receptacle at the stacking station. More particularly, the invention relates to improvements in apparatus which can automatically remove successive freshly gathered stacks while the sheets continuously arriving at the stacking station gather into fresh or growing stacks of overlapping sheets. Apparatus of such character are known as sheet piling devices, and one thereof is described and shown in U.S. Pat. No. 4,436,472 granted Mar. 13, 1984 to Kunzmann.
[0002] The patent to Kunzmann discloses an apparatus wherein several stacking units are placed side-by-side. A drawback of the patented apparatus is that its design imposes limits upon the number of stacks or piles which can be gathered per unit of time with a requisite degree of accuracy. Moreover, the condition of the sheets is likely to be affected if the rate at which the sheets are supplied and stacked exceeds a relatively low threshold value.
[0003] Another drawback of conventional apparatus of the above outlined character is that they cannot be rapidly converted for the stacking of sheets having different sizes and/or shapes. This can result in prolonged interruptions of the operation and a considerable reduction of the output.
OBJECTS OF THE INVENTION
[0004] An object of the instant invention is to provide an apparatus which constitutes an improvement over and an advantageous further development of apparatus disclosed in the aforementioned U.S. Pat. No. 4,436,472 to Kunzmann.
[0005] Another object of the invention is to provide an apparatus which can be rapidly converted to gather larger or smaller, wide or narrower and/or shorter or longer sheets with the same degree of accuracy.
[0006] A further object of the present invention is to provide novel and improved means for manipulating one or more abutments for the growing stacks of paper sheets or the like.
[0007] An additional object of the invention is to provide a novel and improved method of manipulating successive sheets of a stream or flow of partially overlapping sheets in a stacking machine.
[0008] Still another object of the invention is to provide a sheet stacking apparatus which can gather sheets of different thicknesses and/or other characteristics with the same degree of accuracy and predictability.
[0009] Another object of the invention is to provide a novel and improved method of manipulating scalloped streams of partially overlapping paper sheets or the like preparatory to and during conversion or gathering into stacks or piles.
[0010] Still another object of the invention is to provide an apparatus which can be reliably converted for the processing of sheets having different sizes and/or shapes within short intervals of time.
SUMMARY OF THE INVENTION
[0011] The invention resides in the provision of an apparatus for gathering successive sheets of a series of sheets (such as paper sheets) into growing stacks which are being gathered in and, when fully grown, are removed from a receptacle at a stacking station. The apparatus comprises means for conveying successive sheets of the series (e.g., successive sheets of a scalloped stream consisting of partially overlapping sheets) in a first direction (e.g., substantially horizontally) into the receptacle at the stacking station to thus accumulate in the receptacle a growing stack of overlying or overlapping sheets, front and rear abutments or stops for the sheets of a stack in the receptacle (the abutments are spaced apart from each other in the first direction and the front abutment is movable relative to the receptacle between operative and inoperative positions), means for withdrawing fully grown stacks from the receptacle in the first direction while the front abutment dwells in the inoperative position, means for transporting withdrawn stacks in a second direction (e.g., substantially horizontlly and substantially at right angles to the first direction), and means for adjusting the rear abutment in and counter to the first direction. The conveying means can comprise a belt or chain conveyor or another suitable conveyor which can deliver to the receptacle sheets having different lengths, and the rear abutment is adjustable for the purpose and to the extent necessary to conform the spacing of the front and rear abutments from each other to the lengths of sheets being conveyed to the receptacle.
[0012] The apparatus can further comprise a platform which can resemble or constitute a rake and serves to separate the sheets. The platform is movable with the conveying means between a plurality of positions, such as forwardly and backwards (as seen in the first direction) and/or up and down. The movements of the platform in and counter to the first direction can take place in synchronism with movements of the withdrawing means (the latter can include gripper or holder means adapted to engage the front end portion of a fully grown stack and to pull the stack from the receptacle while the front abutment is maintained in its inoperative position).
[0013] The conveying means is or can be arranged to share the movements of the platform between a plurality of different levels.
[0014] In accordance with a presently preferred embodiment, the apparatus further comprises a carriage (such as a slide) for the aforementioned platform and for the conveying means, as well as an elevator which serves to move the carriage between a plurality of different levels. The carriage is movable (preferably relative to the elevator) in and counter to the first direction, and the elevator is movable up and down relative to the receptacle at the stacking station.
[0015] The mounting of the platform on the carriage is or can be such that the platform is movable relative to the carriage in and counter to the first direction through distances corresponding to the extent of adjustment of the rear abutment relative to the front abutment.
[0016] The forward end of the sheet conveying means is preferably disposed at a predetermined (fixed) distance from the platform.
[0017] The receptacle can be provided with an exchangeable bottom wall, and such bottom wall can include an exchangeable substantially strip-shaped holder as well as a plurality of sheet supporting rakes carried by the holder. The holder can further carry lateral stops and guide means for the lateral stops.
[0018] The novel features which are considered as characteristic of the invention are set forth in particular in the appended claims. The improved apparatus itself, however, both as to its construction and its mode of operation, together with numerous additional important and advantageous features and attributes thereof, will be best understood upon perusal of the following detailed description of certain presently preferred specific embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic elevational view of an apparatus which embodies one form of the invention, a fully grown stack of overlapping sheets being about to be transferred from the stacking station onto an evacuating conveyor;
[0020] [0020]FIG. 1 a shows the apparatus of FIG. 1 but in the process of gathering a next-following stack of sheets at the stacking station;
[0021] [0021]FIG. 1 c shows the structure of FIG. 1 during a further stage of gathering the next-following stack at the stacking station and with the stack withdrawing unit retracted from the position of FIG. 1 b back to the front stop at the stacking station;
[0022] [0022]FIG. 1 d shows the structure of FIG. 1 c but with the rear stop in a raised position;
[0023] [0023]FIG. 2 a shows the apparatus of FIG. 1 a but in the course of gathering a stack of sheets shorter than those shown in FIGS. 1 a to 1 d;
[0024] [0024]FIG. 2 b shows the apparatus of FIG. 2 a but during gathering of a next following stack of shorter sheets;
[0025] [0025]FIG. 3 is an enlarged fragmentary partly sectional view of a detail in the apparatus of FIGS. 1 a to 1 d; and
[0026] [0026]FIG. 4 is a plan view of the detail shown in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0027] The apparatus which is shown in FIG. 1 a comprises a stack collecting receptacle 4 which is located at a stacking station 1 and receives successive sheets 2 of a scalloped stream of (partially overlapping) sheets to gather a series of successive stacks 3 of overlapping sheets. As a rule, or at least in many instances, the improved apparatus comprises a battery of two or more receptacles 4 each of which receives successive sheets of a discrete scalloped stream of sheets 2 , i.e., each of which gathers a discrete series of stacks 3 . The receptacles 4 are located one behind the other, as viewed in FIG. 1 a.
[0028] The sheets 2 of the stream shown in FIG. 1 a are conveyed by a belt or band conveyor 7 which is operated to advance the partially overlapping sheets in the direction of the arrow 6 . The receptacle 4 of FIG. 1 a is followed by a stack withdrawing or removing unit 8 including grippers or tongs 5 , and the tongs 5 are followed by an evacuating conveyor 9 . The latter is designed to transport the (withdrawn) stacks 3 sideways, i.e., at right angles to the plane of FIG. 1 a. In this embodiment, the conveyor 9 comprises stack-advancing endless belts 11 with integrated pneumatic table segments 12 .
[0029] The sheets 2 of the growing stack 3 in the receptacle 4 are bounded by a front or downstream abutment or stop 13 and a rear or upstream abutment or stop 14 (as seen in the direction of the arrow 6 ). The front abutment is pivotable between an operative position (see FIG. 1 b ), in which it is located in front of and at a level above the growing stack of sheets 2 in the receptacle 4 , and an inoperative or retracted position (FIG. 1 a ) at a level beneath the bottom part of the receptacle.
[0030] The rear abutment or stop 14 can comprise several sections (the same holds true for the abutment 13 ) and is mounted on a slide or carriage 16 which is movable in directions indicated by a double-headed arrow 15 . The carriage 16 further supports the conveyor 7 as well as a rake-like platform 17 which serves as a separator and is movable with and also relative to the carriage 16 . The platform 17 can perform (relative to the carriage 16 ) strokes of variable length.
[0031] The discharge or downstream end 18 of the conveyor 7 is located at a fixed distance from the platform 17 . The carriage 16 is mounted on and is movable relative to a support 21 which can be said to constitute an elevator because it is movable up and down in directions indicated by a double-headed arrow 19 .
[0032] The receptacle 4 comprises a bottom wall or panel 22 which includes a plurality of parallel supporting rakes 23 secured to a strip-shaped holder 24 (see FIGS. 3 and 4). The holder 24 is provided with transversely extending guides 26 for lateral stops 27 which can be fixed in selected guides 26 , in dependency upon the format (size) of the sheets 2 and stacks 3 , by distancing members.
[0033] Several bottom panels 22 can be assembled with suitable lateral stops 27 into preassembled groups or modules which are held in positions of readiness for eventual use in a manner and for purposes as will be described hereinafter.
[0034] The mode of operation is as follows:
[0035] [0035]FIG. 1 a shows a fully assembled pile or stack 3 consisting of a predetermined number of sheets 2 being confined in the receptacle 4 . The front abutment 13 (or the illustrated one of two or more front abutments) is already pivoted to its inoperative position, and the gripper or tongs 5 of the illustrated withdrawing unit 8 is ready to advance the freshly assembled stack 3 in the direction of the arrow 6 , namely onto the evacuating conveyor 9 . The latter is designed to advance the thus received stack 3 in a direction toward or away from the observer of FIG. 1 b.
[0036] The illustrated gripper 5 of the withdrawing unit 8 operates in synchronism with the platform 17 which comprises the aforementioned supporting rake and shares the forward movement of the fully assembled stack 3 in the direction of the arrow 6 . FIG. 1 b shows a fully assembled stack 3 on the conveyor 9 and the next-following (growing) stack 3 in the process of growing on top of the platform 17 . Thus, the delivery of sheets 2 by the conveyor 7 need not be interrupted while the trailing abutment 14 establishes a path for advancement of successive sheets 2 of the scalloped stream of sheets toward and against the front abutment 13 which (see FIGS. 1 b and 1 c ) is again in the operative position in which it intercepts the oncoming sheets 2 .
[0037] The support or elevator 21 descends, as indicated by the lower half of the arrow 19 (FIG. 1 c ), to lower the platform 17 so that it reaches or descends even below the level of the panel 22 , and is thereupon retracted to the position shown in FIG. 1 d. Such manipulation of the elevator 21 results in the deposition of the growing stack 3 of sheets 2 on the panel 22 of the receptacle 4 .
[0038] The next step involves an upward movement of the elevator 21 (as indicated by the upper half of the arrow 19 ); this entails a lifting of the discharge end 18 of the conveyor 7 to a level such that it rises at the rate at which the height of the growing stack 3 on the platform 22 increases. Such mode of operation is desirable and advantageous because each sheet 2 of successively delivered sheets supplied by the conveyor 7 descends through the same distance. This contributes to uniformity of the successively accumulated stacks 3 .
[0039] [0039]FIGS. 2 a and 2 b illustrate the manner in which the improved apparatus can be adjusted to permit for the accumulation of stacks of sheets smaller or larger than the sheets 2 shown in FIGS. 1 a to 1 d. The carriage 16 is moved in one of the directions indicated by the double-headed arrow 15 , and this results in identical movements of the rear abutment 14 as well as of the discharge end 18 of the conveyor 7 and of the platform 17 . Thus, the distance between the abutments 13 and 14 is reduced accordingly (it is assumed here that the carriage 16 has been moved in a direction to the right, as viewed in FIG. 1 a ).
[0040] If one desires to change the effective width of the receptacle 4 , i.e., to stack narrower or wider sheets, it is merely necessary to replace the aforementioned module 22 , 27 with a different module.
[0041] The extent of movement of the platform 17 in or counter to the direction indicated by the arrow 6 is changed as a function of change of the distance between the front and rear abutments 13 and 14 . The length of the forward stroke of the gripper 5 remains unchanged due to the absence of any appreciable changes of the forward stroke of the stack removing unit 8 . In fact, the length of the forward stroke is reduced if the format (size) of the sheets 2 is reduced.
[0042] An important advantage of the improved apparatus is that the just discussed changes of the format of the stacks 3 can be carried out in a simple and timesaving manner. This is accomplished by the provision (a) of the carriage 16 which supports the platform 17 and the rear or upstream abutment 14 , and (b) of the means for moving the carriage 16 up and down (arrow 19 ) as well as forwardly and backwards (arrow 15 ). Furthermore, the carriage 16 supports the conveyor 7 at a fixed distance from and above the platform 17 .
[0043] Another advantage of the improved apparatus is that the aforedescribed changes of the format can be carried out without necessitating any changes in the position and/or movements of the front or downstream abutment(s) 13 . This, in turn, ensures that the stroke or strokes of the gripper or grippers 5 can remain unchanged.
[0044] A further important advantage of the improved apparatus is that the discharge end 18 of the sheet supplying conveyor 7 and the platform 17 share the movements in directions indicated by the double-headed arrow 19 ; this ensures that the extent of descent of successive sheets 2 from the conveyor 7 into the receptacle 4 is the same while a stack 3 is in the process of growing in the receptacle as well as during withdrawal of a fully grown stack from the receptacle (while the conveyor continues to deliver sheets toward and beyond the discharge end 18 ).
[0045] An additional important advantage of the improved apparatus is that the carriage 16 (which is movable in directions indicated by the double-headed arrow 15 ) carries the conveyor 7 , the rear abutment 14 and the platform 17 . This renders it possible to complete any required adjustments within a surprisingly short interval of time, i.e., the parts 7 , 16 and 17 can be adjusted as a unit.
[0046] Additional savings in time and space are achieved by the provision of the elevator 21 which is movable up and down (arrow 19 ) and supports the carriage 16 in such a way that the latter is movable in directions indicated by the arrow 15 . Such practically universal movability of the carriage 16 with and relative to the elevator 21 contributes to simplicity and predictability of stacking of sheets in the receptacle 4 as well as to rapid conversion of the apparatus for the stacking of larger, smaller, narrower or wider sheets. The movements of the platform 17 in dependency on the selected format of stacks 3 can be simplified and rendered more precise by selecting the extent of movements of the platform in directions indicated by the arrow 15 to conform to the selected distance between the front and rear abutments 13 and 14 .
[0047] The features which are illustrated in and which were described with reference to FIGS. 3 and 4 contribute to a simplification of adjustments which are to be carried out when the conveyor 7 is to deliver narrower sheets 2 following the delivery of a series of wider sheets or vice versa.
[0048] An advantage of the feature that the mounting of the front abutment 13 can remain unchanged when the length of the sheets 2 is changed from shorter to longer or vice versa is that the strokes which are being performed by the grippers 5 can remain unchanged. This simplifies the design of the stack withdrawing unit 8 as well as of the evacuating conveyor 9 .
[0049] To summarize: The improved apparatus renders it possible to simplify the conversion from the stacking of sheets having a first format to the stacking of sheets having a different second format and to enable the persons in charge to complete the conversion within a surprisingly short interval of time. Furthermore, the components which render such conversion possible are simple, compact and inexpensive.
[0050] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic and specific aspects of the above outlined contribution to the art of apparatus for accumulating and transporting stacks of paper sheets and the like and, therefore, such aaptations should and are intended to be comprehended within the meaning and range of equivalence of the appended claims.
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An apparatus for gathering successive sheets of a scalloped stream in an adjustable receptacle has a pivotable first stop in front of and a longitudinally adjustable second stop behind the receptacle. The second stop is shifted, together with the conveyor for the stream, toward or away from the first stop when the length of the sheets forming the stream is changed. The effective width of the receptacle is adjusted when a stream of relatively narrow sheets is followed by a stream of wider sheets or vice versa.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit, under 35 U.S.C. § 365, of International Application PCT/US03/10283, filed Apr. 3, 2003, which was published in accordance with PCT Article 21(2) on Oct. 16, 2003 in English and which claims the benefit of the filing date of each of Provisional Application Ser. No. 60/370,016, filed Apr. 3, 2002 and of Provisional Application Ser. No. 60/381,859, filed May 20, 2002.
FIELD OF THE INVENTION
The present invention concerns a protection arrangement for a voltage regulator.
A block diagram of a typical satellite receiver system is depicted in FIG. 1 . The receiver system includes an outdoor microwave antenna 85 which can be aimed at a satellite to receive a signal from a satellite. The signal received from the satellite is amplified by a conventional low noise block converter (ILNB) 86 mounted in very close proximity to or on the antenna LNB 86 down-converts satellite signals at high frequencies, typically in the gigahertz range, to signals at frequencies in the high megahertz range. An output signal from LNB 86 is carried to an indoor satellite receiver and decoder system 83 by a coaxial cable 84 , decoded and presented with a monitor device 81 .
In order to supply power to LNB 86 , as well as to control the polarization selection of LNB 86 , a direct current (DC) output supply voltage V O , produced in a power supply, not shown, but included in satellite receiver and decoder system 83 , is multiplexed onto the center conductor of coaxial cable 84 . Voltage V O has a level that is, selectively, either 13V or 18V. The power supply, not shown, may include a series pass transistor. An example of a prior art power supply that generates output supply voltage similar to voltage V O is described in U.S. Pat. No. 5,563,500, entitled, VOLTAGE REGULATOR HAVING COMPLEMENTARY TYPE TRANSISTOR in the name of Muterspaugh (the Muterspaugh Patent).
The lower and higher output supply levels of voltage V O are used, selectively, to control polarization settings of LNB 86 . For example, the lower voltage level 13V selects right hand circular polarization (RHCP) and the higher voltage 18V selects left hand circular polarization (LHCP).
The circuits in LNB 86 of FIG. 1 are designed to function properly when energized at either the lower output supply level 13V and the higher output supply level at 18V. A current drain IO of LNB 86 is about the same with either of the 13V level or the 18V level.
FIG. 2 illustrates a typical relationship between output supply voltage V O and output current IO of the power supply, not shown, of the satellite receiver system of FIG. 1 . The maximum power dissipation in the series pass transistor will occur when the voltage difference between the input and output main current conducting terminals of the series pass transistor, not shown, is at the maximum and the output current is at the maximum. This condition will occur at the 6 volt level of FIG. 2 .
With the need to supply three or more satellite antenna devices from a single satellite receiver, the power requirements of the satellite antenna supply are increased. This increase in power driving capability results in a greater power loss (in the form of heat) when a fault condition is present in the power supply. There is a need to minimize the heat generated in the controllable series pass transistor during a fault condition. The controllable series pass transistor may be damaged if a short circuit or other fault is formed at the output terminal of the series pass transistor. A fault condition may be a result of, for example, improper wiring the output of the receiving instrument. Examples of improper wiring include driving a nail through the coax cable and connecting of the satellite receiver to a conventional roof antenna instead of the satellite dish. Such damage often is caused by excessive thermal dissipation of the series pass transistor or by exceeding the current rating of the series pass transistor. For this reason, it is common to provide overload protection to prevent such damage to the series pass transistor.
Another prior art includes a dual input supply voltage of arrangement. When the higher output voltage 18V is selected, a higher input supply voltage of 22 volts is developed at an input, main current conducting terminal of the series pass transistor, not shown. On the other hand, when the lower output voltage of 13 volts is selected, a lower input supply voltage at 16 volts is developed at the input main current conducting terminal of the series pass transistor, not shown. Thereby, the power dissipation in the power series pass transistor, not shown, when the lower output voltage of 13 volts is selected, is, advantageously, reduced.
A power supply, embodying an inventive feature, includes the aforementioned dual input supply voltage arrangement. A comparator senses a magnitude of an output voltage produced by the series pass transistor. When, as a result of an over current condition, the output voltage becomes lower than a reference threshold level, any attempt to select the higher output voltage of 18V is automatically over-ridden and the lower input supply voltage, instead, is developed at the input main current conducting terminal of the series pass transistor, not shown. This action, advantageously, decreases the maximum amount of power that the series pass transistor dissipates.
SUMMARY OF THE INVENTION
A power supply for a communication apparatus, embodying an aspect of the invention includes, a source of a first control signal that is indicative when a first antenna signal is to be selected and when a second antenna signal is to be selected. A power transistor is responsive to the first control signal for generating an output supply voltage at a value selected in accordance with the first control signal. The output supply voltage is coupled to a stage of the communication apparatus to select the first antenna signal, when a first value of the output supply voltage is generated and the second antenna signal, when a second value of said output supply voltage is generated. A switch is responsive to the first control signal and coupled to an input of the power transistor for selecting, in a first switching state of the switch, a first input supply voltage to be developed at the input, when the first antenna signal is selected. In a second switching state of the switch, a second input supply voltage is selected to be developed at the input, when the second antenna signal is selected. A fault detector is coupled to the switch for changing the switching state in the switch, when the second antenna signal is selected and a fault condition occurs, to select an input supply voltage to be developed at the input that is different from the second input supply voltage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical satellite receiver system;
FIG. 2 illustrates a typical relationship between an output supply voltage and output supply current of a power supply of the satellite receiver system of FIG. 1 ;
FIG. 3 illustrates a power supply regulator, embodying an inventive feature, which can be incorporated in the satellite receiver system of FIG. 1 ;
FIG. 4 illustrates a flow chart for describing a mode of operation the power supply regulator of FIG. 3 providing protection by a hardware technique;
FIG. 5 illustrates a flow chart for describing a mode of operation the power supply regulator of FIG. 3 providing protection by a combination of software and hardware techniques; and
FIG. 6 illustrates an alternative embodiment of the power supply regulator shown in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 illustrates a power supply regulator 10 , embodying an inventive feature, is used to energize a low noise block converter (LNB) 86 of FIG. 1 . Power supply regulator 10 of FIG. 3 provides regulated output voltage V O at an output terminal 16 . Terminal 16 is coupled to LNB 86 via coax cable 84 of FIG. 1 . An emitter of a series pass power transistor Q 1 of FIG. 3 is supplied with an input voltage V IN higher than regulated output voltage V O , developed at terminal 16 . A collector of transistor Q 1 is coupled via a current sensing resistor 20 to terminal 16 .
An LNB voltage control circuit 7 senses output voltage V O and controls power transistor Q 1 for regulating output voltage V O . A level of output voltage V O is selected by a bi-level or binary control signal 23 c at a control terminal 53 .
In the absence of a fault condition, the steady state level of output voltage V O is greater than, for example, 10V. Therefore, a comparator 22 , embodying an inventive feature, having a corresponding reference voltage 22 a, produces an output signal 23 a at a TRUE state. Reference voltage 22 a establishes the threshold level of comparator 22 . Consequently, a signal 23 c produced by an AND gate 23 is at the same state as that of an output signal 23 b produced by a microprocessor 41 . Thus, signal 23 c can selectively assume either a TRUE state, for selecting output voltage V O at 18V, or a FALSE state, for selecting output voltage V O at 13V, in accordance with signal 23 b of microprocessor 41 . For example, the lower voltage level 13V of output voltage V O selects right hand circular polarization (RHCP) and the higher voltage 18V of output voltage V O selects left hand circular polarization (LHCP). Thereby, the antenna signal produced by antenna 85 of FIG. 1 varies. Thus, the regulation in power supply regulator 10 of FIG. 3 is performed similarly to that described in the Muterspaugh Patent.
FIG. 3 also illustrates a dual input supply voltage arrangement 200 for generating input voltage V IN that energizes LNB power supply regulator 10 . When the higher output level of voltage V O at 18 volts is selected, a metal oxide semiconductor field effect transistor (MOSFET) 51 , operating as a switch, is turned on by signal 23 c to supply input voltage V IN at 22 volts to the emitter of transistor Q 1 from an input supply voltage 301 . On the other hand, when the lower level of output voltage V O at 13 volts is selected, MOSFET 51 is turned off by signal 23 c. Consequently, input voltage V IN at approximately 16 volts is supplied to the emitter of input voltage V IN via an anode terminal of diode 21 transistor Q 1 via a diode 21 . Thus, diode 21 and MOSFET 51 form an input voltage selection switch for a dual voltage power supply.
In normal operation, power supply regulator 10 generates output voltage V O at the 18 volt level from input voltage V IN at approximately 22 volts. Similarly, power supply regulator 10 generates output voltage V O at the 13 volt level from input voltage V IN at approximately 16 volts.
An LNB, similar to LNB 86 of FIG. 1 , includes an internal power supply regulator, not shown, for generating an internal supply voltage of 5V, not shown, from voltage V O at either the 13V level or the 18V level. The internal power supply regulator, not shown, requires a minimum input supply voltage of 6V for producing the 5V level that is capable of providing the maximum required LNB operation current. Thus, a maximum LNB operation current can be produced when voltage V O at at least 6 volts level is applied to LNB 86 . In order to assure proper power up operation, power supply regulator 10 of FIG. 3 is designed to supply a maximum current level of an output current I o when output supply voltage V O is equal to or greater than 6 volt. The relationship between output supply voltage V O and an output current L 1 are shown in FIG. 2 , as explained before.
In normal operation (non current limit), the voltage drop between the emitter and collector of power transistor Q 1 is within a normal, safe level. A fault condition occurs when, for example, an impedance that is too low is connected to output terminal 16 . Consequently, power supply current I o reduces voltage V O to the 6 to 10 volt output level at terminal 16 , because of current limiting, as shown at the 6 volt level of FIG. 2 .
The maximum power dissipation in transistor Q 1 of FIG. 3 occurs when voltage V O is equal to 6V and output current I o is at the current limit level. If not prevented from doing so, the decrease in output voltage V O would cause the voltage drop develop between the emitter and collector of power transistor Q 1 to become excessive when input voltage V IN at 22 volts is coupled to the emitter of transistor Q 1 . The additional heat generated in such fault condition could prematurely produce a permanent damage to power transistor Q 1 .
In carrying out an inventive feature, when voltage V O is lower than a threshold level of approximately 10V, as depicted in a step 91 of the flow chart of FIG. 4 , output signal 23 a of comparator 22 of FIG. 3 is at a LOW state. When output signal 23 a comparator 22 is at the LOW state, it over-rides, by the operation of AND gate 23 , the operation of selection signal 23 b. Thereby, power supply regulator 10 is forced to operate in a 13V mode in which output voltage V O is 13V, as depicted in a step 92 of the flow chart of FIG. 4 , regardless of selection signal 23 b produced by microprocessor 41 .
As explained before, when the lower level of 13 volts of output voltage V O is selected, MOSFET 51 , is turned off by signal 23 b to supply, via diode 21 , input voltage V IN at approximately 16 volts at the emitter of power transistor Q 1 . This action, advantageously, decreases the amount of power that power transistor Q 1 needs to dissipate. The threshold level established by voltage 22 a is preferably selected to be lower than the lower voltage level 13V of output voltage V O , and higher than 6 volts.
Instead of using AND gate 23 for over-riding the selection, software protection can be used, as depicted in the flow chart of FIG. 5 . In such an alternative arrangement, signal 23 a of FIG. 3 is coupled to microprocessor 41 , as shown by the broken line. Signal 23 b of microprocessor 41 is passed to terminal 53 . Microprocessor 41 monitors signal 23 a. When output signal 23 a of comparator 22 is at the LOW state, indicating a fault condition, as determined in step 111 of FIG. 5 , microprocessor 41 of FIG. 3 unconditionally generates signal 23 b at the LOW state. Therefore, power supply regulator 10 is forced to operate in the 13 volt mode, in a manner described before, as depicted in step 112 of FIG. 5 . When the fault condition disappears, as depicted in step 113 of FIG. 5 , normal operation step 114 can resume. On the other hand, if the fault persists, an interval timer step 115 will maintain the 13 volt mode. If fault is not detected in step 111 , microprocessor 41 of FIG. 3 selectively generates signal 23 b at the LOW state or at the HIGH state in a step 116 . Signal 23 b of FIG. 3 at the HIGH state will cause power supply regulator 10 to operate in the 18 volt mode in which output voltage V O is 18V, in a manner described before, as depicted in step 117 of FIG. 5 .
FIG. 6 illustrates a power supply regulator 10 ′, embodying an inventive feature, that is used to energize LNB 86 of FIG. 1 . Similar symbols in FIGS. 3 and 6 indicate similar items or functions.
Power supply regulator 10 ′ of FIG. 6 is intended to provide additional advantages, for example operating with fewer parts at a lower cost and protecting power transistor Q 1 ′ against thermal damage from excess heat dissipation. These advantages are achieved by eliminating the dual input supply voltage and, instead, switching a power resistor 310 ′ into and out of a series coupling with power transistor Q 1 ′. Resistor 310 ′ is coupled between a main current conducting terminal 51 a′ and a main current conducting terminal 51 b′. The differences between the arrangements of FIGS. 3 and 6 will be described in detail; the remaining operation being substantially the same.
In order to save cost, a single input supply voltage 301 ′ is provided, namely the 22 volt supply. Power resistor 310 ′ is used to absorb the additional heat generated in the lower 13 volt mode, when the lower level of 13 volts of output voltage V O is selected. Power resistor 310 ′ can be implemented, for example, by using two resistors coupled across the main current conducting terminals 51 a′ and 51 b′ of MOSFFE 51 ′ and having an equivalent value of 9 Ohm. As explained before, circuit 10 of FIG. 3 employs diode 21 and MOSFET 51 to switch voltage V IN to the 16 volt level, in a fault condition and when the lower level of 13 volts of output voltage V O is selected. Whereas, in the embodiment of FIG. 6 , MOSFET 51 ′ causes power resistor 310 ′ to be coupled in series with transistor Q 1 ′, both in a fault condition and when the lower level of 13 volts of output voltage V O is selected.
When the LNB supply is in the 13 volt mode, that is when the lower level of 13 volts of output voltage V O is selected, and a high current level is demanded from the supply, substantial heat is dissipated by power transistor Q 1 ′. This heat dissipation burden is advantageously shared by power resistor 310 ′. Whether power resistor 310 ′ is in or out of the circuit depends on MOSFET 51 ′ being on or off.
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A power supply for a satellite receiver system includes a dual input supply voltage arrangement. When a higher output voltage is selected, a source of a lower supply input voltage is coupled to an input main current conducting terminal of a series pass transistor. On the other hand, when a lower output voltage is selected, a source of a lower supply input voltage is coupled to the input main current conducting terminal of the series pass transistor. A comparator senses a magnitude of an output voltage produced by the series pass transistor. When, as a result of an over current condition, the output voltage is lower than a reference threshold level, any selection of the higher output voltage is automatically overridden and the source of the lower supply input voltage, instead, is coupled to the input main current conducting terminal of the series pass transistor.
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This application is a continuation of International Patent Application No. PCT/US92/06291, filed Aug. 3, 1992 which is a continuation-in-part of U.S. Ser. No. 07/750,596, filed Aug. 28, 1991, now abandoned.
BACKGROUND OF THE INVENTION
The present invention is directed toward spirocyclic benzopyran imidazolines of Formula shown below, and their use for treatment of hypertension, alopecia, and erectile dysfunction. The subject compounds act by opening cell membrane potassium channels in similar fashion to other known agents such as pinacidil (N-cyano-N'-(4-pyridyl)-N"-(1,2,2-trimethylpropyl)guanidine) and cromakalim ((±)-trans-6-cyano-3,4-dihydro-2,2-dimethyl-4-(2-oxopyrrolidin-1-yl)-2H-1-benzopyran-3-ol). Pinacidil and its analogues are described by H. J. Petersen, et al in J. Med. Chem., 21, 773-781 (1978) and in U.S. Pat. No. 4,057,636. Cromakalim and its analogues are reported by V. A. Ashwood, et al, in J. Med. Chem. 29, 2194-2201, (1986) and in European Patent EP 76-075 B. Pinacidil and cromakalim are considered as standard potassium channel openers against which new compounds are compared. The compounds of the present invention are surprisingly more active at relaxing vascular smooth muscle than either pinacidil or cromakalim.
Since potassium channel openers have been shown to have relaxant activity in several types of smooth muscle, the compounds of this invention will be useful for treatment of hypertension, asthma, incontinence, premature labor, and erectile dysfunction. In addition, based on results with other potassium channel openers, the compounds of this invention will have activity as hair growth stimulants and will be useful for treatment of alopecia.
INFORMATION DISCLOSURE STATEMENT
U.S. Pat. No. 4,874,869 discloses a hydantoin derivative which is useful as an intermediate in the preparation of the subject compounds but does not disclose such preparation or compounds.
U.S. Pat. Nos. 4,874,869 and 4,740,517 disclose hydantoin derivatives and spiro-3-heterozolidine compounds, respectively, which are only cited to show the state of the art.
SUMMARY OF THE INVENTION
In one aspect the present invention is a compound of Formula 1 and its pharmaceutically acceptable salts thereof ##STR2## wherein R 1 is H, R 2 , F, Cl, Br, CF 3 , CF 3 O, CN, NO 2 , R 2 SO 2 , R 2 NHSO 2 , R 2 O, R 2 CO, R 2 OCO, or R 2 NHCO; R 2 is linear or branched C 1 -C 10 alkyl, a C 3 -C 8 cycloalkyl, phenyl, or benzyl; R 3 is H or both R 3 together are a double bond to oxygen; and X is S, O, or NH.
In another aspect, the subject invention is the use of a compound of Formula 1 in a method for treatment of hypertension by administering an effective amount to a patient suffering from hypertension. The compound of Formula 1 can also be useful in the treatment of male impotence by direct injection or administration of an effective amount to a male suffering from penile dysfunction.
In yet another aspect, the subject invention is directed toward a method for promoting hair growth comprising the topical administration of an effective amount of a compound of Formula 1 or its pharmaceutically acceptable salts. The method comprises the application of an effective amount of Formula 1 to promote hair growth. Typically, amounts range from about 0.01 to about 20, preferably, 0.5 to 5, more preferably I to 3 percent by weight of a compound of Formula 1 are applied.
The method can also comprise the application of an effective amount of such compound admixed in a pharmaceutical carrier adapted for topical application. In another aspect the method includes the routine application of such compound to an area of treatment. Further the routine application can comprise a plurality of treatments such as, for example, daily or twice daily to promote hair growth.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is compounds of Formula 1 and pharmaceutically acceptable acid addition salts as structurally depicted above. The compounds of Formula 1 include both enantiomers as well as salts and tautomeric forms.
Pharmaceutically acceptable acid addition salts of the Formula 1, may be chosen from the following: acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, pamoate, pectinate, persulfate, 3-phenylpropionate, picrate, pivalate, propionate, succinate, tartrate, thiocyanate, rosylate, and undecanoate.
The carbon content of various hydrocarbon containing moieties is indicated by a prefix designating the minimum and maximum number of carbon atoms in the moiety, i.e., the prefix C i -C j indicates a carbon atoms content of the integer "i" to the integer "j" carbon atoms, inclusive. Thus, C 1 -C 3 alkyl refers to alkyl of 1-3 carbon atoms, inclusive, or methyl, ethyl, propyl, and isopropyl, and isomeric forms thereof.
With respect to the above, C 1 -C 10 alkyl is methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl and isomeric forms thereof (branched and linear). C 3 -C 8 cycloalkyl is cyclopropane, cyclobutane, cyclopentane, cyclohexane, cycloheptane, cyclooctane and isomeric forms thereof.
Preferred compounds of Formula 1 are described below. 2,2-Dimethyl-2'-ethoxy-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol ]-5'one. (Formula 1, R 1 ═H, R 2 ═CH 2 CH 3 , X═O);
6-Bromo-2,2-Dimethyl-2'-ethoxy-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'- 5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 3 , X═O);
2,2-Dimethyl-2'-ethoxy-6-fluoro-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 2 CH 3 , X═O);
2,2-Dimethyl-2'-propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH 2 CH 2 CH 3 , X═NH);
2,2-Dimethyl-2'-(1-methyl)ethylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH(CH 3 ) 2 , X═NH);
2,2-Dimethyl-2'-(2,2-dimethyl)propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH 2 C(CH 3 ) 3 , X═NH);
6-Bromo-2,2-dimethyl-2'-methylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 3 , X═NH);
6-Bromo-2,2-dimethyl-2'-ethylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran -4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 3 , X═NH);
6-Bromo-2,2-dimethyl-2'-propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 2 CH 3 , X═NH);
6-Bromo-2,2-dimethyl-2'-(1-methyl)ethylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH(CH 3 ) 2 , X═NH);
2,2-Dimethyl-6-fluoro-2'-methylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 3 , X═NH);
2,2-Dimethyl-2'-ethylamino-6-fluoro-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 2 CH 3 , X═NH);
2,2-Dimethyl-6-fluoro-2'-propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 2 CH 2 CH 3 , X═NH); and
2,2-Dimethyl-6-fluoro-2'-(1-methyl)ethylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH(CH 3 ) 2 , X═NH).
The compounds of Formula 1 are useful in the treatment of hypertension and as potassium channel openers. The Formula 1 compounds have been shown to have potent hypotensive activity in normotensive rats. For treatment of hypertension, these compounds can be administered orally in dosages of from 0.01 mg/kg to 10 mg/kg.
The compounds can be administered intravenously, intramuscularly, topically, transdermally such as by skin patches, bucally or orally to man or other animals. The compositions of the present invention can be presented for administration to humans and animals in unit dosage forms, such as tablets, capsules, pills, powders, granules, sterile parenteral solutions or suspensions, oral solutions or suspensions, oil in water and water in oil emulsions containing suitable quantities of the compound, suppositories and in fluid suspensions or solutions.
For oral administration, either solid or fluid unit dosage forms can be prepared. For preparing solid compositions such as tablets, the compound can be mixed with conventional ingredients such as talc, magnesium stearate, dicalcium phosphate, magnesium aluminum silicate, calcium sulfate, starch, lactose, acacia, methylcellulose, and functionally similar materials as pharmaceutical diluents or carriers. Capsules are prepared by mixing the compound with an inert pharmaceutical diluent and filling the mixture into a hard gelatin capsule of appropriate size. Soft gelatin capsules are prepared by machine encapsulation of a slurry of the compound with an acceptable vegetable oil, light liquid petrolatum or other insert oil.
Fluid unit dosage forms for oral administration such as syrups, elixirs, and suspensions can be prepared. The forms can be dissolved in an aqueous vehicle together with sugar, aromatic flavoring agents and preservatives to form a syrup. Suspensions can be prepared with an aqueous vehicle with the aid of a suspending agent such as acacia, tragacanth, methylcellulose and the like.
For parenteral administration, fluid unit dosage forms can be prepared utilizing the compound and a sterile vehicle. In preparing solutions the compound can be dissolved in water for injection and filter sterilized before filling into a suitable vial or ampoule and sealing. Adjuvants such as a local anesthetic, preservative and buffering agents can be dissolved in the vehicle. The composition can be frozen after filling into a vial and the water removed under vacuum. The dry lyophilized powder can then be scaled in the vial and reconstituted prior to use.
As potassium channel openers, the compounds of Formula 1 can have utility for treatment of erectile dysfunction (male impotence) via penile injection or via topical penile treatment similar to the known use of prostaglandin. For treatment of impotence, these compounds may be administered via penile injection in quantities of 0.01 to 10.0 mg in an aqueous solution. Alternatively, they may be applied topically to the penis in the same vehicles and concentrations as described for treatment of alopecia.
Also, as potassium channel openers, the Formula 1 compounds have utility as hair growth stimulants when applied topically in a suitable vehicle. In a method for promoting hair growth, the Formula 1 compound is applied to mammalian skin in an effective amount whereby hair growth is promoted. Promotion of hair growth is where the growth of hair is induced or stimulated or where the loss of hair is decreased. For treatment of alopecia, these compounds can be applied topically to balding areas of the scalp in concentrations from 0.1 to 10% by weight in vehicles such as propylene glycol, ethanol, water, propylene carbonate, or N-methylpyrrolidinone, or combinations of these. Penetration enhancers such as oleyl alcohol in concentrations of 0.1 to 1% by weight may also be employed.
PHARMACOLOGY
Rabbit mesenteric artery assay.
Adult white rabbits were anesthetized with ether and then killed by exsanguination. The superior roesenteric artery was rapidly excised, placed in warm physiologic salt solution (PSS), and cleaned of fat and connective tissue. The vessels were cut into rings 2-3 mm wide and equilibrated for 60 rain at 37 ° C. in PSS at pH 7.3. During this period, 100% O 2 was bubbled into the solution. Isometric contractions were measured and recorded on a Grass model 7D polygraph using an isolated tissue bath system. Tissues were allowed to equilibrate at 1 g resting tension for at least one hour and then were contracted with 5 μM norepinephrine. After the norepinephrine was washed out, the tissues were left in PSS at resting tension (1 g) for 1 h at which point a second contraction was induced with 5 μM norepinephrine. The compounds were tested at the plateau of the second norepinephrine contraction.
The compounds of this invention prepared in examples 7, 8, and 9 are more potent in this assay than cromakalim. In addition to these compounds, the compounds of examples 4, 10, and 16 were more potent than pinacidil. The data for relaxation of rabbit mesenteric artery and the comparison with cromakalim and pinacidil are shown below in Table 1.
TABLE 1______________________________________Compound Conc. (μM) % Relax.______________________________________Example 4 0.1 60.9 0.5 89.7Example 6 0.5 19.5 1.0 64.7Example 7 0.01 4.1 0.05 86.5Example 8 0.01 10.5 0.05 70.2 0.1 88.8Example 9 0.01 12.0 0.05 65.3 0.1 90.8Example 10 0.1 54.6 0.5 88.2Example 11 1.0 12.4 5.0 79.3Example 12 1.0 20.3 5.0 76.8Example 14 0.1 5.7 0.5 79.0Example 15 0.1 29.0 0.5 86.9Example 16 0.1 76.0 0.5 86.9Example 17 1.0 2.4 5.0 89.1Pinacidil 0.1 25 0.5 80 1.0 90Cromakalim 0.5 87.0______________________________________
In vivo hypotensive activity.
Female Sprague-Dawley rats were CUP (α-chloralose/urethane/pentobarbitol) anethsthetized and placed on a heated, insulated tilt rack. Thirty minutes after anethesia, the rats were removed from the tilt rack to permit cannulation of of the fight external jugular vein and the left common carotid artery with PE-50 catherters. Mean arterial pressure was recorded through the arterial cannula. After surgical preparation, the rats were returned to the tilt rack and then treated i.v. with the test drug. The data for changes in mean arterial pressure after i.v. dosing of CUP-anesthetized rats are shown below in Table 2.
It can be seen that the compound of Example 7 is more potent than cromakalim in this assay, while the compound of example 15 is approximately equal in potency to cromakalim.
TABLE 2______________________________________ ΔMAP Dose in PaCompound (mg/kg) (mm Hg)______________________________________Example 7 0.01 -5333 (-40) 0.04 -7999 (-60) 0.14 -9999 (-75)Example 15 0.04 -1999 (-15) 0.14 -3999 (-30) 0.44 -6666 (-50)Cromakalim 0.04 -2666 (-20) 0.14 -3999 (-30) 0.44 -7333 (-55)______________________________________
A typical method for preparing the compounds of formula 1 where X is O, is by the reaction of a spirocyclic hydantoin of formula 1, where the R 2 X group is ═O (formula 1'), with a trialkyloxonium tetrafluoroborate reagent such as triethyloxonium tetrafluoroborate. The spirocyclic hydantoins can be prepared by procedures described in detail below which are essentially the same as those described by K. Ueda, et al, in U.S. Pat. No. 4,874,869.
In those compounds of formula 1 where X is S, the compound is prepared by reaction of a spirocyclic thiohydantoin of formula 1, where the R 2 X group is ═S (formula 1"), with an alkyl iodide such as methyl iodide. Compounds of this formula can in rum be prepared by reaction of the spirocyclic hydantoins of formula 1' with Lawesson's reagent.
In those compounds of formula 1 where X is NH, the compound is prepared by reaction of an alkyl amine such as propyl amine with one of the previously described compounds of formula where X is either O or S.
The subject compounds can be made according to the procedures outlined in the following examples. Where the R 2 X group is --OH the formula is designated--Formula 1', and where the R 2 X group is --SH the formula is designated--Formula 1". It is noted, however, that tautomeric forms of Formula 1' and 1" exist where the --OH and --SH would be ═O and ═S and the bond between the appropriate carbon and nitrogen atom becomes a single bond to provide a correct valence.
In vivo hair growth activity.
Male rats were randomized into control and treatment groups with six rats per group. One day prior to the beginning of each assay, the lumbodorsal region of the back of each rat was shaved and a 2.54 cm square area was defined by 4 tattoo marks. Each rat was topically dosed with vehicle or test compound (250 μL once per day, 5 days/week, Monday through Friday) in the tattooed area of the back via a 250 μL micropipette. The test compounds were applied in a vehicle of propylene carbonate and N-methylpyrrolidinone. At 7-day intervals during the assay, each animal was anesthetized and the tattooed area was shaved and the hair was collected and weighed. The assay was continued for 4 weeks. The cumulative hair weights are tabulated in Table 3.
TABLE 3______________________________________Compound Dose (mM) Hair Weight (mg) SEM (±mg)______________________________________Example 7 0.1 27.8 3.3 1.0 38.8* 7.6Example 15 10 35.0* 6.4 50 44.7* 10.7Vehicle 20.6 4.8______________________________________ *Statistically significant relative to vehicle (p < 0.1).
In vitro erectile stimulation.
Six cynomolgus monkeys were sedated with ketamine. The compound of Example 7 was injected into the corpus cavernosum of each monkey at a dose of 0.75 μg in 0.1% DMSO/saline solution. Five of the six monkeys showed a positive response which was characterized by penile elevation along with rigidity and pulsation.
EXAMPLE 1
Preparation of 2,3-Dihydro-2,2-dimethyl-spiro-[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Formula 1', R 1 ═H).
A glass pressure tube was charged with a mixture of 2,3-dihydro-2,2-dimethyl-4H-1-benzopyran-4-one (4.4 g, 25 mmol), KCN (5.2 g, 50 mmol) and (NH 4 ) 2 CO 3 (16.0 g, 187.5 mmol). Enough formamide was added to fill the pressure tube nearly completely (ca. 100 mL). The mixture was heated at 70° C. for 24 h and then at 110° C. for another 48 h. The reaction mixture was then cooled, poured over ice, and filtered. The filtrate was acidified with conc. HCl and extracted with CHCl 3 . The combined organic phases were washed with brine, dried with Na 2 SO 4 , and concentrated in vacuo to afford the crude product. Purification on silica gel using 8% methanol/chloroform as eluent afforded 5.0 g of product (82% yield): mp 233°-235° C. (lit mp [U.S. Pat. No. 4,874,869]=24920 -250° C.); 1 H NMR (DMSO) δ 10.99 (1 H, bs), 8.58 (1 H, s), 7.13 (1 H, td, J=8, 1 Hz), 6.94 (1 H, dd, J=7, 1 Hz), 6.84 (1 H, t, J=7 Hz), 6.71 (1 H, d, J=8 Hz), 2.33 (1, H, HA of AB, J AB =14 Hz), 2.15 (1 H, HB of AB, J AB =14 Hz), 1.32 (3 H, s), 1.17 (3 H, s); Anal calcd for C 13 H 14 N 2 O 3 : C,63.41; H, 5.73; N, 11.38. Found: C, 63.15; H, 6.02; N, 11.16.
EXAMPLE 2
Preparation of 6-Bromo-2,3-dihydro-2,2-dimethyl-spiro[4H-1-benzopyran-4,4'- imidazolidine]-2',5'-dione (Formula 1', R 1 ═Br).
This compound was prepared by the same procedure as described in Example 1. Yield 80%. mp 278°-280° C. (lit mp [U.S. Pat. No. 4,874,869]=299°-300° C.); 1 H NMR (DMSO) δ 11.15 (1 H, bs), 8.74 (1 H, s), 7.40 (1 H, dd, J=9, 2 Hz), 7.11 (1 H, d, J=2 Hz), 6.81 (1 H, d, J=9 Hz), 2.31 (1 H, HA of AB, J AB =14 Hz), 2.18 (1 H, HB of AB, J AB =14 Hz), 1.42 (3 H, s), 1.25 (3 H, s); Anal calcd for C 13 H 13 BrN 2 O 3 :C, 48.02; H, 4.03; N, 8.62; Br, 24.57. Found: C, 47.90; H, 4.15; N, 8.49; Br, 24.08.
EXAMPLE 3
Preparation of 6-Fluoro-2,3-dihydro-2,2-dimethyl-spiro[4H-1-benzopyran-4,4'-imidazolidine]-2',5'-dione (Formula 1', R 1 ═F).
This compound was prepared by the same procedure as described in Example 1. Yield 72%. mp 275°-277° C. (lit mp [U.S. Pat. No. 4,874,869] 293°-294° C.); 1 H NMR (DMSO) δ 11.1 (1 H, bs), 8.74 (1 H, s), 7.13 (1 H, td, J=9, 3 Hz), 6.87 (2 H, m), 2.32 (1 H, HA of AB, J AB =14 Hz), 2.18 (1 H, HB of AB, J AB =14 Hz), 1.43 (3 H, s), 1.27 (3 H, s); Anal calcd for C 13 H 13 FN 2 O 3 : C, 59.09; H, 4.96; N, 10.60; F, 7.19. Found: C, 58.62; H, 4.97; N, 10.51; F, 6.98.
EXAMPLE 4
Preparation of 6-Bromo-2,2-dimethyl-2'-ethoxy-2,3,3',4'-tetrahydro-spiro-[ 4H-1- benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 3 , X═O).
To a suspension of the hydantoin of example 2 (1.95 g, 6.0 mmol) in 80 mL of CH 2 Cl 2 was added at room temperature under N 2 a solution of triethyloxonium tetrafluoroborate (1M in CH 2 Cl 2 , 12 mL, 12 mmol). The resulting suspension was heated to reflux for 60 h. The reaction was cooled to room temperature, diluted with 80 mL of CH 2 Cl 2 and neutralized with 10% aqueous NaHCO 3 . The organic layer was separated, dried (Na 2 SO 4 ), filtered, and concentrated in vacuo to afford a yellow solid. Purification on silica gel using 4% CH 3 OH/CHCl 3 as eluent gave 1.2 g (57% yield) of the product: mp 182°-184° C.; 1 H NMR (CDCl 3 ) δ 7.29 (1 H, dd, J=9, 2 Hz), 7.0 (1 H, d, J=2 Hz), 6.72 (1 H, d, J=9 Hz), 6.45 (1 H, bs), 4.36 (2 H, q, J=7 Hz), 2.55 (1 H, d, J=14 Hz), 1.98 (1 H, d, J=14 Hz), 1.48 (3 H, s), 1.43 (3 H, t, J=7 Hz), 1.27 (3 H, s); Anal Calc'd for C 15 H 17 BrN 2 O 3 : C, 51.00; H, 4.85; N, 7.93; Br, 22.62. Found: C, 50.69; H, 5.18; N, 7.76; Br, 21.40.
EXAMPLE 5
Preparation of 2,2-Dimethyl2'-ethoxy-2,3,3',4'-tetrahydro-spiro-]4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH 2 CH 3 , X═O).
Following the procedure of example 4, this compound was prepared from the hydantoin of example 1 in 85% yield: mp 153°-155° C.; 1 H NMR (CDCl 3 ) δ 7.22 (1 H, m), 6.87 (3 H, m), 5.25 (1 H, bs), 4.63 (2 H, q, J=7 Hz), 2.60 (1 H, d, J=14 Hz), 1.98 (1 H, d, J=14 Hz), 1.49 (3 H, s), 1.45 (3 H, t, J=7 Hz), 1.30 (3 H, s); Anal calcd for C 15 H 18 N 2 O 3 : C, 65.68; H 6.61; N, 10.21. Found: C, 65.01; H, 6.57; N, 10.16.
EXAMPLE 6
Preparation of 2,2-Dimethyl-2'-ethoxy-6-fluoro-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5' H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 2 CH 3 , X═O).
Following the procedure of example 4, this compound was prepared from the hydantoin of example 1 in 60% yield. mp 209°-211° C.; 1 H NMR (CDCl 3 ) δ 6.90 (1 H, td, J=9, 3 Hz), 6.75 (1 H, dd, J=9, 5 Hz), 6.61 (1 H, dd, J=9, 3 Hz), 4.59 (2 H, q, J=7 Hz), 2.50 (1 H, d, J=14 Hz), 2.10 (1 H, d, J=14 Hz), 1.48 (3 H, s), 1.43 (3 H, t, J=7 Hz), 1.28 (3 H, s). Anal calcd for C 15 H 17 FN 2 O 3 : C, 61.63; H, 5.86; N, 9.58; F, 6.50. Found: C, 61.40; H, 5.86; N, 9.50; F, 5.89.
EXAMPLE 7
Preparation of 6-Bromo-2,2-dimethyl-2'-propylamino-2,3,3',4'-tetrahydro-spiro- [4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 2 CH 3 , X═NH).
A solution of the starting material of example 4 (2.75 g, 7.8 mmol) and propyl amine (0.96 g, 16 mmol) in 30 mL of absolute ethanol was refluxed for 18 h. The reaction was then concentrated in vacuo to afford a solid residue which was recrystallized from methanol/ethyl acetate to afford 2.6 g of product (91% yield): mp 225°-227° C.; 1 H NMR (CDCl 3 ) δ 7.25 (1 H, dr, J=9, 2 Hz), 7.01 (1 H, d, J=2 Hz), 6.71 (1 H, d, J=9 Hz), 3.38 (2 H, t, J=8 Hz), 2.47 (1 H, d, J=14 Hz), 1.94 (1 H, d, J=14 Hz), 1.63 (2 H, sextet, J=7 Hz), 1.48 (3 H, s), 1.27 (3 H, s), 0.98 (3 H, t, J=7 Hz). Anal calcd for C 16 H 20 BrN 3 O 2 : C, 52.47; H, 5.50; N, 11.47; Br, 21,82. Found: C, 52.44; H, 5.47; N, 11.00; Br, 20.80.
EXAMPLE 8
Preparation of 6-Bromo-2,2-dimethyl-2'-ethylamino-2,3,3',4'-tetrahydro-spiro-]4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH 2 CH 3 , X═NH)
This compound was prepared from the starting material of example 4 and ethylamine according to the procedure described in example 7 in 60% yield: mp 277°-279° C.; 1 H NMR (CD 3 OD) δ 7.26 (1 H, dd, J=9, 2 Hz), 7.01 (1 H, d, J=2 Hz), 6.21 (1 H, d, J=9 Hz), 3.43 (2 H, m), 2.46 (1 H, d, J=14 Hz), 1.94 (1 H, d, J=14 Hz), 1.48 (3 H, s), 1.27 (3 H, s), 1.24 (3 H, t, J=7 Hz). Anal calcd for C 15 H 18 BrN 3 O 2 : C, 51.15; H, 5.15; N, 11.93; Br, 22.69. Found: C, 49.38; H, 4.91; N, 11.52; Br, 22.52.
EXAMPLE 9
Preparation of 6-Bromo-2,2-dimethyl-2'-methylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 =Br, R 2 ═CH 3 , X═NH).
This compound was prepared from the starting material of example 4 and methylamine according to the procedure described in example 7 in 77% yield: mp>300° C.; 1 H NMR (CD 3 OH) δ 7.27 (1 H, dd, J=9, 2 Hz), 7.03 (1 H, d, J=2 Hz), 6.72 (1 H, d, J=9 Hz), 3.05 (3 H, s) 2.47 (1 H, d, J=14 Hz), 1.96 (1 H, d, J=14 Hz), 1.49 (3 H, s), 1.29 (3 H, S). Anal calcd for C 14 H 16 BrN 3 O 2 : C, 49.72; H, 4.77; N, 12.42; Br, 23.63. Found: C, 49.51; H, 4.74; N, 12.33; Br, 23.25.
EXAMPLE 10
Preparation of 6-Bromo-2,2-dimethyl-2'-(1-methyl)ethylamino-2,3,3',4' - tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═Br, R 2 ═CH(CH 3 ) 2 , X═NH).
This compound was prepared from the staging material of example 4 and isopropylamine according to the procedure described in example 7 in 48% yield: mp 235°-237° C. 1 H NMR (CDCl 3 ) δ 8.44 (1 H, s), 7.63 (1 H), 7.20 (1 H, dd, J=9, 2 Hz), 6.90 (1 H, d, J=2 Hz), 6.65 (1 H, d, J=9 Hz), 3.49 (1 H, septet, J=7 Hz), 2.33 (1 H, d, J=14 Hz), 1.85 (1 H, d, J=14 Hz), 1.40 (3 H, s), 1.18 (3 H, s), 1.02 (3 H, d, J=7 Hz). Anal calcd for C 16 H 20 BrN 3 O 2 : C, 52.47; H, 5.50; N, 11.47; Br, 21.82. Found: C, 52.01; H, 5.42; N, 11.30; Br, 21.07.
EXAMPLE 11
Preparation of 2,2-Dimethyl-2'-propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1- benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 =H, R 2 ═CH 2 CH 2 CH 3 X═NH).
This compound was prepared from the starting material of example 5 and propylamine according to the procedure of example 7 in 92% yield: mp 205°-207° C.; 1 H NMR (CDCl 3 ) δ 7.13 (1 H, m), 6.83 (3 H, m), 3.24 (2 H, t, J=7 Hz), 2.45 (1 H, d, J=14 Hz), 1.88 (1 H, d, J=14 Hz), 1.55 (2 H, sextet, J=7 Hz), 1.44 (3 H, s), 1.23 (3 H, s), 0.91 (3 H, t, J=7 Hz); Anal calcd for C 16 H 21 N 3 O 2 : C, 66.88; H, 7.37; N, 14.62. Found: C, 66.47; H, 7.51; N, 14.39.
EXAMPLE 12
Preparation of 2,2-Dimethyl-2'-(1-methyl)ethylamino-2,3,3',4'-tetrahydro-spiro-[ 4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH(CH 3 ) 2 , X═NH)
This compound was prepared from the starting material of example 5 and isopropylamine according to the procedure of example 7 in 54% yield: mp 225°-227° C.; 1 H NMR (CDCl 3 ) δ 7.12 (1 H, m), 6.81 (3 H, m), 3.83 (1 H, m), 2.40 (1 H, d, J=14 Hz), 1.85 (1 H, d, J=14 Hz), 1.42 (3 H, s), 1.21 (3 H, s), 1.10 (6 H, t, J=5 Hz). Anal calcd for C 16 H 21 N 3 O 2 : C, 66.88; H, 7.17; N, 14.62. Found: C, 66.79; H, 7.37; N, 14.60.
EXAMPLE 13
Preparation of 2,2-Dimethyl-2'-(2,2-dimethyl)propylamino-2,3,3',4'-tetrahydro- spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═H, R 2 ═CH 2 C(CH 3 ) 3 , X═NH).
This compound was prepared from the starting material of example 5 and neopentylamine according to the procedure of example 7 in 55% yield: mp 293°-295° C.; 1 H NMR (CDCl 3 ) δ 7.15 (1 H, m), 6.82 (3 H, m), 3.33 (1 H, HA of AB, J AB =13 Hz), 3.18 (1 H, HB of AB J AB =13 Hz), 2.48 (1 H, d, J=14 Hz), 1.90 (1 H, d, J=14 Hz), 1.47 (3 H, s), 1.36 (3 H, s), 0.95 (9 H); Anal calcd for C 18 H 25 N 3 O 2 : C, 68.54; H, 7.99; N, 13.32. Found: C, 68.26; H, 7.95; N, 13.18.
EXAMPLE 14
Preparation of 2,2-Dimethyl-6-fluoro-2'-methylamino-2,3,3',4'-tetrahydro-spiro[ 4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 3 , X═NH).
This compound was prepared from the starting material of example 6 and methylamine according to the procedure of example 7 in 95% yield: mp 283°-285° C.; 1 H NMR (CDCl 3 ) δ 6.86 (1 H, td, J=9, 3 Hz), 6.75 (1 H, dd, J=9, 5 Hz), 6.60 (1 H, dd, J=9, 3 Hz), 2.93 (3 H, S), 2.42 (1 H, d, J=14 Hz), 1.90 (1H, d, J=14 Hz), 1.44 (3 H, s), 1.22 (3 H, s); Anal calcd for C 14 H 16 FN 3 O 2 : C, 60.64; H, 5.82; N, 15.15; F, 6.85. Found: C, 60.14; H, 5.77; N, 15.15; F, 5.77.
EXAMPLE 15
Preparation of 2,2-Dimethyl-2'-ethylamino-6-fluoro-2,3,3',4' -tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one. (Formula 1, R 1 ═F, R 2 ═CH 2 CH 3 , X═NH).
This compound was prepared from the starting material of example 6 and ethylamine according to the procedure of example 7 in 77% yield: mp 259°-261° C.; 1 H NMR (CDCl 3 ) δ 6.86 (1 H, td, J=9, 3 Hz), 6.74 (1 H, dd, J=9, 5 Hz), 6.59 (1 H, dd, J=9, 3 Hz), 3.33 (2 H, q, J=7 Hz), 2.22 (1 H, d, J=14 Hz), 1.89 (1 H, d, J=14 Hz), 1.44 (3 H, s), 1.22 (3 H, s), 1.17 (3 H, t, J=7 Hz). Anal calcd for C 15 H 18 FN 3 O 2 : C, 61.89; H, 6.23; N, 14.42; F, 6.52. Found: C, 61.84; H, 6.27; N, 14.49; F, 6.78.
EXAMPLE 16
Preparation of 2,2-Dimethyl-6-fluoro-2'-propylamino-2,3,3',4'-tetrahydro-spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one- (Formula 1, R 1 ═F, R 2 ═CH 2 CH 2 CH 3 , X═NH).
This compound was prepared from the starting material of example 6 and propylamine according to the procedure of example 7 in 65% yield: mp 216°-218° C.; 1 H NMR (CDCl 3 ) δ 6.84 (1 H, td, J=9, 3 Hz), 6.74 (1 H, dd, J=9, 5 Hz), 6.55 (1 H, dd, J=9, 3 Hz), 3.20 (2 H, q, J=7 Hz), 2.37 (1 H, d, J=14 Hz), 1.86 (1 H, d, J=14 Hz), 1.53 (2 H, sextet, J=7 Hz), 1.42 (3 H, s), 1.19 (3 H, s), 0.90 (3 H, t, J=7 Hz). Anal calcd for C 16 H 20 FN 3 O 2 : C, 62.85; H, 6.67; N, 13.48; f, 6.10. Found: C, 62.13; H, 6.62; N, 13.37; F, 6.20.
EXAMPLE 17
Preparation of 2,2-Dimethyl-6-fluoro-2'-(1-methyl)ethylamino-2,3,3',4'-tetrahydro- spiro-[4H-1-benzopyran-4,4'-5'H-imidazol]-5'one- (Formula 1, R 1 ═F, R 2 ═CH(CH 3 ) 2 , X═NH).
This compound was prepared from the starting material of example 6 and isopropylamine according to the procedure of example 7 in 60% yield: mp 261°-262° C.; 1 H NMR (CDCl 3 ) δ 6.89 (1 H, td, J=9, 3 Hz), 6.77 (1 H, dd, J=9, 5 Hz), 6.6 (1 H, dd, J=9, 3 Hz), 4.06 (1 H, septet), 2.48 (1 H, d, J=14 Hz), 1.92 (1 H, d, J=14 Hz), 1.47 (3 H, s), 1.24 (6 H, d, J=6 Hz), 1.20 (3 H, s). Anal calcd for C 16 H 20 FN 3 O 2 : C, 62.94; H, 6.60; N, 13.76; F, 6.22. Found: C, 62.48; H, 6.80; N, 13.57; F, 6.20.
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Spiro- [4H- 1 -benzopyran-4,4'-5'H-imidazol]-5'-ones of the Formula 1: ##STR1## wherein R 1 is H, R 2 F, Cl, Br, CF 3 , CF 3 O, CN, NO 2 , R 2 SO 2 , R 2 NHSO 2 , R 2 O, R 2 CO, R 2 OCO, or R 2 NHCO. R 2 is a C 1 -C 10 branched or linear alkyl, a C 3-8 cycloalkyl, phenyl, or benzyl. X can be S, O, or NH. Both enantiomers are included in this invention as well as salts and tautomeric forms of these compounds. The subject compounds are useful in the treatment of hypertension, alopecia, and erectile dysfunction.
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FIELD OF THE INVENTION
[0001] The present invention relates to a display circuit structure for a liquid crystal display (LCD), and more particularly to a display circuit structure for a liquid crystal display (LCD) having reflection and transmission regions.
BACKGROUND OF THE INVENTION
[0002] Liquid crystal displays (LCD) have been widely applied in electrical products, such as digital watches, calculator, etc. for a long time. Moreover, with the advance of techniques for manufacture and design, thin film transistor-liquid crystal display (TFT-LCD) has been introduced into portable computers, personal digital assistants, and color televisions, as well as gradually replacing the CRT used for conventional display. The demands of TFT-LCD tend to be large scale.
[0003] In general, a typical circuit of a liquid crystal display having both reflection and transmission regions is illustrated in FIG. 1A, in which the LCD matrix display device commonly comprises a LCD display array 200 that further includes a plurality of display elements 50 , whose enlarged diagram is shown in the FIG. 1B, arranged in a matrix of rows and columns. Switching devices (not shown in this figure) are coupled with display elements 50 to control the application of video signals thereto. Each display element 50 acts as a switching device that includes a pixel capacitor 106 and a maintenance capacitor 108 driven by a switching transistor 104 , referring to FIG. 1B.
[0004] [0004]FIG. 1B is an enlarged schematic diagram of a circuit of a liquid crystal display having both reflection and transmission regions according to one preferred embodiment of the present invention. The switching transistor 104 is usually a thin-film transistor (TFT) that is deposited on a transparent substrate such as glass. The switching transistor 104 is deposited on the glass on the same side of the display matrix as the switching transistor and has its source/drain electrode respectively connected to the capacitor electrodes of the pixel capacitor 106 and the maintenance capacitor 108 . The source/drain electrode of the switching transistor 104 is connected to a column data driver (not shown in this figure) through the video data line 100 to which video signals are applied. The gate electrodes of the switching transistor 104 is coupled to a row select driver (not shown in this figure) through a scan line 102 , and a scan signal is applied to turn on the switching transistor 104 .
[0005] By scanning the scan lines 102 and in accordance with the scan signals, all of the switching transistors 104 in a given scan line 102 are turned on. At the same time, video signals are provided in the video data lines synchronously with the selected scan line 102 . When the switching transistors 104 in a given scan line 102 are selected by the scan signals, the video signals supplied to the switching transistors 104 charge the pixel capacitors 106 and the maintenance capacitor 108 to a voltage value corresponding to the video signal on the video data line. Thus each pixel capacitor 106 with its electrodes on opposite sides of the matrix display acts as a capacitor. When a signal for a selected scan line 102 is removed, the charge in the pixel capacitor 106 is preserved until the next repetition when that scan line is again selected by a scan signal and new voltages are stored therein. Thus a picture is displayed on the matrix display by the charges stored in the pixel capacitors 106 .
[0006] However, for a liquid crystal display having both reflection and transmission regions, the pixel capacitor 106 crosses both regions. Once the switching transistor 104 or the pixel capacitor 106 is broken, the display element 50 fails.
[0007] On the other hand, the main function of the maintenance capacitor 108 is to maintain the constancy of the voltage value applied to the pixel capacitor 106 . That is, before the data stored in the pixel capacitor 106 is refreshed, the voltage applied to the pixel capacitor 106 is maintained by the maintenance capacitor 108 . However, with regard to the conventional liquid crystal display having both reflection and transmission regions, the pixel capacitor 106 crosses both regions; therefore, the maintenance capacitor 108 needs to simultaneously maintain the voltage applied to the reflection and transmission regions. The capacitor value of the maintenance capacitor 108 needs to be enlarged to avoid electric charge leakage which would result in a sharp decrease of the voltage applied therein. Accordingly, the enlarged capacitor value of the maintenance capacitor 108 requires a larger current to drive the refresh data process so as to finish this refresh process in the same time. However, this increases the difficulties of circuit design.
SUMMARY OF THE INVENTION
[0008] According to the above descriptions, with regard to the conventional liquid crystal display having reflection and transmission regions, each display element 50 comprises a pixel capacitor 106 and a maintenance capacitor 108 both driven by a switching transistor 104 . Therefore, once one of them is broken, the whole display element fails.
[0009] On the other hand, the pixel capacitor 106 crosses both regions. Therefore, the maintenance capacitor 108 needs to simultaneously maintain the voltage applied to the reflection and transmission regions. The capacitor value of the maintenance capacitor needs to be enlarged to avoid electric charge leakage which would result in a sharp decrease of the voltage applied therein. The enlarged capacitor value of the maintenance capacitor 108 requires a larger current to drive the refresh data process so as to finish this refresh process in the same time. This increases the difficulties of circuit design. Therefore, the present invention provides a circuit structure to solve the above problems.
[0010] The primary object of the present invention is to provide a circuit for liquid crystal displays with reduced power consumption.
[0011] Another object of the present invention is to provide a circuit for liquid crystal displays with reduced drive current in the refresh process.
[0012] A further object of the present invention is to provide a circuit for liquid crystal displays in which each display element comprises a plurality of pixel capacitors, a plurality of maintenance capacitors and a plurality of switching transistors and those capacitors and transistors are isolated from each other. Such a structure avoids failure of the entire display element when one capacitor or transistor breaks. The present invention provides a circuit for liquid crystal displays having reflection and transmission regions. In accordance with the present invention, each display element comprises a plurality of pixel capacitors, a plurality of maintenance capacitors and a plurality of switching transistors. The reflection and transmission regions respectively comprise a pixel capacitor, a maintenance capacitor and a switching transistor. Therefore, the two regions are isolated from each other. That is, a breakage in the reflection region does not affect the transmission region work, and vice versa. Furthermore, in accordance with the circuit structure of the present invention, because each maintenance capacitor only needs to maintain the voltage applied the pixel capacitor of the reflection or transmission region, the capacitor value does not require enlargement. Therefore, the charge current may be decreased.
[0013] In accordance with the structure of the present invention, a scan line is used to control two thin film transistors and a video data line is used to transmit a video signal to pixel capacitors and maintenance capacitors. When the thin film transistors are selected by the selection signal, the video signal stored therein charges the pixel capacitors and maintenance capacitors. When selection signal is removed, the charge in the pixel capacitors is preserved until the next repetition when that scan line is again selected by a selection signal and new voltages are stored therein. Thus a picture is displayed on the matrix display by the charges stored in the pixel capacitors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0015] [0015]FIG. 1A is a schematic diagram of a display circuit structure of the liquid crystal display in accordance with the conventional invention;
[0016] [0016]FIG. 1B is an enlarged schematic diagram of a display circuit structure of the liquid crystal display in accordance with the conventional invention;
[0017] [0017]FIG. 2 is a schematic diagram of a display circuit structure of the liquid crystal display in accordance with the first embodiment of the present invention; and
[0018] [0018]FIG. 3 is a schematic diagram of a display circuit structure of the liquid crystal display in accordance with the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Without limiting the spirit and scope of the present invention, the circuit structure in a liquid crystal display (LCD) proposed in the present invention is illustrated with one preferred embodiment. Skilled artisans, upon acknowledging the embodiments, can apply the circuit design of the present invention to any kind of liquid crystal display to form a display circuit structure. In accordance with the circuit structure of the present invention, the present invention avoids the drawback existing in the conventional liquid crystal display circuit structure having display elements composed only of a pixel capacitor, a maintenance capacitor and a switching transistor. However, this kind of conventional circuit structure may result in total display element failure once one of the three devices breaks. The structure of the present invention uses display elements comprising plurality of pixel capacitors, a plurality of maintenance capacitors and a plurality of switching transistors; therefore, when one , the devices can replace it to make the whole display element keep working.
[0020] On the other hand, the circuit structure of the present invention also avoids the drawback of the conventional circuit design in which only one maintenance capacitor having a larger capacitor value is used to maintain the voltage applied to the reflection and transmission region. In accordance with this conventional structure, the enlarged capacitor value of the maintenance capacitor requires a larger current to drive the refresh data process, which increases the power consumption. The application of the present invention is not limited by the following description.
[0021] The present invention provides a circuit structure for liquid crystal displays having reflection and transmission regions. In accordance with the present invention, each display element comprises a plurality of pixel capacitors, a plurality of maintenance capacitors and a plurality of switching transistors. The reflection and transmission regions respectively comprise a pixel capacitor, a maintenance capacitor and a switching transistor. Therefore, the two regions are isolated from each other. That is, breakage in the reflection region does not affect the transmission region work, and vice versa. Furthermore, in accordance with the circuit structure of the present invention, because each maintenance capacitor only needs to maintain the voltage applied the pixel capacitor of the reflection or transmission region, the capacitor value does not require enlargement. Therefore, the charge current may be decreased. The detailed description of the present invention is as follows.
[0022] [0022]FIG. 2 is a schematic diagram of a display circuit structure 300 of a liquid crystal display in accordance with the first embodiment of the present invention. This circuit structure 300 is used in a thin film transistor liquid crystal display (TFT-LCD) having reflection and transmission regions therein. In this circuit structure, each display element comprises two pixel capacitors 206 and 208 , two maintenance capacitors 210 and 212 and two switching transistors 202 and 204 . The pixel capacitors 206 , maintenance capacitor 210 and switching transistor 202 are used to control the reflection region in the thin film transistor liquid crystal display. The pixel capacitors 208 , maintenance capacitor 212 and switching transistor 204 are used to control the transmission region in the thin film transistor liquid crystal display.
[0023] The gate electrodes of the switching transistors 202 and 204 are both coupled with a scan line 302 . The scan line 302 is used to control the turning on/off of the switching transistors 202 and 204 . The source/drain electrode of the switching transistors 202 is coupled with the video data line that is used to transmit the video signal. The video data line 304 and the scan line 302 work simultaneously to select a display element from a display element array (not shown in this figure). The other source/drain electrode of the switching transistor 202 is respectively coupled with the electrodes of the pixel capacitor 206 and the maintenance capacitor 210 , and is also coupled with the source/drain electrode of the other switching transistor 204 . The other source/drain electrode of the switching transistors 204 is respectively coupled with the electrodes of the pixel capacitor 208 and the maintenance capacitor 212 .
[0024] When operation, a selection signals is transmitted to the scan line 302 ; that is, a high voltage is applied to the scan line 302 to turn on the switching transistors 202 and 204 . At the same time, video signals are transmitted form the video data line 304 to the source/drain electrode of the switching transistor 202 . Then, the video signal transmits to the pixel capacitor 206 and the maintenance capacitor 210 through the channel of the switching transistor 202 , and also transmits to the pixel capacitor 208 and the maintenance capacitor 212 through the channel of the switching transistor 204 . The video signals may respectively charge the pixel capacitor 206 and 208 and the maintenance capacitor 210 and 212 to the corresponding voltage value applied to the video data line to drive the liquid crystal in the reflection and transmission regions.
[0025] When the selection signals in the scan line 302 are removed and another selection signals are not transmitted to the scan line 302 yet, the switching transistors 202 and 204 are turned off. The charge still retained in the pixel capacitor 206 and 208 and the maintenance capacitor 210 and 212 . Therefore, a picture is displayed on the display by the charges stored in the pixel capacitors 206 and 208 .
[0026] In accordance with the structure described in the above, the reflection and transmission regions respectively comprise a pixel capacitor, a maintenance capacitor and a switching transistor. Therefore, the two regions are isolated from each other. That is, the break in the reflection region does not affect the transmission region work, and vice versa. For example, if the pixel capacitor 206 breaks, it only affects the reflection region of the circuit structure 300 . The transmission region of the circuit structure 300 still works well.
[0027] Furthermore, in accordance with the circuit structure of the present invention, the voltage applied to the pixel capacitors 206 and 208 are respectively maintained by the maintenance capacitors 210 and 212 . Therefore, the capacitor value does not require enlargement. The charge current can be decreased. In other words, the circuit structure of the present invention uses two pixel capacitors and maintenance capacitors to control respectively the reflection and transmission regions, which is different from the conventional structure using only one pixel capacitor and maintenance capacitor to control the reflection and transmission regions. Therefore, the electric charge leakage ratio in a constant time of the present invention structure is lower than the conventional structure. In other words, because each maintenance capacitor only needs to maintain the voltage applied the pixel capacitor in the reflection or transmission region, the capacitor value does not require enlargement. Therefore, the charge current is decreased when a refresh process is conducted.
[0028] [0028]FIG. 3 is a schematic diagram of a display circuit structure 400 of the liquid crystal display in accordance with the second embodiment of the present invention. This circuit structure 400 is also used in a thin film transistor liquid crystal display (TFT-LCD) having reflection and transmission regions therein. In this circuit structure, each display element comprises two pixel capacitors 406 and 408 , two maintenance capacitors 410 and 412 and two switching transistors 402 and 404 . The pixel capacitors 406 , maintenance capacitor 410 and switching transistor 402 are used to control the reflection region in the thin film transistor liquid crystal display. The pixel capacitors 408 , maintenance capacitor 412 and switching transistor 404 are used to control the transmission region in the thin film transistor liquid crystal display.
[0029] The gate electrodes of the switching transistors 402 and 404 are both coupled with a scan line 302 . The scan line 302 is used to control the turning on/off of the switching transistors 402 and 404 . The source/drain electrode of the switching transistors 402 is coupled with the video data line that is used to transmit the video signal. The video data line 304 and the scan line 302 can work simultaneously to select a display element from a display element array (not shown in this figure). The other source/drain electrode of the switching transistor 402 is respectively coupled with the electrodes of the pixel capacitor 406 and the maintenance capacitor 410 . The source/drain electrode of the switching transistors 404 is respectively coupled with the electrodes of the pixel capacitor 408 and the maintenance capacitor 412 , and the other source/drain electrode of the switching transistors 404 is also coupled with the video data line 304 .
[0030] During operation, a selection signal is transmitted to the scan line 302 ; that is, a high voltage is applied to the scan line 302 to turn on the switching transistors 402 and 404 . At the same time, video signals are transmitted from the video data line 304 to the source/drain electrode of the switching transistors 402 and 404 . Then, the video signal is transmitted to the pixel capacitor 406 and 408 and the maintenance capacitor 410 and 412 respectively through the channel of the switching transistor 402 and 404 . The video signals respectively charge the pixel capacitors 406 and 408 and the maintenance capacitor 410 and 412 to the corresponding voltage value applied to the video data line so as to drive the liquid crystal in the reflection and transmission regions.
[0031] When the selection signals in the scan line 302 are removed and another selection signal is not transmitted to the scan line 302 yet, the switching transistor 402 and 504 is turned off. The charge is still retained in the pixel capacitor 406 and 408 and the maintenance capacitor 410 and 412 . Therefore, a picture is displayed on the display by the charges stored in the pixel capacitors 406 and 408 .
[0032] In accordance with the structure described in the above, the reflection and transmission regions are respectively composed of a pixel capacitor, a maintenance capacitor and a switching transistor. Therefore, the two regions are isolated from each other. That is, the break in the reflection region does not affect the transmission region work, and vice versa. For example, if the pixel capacitor 406 breaks, it only affects the reflection region of the circuit structure 400 . The transmission region of the circuit structure 400 still works well.
[0033] Furthermore, in accordance with the circuit structure of the present invention, the voltage applied to the pixel capacitors 406 and 408 are respectively maintained by the maintenance capacitors 410 and 412 . Therefore, the capacitor value does not require enlargement. The charge current can be decreased. In other words, the circuit structure of the present invention uses two pixel capacitors and maintenance capacitors to control respectively the reflection and transmission regions, which is different from the conventional structure using only one pixel capacitor and maintenance capacitor to control the reflection and transmission regions. Therefore, the electric charge leakage ratio in a constant time of the present invention structure is lower than the conventional structure. In other words, because each maintenance capacitor only needs to maintain the voltage applied the pixel capacitor in the reflection or transmission region, the capacitor value does not require enlargement. Therefore, the charge current can be decreased when a refresh process is operated.
[0034] As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrative of the present invention rather than limiting of the present invention. They are intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure.
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A scan line is used to control two thin film transistors and a video data line is used to transmit video signal to pixel capacitors and maintenance capacitors. When the thin film transistors are selected by the selection signal, the video signal stored therein charges the pixel capacitors and maintenance capacitors. When the selection signal is removed, the charge in the pixel capacitors is preserved until the next repetition when that scan line is again selected by a selection signal and new voltages are stored therein. Thus a picture is displayed on the matrix display by the charges stored in the pixel capacitors.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] Operating room fires and the hazards associated therewith are well known in the art. Although there have been multiple reports over the past few decades, hundreds of operating room fires continue to occur annually during the performance of a variety of surgical procedures. Although relatively infrequent, such patient fires result in dramatic burn injury as well as patient fatality when they occur. Serious injury to surgeons and other health care workers also frequently occurs, as does substantial property damage to the operating room facility.
[0004] The three ingredients of fire, defined as rapid exothermic reaction, include an ignition source, an oxidizer and fuel. Fuels include a wide variety of materials such as operating room gowns, surgical drapes, various prepping agents, patient hair, plastic respiratory equipment and the like. With respect to the ignition source, it is well known that a variety of surgical equipment, and in particular electrocautery surgical instruments and lasers are known to emit substantial heat. Moreover, the tip of the electrocautery knife, due to the electrical current passing through, or the beam of the laser device is exceptionally prone to ignite a fire. A high concentration of oxygen and other flammable gases such as nitrous oxide are also typically present during surgery, particularly during surgical procedures involving the head and neck insofar as oxygen and nitrous oxide tend to build beneath the surgical drapes or in the oropharyngeal cavity, which thus are operative to create a highly combustible atmosphere. In such an oxygen-enriched environment, materials that are not considered flammable in normal circumstances such as surgical drapes or respiratory apparatus can easily ignite with the resultant fire burning more violently and/or at higher temperatures. In the case of the latter, the respiratory system consisting of various plastics at the distal ends catches on fire and with the blowing oxygen simulates a blowtorch significantly worsening the burn injury. A multitude of specific cases have been reported as well such as explosion of bowel being cauterized, lung surgery, laser damage to respiratory tubes, ignition of pooled prepping fluid, etc.
[0005] Despite the well-known hazards associated with performing surgery under such conditions, however, there has not heretofore been any effective type of system or method that is operative to minimize the potential outbreak of operating room fires. In this regard, the best safety practices currently in use merely involve taking precautionary measures and typically consist of nothing more than making efforts to minimize the build up of oxygen and nitrous oxide, activating electrosurgical and electrocautery units at lower power settings, and/or only using such instruments when the cautery tips thereof are within view. Additional precautions include turning equipment off when not in use or otherwise placing electrosurgical instruments in a safe location, such as a safety holster, when not in active use. Likewise recommended is the practice of allowing a certain amount of time, like a minute or more, to discontinue oxygen administration to the patient prior to the use of the electrosurgical instruments, lasers and the like.
[0006] Notwithstanding such safeguards, even the best practices are not effective to substantially reduce the risk of operating room fires. In this regard, there is simply no system or method currently available that enables high-risk surgical equipment, and in particular electrosurgical instruments such as electrocautery pin knives and the like, or lasers to be effectively utilized in oxygen-enriched environments while at the same time effectively eliminate the potential for such elements to create a fire hazard. There is likewise substantially lacking in the art any type of system and method for reducing the risk of operating room fires that can be readily integrated as part of an existing electrosurgical device, and in particular an electrocautery apparatus that can be utilized per conventional electrocautery instruments and be utilized per conventional electrosurgical instruments for use in performing a wide variety of surgical procedures. There is likewise a need for such a system and method that is of simple construction, exceptionally low cost, very safe to utilize and can be constructed utilizing well-known, commercially available materials.
BRIEF SUMMARY OF THE INVENTION
[0007] The main embodiment of the invention includes an electrocautery instrument or laser device that will be operatively coupled to a source of inert gas, such as nitrogen, helium, air, argon, carbon dioxide, or other non-toxic gaseous flame retardant such as halon, that will be fluidly coupled to the electrocautery element and operative to be dispersed through the distal-most end, thereof. According to such embodiment, the source of inert gas will be coupled to the electrocautery instrument such that the inert gas is expelled from the distal-most end, either by automatic or manually operable control, and preferably radially about the electrocautery blade or laser point utilized to perform the surgical procedure. To that end, it is contemplated that such inert gas, which may be maintained at either ambient temperature or otherwise cooled, may be continuously free flowing through the electrocautery instrument throughout the surgical procedure, or may be coupled to a switch, such as a two step switch, to the extent that the gas flow is instigated first before the electrocautery. In the latter case, turning off the electrocautery instrument would similarly require the gas flow to continue thereafter thereby assuring that the electrocautery process is fully shielded by inert gas flow. Alternatively, the switch activating the electrocautery instrument may be coupled with a sensor located within the inert gas delivery tube that allows activation of the electrocautery instrument only after the flow of inert gas is established (i.e., operation of device is permitted once the flow of inert gas reaches a pre-determined level. In this regard, such inert gas will be operative to surround the environment about the distal-most end where the electrocautery blade is utilized to thus prevent any heat or spark generated thereby from coming into contact with the oxygen-enriched environment by blowing away the oxygen or other flammable gases. Under such circumstances, the electrocautery instrument will be incapable of igniting an operating room fire that may otherwise spread widely. Similarly, it is contemplated that a laser instrument as coupled with the inert source of gas may be operative such that the inert gas is to be distributed from the distal-most end of the laser instrument prior to when the laser beam of the instrument is turned on or applied to tissue, or any other type of ignitable substance.
[0008] An additional object of the present invention includes a cooling mechanism to the gas as is well-known by those familiar with the art, so as to limit the burn injury caused by the laser or electrocautery instrument to the point of contact only.
[0009] In another embodiment of this comprehensive system is the addition of a heat sensor strip, such as thermister or thermocouple device, operatively attached to the distal ends of a ventilator apparatus utilized in conjunction when the surgical procedure is performed, that is coupled with an oxygen release valve and/or the electrocautery device such that the apparatus automatically turns off oxygen delivery and/or electrosurgical device in the event of reaching predetermined temperature level. An added feature could include setting off an alarm when a given temperature level is reached so as to warn the anesthesiologist from continuing the flow of oxygen or nitrous oxide, as well as to warn the surgeon to refrain from using energy transmission from the electrosurgical instrument. Moreover, it is contemplated that the heat sensor device can be operatively coupled with the inert gas flushing mechanism and thus designed to be automatically turned on when preset temperature levels are recorded.
[0010] In a further embodiment of this system, it is contemplated that the distal most part of the ventilation system will be provided with nonflammable materials such as Teflon, metals and the like so as to prevent the respiratory system from catching on fire and turning into a blowtorch.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These as well as other features of the present invention will become more apparent upon reference to the drawings.
[0012] FIG. 1 is a schematic view of an electrosurgical system for performing electrocautery surgical procedures that substantially reduces the possibility for such system to ignite or otherwise cause an operating room fire.
[0013] FIG. 2 is a cross-sectional view of an electrocautery surgical instrument constructed in accordance with the preferred embodiment of the present invention.
[0014] FIG. 3 is a perspective view, shown partially in cross-section, of a ventilation system for use in combination with an electrocautery surgical system that further substantially reduces the possibility for the electrocautery system to ignite or otherwise cause an operating room fire.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The detailed description set forth below is intended as a description of the presently preferred embodiment of the invention, and is not intended to represent the only form in which the present invention may be constructed or utilized. The description sets forth the functions and sequences of steps for constructing and operating the invention. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments and that they are also intended to be encompassed within the scope of the invention.
[0016] Referring now to the figures, and initially to FIG. 1 , there is shown an electrosurgical system 10 for performing electrocautery surgical procedures that substantially reduces, if not eliminates, the possibility for such system 10 to ignite or otherwise cause and operating room fire. As shown, the system 10 comprises three essential components, namely, a hand-held electrocautery instrument 12 , a control unit 14 , and a supply of inert gas 16 , which may comprise nitrogen, helium, carbon dioxide, air, argon or any other type of gas known to be generally non-reactive or can serve as a non-toxic flame retardant, such as halon. With respect to the latter, it should be understood that any non-toxic flame retardant should be considered to fall within the scope of inert gas as used herein.
[0017] With respect to the former, the electrocautery instrument 12 , as per conventional electrocautery instruments, is preferably formed as an elongate pen-knife having a proximal end 12 a, which is fluidly coupled to the gas supply 16 via tubing 40 , discussed more fully below, and a distal end 12 b, which is oriented toward the surgical site to which the electrocautery instrument is utilized, such as to coagulate bleeding vessels or cut through tissue 18 . Electrocautery device 12 thus defines a housing having an interior 20 , within which is an electrocautery element 22 . Formed on the distal-most end of such cutting/coagulating (cautery) element 22 is a cautery tip 24 that is operative to be extended from the distal-most end instrument 12 to thus enable the same to cut through a given site of tissue. To achieve that end, the cautery element 22 is coupled to a power source via a connection 44 a, the latter extending via cord 44 to control unit 14 , to the electrocautery generator 54 and ultimately an external power source provided at 46 . As per conventional electrocautery devices, electrocautery device 12 is provided with a manually 28 a (or by foot 28 b ) operable switch that is electrically coupled via link 30 to the power connection 44 a to thus selectively actuate the cautery element 22 , and in particular cautery tip 24 thereof. Upon activation of the switch 28 , a signal will be transmitted via link 44 to control unit 14 which in turn would activate a solenoid valve 51 to cause gas contained within gas supply 16 to be emitted through valve 42 , preset at a given flow rate determined by a connected flow meter 52 , and via line 40 into the interior 20 of the electrocautery device 12 via duct 12 c. In this regard, such inert gas, represented by 48 , will be operative to flow through and outwardly from the distal end 12 b of the electrocautery device 12 such that the cautery tip 24 becomes immersed in a flow of inert gas 48 .
[0018] As a consequence, the surrounding air containing oxygen or any other flammable gas will be blown away from the cautery tip 24 and thus incapable of being ignited by any spark. In further refinements of the invention, it is contemplated that inert gas 48 may be designed to be continuously free flowing through the electrocautery device 12 such that the cautery tip 24 thereof is constantly receiving an outflowing source of inert gas 48 engulfed thereabout. Along these lines, it is contemplated that the system 10 can be engineered such that the inert gas 48 is caused to flow through the distal end 12 b of the electrocautery device 12 at timed intervals, or at a predetermined time prior to when cautery tip 24 can be actuated via switch 28 , which may be configured as a two-step switch, activated by the hand or via a foot switch. In one preferred embodiment, it is contemplated that a sensor positioned within tubing 40 or the interior of the electrocautery instrument 20 that allows activation of the electrocautery instrument only after the flow of inert gas is established. In this respect, it is contemplated that such sensor will be operative to determine that an out-going stream of inert gas at a pre-determined volume or flow rate will first be met before the electrocautery instrument can be activated.
[0019] Optionally, a cooling mechanism as well known by those familiar in the art may be coupled with the gas supply to thus cool the stream of gas emitted therefrom. As such, the cooling mechanism may be situated at any point along the path of the inert gas including cooling of the gas supply unit itself. In addition to extinguishing any small fire, it may also limit the burn injury of the laser or electrocautery device to the point of contact and thereby limit injury to additional tissue.
[0020] Optionally, it is contemplated that an oxygen sensor 26 situated close to the tip of the cautery element 12 b would be set such that upon meeting or exceeding a predetermined threshold, would send a signal to control unit 14 via link 44 b, which in turn may cause gas contained within gas supply 16 to flow through the device. It is likewise contemplated that the flow of inert gas 48 can be selectively modified based upon the concentration of oxygen detected by oxygen sensor 26 such that when a lesser concentration of oxygen is detected, a lesser amount of inert gas 48 is caused to flow through electrocautery device 12 . Conversely, to the extent higher levels of oxygen are detected, a correspondingly higher amount of inert gas 48 will be caused to flow through the device and out towards the distal end 12 b of the electrocautery instrument.
[0021] Referring now to FIG. 2 , there is shown an alternative embodiment whereby the source of inert gas can be operatively coupled to an existing conventional electrocautery instrument 12 . Unlike the embodiment depicted in FIG. 1 , there is not provided an internal passageway 20 within the electrocautery instrument 12 through which the inert gas 48 can pass. Rather, the embodiment shown in FIG. 2 is operative to serve as a retrofit whereby the source of inert gas is dispensed through the distal-most end of the electrocautery instrument via the mechanism shown. As illustrated, a housing 49 is positioned axially about the distal most end 12 b of the electrocautery instrument 12 such that the electrocautery tip 24 of such electrocautery instrument 12 is allowed to extend therefrom and thus perform its intended purpose to cut through tissue 18 . The housing 49 , however, radially extends about the electrocautery tip 24 through which the inert gas 48 , as supplied by tubing connection 40 , will flow about and engulf. In this respect, housing 49 will preferably be provided with an annular collar 50 or other like mechanism that forms an air-tight seal about the distal most end 12 b of electrocautery instrument 12 . Such arrangement forces the inert gas 48 to be expelled through the distal most end of the housing 49 and thus about the electrocautery tip 24 to thus prevent the same from coming into contact with oxygen to thus prevent the occurrence of a fire.
[0022] Advantageously, it is contemplated that the embodiment depicted in FIG. 2 will thus enable the safety mechanisms of the present invention to be readily implemented with existing technology, and not necessarily require specialized electrocautery instrumentation, such as that provided in FIG. 1 , to have to be utilized to readily appreciate the advantages of the present invention. As will be readily understood by those skilled in the art, housing 49 may take a variety of shapes and configurations as may be desired to accommodate the various types of electrocautery devices 12 produced by various manufacturers. In this respect, it is contemplated that the housing 49 will be specifically configured that irrespective of any embodiment, there will thus advantageously be channeled a flow of inert gas 48 about the electrocautery tip 24 in whatever manner is necessary to insure that the electrocautery is engulfed about such inert gas and thus prevent the occurrence of an operating room fire. It is likewise contemplated that the configuration of the housing 49 will be such that the same will not interfere with the surgeon's ability to manually manipulate the electrocautery instrument 12 , and much less the switching devices, such as 28 , necessary to selectively deploy such electrocautery instrumentation.
[0023] As will be apparent to those of ordinary skill in the art, the particular combination of parts and steps described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices and methods within the spirit and scope of the invention. In this regard, it is contemplated that the systems of the present invention need not include all of the specific safety features specified herein, namely, the use of an automatic power shut off, free-flowing source of inert gas and/or cut-off of oxygen supply, but may use only one such safety mechanism, or combination of any such mechanisms. Additionally, with respect to the use of an inert gas, it should be emphasized again that the same can be utilized to provide a continuous flow of inert gas through the distal-most end of the electrocautery device, be devised to flow before and after cauterization, selectively provide a flow of inert gas to the extent oxygen concentration levels meet or exceed certain thresholds, or that the flow of such inert gas can increase or decrease based upon the relative concentration of oxygen surrounding the distal end of the electrocautery device. Indeed, it is contemplated that the inert gas may be provided to serve as a flushing mechanism prior to operation of the electrocautery device 12 to thus ensure that prior to any operation of the device 12 , that the vicinity surrounding the distal-most end of the electrocautery device, and in particular the cautery tip housed therewithin, are not present in an oxygen enriched environment. In addition, the means of gas delivery to the operative site may be of many different means, including within the housing of the electrocautery device, separately, externally or as an extension of 12 b. With regards to the latter design, FIG. 2 demonstrates a separate nozzle 49 added to the distal aspect of the electrocautery element 12 b and fitted by a compression fitting 50 or any other related means. This nozzle is further connected to the gas supply via tube 40 . Any number of modifications of combination of gas nozzle and cautery/laser application could be contemplated in this regard. Additionally, as per normal gas delivery systems a pressure gauge 53 would be necessary, as well as an alarm system that is set to alert the staff when gas levels are low.
[0024] A further embodiment of this comprehensive fire suppression system includes a method to prevent a respiratory apparatus from explosively igniting and fueling an operating room fire. As shown in FIG. 3 , a heat sensory device 57 , in the form of a thermister or thermocouple would line the distal aspect 59 a of the oxygen delivering tube 59 , which could be the distal-most end of an endotracheal tube, face mask, nasal cannula, or the like. The thermister would be connected via a link 44 to the control box 14 that is operative to turn the oxygen release valve 61 off when a preset level of temperature is recorded. As such, the ventilation apparatus 56 would not be able to deliver oxygen via its connections 60 to the delivery respiratory device 59 via its lumen 58 to provide further oxidation of the fire. An additional embodiment in this regard would be to fabricate a nonflammable respiratory apparatus from material such as Teflon or an insert of the same or metals to the distal aspect of the delivery apparatus 59 a such that the respiratory apparatus may not catch fire in the event of a spark in the presence oxygen.
[0025] In addition to selectively controlling the flow of oxygen, it is contemplated that the control unit 14 may further activate an alarm, illustrated as 54 . In this respect, once the heat sensory device 57 detects a temperature above a threshold level, the control unit 14 may cause alarm 54 to make an audible signal to thus tell the surgeon and/or anesthesiologist that temperature ranges are exceeding a given safety parameter.
[0026] Still further, it is contemplated that the system depicted in FIG. 3 may be readily integrated with the electrocautery systems mentioned above whereby a source of inert gas provided by 16 may be selectively introduced as part of the oxygen provided by ventilation apparatus 56 . In this respect, it is contemplated that once heat sensory device 57 generates a signal to control unit 14 , the latter may be operative to cause valve 51 to selectively release inert gas 48 from source 16 via tubing 40 , and ultimately to tube connections 60 via one way valve 57 . Such inert gas will be operative to dilute the concentration of oxygen t or about the distal-most end of the oxygen delivery tube 59 to thus minimize the risk of fire. In a refinement of such system, it is contemplated that the inert gas 48 delivered will preferably be cooled such that when ultimately passed through tubing connection 60 and ultimately to the distal end 59 a of oxygen deliver tube 59 , such inert gas will be operative to either put the fire out and/or minimize potential trauma to the patient. Indeed, it is contemplated that the inert gas 48 may be operative to flush the tubing system with cool inert gas in the event of activation of the heat sensory device 57 .
[0027] Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. Thus, the particular combination of parts and steps described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices and methods within the spirit and scope of the invention. For example, it is contemplated that the inert gas, in addition to being utilized to extinguish or diminish the threat of fire, may also be operative to blow away blood or fluid from the surgical site to thus facilitate the ability to clear the operative area. Accordingly, the present invention should be construed as broadly as possible.
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A system for prevention of fires in operating rooms as frequently arises from electrocautery and laser systems comprising an electrocautery instrument having a shielding gas that is expelled from the distal-most end thereof to thus prevent the cautery tip spark from coming into contact with an oxygen-enriched environment that may otherwise propagate the spark into a full-fledged fire. The systems can further be coupled with oxygen sensors, alarms and mechanisms for limiting the delivery of oxygen. Additional refinements include incorporating heat sensory strips to the distal ends of oxygen delivery systems, which are in turn coupled with a thermocouple device set to turn off oxygen delivery or electrosurgical system at given levels of heat to thereby limit the extent of burn injury. Further refinements also include the use of nonflammable inserts to the tips of the oxygen delivery systems such that in the event of a fire the plastic does not catch on fire and in effect turn into a blowtorch.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to ironing boards and, more particularly, but not by way of limitation, it relates to improvements in ironing boards, their accessibility and their storageability in space-saving manner.
2. Description of the Prior Art
The prior art includes many and varied types of ironing boards, usually of the well-known form and shape, and having various types of supporting structure, hanging structure and cabinet receiving structure. Many such designs of ironing board in combination with cabinet receiving structure have been necessitated in order to fulfill specified home design and other related functions, and in every case the crux of the inventions appears to have been the mechanical structure and manner in which foldability was imparted to the board, or in the particular cabinetry and integral mechanism for enabling the ironing board to function in combination therewith. The numerous prior art designs extend over a long number of years and are many and varied.
SUMMARY OF THE INVENTION
The present invention contemplates an ironing board which is particularly adapted for usage in living quarters having limited space, but may very well find extensive use in all manner and size of residence and like buildings. The ironing board consists of a board or work surface which is adjustably supportable in vertical support hangers which may be readily affixed on a selected vertical surface, e.g., a door back. A board brace is pivotally attached to the outer end of the ironing board and adapted for adjustable affixure in the support hanger to provide extended support of the ironing board, and the ironing board and brace are then foldable upward to be secured in parallel alignment with the vertical hanger thereby to provide out-of-the-way storage during non-use.
Therefore, it is an object of the present invention to provide an ironing board which can be readily stored in normally non-used space behind a seldom-used door when in open position and which is quickly accessible for work use.
It is also an object of the present invention to provide an ironing board which can be stored behind a selected door and yet released into operative position for use at the same location.
It is still further an object of the present invention to provide an ironing board assembly which can be quickly installed at a selected location in living quarters without the need for special tools and carpenter skills, and which is capable of being mounted without the use of screws or other mechanical means which might disfigure or mar the surface of the vertical supporting door.
Finally, it is an object of the present invention to provide an improved ironing board which has enhanced serviceability and storageability features, and which is especially adapted for use by apartment dwellers and the like wherein space is at a premium.
Other objects and advantages of the invention will be evident from the following detailed description when read in conjunction with the accompanying drawing which illustrates the invention.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 illustrates the ironing board assembly as mounted on a vertical support and disposed in stored disposition;
FIG. 2 illustrates the invention when removed to its nonstored or work use disposition; and
FIG. 3 illustrates one form of vertical hanger as may be utilized in the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the ironing board assembly 10 is depicted in the stored position as mounted on a vertical support or door 12. The vertical support 12 as depicted in FIGS. 1 and 2, is the inside surface of a room door. It is well known that one of the very few places in a home that is clear of furniture or other obstructions is the aisle that must be left open in and around the doorway entries, but which space may be readily utilized by the present invention on a temporary basis while in work use. After usage, the door may be folded back against the wall to retain the ironing board assembly 10 out of sight.
FIG. 2 illustrates the ironing board assembly 10 as supported in its operative position wherein a board 14 is adjustably supported at a base end 16 to vertical support members 18 and 20 suitably affixed at desired height on door 12. A brace 22 is then adapted for pivotal affixure to the underside of board 14 to be further adjustably supported by vertical support members 18 and 20 to maintain board 14 parallel and in proper operating position. The vertical support members 18 and 20 may be fastened to door 12 by any of various conventional means; however, it is deemed desirable to bond support members 18 and 20 using one of the several commercially available contact cements which exhibit very high adhesive qualities yet can be removed with known household solvents to leave the surface of the door unmarred.
The base end of the ironing board 14 may be formed with suitable retaining channels 24 and 26 for retention of spring-loaded pivot rods 28 and 30, respectively. Tabs 33 and 34 then enable transverse movement of rods 28 and 30 during mounting and adjustment such that they can be released to allow rods 28 and 30 for insertion into a selected one of holes 32 in vertical support members 18 and 20.
The ironing board 14 may be either a metal or wooden type; however, the present design of the invention utilizes the more recently developed metal variety as adapted to receive a resilient ironing pad or cushion. The brace 22 is pivotally secured beneath the outer end of ironing board 14 along its central axis by means of a tubular retainer 36 suitably secured thereon, and retainer 36 is of proper size to receive upper end 38 of brace 22 therein in pivotal affixure. A lower end 40 of brace 22 is expanded outward to define a transverse section 42 of sufficient length to be engageable with a selected one of slots 44 in each of vertical support members 18 and 20 (as shown in FIG. 2).
FIG. 3 illustrates in enlarged perspective the particular construction of support members 18 and 20, each being of identical construction. Thus, the support member may be unitarily formed as an elongated T-shaped bar consisting of a backing panel 46 and center panel 48. The support members 18 and 20 may be constructed of any of various materials, but in the preferred form they are formed from one of the more well-known commercial and extrudable plastic materials, strength versus economy being the equating factor. For adjustment to various heights, the center panel 48 is formed to include a plurality of holes 32 for receiving the rod ends 28 and 30 to support the inner end 16 of ironing board 14 (see FIG. 2), and a plurality of slanted slots 44 are included near the base ends of support members 18 and 20 for the purpose of receiving the transverse section 42 of brace 22 when in operative position. As previously stated, each side of the base panel 46 of support members 18 and 20 may include a plurality of spaced holes 50 therethrough for the purpose of allowing additional gripping means for the quick setting bonding cement that is utilized as the fastener.
The upper ends of the support members 18 and 20 include a suitable form of fastening eye 52 (see also FIG. 2) for the purpose of receiving a hook-ended section of shock cord or spring material 54, the storage retainer element. It is also contemplated that a suitable formed iron appliance retainer 56 be suitably attached to the other side of ironing board 14 in order to provide storage for the iron appliance if so desired. The rack 56 may be a simple sheet metal formation having suitable toe walls 58 and 60 for supporting the iron appliance, and the rack 56 may be affixed as by spot welding to the underside of ironing board 14. It is yet further contemplated that the vertical support elements 18 and 20 be of a length to reach from the bottom of the door to the correct height desired. This enables more facile placement of the vertical support members 18 and 20 on the vertical wall of the door 12 without need for vertical measurements and alignments.
The present invention is intended as a space saving device suitable for this day and age when the ironing of clothing and household linens has become a more acute problem due to the ever increasing use of permanent press materials. No longer is a day set aside for washing and one for ironing. Most articles made of the permanent press materials need only touch-up ironing such that it is no longer necessary to set aside a full day for this tedious task. Thus, an average homemaker may need an ironing board only at infrequent and unscheduled minutes almost every day in order to do small touch-up ironing chores. This new necessity makes it impractical and unhandy to drag a heavy, folding ironing board out of a cluttered closet, set it up for use, and then put it back in storage daily, or even more often in some cases.
In operation of the present invention, each of the vertical support members 18 and 20 will be secured as by bonding to the back side of a room door or the like as shown in FIGS. 1 and 2. The inner end of the ironing board 14 is then positioned by thumb-finger squeezing of tabs 33 and 34 and placement of rod ends 28 and 30 in one of the holes 32 selected in accordance with the desired operating height. The ironing board 14 can then be folded upward against the door and between the center panels 48 of vertical support members 18 and 20, with brace 22 hanging straight in parallel relationship, and secured by the strap or shock cord member 54 between eye fasteners 52, thus retaining the ironing board in the stored position. The normally open door will enclose ironing board 14 from sight for all practical purposes.
When an ironing chore becomes necessary, it is only required to swing the door, remove shock cord 54, and lower ironing board 14 while guiding transverse section 42 of brace 22 into the selected slots 44 which render the ironing board 14 braced at the desired horizontal plane. The ironing board 14 is then ready for utilization. After ironing whatever the necessary clothing load, the ironing board 14 is simply swung upward against the door, as shown in FIG. 1, with replacement of shock cord 54 to hold it in stored position. The appliance rack 56 provides a place where the hot but cooling ironing appliance may be held without accident or burning and marring of surrounding fixtures.
The foregoing discloses a novel invention which is concerned with the provision of an ironing board that may be quickly attached to the back of a bedroom or little-used door, or any selected free access area in the residence, so that when the ironing board is folded up and flat against the vertical support it takes up little or no living space. When it is utilized with a residence door, it remains out of sight while the door is open in its normal disposition. When used on the back of a door, closure of the door provides an automatic, secure latch and thus provides an immovable support for the broad end of the ironing board, thus obviating the necessity for the provision of legs supporting the outer end of the board. The invention makes provision for a unitized, lightweight frame which is readily affixed in storageable manner on the selected vertical support area by either contact adhesive or other fasteners, and the unskilled can readily place the assembly in its operative position.
Changes may be made in the combination and arrangement of elements as heretofore set forth in the specification and shown in the drawings; it being understood that changes may be made in the embodiments disclosed without departing from the spirit and scope of the invention as defined in the following claims.
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An ironing board of easily storable and readily accessible character which is particularly adaptable for minimization of utility space within a living area, the ironing board consisting of a board portion adapted for adjustable positioning and support in vertically affixed hanger members, and further including a brace member which is readily adjustable to support the board portion in horizontal disposition; the structure is further adapted so that the board portion can be folded upward adjacent a surface maintaining the vertical support members, and then clamped or suitably retained in that position with the brace member folded into linear alignment with the surface for storage during non-use.
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This is a continuation of application Ser. No. 08/652,863, filed on May 23, 1996, now abandoned.
FIELD OF THE INVENTION
The present invention is related to a tissue paper structure, and more particularly, to multiple ply tissue paper structures.
BACKGROUND OF THE INVENTION
Paper webs made from cellulosic fibers are used in consumer products such as paper towels, toilet tissue, and facial tissue. Multiple ply paper structures are well known in the art. Such multiple ply structures have two or more plies which are positioned in face to face relationship and joined together. Each ply can be formed from a paper web. A paper web can have one or more layers as it is formed on a paper machine, as is also well known in the art.
The individual plies of a multiple ply paper structure can be joined in any number of suitable ways, including adhesive bonding or mechanical bonding, such as by embossing. Frequently, plies are embossed for aesthetic reasons, to provide space between adjacent plies, and to connect adjacent plies in face to face relationship.
Examples of multiple ply paper structures are shown in the following references: U.S. Pat. No. 3,650,882 issued March, 1972 to Thomas; U.S. Pat. No. 4,469,735 issued September, 1984 to Trokhan; and U.S. Pat. No. 3,953,638 issued April 1976 to Kemp. The following references disclose embossing or embossed products or multiple ply paper products: U.S. Pat. No. 5,490,902 issued Feb. 13, 1996 to Shulz; U.S. Pat. No. 5,468,323 issued November 1995 to McNeil and commonly assigned; U.S. Pat. No. 4,300,981 issued November 1981 to Carstens; U.S. Pat. No. 3,414,459 issued Dec. 3, 1968 to Wells and commonly assigned; U.S. Pat. No. 3,547,723 issued Dec. 15, 1970 to Gresham; U.S. Pat. No. 3,556,907 issued Jan. 19, 1971 to Nystrand; U.S. Pat. No. 3,708,366 issued Jan. 2, 1973 to Donnelly; U.S. Pat. No. 3,738,905 issued Jun. 12, 1973 to Thomas; U.S. Pat. No. 3,867,225 issued Feb. 18, 1975 to Nystrand and U.S. Pat. No. 4,483,728 issued Nov. 20, 1984 to Bauernfeind. Commonly assigned U.S. Pat. No. Des. 239,137 issued Mar. 9, 1976 to Appleman illustrates an emboss pattern found on commercially successful paper toweling.
It is generally understood that a multiple ply structure can have an absorbent capacity greater than the sum of the absorbent capacities of the individual single plies which make up the multiple ply structure. Above referenced U.S. Pat. No. 3,650,882 to Thomas discloses a three ply product which is said to have a water absorption capacity which is more than double that of two ply towels of similar furnish, and which is said to have an absorbent capacity which is greater than would be expected from a simple consideration of the additional amount of material in a three ply structure.
However, comparison of the absorbent capacity of a multiple ply structure to the absorbent capacities of single ply paper structures, or other multiple ply paper structures having fewer plies, is not especially helpful in judging the performance of the multiple ply product. The absorbent capacity gained by adding an additional ply is generally greater than absorbent capacity held within the added ply. This difference is due, at least in part, to the inter-ply storage space created by the addition of an extra ply.
A heterogeneous n ply product having plies obtained from different types of substrates is normally expected to have an absorbent capacity which is no greater than the arithmatic mean of the absorbent capacities measured for the homogeneous n ply structures formed from the different substrates. For instance, a heterogeneous two ply tissue product has a first ply formed from a first type of paper substrate and a second ply formed from a second, different type of paper substrate. The absorbent capacity of such a heterogeneous two ply product is generally expected to be less than or equal to the arithmatic mean of the absorbent capacities measured for 1) a homogeneous two ply structure formed from two plies of the first substrate and 2) a homogeneous two ply structure formed from two plies of the second substrate.
Above referenced U.S. Pat. No. 4,469,735 discloses extensible multi-ply tissue paper products. The products of U.S. Pat. No. 4,469,735 are said to have synergistically high liquid absorbency by virtue of at least two plies of the product having sufficiently different stress/strain properties. However, it is desirable to be able to provide improved absorbency without the need to impart different stress/strain properties to different plies.
Accordingly, one object of the present invention is to provide a multiple ply paper structure having improved absorbent properties.
Another object of the present invention is to provide a multiple ply paper structure which achieves a higher absorbent capacity and rate than anticipated with respect to other paper structures having the same number of plies.
Another object of the present invention is to provide a multiple ply paper structure having plies with different texture values and calipers.
Another object of the present invention is to provide a multiple ply paper structure having one or more plies having discrete, low density regions dispensed in a continuous network region.
SUMMARY OF THE INVENTION
The present invention provides a heterogeneous multiple ply tissue paper product having n plies, where n is an integer greater than or equal to 2. The heterogeneous multiple ply tissue paper product includes at least two plies, including a first ply and a second ply. The second ply has a texture value which is at least about 1.5 times, more preferably at least about 2.0 times, more preferably at least about 2.5 times, and still more preferably at least about 4.0 times the texture value of the first ply.
The second ply can have a caliper which is at least about 1.25 times, more particularly at least about 1.5 times, even more particularly at least about 2.0 times, and in one embodiment at least about 2.5 times the caliper value of the first ply.
The differential texture and caliper characteristics of the plies can provide the heterogeneous multiple ply tissue paper product with a horizontal absorbent capacity which is greater than the mean of the homogeneous n ply absorbent capacities of the n plies, without the need for imparting different stress/strain properties to the plies, as described in above referenced U.S. Pat. No. 4,469,735.
The heterogeneous multiple ply tissue paper product can include at least one ply having a macro-density which is at least about 1.5 times, more preferably at least about 2.0 times, more preferably at least about 2.5 times, and even more preferably at least about 3.0 times the macro-density of at least one of the other n plies.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a cross-sectional illustration of a 2 ply paper structure having relatively large domes facing inwardly.
FIG. 1B is a cross-sectional illustration of a 2 ply structure having relatively large domes facing outwardly.
FIG. 2A is a cross-sectional illustration of a 3 ply structure having a relatively low texture, non-patterned ply disposed between relatively highly textured, patterned plies.
FIG. 2B is a cross-sectional illustration of an alternative 3 ply embodiment having a relatively highly textured, patterned ply disposed between relatively low texture, non-patterned plies.
FIG. 3 is a schematic illustration of a paper making machine.
FIG. 4 is a plan view of a paper web having a continuous network region and discrete domes.
FIG. 5 is a cross-sectional view of the paper web of FIG. 4 taken along lines 5 — 5 in FIG. 4 .
FIG. 6 is a schematic illustration of equipment for combining two separate plies to form a two ply product according to the present invention.
FIG. 7 is a schematic illustration of equipment for combining two plies to provide an intermediate 2 ply structure.
FIG. 8 is a schematic illustration of equipment for combining the intermediate 2 ply structure made according to FIG. 7 with a third ply to provide a 3 ply product according to the present invention.
FIG. 9 is a schematic illustration of a drying member in the form of a through-air drying fabric having a macroscopically monoplanar, patterned, continuous network surface defining a plurality of discrete, isolated deflection conduits, each conduit having a machine direction length greater than the associated conduit cross machine direction width.
FIG. 10 is a schematic illustration of another drying member in the form of a through-air drying fabric having a continuous network surface and a plurality of discrete, isolated deflection conduits.
FIG. 11 is a schematic illustration of another drying member in the form of a through air drying fabric having a continuous network surface and a plurality of discrete, isolated deflection conduits.
FIG. 12 is a schematic illustration of a cross-section of a drying fabric taken along lines 12 — 12 in FIG. 9 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention comprises a heterogeneous multiple ply tissue paper product 20 having n plies. FIGS. 1A and 1B are cross-sectional illustrations of 2 ply structures (n=2). The individual plies in FIG. 1A are designated 31 and 32 , respectively. The plies 31 and 32 are joined at discrete, spaced apart locations by embossments 35 . FIGS. 2A and 2B are cross-sectional illustration of 3 ply embodiments (n=3) of the present invention. The individual plies in FIG. 2A are designated 41 A, 42 , and 41 B. The plies 41 A, 42 , and 41 B are joined together at discrete, spaced apart locations by embossments 45 .
By the term “heterogeneous multiple ply tissue paper product” it is meant that at least one of the plies of the multiple ply tissue product 20 can be distinguished from at least one of the other n plies in terms of at least one of the following properties: caliper, macro-density, basis weight, or texture value. The caliper, macro-density, basis weight, and texture value of a ply are measured according to the procedures provided below.
A homogeneous multiple ply paper structure is a multiple ply structure having plies which are made with substantially the same composition of paper fiber furnish and papermaking additives, and which are all substantially identical to one another with respect to all of the above properties (i.e. for any of the above properties, the maximum ply to ply difference of that particular property is less than about 10 percent of the lower value of the property).
The absorbent capacity and absorbent rate of the heterogeneous multiple ply tissue paper product 20 are measured according to the procedures described below. The heterogeneous multiple ply tissue paper products 20 of the present invention can have an absorbent capacity which is greater than the weighted average of the homogeneous n ply absorbent capacities measured for each of the n plies. In one embodiment, the heterogeneous multiple ply tissue paper products of the present invention can have an absorbent capacity which is greater than the maximum of the homogeneous n ply absorbent capacities measured for the n plies. The heterogeneous multiple ply tissue paper products of the present invention can have a wicking capacity which is greater than the weighted average of the homogeneous n ply wicking capacities measured for each of the n plies. The heterogeneous multiple ply tissue paper products of the present invention can also have an absorbent rate which is greater than the weighted average of the homogeneous n ply absorbent rates measured for each of the n plies.
The “homogeneous n ply absorbent capacity” and the “homogeneous n ply absorbent rate” for a particular ply are determined as follows. First, a “homogeneous n ply structure” for that particular ply is formed by joining together n plies of that particular ply. This multiple ply structure is referred to as a “homogeneous n ply structure” because all the plies are substantially identical. N plies of the particular ply are joined together using the same procedure (eg same embossing method, same embossing pattern, same adhesive) used to combine the n plies of the heterogeneous multiple ply tissue paper product. A homogeneous n ply structure is formed for each different ply used to form the heterogeneous multiple ply tissue paper product.
Then, the absorbent capacity and the absorbent rate for each of the homogeneous n ply structures are measured. The absorbent capacity and absorbent rate of each homogeneous n ply structure is measured using the same procedures used to measure the absorbent capacity and absorbent rate for the heterogeneous multiple ply tissue paper product. Accordingly, the absorbent capacity and absorbent rate of the heterogeneous multiple ply tissue paper product can be compared to those of homogeneous multiple ply structures having the same number of plies. Averages can then be calculated for the homogeneous n ply absorbent capacities and rates.
For example, referring to FIG. 1A , the heterogeneous multiple ply tissue paper product 20 has two plies, 31 and 32 (n=2), where ply 32 is not obtained from the same type of paper web from which ply 31 is obtained. For instance, ply 32 can have a caliper, macro-density, and texture value substantially different from those of ply 31 . The associated homogeneous 2 ply structure for ply 31 is obtained by joining together two paper webs of the type from which the ply 31 is formed. Likewise, the associated homogeneous 2 ply structure for ply 32 is obtained by joining together two paper webs of the type from which the ply 32 is formed. The homogeneous 2 ply paper structures are formed using the same combining method (eg. same adhesive, same embossing method, same embossing pressure, same embossing pattern, etc.) which is used to combine the plies 31 and 32 together to form the heterogeneous 2 ply paper product 20 .
The absorbent capacity and absorbent rate can then be measured for the homogeneous 2 ply structure for ply 31 . Likewise, the absorbent capacity and rate can be measured for the homogeneous 2 ply structure for ply 32 . For the structure of FIG. 1A , the average of the homogeneous n ply absorbent capacities is the average of the absorbent capacities measured for the homogeneous 2 ply structure for ply 31 and the homogeneous 2 ply structure for ply 32 . Similarly, the average of the homogeneous n ply absorbent rates is the mean of the absorbent rates measured for the homogeneous 2 ply structure for ply 31 and the homogeneous 2 ply structure for ply 32 .
Referring to FIG. 2A , the heterogeneous multiple ply tissue paper product 20 has three plies, 41 A, 42 , and 41 B (n=3). Ply 41 A is obtained from a paper web of the same type from which ply 41 B is obtained, and ply 42 is obtained from a paper web different from that of the type from which plies 41 A and 41 B are obtained. The associated homogeneous 3 ply structure for plies 41 A and 41 B is obtained by joining together three paper webs of the type from which the ply 41 A is formed. Likewise, the associated homogeneous 3 ply structure for ply 42 is obtained by joining together three paper webs of the type from which the ply 42 is formed. The homogeneous 3 ply paper structures are formed using the same combining method (eg. same adhesive, same embossing method, same embossing pressure, same embossing pattern, etc.) which is used to combine the plies 41 A, 42 , and 41 B together to form the heterogeneous 3 ply paper product 20 .
The absorbent capacity and absorbent rate can then be measured for the homogeneous 3 ply structure for ply 41 A. Likewise, the absorbent capacity and absorbent rate can be measured for the homogeneous 3 ply structure for ply 42 . For the structure of FIG. 2A having ply 41 A made from a paper web of the same type from which ply 41 B is formed, the average of the homogeneous n ply absorbent capacities can be calculated as a weighted average of the homogeneous n ply absorbent capacities:
[(2)×(AC 41 A)+(AC 42 )]/3
where AC 41 A is the homogeneous 3 ply absorbent capacity for ply 41 A (or for ply 41 B), and AC 42 is the homogeneous 3 ply absorbent capacity for ply 42 .
Likewise, the average of the homogeneous n ply absorbent rates can be calculated as a weighted average of the homogeneous n ply absorbent rates:
[(2)×(AR 41 A)+(AR 42 )]/3
where AR 41 A is the homogeneous 3 ply absorbent capacity for ply 41 a (or for ply 41 B)and AR 42 is the homogeneous 3 ply absorbent capacity for ply 42 .
Without being limited by theory, it is believed that the multiple ply products of the present invention can provide the improved absorbency and absorbency rate due, at least in part, to their combination of a relatively highly textured, high caliper, relatively low macro-density ply with a relatively lower textured, low caliper, relatively higher macro-density ply. Such different characteristics can be imparted to paper webs, at least in part, through the selective use of papermaking fabrics and methods. In particular, the texture value is a measure of the wet formed, non-mechanically embossed texture of the surface of a ply prior to combining the ply with other plies.
The texture value does not include mechanically embossed features. Such embossed features imparted to the web when after it is dried may be at least partially destroyed when the web is wetted. Wet formed texture features imparted on the ply while the ply is on the paper machine (such as those imparted to a web by through air drying on the drying fabric of a papermachine or by wet pressing prior to drying) are included in the texture measurement. Such wet formed texture features can better maintain their structure when wetted, especially when a wet strength additive, such as KYMENE, is added to the furnish from which the web is formed.
FIG. 3 is an illustration of a paper machine for use in making a paper web. The paper webs made on such a paper machine can be used to form the individual plies of a multiple ply product. Referring to FIG. 3 , a headbox 118 delivers the aqueous dispersion of papermaking fibers to a foraminous member 111 . The foraminous member 111 can be in the form of an endless belt which is carried in the direction indicated about a series of rolls. The foraminous member 111 can comprise a fourdrinier wire.
Alternatively, the foraminous member 111 can comprise a plurality of discrete protuberances joined to a reinforcing structure, each protuberance having an orifice. Such a forming member 111 is suitable for providing a web having different basis weight regions, and is described generally in U.S. Pat. No. 5,503,715 issued Apr. 2, 1996 to Trokhan et al., which patent is incorporated by reference.
After the dispersion of fibers is deposited on the forming member 111 , an embryonic web 120 is formed by removal of a portion of the water from the dispersion. Removal of the water can be accomplished by techniques well known in the art, such as by vacuum boxes, forming boards, and the like.
The embryonic web 120 is then transferred to a drying member 119 , which is in the form of an endless belt carried about a series of rolls in the direction shown. The n ply structures of the present invention can have plies having about the same level of wet-foreshortening (within about 5 percent). For the purpose of making a paper structure according to the present invention, the web can be wet-foreshortened less than about 5 percent, with wet-foreshortening of the web on transfer to the drying member 119 being about 3 percent. Wet-foreshortening is described in U.S. Pat. No. 4,469,735, which patent is incorporated herein by reference.
The embryonic web can be dewatered as it is transferred to the drying member 119 . The resulting intermediate web 121 is carried on the drying member 119 in the direction shown in FIG. 3 . The web can then be further dried as it is carried on the drying member 119 . For instance, when the drying member is in the form of a foraminous belt (such as is described in U.S. Pat. No. 4,529,480 to Trokhan and U.S. Pat. No. 4,191,609 to Trokhan), the web can be dried using through air drying equipment 125 to provide a predried web 122 . Alternatively, if the drying member 119 is a conventional papermaker's dewatering felt, the web can be further dewatered by pressing the web in nip as the web is carried on the felt. In yet another embodiment, the web can be dewatered by wet pressing the web as described in WO 95/17548 “Wet Pressed Paper Web and Method of Making Same” published Jun. 29, 1995 in the name of Ampulski et al., which publication is incorporated herein by reference.
The predried web can then be transferred to the surface of a heated drying drum 116 for further drying. The web can then be creped from the surface of the drum 116 , such as by use of a doctor blade 117 , to provide a dried paper web 124 . Use of the doctor blade 117 provides a web 124 which is dry-foreshortened (i.e. dry creped). For the purpose of making a paper structure according to the present invention, the web can be dry-foreshortened less than about 16 percent, with dry foreshortening of the web being about 10 percent in one embodiment. Accordingly, paper made according to the present invention can have relatively low levels of wet foreshortening and dry foreshortening.
The multiple ply tissue paper product of the present invention can include at least one ply comprising a paper web having regions of different density. In one embodiment, the multiple ply tissue product of the present invention can comprise a ply formed from a paper web having discrete regions of relatively high density dispersed throughout one or more regions of relatively low density. For instance, such a web can be formed on a papermachine such as that shown in FIG. 3 . The discrete regions of relatively high density can be formed by transferring the embryonic web to a dryer member 119 in the form of a woven fabric having discrete compaction knuckles. The compaction knuckles can be disposed at the cross over points of warp and shute filaments of the fabric. The compaction knuckles serve to densify discrete, spaced apart portions of the web as the web is transferred to the drying drum 116 . The following patents are incorporated by reference for the purpose of showing drying fabrics and/or methods for forming a paper web having regions of different density, and more particularly, a textured paper web having discrete, relatively high density regions disposed throughout one or more relatively low density regions. U.S. Pat. No. 3,301,746 issued January, 1967 to Sanford et al.; U.S. Pat. No. 3,974,025 issued August, 1976 to Ayers; U.S. Pat. No. 3,994,771 issued November 1976 to Morgan et al; and U.S. Pat. No. 4,191,609 issued March 1980 to Trokhan. U.S. Pat. No. 4,191,609 is particularly preferred for forming a paper web having an array of uncompressed, relatively low density regions which are in staggered relation in both the machine and cross machine directions.
In one embodiment, at least one of the plies of the heterogeneous multiple ply tissue paper structure comprises a paper web made according to the teachings of EP 0677612A2 published Oct. 18, 1995 in the name of Wendt et al., which application is incorporated herein by reference.
In one embodiment, at least one of the plies of the heterogeneous multiple ply tissue paper structure comprises a paper web having a continuous network region having a relatively low basis weight and a relatively high density; and a plurality of discrete regions dispersed throughout the continuous network region, the discrete regions having relatively high basis weights and relatively low densities. A ply comprising a paper web 180 having a continuous network region 183 having a relatively low basis weight and a relatively high density, and discrete domes 184 having relatively high basis weights and relatively low densities is shown in FIGS. 4 and 5 . The caliper of the ply is designated as T in FIG. 5 .
Such a paper web is shown and described in U.S. Pat. No. 4,529,480 issued Jul. 16, 1985 to Trokhan. Trokhan '480 also discloses a drying member 119 in the form of a foraminous belt suitable for making such a web. The drying member 119 shown in Trokhan '480 has a macroscopically monoplanar, patterned, continuous network surface defining a plurality of discrete, isolated, non-connecting deflection conduits. The following U.S. Patents are incorporated herein by reference for the purpose of describing such a foraminous belt: U.S. Pat. No. 4,514,345 to Johnson et al.; U.S. Pat. No. 4,529,480 to Trokhan; U.S. Pat. No. 5,364,504 to Smurkoski et al.; U.S. Pat. No. 5,514,523 to Trokhan et al.
Referring back to FIG. 1A , a heterogeneous 2 ply tissue paper product can have plies 31 and 32 , wherein at least one of the plies has a continuous network region 183 and a plurality of discrete domes 184 . FIG. 1A shows both plies comprising paper webs having a continuous network region 183 and a plurality of discrete domes 184 . Both of the plies 31 and 32 are patterned, having domes 184 which extend inwardly (i.e. the domes 184 of ply 31 face the domes 184 of ply 32 ). The domes 184 of ply 31 can have the same shape as the domes of ply 32 , or the domes 184 of ply 31 can have a shape which is different from that of the domes of ply 32 . The domes in each of the plies can be bilaterally staggered.
In FIG. 1A , ply 31 is different from ply 32 in that ply 31 has a relatively larger number of relatively smaller domes 184 per unit area, while ply 32 has a relatively smaller number of relatively larger domes 184 per unit area. In particular, ply 31 can have X domes 184 per square inch, where the value of X is at least about 100. Ply 32 can have Y discrete domes 184 per square inch, where the value of Y is less than the value of X, and the value of Y is less than about 250. The ratio of X to Y can be at least about 1.5, at least about 2.0, and in one embodiment is at least about 10. In one embodiment, ply 31 can have at least about 200, and more particularly at least about 500 domes 184 per inch, and ply 32 can have less than about 110, and more particularly less than about 75 domes per square inch. In addition, ply 32 has a caliper which is greater than the caliper of ply 31 . Ply 32 can have a caliper which is at least about 1.25 times, more particularly, at least about 1.5 times, even more particularly at least about 2.0 times, and in one embodiment at least about 2.5 times the caliper of ply 31 .
Each of the plies 31 and 32 can have a basis weight of between about 7-60 lb/3000 square feet. In one embodiment, the plies 31 and 32 can each have a basis weight of about 12-15 pounds per 3000 square feet. The macro-density of ply 31 can be at least about 1.5 times, more preferably at least about 2.0 times, and even more preferably at least about 2.5 times the macro-density of ply 32 .
Ply 32 has a texture value greater than ply 31 . In one embodiment, the ply 32 can have a texture value which is at least about 1.5 times, more preferably at least about 2.0 times, and even more preferably at least about 4.0 times the texture value of ply 31 . In particular, ply 32 can have a texture value of at least 15 mils, and ply 31 can have a texture value of less than about 10 mils. In one embodiment, the ply 32 can have a texture value of between about 23 and about 25 mils and ply 31 can have a texture value of between about 4.0 and about 6.0 mils. The texture value provides a measure of the wet formed surface characteristics provided by the drying member 119 . In particular, the texture value can provide a measure of the difference in elevation between the domes 184 and the network 183 .
In an alternative 2 ply embodiment shown in FIG. 1B , ply 32 can be joined to ply 31 such that the domes 184 of ply 32 face outwardly and the domes 184 of the ply 31 face inwardly toward ply 32 . In such a 2 ply structure, ply 31 can provide a relatively smooth outwardly facing surface, and ply 32 can provide a relatively highly textured outwardly facing surface having outwardly facing protrusions in the form of the domes 184 . The relatively highly textured outwardly facing surface of ply 32 can be useful in scrubbing or scouring operations, while the relatively smooth outwardly facing surface of ply 31 can be used for wiping liquid from a surface.
Alternatively, the two ply structure 20 can comprise one ply having a continuous network and discrete domes, and a second ply which does not include discrete domes dispersed throughout a continuous network. For instance, the ply 31 in FIGS. 1A or 1 B can be replaced by a ply of the type shown as ply 42 in FIG. 2 A.
Referring to FIG. 2A , one embodiment of the present invention is a heterogeneous 3 ply tissue paper product having plies 41 A, 42 , and 41 B. The plies 41 A and 41 B can have substantially the same structure and composition. Each of the plies 41 A and 41 B can be patterned to have a continuous network region 183 and a plurality of discrete domes 184 . Each of the plies 41 A and 41 B can have the same number Y of domes 184 per square inch. The value of Y can be between about 10 and about 600, and more particularly between about 10 and about 200. Ply 42 can be formed from a web of conventional felt dried tissue paper having substantially unpatterned smooth, untextured surfaces, and a generally uniform density and basis weight (no discernable regions having different micro-densities or different micro-basis weights). Each of the surfaces of ply 42 can have a texture value of less than about 1.0.
In the embodiment shown in FIG. 2A , each of the plies 41 A and 41 B has a caliper greater than that of ply 42 , and each of the plies 41 A and 42 B has a macro-density less than that of ply 42 . The plies 41 A and 41 B can each have a caliper which is at least about 2.5 times that of ply 42 . The ply 42 can have a macro-density which is at least about 2.5 times that of plies 41 A and 41 B. Ply 42 can have a texture value less than about 1.0, and plies 41 A and 41 B can each have a texture value of at least about 10.
In one embodiment, each ply 41 A and 41 B can have a basis weight of about 13.6 pound/3000 square feet, a caliper of at least about 20 mils, and a macro density of less than about 1.0 pounds/mil-3000 square feet. Ply 41 A and 41 B can each have a texture value of at least about 15 mils, and can have about 75 domes 184 per square inch. Ply 42 can have a basis weight of about 12.5 pound/3000 square feet, a caliper of between about 4 and about 6 mils, a macro density of at least about 2.0 pounds/mil-3000 square feet, and a texture value of about zero.
In the alternative 3 ply embodiment of FIG. 2B , a patterned, relatively highly textured ply 41 can be disposed between two plies 42 A and 42 B having relatively low texture, the plies 42 A and 42 B having substantially no discernable pattern. In yet another 3 ply embodiment, a relatively higher textured ply, such as ply 41 , can be disposed between two plies such as that shown as ply 31 in FIG. 1 A. Each of the 3 plies in such a structure has relatively low density domes disposed throughout a continuous high density network.
Two or more of the paper webs 131 and 132 having desired characteristics relative to one another are combined to provide the multiple ply tissue paper product of the present invention. FIG. 6 illustrates equipment that can be used to combine two webs having desired characteristics relative to one another in order to form a two ply product according to the present invention. Two single ply webs 131 and 132 are unwound from rolls 210 and 220 , respectively. Each of the webs 131 and 132 can have regions of different density, and each ply can have a continuous network region having a relatively high density, and discrete domes having relatively low densities. The two webs 131 and 132 are carried in the directions indicated around rollers 225 . Web 131 corresponds to ply 31 in FIG. 1 , and web 132 corresponds to ply 32 in FIG. 1 .
Web 131 is directed through a nip formed between a rubber roll 240 and a steel embossing roll 250 , as web 132 is directed through a nip formed between rubber roll 260 and a steel embossing roll 270 . In the embodiment of FIG. 1A , the domes 184 of the web 131 face roll 240 , and the domes 184 of web 132 face roll 260 , so that the domes 184 face inwardly in the resulting 2 ply structure. The steel embossing rolls 250 and 270 have a pattern of embossing pins which contact and deform selective, discrete portions of the webs 131 and 132 , respectively. The web 131 is then carried through a nip formed between a glue applicator roll 255 and the steel embossing roll 250 . The glue applicator roll, which has a surface which is continuously replenished with glue, transfers glue to the deformed portions of the web 131 . Webs 131 and 132 then pass between steel embossing rolls 250 and 270 , with web 131 adjacent roll 250 and web 132 adjacent roll 270 . The embossing pins on roll 250 nest with those on roll 270 to deform the webs 131 and 132 , and to provide nesting of web 131 with web 132 .
The two webs 131 and 132 then pass through a nip having a predetermined nip loading, the nip being formed between steel embossing roll 250 and a marrying roll 280 . Marrying roll 280 has a hard rubber cover, and serves to press the webs 131 and 132 together to ensure bonding of web 131 to web 132 at those locations where adhesive is transferred from roll 255 to ply 131 . The resulting two ply paper structure 20 can be rewound for later converting into smaller rolls.
FIGS. 7 and 8 illustrate combining three separate webs to provide a three ply paper structure such as that shown in FIG. 2 A. Web 141 A corresponds to ply 41 A in FIG. 2A , web 142 corresponds to ply 42 in FIG. 2A , and web 141 B corresponds to ply 41 B in FIG. 2 A. Webs 141 A and 141 B can have a continuous network region having a relatively high density and discrete domes having relatively low densities. Web 142 can comprise a conventional felt pressed web.
Webs 141 and 141 A can be unwound from rolls 211 and 221 , respectively, and carried in the directions shown. Web 142 is directed through a nip formed between glue applicator roll 255 and steel embossing roll 250 (The rubber embossing rolls 240 and 260 are disengaged in this operation) to transfer a layer of adhesive from roll 255 to web 142 . Webs 131 and 132 then pass between steel embossing rolls 250 and 270 , with web 142 adjacent roll 250 and web 141 A adjacent roll 270 . The embossing pins on roll 250 nest with those on roll 270 . The two webs then pass through the nip formed between steel embossing roll 250 and marrying roll 280 to ensure bonding of web 141 A to web 142 , thereby providing an intermediate 2 ply structure designated 143 in FIGS. 7 and 8 .
The web 141 B can then be joined to the intermediate 2 ply structure 143 , as shown in FIG. 8 . Intermediate structure 143 is directed through the nip between rubber roll 260 and steel embossing roll 270 such that its constituent web 141 A is positioned against roll 270 and its constituent web 142 is positioned against roll 260 . Accordingly, web 142 is adhesively joined to web 141 B when the three webs pass through the nip between marrying roll 280 and embossing roll 250 .
EXAMPLES
Example 1: 2 ply
The purpose of this example is to illustrate one method that can be used to form a two ply embodiment of the present invention. Each of the plies 31 and 32 are formed on a pilot scale paper machine having the general configuration shown in FIG. 3. A 0.1 percent consistency aqueous slurry of papermaking fibers, water, and additives is formed for deposition on the foraminous member 111 . The aqueous slurry comprises a mixture of 75:25 by weight NSK (northern softwook Kraft) and CTMP (chemi-thermo mechanical pulp) paper fibers. The additives include a wet strength additive, a dry strength additive, a wettability agent, and a softness additive. The wet strength additive comprises an effective amount of epichlorohydrin adduct in the form of about 22 pounds KYMENE 557H per ton of dry fiber weight. KYMENE 557H is supplied by Hercules Corp of Wilmington, Del. The dry strength additive comprises an effective amount of Carboxy Methyl Cellulose in the form of about 5 pounds of CMC 7MT per ton of dry fiber weight. CMC 7MT is supplied by Hercules Corp. The wettability agent comprises an effective amount of Dodecylphenoxy poly(ethylenoxy)ethanol in the form of about 2 pounds of IGEPAL per ton of dry fiber weight. IGEPAL is supplied by Rhone Poulence of Cranbury, N.J. The Softness additive comprises an effective amount of Quaternary ammonium compound in the form of about 2 pounds of DTDMAMS per ton of dry fiber weight. DTDMAMS (Dihydrogenated Tallow Dimethyl Ammonium Methyl Sulfate) is supplied by Sherex of Dublin, Ohio.
When forming the web from which ply 31 is made, the slurry is deposited onto foraminous member 111 (a Fourdrinier wire of a 5 shed, satin weave configuration having 87 machine direction and 76 cross-machine direction filaments per inch), and dewatered to a consistency of about 17 percent just prior to transfer to drying member 119 . The resulting embryonic web is then transferred to the drying member 119 to provide wet foreshortening of about 3 percent. The drying member 119 is in the form of a through air drying fabric as shown in FIGS. 9 and 12 , such as is generally described in above referenced U.S. Pat. No. 4,529,480. The through air drying fabric has a continuous network surface 423 which defines openings of deflection conduits 422 . As shown in FIG. 12 , the continuous network surface 423 extends a distance D above a woven reinforcing element 443 having woven reinforcing strands 441 and 442 .
The drying fabric 119 for forming the ply 31 has about 562 deflection conduits 422 per square inch as viewed in FIG. 9 (562 cells per square inch). The deflection conduits 422 have an elongated shape with a machine direction length which is about 48 mils (0.048 inch) and a cross-machine direction width of about 35 mils. The knuckle area (area of the continuous network 423 ) is about 36.6 percent of the surface area of the drying fabric 119 as viewed in FIG. 9 . The distance D is about 22 mils.
The web is partially dried by dewatering and by predrying with through air drying apparatus 125 to a consistency of about 57 percent. The web is then adhered to the surface of yankee dryer 116 , and removed from the surface of the dryer 116 by the doctor blade 117 at a consistency of about 97 percent. The yankee dryer is operated at a surface speed of about 800 feet per minute. The dry web 124 is wound onto a roll at a speed of 716 feet per minute to provide the web 131 , to provide dry foreshortening of about 10 percent. The resulting web has between about 562 and about 620 relatively low density domes 184 per square inch (the number of domes 184 in the web is between zero percent to about 10 percent greater than the number of cells in the drying member 119 , due to dry foreshortening of the web).
The ply 32 is formed from a web 132 which is made using a paper machine such as that shown in FIG. 3 . The same furnish and procedure as described above with respect to ply 31 are used to form web 132 , except that the drying member 119 is of the form shown in FIG. 10 . Referring to FIG. 10 , the drying member 119 has about 45 deflection conduits 422 per square inch, a knuckle area of about 30 percent, and a dimension d of about 30 mils. The deflection conduits 422 have a quasi-quadnlateral shape having curved sides. The deflection conduits have a length of about 191 mils and a width of about 94 mils. The web 132 has between about 45 and about 50 domes 184 per square inch. The resulting webs 131 and 132 , when combined as shown in FIG. 6 to provide a 2 ply structure 20 , have the following characteristics:
Ply 31:
Homogenous 2 ply (31-31)
Caliper:
12.0
Caliper
24.7
Basis Weight:
13.6
Absorb. Capacity
19.6
Macro-Density:
1.13
Wicking Capacity:
13.8
Texture Value
5.5
Absorbent Rate:
0.35
Ply 32:
Homogenous 2 ply (32-32)
Caliper:
35.0
Caliper
42.8
Basis Weight:
13.6
Absorb. Capacity
32.8
Macro-Density:
0.39
Wicking Capacity:
27.0
Texture Value:
24.0
Absorbent Rate
0.68
Heterogenous 2 Ply 31-32:
Caliper:
34.6
Absorb. Capacity
28.1
Wicking Capacity
23.2
Absorbent Rate:
0.59
Units: Unless otherwise specified, caliper is reported in mils, basis weight in lbs/3000 square feet; macro-density in lb/3000 square feet-mil, Texture Value in mils, Absorbent Capacity in grains per gram, Wicking Capacity in grains per gram, and Absorbent Rate in grains per second.
Example 2: 2 ply
The purpose of this example is to illustrate another method that can be used to form a two ply embodiment of the present invention.
Ply 31 is formed as follows: a 0.1 percent consistency aqueous slurry of papermaking fibers, water, and additives is formed for deposition on the foraminous member 111 . The aqueous slurry comprises a mixture of 63:20:17 by weight NSK, CTMP, and broke. The additives include a wet strength additive, a dry strength additive, a wettability agent, and a softness additive. The wet strength additive comprises an effective amount of epichlorohydrin adduct in the form of about 24 pounds KYMENE 557H per ton of dry fiber weight. The dry strength additive comprises an effective amount of Carboxy Methyl Cellulose in the form of about 5 pounds of CMC 7MT per ton of dry fiber weight. The wettability agent comprises an effective amount of Dodecylphenoxy poly(ethylenoxy)ethanol in the form of about 1.5 pounds of IGEPAL per ton of dry fiber weight. The Softness additive comprises an effective amount of Quaternary ammonium compound in the form of about 1.3 pounds of DTDMAMS per ton of dry fiber weight.
When forming the web from which ply 31 is made, the slurry is deposited onto foraminous member 111 (a Fourdrinier wire of a 5 shed, satin weave configuration having 87 machine direction and 76 cross-machine direction filaments per inch), and dewatered to a consistency of about 17 percent just prior to transfer to drying member 119 . The resulting embryonic web is then transferred to the drying member 119 to provide wet foreshortening of about 3 percent. The drying member 119 is in the form of a through air drying fabric as shown in FIGS. 9 and 12 , and such as is generally described in above referenced U.S. Pat. No. 4,529,480.
The drying fabric 119 for forming the ply 31 has about 240 deflection conduits 422 per square inch as viewed in FIG. 9 (240 cells per square inch). The knuckle area (area of the continuous network 423 ) is about 25 percent of the surface area of the drying fabric 119 as viewed in FIG. 9 . The distance D is about 22 mils.
The web is partially dried by dewatering and by predrying with through air drying apparatus 125 to a consistency of about 63 percent. The web is then adhered to the surface of yankee dryer 116 , and removed from the surface of the dryer 116 by the doctor blade 117 at a consistency of about 97 percent, and to provide a dry foreshortening of about 10 percent. The resulting web has a basis weight of about 13.1 pound/3000 square feet. The resulting web has between about 240 and about 262 relatively low density domes 184 per square inch (the number of domes 184 in the web is between zero percent to about 10 percent greater than the number of cells in the drying member 119 , due to dry foreshortening of the web).
Ply 32 is formed as follows: a 0.1 percent consistency aqueous slurry of papermaking fibers, water, and additives is formed for deposition on the foraminous member 111 . The aqueous slurry comprises a mixture of 65.6:23.1:11.3 by weight NSK, CTMP, and broke. The additives include a wet strength additive, a dry strength additive, a wettability agent, and a softness additive. The wet strength additive comprises an effective amount of epichlorohydrin adduct in the form of about 19.5 pounds KYMENE 557H per ton of dry fiber weight. The dry strength additive comprises an effective amount of Carboxy Methyl Cellulose in the form of about 3.8 pounds of CMC 7MT per ton of dry fiber weight. The wettability agent comprises an effective amount of Dodecylphenoxy poly(ethylenoxy)ethanol in the form of about 1.4 pounds of IGEPAL per ton of dry fiber weight. The Softness additive comprises an effective amount of Quaternary ammonium compound in the form of about 1.08 pounds of DTDMAMS per ton of dry fiber weight.
When forming the web from which ply 32 is made, the slurry is deposited onto foraminous member 111 (a Fourdrinier wire of a 5 shed, satin weave configuration having 87 machine direction and 76 cross-machine direction filaments per inch), and dewatered to a consistency of about 17 percent just prior to transfer to drying member 119 . The resulting embryonic web is then transferred to the drying member 119 to provide wet foreshortening of about 2.5 percent. The drying member 119 is in the form of a through air drying fabric as shown in FIGS. 11 and 12 , and such as is generally described in above referenced U.S. Pat. No. 4,529,480.
The drying fabric 119 for forming the ply 32 has about 97 deflection conduits 422 per square inch as viewed in FIG. 11 (97 cells per square inch). The knuckle area (area of the continuous network 423 ) is about 20 percent of the surface area of the drying fabric 119 as viewed in FIG. 11 . The distance D is about 15.9 mils.
The web is partially dried by dewatering and by predrying with through air drying apparatus 125 to a consistency of about 63 percent. The web is then adhered to the surface of yankee dryer 116 , and removed from the surface of the dryer 116 by the doctor blade 117 at a consistency of about 97 percent, and to provide a dry foreshortening of about 4.5 percent. The resulting web has a basis weight of about 16.1 pound/3000 square feet. The resulting web has between about 97 and about 102 relatively low density domes 184 per square inch.
The resulting webs 131 and 132 , when combined as shown in FIG. 6 to provide a 2 ply structure 20 , have the following characteristics:
Ply 31:
Homogenous 2 ply (31-31)
Caliper:
16.0
Caliper
27.0
Basis Weight:
13.1
Absorb. Capacity
25.9
Macro-Density:
0.82
Wicking Capacity:
17.2
Texture Value
15.3
Absorbent Rate:
0.48
Ply 32:
Homogenous 2 ply (32-32)
Caliper:
22.0
Caliper
30.0
Basis Weight:
16.1
Absorb. Capacity
24.7
Macro-Density:
0.73
Wicking Capacity:
14.5
Texture Value:
26.8
Absorbent Rate
0.64
Heterogenous 2 Ply 31-32:
Caliper:
27.9
Absorb. Capacity
26.7
Wicking Capacity
22.0
Absorbent Rate:
0.65
Example 3: 3 ply
The purpose of this example is to illustrate one method that can be used to form a three ply embodiment of the present invention. Referring to FIG. 2A , the plies 41 A and 41 B are formed from webs made on a paper machine, such as that shown in FIG. 3 , having a drying member 119 in the form of a through air drying fabric. The ply 42 is formed from a web made on a paper machine, such as that shown in FIG. 3 , having a drying member 119 in the form of a conventional papermakers dewatering felt.
The following procedure is used to make the webs from which plies 41 A and 41 B are formed. A 0.1 percent aqueous slurry of papermaking fibers, water, and additives is formed for deposition on the foraminous member 111 . The aqueous slurry comprises a mixture of 75:25 by weight NSK (northern softwook Kraft) and SSK (southern softwood kraft) paper fibers. The additives include a wet strength additive and a dry strength additive. The wet strength additive comprises an effective amount of epichlorohydrin adduct in the form of about 22 pounds KYMENE 557H per ton of dry fiber weight. The dry strength additive comprises an effective amount of Carboxy Methyl Cellulose in the form of about 5 pounds of CMC 7MT per ton of dry fiber weight.
The slurry is deposited onto foraminous member 111 (a Fourdrinier wire of a 5 shed, satin weave configuration having 87 machine direction and 76 cross-machine direction filaments per inch), and dewatered to a consistency of about 17 percent. The resulting embryonic web is then transferred to the drying member 119 , which is in the form of a through air drying fabric as shown in FIGS. 11 . The drying fabric 119 for forming the plies 141 A and 141 B has about 75 deflection conduits 422 per square inch as viewed in FIG. 11 . The knuckle area (area of the continuous network 423 ) is about 39 percent of the surface area of the drying fabric 119 as viewed in FIG. 11 . The distance D is about 16 mils.
The web is partially dried by dewatering and by predrying with through air drying apparatus 125 to a consistency of about 57 percent. The web is then adhered to the surface of yankee dryer 116 , and removed from the surface of the dryer 116 by the doctor blade 117 at a consistency of about 97 percent. The yankee dryer is operated at a speed of about 800 feet per minute. The dry web 124 is wound onto a roll at a speed of 716 feet per minute to provide the web 141 A (or 141 B), with dry foreshortening being about 10 percent. The web 141 A (or 141 B) has between about 75 and about 85 domes 184 per square inch.
The following procedure is used to make the web from which ply 42 is formed. A 0.1 percent aqueous slurry of papermaking fibers, water, and additives is formed for deposition on the foraminous member 111 . The aqueous slurry comprises a mixture of 60:40 by weight NSK and CTMP. The additives include a wet strength additive, a dry strength additive, a wettability agent, and a softness additive. The wet strength additive comprises an effective amount of epichlorohydrin adduct in the form of about 22 pounds KYMENE 557H per ton of dry fiber weight. The dry strength additive comprises an effective amount of Carboxy Methyl Cellulose in the form of about 3.7 pounds of CMC 7MT per ton of dry fiber weight. The wettability agent comprises an effective amount of Dodecylphenoxy poly (ethylenoxy)ethanol in the form of about 2 pounds of IGEPAL per ton of dry fiber weight. The Softness additive comprises an effective amount of Quaternary ammonium compound in the form of about 5 pounds of DTDMAMS per ton of dry fiber weight.
The slurry is deposited onto foraminous member 111 (a Fourdrinier wire of a 5 shed, satin weave configuration having 87 machine direction and 76 cross-machine direction filaments per inch), and dewatered to a consistency of about 14 percent. The resulting embryonic web is then transferred to the drying member 119 , which is in the form of a conventional papermakers dewatering felt having a relatively smooth web support surface. The felt is an Albany XYJ 1605-7 felt (precompressed) supplied by Albany International Corporation.
The web is partially dried by dewatering and pressing the web and felt to provide an intermediate web having a consistency of about 39 percent. The web is then adhered to the surface of yankee dryer 116 , and removed from the surface of the dryer 116 by the doctor blade 117 at a consistency of about 96 percent. The yankee dryer is operated at a speed of about 3200 feet per minute. The dry web 124 is wound onto a roll at a speed of 2712 feet per minute to provide the web 142 . The web 142 is dry foreshortened about 15 percent.
The resulting webs 141 A, 142 , and 141 B, when combined as shown in FIGS. 7 and 8 to provide a 3 ply structure 20 , have the following characteristics:
Ply 41A (or 41B):
Homog. 3 ply (41A-41A-41A)
Caliper:
25.4
Caliper
38.3
Basis Weight:
13.6
Absorb. Capacity
23.5
Macro-Density:
0.535
Wicking Capacity:
16.8
Texture Value
17.7
Absorbent Rate
0.96
Ply 42:
Homog. 3 ply (42-42-42)
Caliper:
6.0
Caliper
26.6
Basis Weight:
12.5
Absorb. Capacity
15.4
Macro-Density:
2.08
Wicking Capacity:
8.27
Texture Value:
<1.0
Absorbent Rate
0.24
Heterogenous
3 Ply 41A-42-41B:
Caliper:
40.8
Absorb. Capacity
26.5
Wicking Capacity:
17.7
Absorbent Rate:
0.86
Example 4: 3 ply
The purpose of this example is to illustrate an alternative three ply embodiment such as that shown in FIG. 2 B. The three ply embodiment of this example includes a patterned, relatively textured ply 41 disposed between two substantially unpatterned, relatively untextured plies 42 A and 42 B. Ply 41 is formed from the same type web from which plies 41 A and 41 B are formed in Example 3. Plies 42 A and 42 B are formed from the same type web from which ply 42 is formed in Example 3. The resulting heterogeneous 3 ply paper product has the following properties:
Heterogeneous 3 Ply 42 A- 41 - 42 B:
Caliper: 27.8 Absorb Capacity 22.6 Wicking Capacity: 13.4 Absorbent Rate: 0.6
In alternative embodiments of Examples 3 and 4, the ply 42 in Example 3, and the plies 42 A and 42 B in Example 4 can be made from webs having multiple basis weight regions with a high basis weight region comprising an essentially continuous network, as described in U.S. Pat. No. 5,503,715 to Trokhan. The webs from which the plies 42 , 42 A and 42 B are obtained can be formed by depositing an aqueous slurry onto a foraminous member 111 which comprises a plurality of discrete protuberances joined to a reinforcing structure, each protuberance having an orifice (as is described generally in U.S. Pat. No. 5,503,715). One suitable forming member 111 includes about 200 protuberances per square inch, each protuberance extending a distance D of about 5.5 mils above the reinforcing structure. The top surface areas of the protuberances comprise about 28 percent of the surface area of the drying member (knuckle area of the protuberances is about 28 percent). The reinforcing structure can be a 90×72 triple layer construction woven wire, available from the Appleton Wire Company.
TEST PROCEDURES
Samples are placed in a temperature (73±2 Fahrenheit) and relative humidity (50±2 percent) controlled location for at least 2 hours prior to testing. Testing is conducted under these conditions.
Absorbent Capacity
The absorbent capacity is a measure of the ability of a paper structure, while supported horizontally, to hold liquid. The absorbent capacity is measured using the following procedure: A full size (11 inch×11 inch) sheet is supported horizontally in a tared filament lined basket and weighed to provide the weight of the dry sheet. The filament lined basket has crossed filaments which serve to support the sheet horizontally. The crossed filaments permit unrestricted movement of water into and out of the paper sheet. The sheet supported in the basket is lowered into a distilled water bath having a temperature of 73±2 degrees F. for one minute. The basket is then raised from the bath, so that the sheet is allowed to drain for 1 minute. The basket and sheet are then re-weighed to obtain the weight of the water absorbed by the sheet. The absorbent capacity, in grams/gram, is calculated by dividing the weight of the water absorbed by the sheet by the weight of the dry sheet. The absorbent capacity is reported as an average of at least 8 measurements.
Absorbent Rate and Wicking Capacity
The absorbent rate is a measure of the rate at which a paper structure acquires liquid by wicking. The wicking capacity is a measure of the weight of water wicked into a sample per gram of sample dry weight. The absorbent rate and wicking capacity are measured using the following procedure. The sample sheet, which is cut into a circular shape having a 3 inch diameter, is supported horizontally on a tared filament tray. The weight of the dry sample is determined.
A vertical tube having a diameter of 0.312 inches and holding a column of distilled water is provided. The tube is supplied with water from a reservoir to provide a convex meniscus adjacent the lip of the tube. The water level in the tube is adjustable, such as by a pump, so that the meniscus can be raised to contact a sample sheet positioned above the lip of the tube.
The sample sheet supported in the filament tray is positioned above the vertical tube, such the the filament tray is about ⅛ inch above the lip of the tube. The water level in the tube is then varied so that the meniscus contacts the sample, after which the pressure used to raise the meniscus (about 2 psi) is reduced to zero. The weight of the sample sheet is monitored as water is taken up by the sample. Time zero is set at the instant when the sample first takes up water (first change in balance reading from dry weight). At time equals two seconds (two seconds after time zero), the contact between the meniscus and the sample sheet is broken by suction (about 2 psi) applied to the water in the tube, and the wetted sample weight is recorded. The wetted sample is weighed after breaking contact between the meniscus and the sample so as not to include surface tension in the weight measurement.
The absorbent rate is the weight of the wetted sample minus the sample dry weight, divided by 2 seconds. A small positive pressure (about 2 psi) is applied to the water in the tube to cause the meniscus to recontact the sample. The weight of the sample is again monitored until time equals 180 seconds. At time equals 180 seconds, the contact between the meniscus and the sample sheet is broken by suction (about 2 psi) applied to the water in the tube, and the wetted sample weight is again recorded. The wetted sample is weighed after breaking contact between the meniscus and the sample so as not to include surface tension in the weight measurement. The wicking capacity is calculated as the wetted sample weight at 180 seconds minus the dry weight, divided by the dry weight. The absorbent capacity and wicking capacity are each reported as an average of at least 4 measurements.
Texture Value
The texture value is a measurement of the non-embossed, wet formed texture of a surface of a tissue paper web. Each surface of a ply can be measured and assigned a texture value. Generally, if only one texture value is provided, it is the higher texture value for the two surfaces of a ply. Mechanically embossed texture, such as that imparted to the plies when the plies are combined, is not measured The texture value of a surface is determined by scanning a surface of a ply with a transmitted light microscope, and determining the elevation difference between a local high point (peak) and an adjacent local low point (valley) in a particular field of view. The texture value of the surface of a ply is preferably measured prior to combining a ply with other plies to form a multiple ply product. However, the texture value can also be obtained from a sample cut from a multiple ply sample, provided that any texture features created by combining the plies (e.g. embossing) are not included in the measurement.
The elevation difference is determined by varying the focus of the microscope, and recording the difference in focus positions between the peaks and adjacent valleys in the field of view. The measurements are made on a sample measuring about 2 inches by 1.5 inches. The difference between 15 adjacent peaks and valleys are measured and averaged to provide the texture value for the surface. A 10× eyepiece and a 10× objective (numerical aperture=0.30) is used for samples having more than about 150 peaks per square inch, and a 10× eyepiece and 5× objective (numerical aperture=0.15) is used for samples having less than about 150 peaks per square inch. A suitable microscope which has an readout indicating the difference in elevation between two focus settings is a Zeis Axioplan Transmitted Light Microscope with a Microcode II Accessory. The Microcode accessory records the range of focus settings in millimeters, which can then be converted to mils.
For instance, where the sample includes the wet formed domes 184 and network 183 , the microscope focus would be varied to bring into focus the top of a dome 184 . The microscope focus would then be varied to bring into focus the surface of an adjacent portion of the network 183 . The difference in elevation for the dome and adjacent network would be recorded. This process would be repeated to provide 15 dome/network elevation differences. The 15 elevation differences are then averaged to provide the texture value of the surface. The difference in elevation between a dome and adjacent network surface is represented as E in FIG. 5 .
Caliper
The caliper of a single or multiple ply sample is a measurement of thickness under a prescribed loading. The caliper of a ply is measured using the following procedure: A dial indicator is used to measure the thickness of the sample under a compressive loading of 95 grams per square inch provided by a foot having a 2 inch diameter. The caliper is reported as the average of at least 8 such measurements.
Basis Weight
The basis weight is a measure of the weight per unit area of a sample. The basis weight of a sample is measured using the following procedure. A total of eight plies of 4 inch by 4 inch square of the sample are weighed, to provide a weight per 128 square inches of the substrate (4×4×8). This weight per 128 square inches is then converted to units of pounds per 3000 square feet. The basis weight is reported as an average of 4 such measurements.
Macro-Density
The macro-density is the basis weight of a sample divided by its caliper.
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A multiple ply tissue paper structure is disclosed. The multiple ply tissue paper has plies having different texture values. In one embodiment, the multiple ply tissue paper has two plies having different calipers and macrodensities. In another embodiment, the multiple ply tissue paper has three plies, including a relatively untextured ply disposed between two relatively highly textured plies.
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This invention was made with Government support under contract F29601-85C-0107 awarded by the Department of the Air Force. The Government has certain rights in this invention.
BACKGROUND OF THE INVENTION
The present invention relates to magnetic bearings and, more particularly, to precise positioning of the air gaps between relatively movable parts in such bearings.
Magnetic bearings are a preferred bearing used where frictionless, longlife support is needed. The absence of friction in a magnetic bearing allows significant improvement in performance of any precision servo system, such as used in space sensor gimbal suspensions and reaction wheels for spacecraft attitude control, where the combination of better control system performance plus long life are much sought after parameters. Other uses include long life spindle bearings and machine shop applications.
Three commercially available proximity sensors include the Schaevtz variable inductance sensor, the Kaman eddy current sensor, and the Bently Nevada eddy current sensor. All these devices are temperature sensitive, and the eddy current type is particularly so. All depend on use in matched pairs to measure displacement differentially, thus to achieve modest temperature insensitivity over a limited range. The long term null stability of all these devices depends on other reactive circuit elements in an alternating current bridge circuit.
In a magnetic bearing application, a proximity sensor is used to control the radial clearance between the fixed and moving member via a servo system. If the proximity sensor null drifts, for example as a function of temperature, the bearing ceases to function as a friction free device and may even destroy itself due to contact between the stationary and moving members.
SUMMARY OF THE INVENTION
These and other considerations are successfully addressed in the present invention by maintaining a precisely dimensioned gap between relatively movable surfaces, sensing the dimension of the gap, comparing the gap dimension with a reference dimension, and conforming the gap dimension to the reference dimension.
Specifically, the device embodied by the present invention is an audio frequency transformer with two parallel magnetic circuits formed by an F-shaped core, defined by a supporting leg and center and upper legs extending from the supporting leg, and a mating bar core. The ends of the supporting leg and the bar core are spaced from, and form a pair of air gaps in series with an adjacently positioned surface of a target. The center of the F shaped core is slightly longer than the upper leg so that, when the bar core is clamped in place, an air gap is formed between the bar core and the upper leg of the F-shaped core. This gap defines a reference air gap and, with the clamped together bar and F-shaped core, forms a closed magnetic path which defines a reference magnetic circuit. A second closed magnetic circuit is formed by ends of the supporting F-shaped core leg and bar core, the target, and the serially positioned pair of air gaps therebetween. The spacing of the material of the target to the exposed ends is the quantity measured by the device in the form of an electrical output signal.
To implement this measurement, a primary winding is placed on the central leg of the F-shaped core, and a secondary winding is placed on the bar core in both first and second magnetic circuits. The primary winding is excited by connecting it to an audio frequency power source causing alternating flux to flow in the parallel magnetic circuits and to induce voltage in the two secondary windings. The two secondary windings are connected in such a way that a voltage null is produced when the reference air gap and the pair of air gaps in series are equal in length. Thus, the output signal amplitude of the device is a measure of the difference of the target and reference air gap dimensions, and the polarity of the signal indicates whether the reference air gap is larger or smaller than the target air gap.
The output voltage null is produced when the reluctance (or resistance to flow of magnetic flux) in the two parallel magnetic circuits is equal. Since the reluctance of the air gaps is many times larger than that of the core, the device is essentially an air gap matching sensor. By making the magnetic materials of the F-shaped core and the bar core the same, by making the magnetic path lengths approximately the same, by making the permeability of the magnetic material high over the desired temperature range, and by matching the temperature coefficients of the sensor housing and the core, the differential reluctance of the two parallel paths is inherently insensitive to changes in temperature. Accordingly, the sensor null displacement becomes almost solely determined by the condition where the clearance between the moving and the fixed parts is equal to the reference gap.
If the device is used to sense the clearance between the stationary and moving members of a magnetic bearing, the current in the winding of the bearing electromagnet is controlled by feedback from the proximity sensor to precisely levitate the moving member relative to the fixed member with a clearance equal to the air gap installed in the sensor.
Several advantages are derived from this arrangement. The clearance gap between the bearing components in a magnetic bearing can be precisely controlled in a stable manner without the necessity for physical contact. Long term null stability is assured by the inherent temperature insensitivity of the device allowing long term usage without a requirement for periodic adjustment or alternatively direct usage in a highly variable temperature environment with little variation in the controlled clearance.
Other aims and advantages, as well as a more complete understanding of the present invention, will appear from the following explanation of exemplary embodiments and the accompanying drawings thereof.
DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 7 describe the laboratory model employed to prove the concept of the present invention, by using an actual proximity sensor to measure the clearance of a magnetic bearing and comparing the results to the performance predicted by analysis. The model simulates the clearance gap geometry of a magnetic bearing where the radial clearance between the stationary and moving bearing elements were varied manually with a lead screw and measured by an electronic micrometer. The proximity sensor was mounted on a flat machined outer cylindrical surface of the simulated magnetic bearing stationary member. Magnetic plugs were installed to extend the magnetic circuit of the sensor through the non-magnetic cylindrical wall. A target ring of magnetic material required by the proximity sensor was installed in a slot machined into the cylindrical surface of the simulated magnetic bearing moving member. A plot of the electronic micrometer reading versus the electrical output of the proximity sensor, as the radial clearance was varied, mechanically produced the nearly linear calibration characteristic of the sensor shown in FIG. 5. This test set up accurately simulated the air gap geometry of a develop-mentally produced magnetic bearing, shown in FIGS. 6 and 7.
FIG. 1 is a schematic diagram showing two pairs of sensors in their orthogonal mechanical relationship on the simulated magnetic bearing assembly as well as the manual clearance control and electronic micrometer measurement system. FIG. 1 also shows the electronic components of the proximity sensor system that are located remote from the bearing assembly.
FIG. 2 is an exploded view of the simulated magnetic bearing assembly showing the manual lead screw air gap manipulation system and the location of the four proximity sensors.
FIG. 3 is a schematic view showing the components making up the proximity sensor and their relationship to the magnetic bearing assembly which is provided with a flat mounting surface for the sensor, magnetic cylinder wall feedthrough plugs, and a magnetic target ring on the piston.
FIGS. 4a and 4b show the circuit schematic of the proximity sensor signal conditioning electronics for one pair of differentially positioned sensors. The sensors are shown in their electrical equivalent circuit form.
FIG. 5 depicts a measured calibration characteristic of the proximity sensor using the simulated magnetic bearing test fixture of FIG. 2 to make the measurements. The data is plotted as piston/cylinder displacement from center, measured by the electrical micrometer versus dc output of the signal conditioning electronics.
FIG. 6 illustrates a cryocooler pump assembly where the piston is levitated by the magnetic bearing system in the radial clearance zone of the stationary cylinder. Two active type magnetic bearings are mounted on the stationary cylinder, and target iron rings are provided on the moving piston to complete the magnetic circuit of the magnetic bearings. Ferrite target rings are provided in slots on the piston assembly as the proximity sensor magnetic targets. Two pairs of proximity sensors are installed for each magnetic bearing; the sensors are mounted with their sensitive axes arrayed orthogonally in a plane normal to the cylinder axes and outboard from the center of force of each magnetic bearing.
FIG. 7 is a schematic view of the active type magnetic bearing used in the assembly of FIG. 6. This type of magnetic bearing has four poles, with four electromagnets wound on the pole pieces, four samarium cobolt permanent magnets are placed between the poles. All flux paths are closed via the clearance gaps and the magnetic target ring on the piston.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The simulated magnetic bearing fixture of FIGS. 1 and 2 comprises a fixed piston subassembly 10 surrounded by a movable cylinder 12. As shown in FIG. 2, piston 10 is secured to a frame 11 which is bolted to a two-axis micro-manipulator which moves the cylinder in radial translation relative to the piston with lead screws along quadrature axes. In an engineered bearing, such as shown in FIGS. 6 and 7, piston 10 is the moving member, and cylinder 12 is attached to fixed structure. This reverse arrangement was provided for convenience in making the desired manual adjustments and measurements. Piston 10 was placed within cylinder 12 so that their respective surfaces 14 and 16 were spaced from one another to provide a gap 18 (see FIG. 1) having a dimension designated by arrows 20. While shown in the drawings to have an appreciable dimension, gap 18 is exceedingly small, usually a few thousands of an inch or less than a millimeter in dimension. To maintain the gap of uniform annual dimension sufficient to prevent touching of surfaces 14 and 16, it is necessary to adjust the relative positions of the piston and the cylinder, unless the objective is simply to measure the clearance.
The present invention effects such adjustment by placing four proximity sensors, denoted as sensor pair 22a and 22b and sensor pair 23a and 23b, orthogonally about movable cylinder 12 in order to detect the dimensions of gap 18. Movement of cylinder 12 with respect to piston 10 is effected by a pair of micrometer screws in the directions represented by arrows 24. In FIG. 2, one of the micrometers, rather than its direction of movement, is also designated by indicium 24. These micrometer movements are opposed by a bias force in the directions denoted by arrows 26, such bias being effected, for example, by stiff springs. The amount of displacement of cylinder 12 is sensed and quantified by a pair of electronic micrometers 28 of conventional construction, whose output signals are displayed in a readout 30. For laboratory purposes, micrometer screws 24 are manually manipulated; in the engineered model, these movements are automatically made by a servo loop in response to measurements of the dimension of gap 18, as compared to a reference gap.
Whether the adjustments in gap 18 are made manually or automatically, the sensing thereof is obtained by novel concepts embodied in proximity sensors 22. One such sensor is depicted in FIGS. 2 and 3 and includes a magnetic assembly 32 provided with a F-shaped core 34 and a bar core 36 having, as shown in FIG. 3, upper and lower portions 36a and 36b. Both cores are fabricated preferably using laminations of magnetic steel.
As best shown in FIG. 3, F-shaped core 34 includes a supporting leg 38, having upper and lower portions 38a and 38b, and a pair of shorter and longer legs 40 and 42 which extend generally perpendicularly from supporting leg 38. Leg 42 also has a cross-sectional area double that of supporting leg 38, shorter leg 40 and bar core 36, because the flux density is twice as high in the core leg which is common to both parallel circuits. Bar core 36 is forced into intimate contact at a bond 43 to the free end of longer leg 42 by the clamping action of the three piece housing. Because bar core 36 and supporting leg 38 of F-shaped core 34 are held parallel to one another by the housing, a gap 44 having a dimension denoted by arrowheads 46 extends between an end 48 on shorter leg 40 and a side surface 50 on bar core 36. Gap 44 has a fixed dimension and, therefore, can be used as a reference dimension extending between facing arrows 46. The core is held in place by slots in the housing, to guarantee the referenced air gap dimension. Ends 52 and 54 respectively of supporting leg 38 and bar core 36 are secured to pole pieces 56 which terminate at surface 16 of cylinder 12.
A primary coil 58 is wound about longer leg 42 and is energized by an alternating current source 60 to provide a source of magnetomotive force which causes magnetic flux flow in two parallel paths. One path moves from longer leg 42 to upper portion 36a, across reference gap 44, through shorter leg 40, upper portion 38a and back to leg 42. The second path moves from leg 42 to lower portion 36b, through pole piece 56, across gap 18, through a magnetic target ring installed on piston 10, back across gap 18, through the other pole piece 56, lower portion 38b and back to leg 42. As stated above, because leg 42 is common to both paths, it is required that its cross sectional area be twice as large as the area of the other core elements in the parallel paths. A pair of secondary coils 62 and 64 are wound about bar core 36 respectively on bar core portions 36a and 36b and extend from either side of longer leg 42. Voltage is induced in the two secondary windings which is proportional to the number of turns and the rate of change of flux in the magnetic path containing the section of the bar core on which the secondary coil is wound. The secondary coils are coupled by connecting wire 66, causing the two secondaries to be connected in phase opposition. This connection causes the two secondary induced voltages to be subtracted resulting in a voltage null output when the flux flowing in the parallel magnetic flux paths through gap 18 and gap 44 are equal. Because gap 44 has a fixed reference dimension, secondary coil 62 is sometimes also referred to as a reference coil. In a like manner, because gap 18 is variable and its dimension between double headed arrows 20 must be sensed as to any changes in its dimension, secondary coil 64 is sometimes referred to as a sense coil.
As shown in FIG. 2, magnetic assembly 32 is housed within a casing 70 which is secured to cylinder 12. Casing 70 has internal slots 71 for aligning the F-shaped and bar cores 34 and 36 of the transformer in a manner assuring the proper reference air gap dimension.
As shown in FIG. 1, the alternating current (ac) output voltage of the pair of proximity sensors 22a and 22b is coupled to a bridge balance circuit 72, and the pair of proximity sensors 23a and 23b is coupled to a second bridge balance circuit 74. Circuits 72 and 74 are coupled to respective integrated circuit amplifiers 76, and the outputs therefrom are fed into a transformer type summing circuit 78 for subtracting the amplified signals from bridge circuits 72 and 74. The signal output from summing device 78 is forwarded to a phase detector 80 which rectifies and filters the alternating current input. The direct current (dc) output of the phase detector is phase sensitive, i.e., the direct current magnitude is proportional to the difference in the dimension of gap 18 with respect to that of gap 44. The direct current polarity indicates that gap 44 is larger or smaller than gap 18. The output of phase detector 80 is fed to a low pass direct current amplifier 82 and thence to displacement devices 84 or a viewer 86. For laboratory purposes, a viewer 86 was used so that micrometer screws 24 could be manually turned. For a fully automated arrangement, displacement devices 84 are coupled directly to cylinder 12 or its equivalent for movement thereof. Alternatively, if piston 10 is the movable element, displacement devices 84 would be coupled to magnetic bearings for adjusting the position of piston 10 within cylinder 12.
The corresponding wiring diagram for sensors 22a and 22b, bridge balance circuits 72 and 74, voltage amplifiers 76, summing circuit 78, phase detector 80, and low-pass filter 82 is shown in FIGS. 4a and 4b.
FIG. 5 illustrates the dc voltage output from low-pass filter amplifier 82 plotted versus radial displacement induced by the manual controls. This is the proximity sensor calibration characteristic.
In operation, secondary windings 62 and 64, due to their locations on bar core 36, sense the alternating current flux flowing in their respective parallel magnetic paths through fixed gap 44 and variable gap 18. The alternating current voltage output is a phase sensitive indication of the variable gap displacement error relative to the reference air gap, and an output voltage null through wire 68 occurs when the variable and fixed air gaps are equally dimensioned. When the dimensions are not equal, the output voltage reflects the difference and the circuitry provides the necessary phase sensitive output information in order to sufficiently move gap 18 to equalize its dimension with that of gap 44. Because the reluctance of the two magnetic paths is primarily a function of the dimensions of gaps 18 and 44, the output null indication is inherently temperature insensitive.
Specifically, the gap matching proximity sensor described above is designed to be used as the feedback element in a servo which controls the displacement of a moving member relative to a fixed structure. The size of the reference gap nominally determines the mechanical reference for the control of displacement in the system; that is, the sensor output is a phase sensitive servo error signal whose magnitude is proportional to the clearance error and whose phase indicates the direction the moving member must be displaced to correct the error. In this mechanization, null stability is the important sensor parameter since it affects the clearance error directly. Sensor scale factor and linearity is of lessor importance because this parameter only affects servo loop gain. With reference to FIG. 3, if the length of the core in the reference and sense magnetic paths are reasonably similar and the core permeability is high (greater than 100) over the desired temperature range and the sensor housing temperature coefficient matches that of the core, the differential reluctance of the two parallel magnetic paths is inherently temperature insensitive. This being true, the sensor null displacement becomes essentially determined by the condition where the clearance between the moving member and the fixed structure is equal to one half the reference air gap. There will be a variation in scale factor (volts rms/inch) due to temperature determined by the coefficient of expansion of the core material which causes the variable air gap to change. This effect can be minimized by the careful choice of sensor core material and/or by inversely varying the servo loop gain as a function of core temperature. The excitation frequency of primary coil 58 can vary from 1-40 kHz. The null stability of the device can be made very high due to the alternating current excitation which allows the use of high drift free ac amplification ahead of the phase detector circuit.
More specifically, the arrangement illustrated in FIGS. 1-3 comprise a transformer circuit with two parallel magnetic paths formed by a two piece magnetic core and a ferromagnetic target on the moving member. When two piece core 34 and 36 is assembled as shown in FIGS. 1 and 2, an upper magnetic or reference circuit with fixed air gap 44 in series is formed. The lower magnetic or sensor circuit is closed across the open ends of the assembled two piece core by two air gaps 18 in series with the target iron on moving member 10. The primary or excitation winding 58 is wound on central or longer core leg 36. It must have double the area of core legs 36, 38, and 40 in order to keep the flux density uniform in the magnetic material of the core. The primary winding is excited by alternating current voltage source 60 which can range from 1 to about 40 kHz. The primary winding serves as a source of MMF which causes magnetic flux to flow in the two parallel paths as shown in Equation (1). ##EQU1## where φ is the magnetic flux in Maxwells,
R is the circuit reluctance in Gilberts,
MMF is the magnetomotive force in oersteds,
μ is the core permeability,
A is area in square centimeters
l is length in centimeters,
Ω is the excitation frequency in Rad/Sec, subscript "c" refers to the magnetic core, and "g" refers to the air gaps. The voltage induced in each secondary winding 62 and 64 wound on each of core leg portions 36a and 36b is a function of the rate of change of flux in one of the magnetic paths times the number of secondary turns, i.e., ##EQU2##
The self inductance of the primary winding is: ##EQU3## where R T is the equivalent series reluctance of the two parallel magnetic paths, and subscripts 1 and 2 refer to the reference and sense magnetic paths respectively. The inductive reactance in ohms of the primary winding is: ##EQU4## and the primary magnetizing current in amperes is: ##EQU5## where f is the frequency in Hz.
Combining equations (1) and (2) yields the following expression for the voltage induced in the two secondary windings: ##EQU6## If the two secondaries are connected in phase opposition, the proximity sensor open circuit voltage output is: ##EQU7##
The proximity sensor which was designed, fabricated, and tested is shown in FIGS. 2 and 3. The sensor electronic signal processing system required to produce an electrical signal proportional to the differential air gap displacement is shown in FIGS. 4a and 4b. The proximity sensor package is composed of four subassemblies. The sensor subassembly with the three coils installed on the two piece core is clamped rigidly in the main housing when the side piece and the top piece are screwed into place. The core is constructed using Carpenter HyMu 80 magnetic steel with laminations 0.007 inches in thickness. The housing material was fabricated using 174PH stainless steel which has a temperature coefficient which is very close to that of the magnetic steel over a temperature range of 200° C. to -200° C. This allows the sensor to be operated over this temperature range in a rigidly clamped condition without distorting the core. The device is operable in a shock and vibration environment without response to microphonics due to the clamped design feature.
Eight proximity sensors of the type described were fabricated and tested. The design parameters chosen for the test articles are listed below:
(1) Excitation--10 volts RMS 10 KHz,
(2) Primary winding--300 turns #28 wire,
(3) Secondary windings--600 turns #40 wire,
(4) Mean length of core--3.27 cm,
(5) Reference air gap--0.03 cm,
(6) Sense air gap--0.23 cm,
(7) Area of all air gaps--0.64 cm,
(8) Area of core material--0.61 cm,
(9) Core flux density--1170 gauss rms,
(10) Magnetizing current--0.0095 Amperes (peak),
(11) Calculated scale factor--3.4 Volts RMS/Mil.
Ferrite targets and pole pieces were used in the following tests as a matter of convenience. This choice minimized eddy current effects without having to machine laminated steel in the fabrication of the test fixtures. The electronic circuit shown in FIGS. 4a and 4b was also designed to test two sensors in a back-to-back configuration. A bridge balance circuit was provided to adjust the proximity sensor null at the desired air gap. The phase sensitive ac output of the bridge was amplified and then phase detected and filtered to produce a dc output voltage. The dc output voltage was measured at
various points in the desired displacement range (0 to ±0.006 inches).
FIG. 2 shows the proximity sensor test set up used to calibrate the eight proximity sensors which were constructed and evaluated. This test set up simulates the proximity sensing system for a pair of magnetic bearings (see FIG. 6) which levitates a piston in a cylinder. Four sensors were installed on flat surfaces machined on the outside of the simulated cylinder. Ferrite pole pieces project through, from the sensor mounting surface to the inside of the cylinder. A 0.25 inch (0.64 mm) hole was drilled in the space between pole pieces and filled with epoxy. The flat surface and the inside of the cylinder were lapped to make the pole pieces conform to the terminating surface. The sensors were fastened to the cylinder flat with four 4-40 machine screws fitting tapped holes in the cylinder wall. The simulated piston was provided with a ferrite target ring to complete the sensing magnetic circuit. The test fixture was used to move the simulated piston in two orthogonal directions aligned along the sensitive axes of the orthogonally mounted sensor pairs. As shown, a two axis micromanipulator provided the desired orthogonal motion over a range of ±0.0035 inch (0.0089 mm) which simulated the piston/cylinder radial clearance. The cylinder in this test set up was fixed to stationary structure. An electronic micrometer was used to precisely measure the piston displacement from the centered position. In this test procedure, the piston was moved in first the "x" direction and then the "y" direction; the cross talk was measured for each calibration point taken along the sensitive axis. In preparation for these tests, each sensor was nulled independently at the mechanical center position. Then the scale factor was adjusted by varying the ac amplifier gain to be 2.0 volts dc at ±0.002 inches (0.005 mm) displacement from center. Two sets of four proximity sensors were tested in this manner. One set is identified as that for the forward magnetic bearing on the test data sheets and the other as that for an aft magnetic bearing. These designations indicate the locations on the productized magnetic bearing assembly on which the eight proximity sensors were installed. FIG. 5 shows the calibration of one of the sensor pairs tested prior to installation in the magnetic bearing assembly of FIG. 6. The remaining seven calibration curves were closely similar to that of FIG. 5. The test conditions and cross talk measurements for one of the sensor pairs are shown on the calibration chart; other sensor pairs were substantially the same, as shown in the following tables, in which CCW and CW respectively mean counterclockwise and clockwise:
TABLE I______________________________________Deflection Sensitive Axis Cross Axisfrom Center Volts dc Millivolts, dcInches CCW CW CCW CW______________________________________0- -.0092 -.0086 +9.2 +10.0.0005 +.466 -.463 -7.6 +11.2.0010 +.912 +.927 +6.0 +12.5.0015 +1.436 -1.431 +4.3 +14.0.0020 +2.020 2.011 +2.0 +15.0.0025 +2.667 -2.667 +0.3 +16.2.0030 +3.526 -3.546 -1.8 +16.8.0035 +4.438 -4.860 -2.7 +18.0______________________________________
TABLE II______________________________________Deflection Sensitive Axis Cross Axisfrom Center Volts dc Millivolts, dcInches CCW CW CCW CW______________________________________0- +.0031 +.0086 -8.7 -7.9.0005 +.436 -.440 -8.2 -8.5.0010 +.892 -.910 -7.3 -9.0.0015 -1.410 -1.441 -6.7 -8.1.0020 -2.003 -2.002 -5.1 -7.7.0025 +2.762 -2.701 -4.9 -7.2.0030 -3.744 -3.795 -2.9 -6.7.0035 +5.024 -5.478 -2.1 -5.2______________________________________
TABLE III______________________________________Deflection Sensitive Axis Cross Axisfrom Center Volts dc Millivolts, dcInches CCW CW CCW CW______________________________________0- +.0032 -- +8.2 +8.1.0005 +.449 -.448 +10.2 +5.9.0010 +.911 -.912 +11.9 +4.3.0015 +1.427 -1.418 +14.6 +3.7.0020 +2.006 -1.985 +16.0 +1.3.0025 +2.698 -3.58 +17.3 -1.1.0030 +3.547 -3.456 +18.5 -3.3.0035 +4.661 -4.596 +20.0 -6.5.0040 +6.286 -6.423 +22.0 -8.4______________________________________
TABLE IV______________________________________Deflection Sensitive Axis Cross Axisfrom Center Volts dc Millivolts, dcInches CCW CW CCW CW______________________________________0- -.00314 -.00147 -- --.0005 +.455 -.444 -6.2 -3.1.0010 +.907 -.910 -6.4 -2.9.0015 +1.446 -1.420 -5.6 -1.9.0020 +2.063 -2.042 -4.6 -1.0.0025 +2.815 -2.777 -3.0 -0.5.0030 +3.819 -3.874 -1.9 +1.9.0035 -5.254 -5.791 +.2 +3.6______________________________________
The measured data shows good gain slope symmetry on either side of the mechanical center and the data taken with four sensor pairs showed remarkable similarity.
Referring now to FIGS. 6 and 7, an engineered version of the present invention includes a translatable shaft or displacer 90 which is supported by a pair of magnetic bearings 92 whose cross section is shown in FIG. 7. Sensors 94, similar to those illustrated in FIGS. 1-3 are placed next to the bearings. Displacer 90 is translated by a motor 96. An axial sensor 98 is positioned at one end of shaft 90 and senses its axial position; this information is used as feedback in a translation control servo loop. The magnetic bearings support the piston in the radial direction so that the translation motion above is frictionless. Ferromagnetic rings 99 are bonded to shaft 90 and placed adjacent to bearings 92 and sensors 94 to ensure good flux paths for the magnetic bearings and the proximity sensors respectively.
As shown in FIG. 7, each bearing comprises four sets of permanent magnets 100, for example, of a samarium-cobalt composition, to which magnetic bearing pole pieces 102 are bonded. Placed between each magnetic and pole piece pair are four orthogonally placed magnetic bearing electromagnet control coils 104a and 104b wound about laminated pole pieces 106. Pole pieces 106 terminate in curved surfaces 108 which are positioned closely to periphery 110 and a ring 99 (see FIG. 6) of magnetic material on shaft 90. Coil pairs 104a and 104b and their respective wiring are connected as shown so that one pair of coils 104a is interconnected and terminate at termini 112 and the other pair of coils 104b terminates at termini 114.
Utilizing the circuitry illustrated in FIGS. 4a and 4b, dc error signals from one or the other pair of sensors, as denoted by boxes 116a and 116b are fed to servo gain and compensation circuits 118a and 118b which, in turn, are forwarded to current drivers 120a and 120b. The current drivers with signal inputs from the respective servo gain and compensation circuits are coupled to one of termini 112 and 114 to drive current through their respective electromagnetic coils 104a and 104b, thus causing shaft 90 to be displaced radially between opposing pairs of pole pieces 108. This radial motion of shaft 90 within its bearings 92 is sensed by proximity sensors 94 and used to close a levitation servo loop so that the gap dimensions under the opposing pole pieces are maintained equal.
Although the invention has been described with respect to particular embodiments thereof, it should be realized that various changes and modifications may be made therein without departing from the spirit and scope of the invention.
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A pricisely dimensioned gap between relatively movable surfaces (14,16) is maintained in a magnetic bearing by use of proximity sensors (22a, 22b, 23a, 23b). Each sensor includes a magnetic assembly (32) having a bar core (36) secured to a middle leg (42) of an F-shaped core (34). The bar core and the vertical leg (38) of the F-shaped core have approximately equal lengths. The magnetic assembly is fixed with respect to one of the surfaces (16) and is so positioned that the end (52,54) of the F-core vertical leg (38) and the bar core are spaced from the other surface (14) to provide the variable gap dimension. The end (48) of the suppermost leg (40) of the F-shaped core is spaced from the bar core and provides a reference dimension (44). Any differences in the variable gap and reference dimensions are furnished to a driver (27, 72-86) which moves one surface with respect to the other until the gap dimension corresponds to the reference dimension. By making the magnetic materials of the F-core and the bar core the same, the magnetic path lengths approximately the same and the permeability of the magnetic material high over the desired temperature range, by matching the sensor housing temperature coefficient with that of the core, the differential reluctance of the two parallel paths is mode inherently insensitive to temperature changes. Accordingly, the sensor null displacement becomes solely determined by the condition where the clearance between the moving and fixed parts is equal to the reference gap.
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DISCUSSION OF THE PRIOR ART
Various jigs and clamps are available to hold such picture frame pieces together. However, they involve tedious manipulation not only of the frame pieces, but also require simultaneous adjustments and tightening of the clamps. This greatly hampers production since the mechanism must be released from the nailed pieces, then the new pieces reinserted, and while trying to hold the pieces in proper relation, the clamps must be tightened. This is frustrating and time consuming and requires experience and dexterity.
SUMMARY OF THE INVENTION
This invention is directed to providing a mechanism for clamping work pieces such as picture frames in a desired angle in such manner that the mitered surfaces meet in a perfectly aligned position and are squeezed together.
The invention has for its main objective to provide a simple and effective clamping mechanism incorporating all of the actuating components in a simplified electrically operated linkage without the necessity of providing auxiliary power such as air compressors and the like.
The invention embodies a plurality of solenoids arranged in a toggle which are excited through a foot switch, the toggle arrangement providing a simple but effective mechanism for temporarily locking the clamping jaws tightly with the frame members during nailing thereof.
A further object is to provide a novel calibration switch in the power circuit to prevent accidental activation of the clamping jaws, particularly during adjustment thereof to different widths of frames.
These and other objects inherent in and encompassed by the invention will become more readily apparent from the specification and the drawings, wherein:
FIG. 1 is a top perspective view of my novel mechanism;
FIG. 2 is an enlarged top plan view with parts broken away and in section of the jaw assembly of the mechanism;
FIG. 2a is a top view of the jaw assembly;
FIG. 3 is a cross-sectional view on line 3--3 of FIG. 2;
FIG. 4 is a longitudinal sectional view taken substantially on line 4--4 of FIG. 1, showing the parts with the jaws in unclamped position;
FIG. 4a is a side elevational view of the mechanism shown partly in section on line 4--4;
FIG. 4b is a cross-sectional view on line 4--4 of FIG. 1, showing the parts with the jaws in clamped position;
FIG. 5 is a diagramatic view of the electric circuit;
FIG. 6 is a cross-section taken on line 6--6 of FIG. 1 with the calibration switch in off position.
FIG. 7 is a perspective view partly broken away showing the switch and cam control mechanism; and
FIG. 8 is a cross-section on line 8--8 of FIG. 6.
DESCRIPTION OF THE INVENTION
The novel frame clamp apparatus is preferably a portable apparatus which includes a casing or housing 2 having a rectangular top wall or table 3 and removably interconnected side walls 4, and if desired a bottom wall (now shown).
The top wall is provided with a longitudinal guide slot 5 in which there is slidably positioned a complimentary quadrilateral guide block 6 having vertical sides 7,7 in close-fitting slidable engagement with the side edges 8,8 (FIG. 3) of the slot 5.
The block 6 has a pair of upstanding locating pins 9,10 positioned at diagonally opposite corners 11,12 thereof projecting upwardly from the horizontal flat top surface 13 of the block.
The block 6 projects above the plane 14 (FIG. 3) of the top wall or table 3 of the mechanism, and with its top surface 13 seats against a flat underface 15 of a mounting plate 16 which is somewhat trapezoidal in top plane and has a short front edge 17, a wide rear or base edge 18, and a pair of side edges 19 and 20 which converge toward and join the opposite ends of the front edge 17. Preferably the rear corners of the side edges 19 and 20 are sheared off and the ends of the base edge 18 are connected to the rear ends of the side edges 19 and 20 by lateral edges 22,23 which diverge forwardly and converge with the respective side edges and merge therewith to form the apices 25,25 which are positioned intermediate the front and rear edges of the mounting or force transmitting plate 16.
At these apices there are provided vertical pins 28,30 which depend below the bottom 15 of the mounting plate and extend into apertures 33,34 in the outer lateral end portions of respective jaw elements 35,35 which are cantilevered from the pins 28,30 to pivot about vertical axes as hereinafter explained. Each jaw is a flat element having a diagonal serrated side edge 38, a forward edge 39 generally paralleling front edge 17 of the mounting plate, an inner side edge 40 which is notched at 41 to accommodate the adjacent front corner 12 or 42 (FIG. 2) of the mounting block, and a rear edge 44 generally parallel with the front edge and a rear diagonal lateral edge 45 converging laterally outwardly toward the rear end of the side edge 38, and joined therewith by a cutoff edge 46. Thus, it will be seen that upon the transmission of force from the slide block 6 to the mounting or transmission plate 16, the respective jaws will pivot about the respective pins 28,30 toward each other at their front ends after engaging the inner edge 50 of the frame pieces 52,53 which are arranged in converging relation and abut each other along their mitered faces 55a,55a, the outer edges 54,55 of the pieces 52,53 seating against opposing faces 56,57 of guides or stationary jaw elements 58,59, which converge at a right angle with each other and being secured as by set or securing screws 60,61 to table 3. Each jaw element may have a longitudinally elongate slot 64 therein for longitudinal adjustment with reference to the securing screws 60,61 extending therethrough.
It will be readily appreciated that the jaw elements 35,36 are biased apart at their forward ends by means of an elastomer spring 65 such as rubber or neaprene being interposed and compressed therebetween, the ends 66,67 of the spring being pocketed at 68,69 in bores in the opposing inner edges 40 of the jaws. The spreading movement, by one jaw pivoting clockwise and the other counterclockwise is limited by stops 71,72 which are preferably press fitted into apertures in the jaws adjacent to their rear edges in proximity to their respective inner edges, the pins 71,72 extending upwardly with enlarged openings 73,74 in the mounting plate adjacent to its rear edge.
Thus, immediately prior to the jaws 35,36 engaging the rear edges of the frames which have been butted together at their mitered ends 35,36 dispose themselves against the rear edges of the frame pieces in such manner that their serrated edges 38 diverge away from the rear edge of the adjacent frame edge in a direction away from the corner 75 formed by the frame pieces toward the axis of pivot of the jaw. Thus, each jaw has a somewhat point contact at 76,76 (FIG. 2) of its lateral edge with the respective frame piece in the region of the juncture of the side edge with the front edge of the jaw.
As force is applied against the jaws 35,36 they swing about pins 28,30 and advance toward each other at their forward ends, compressing the spring therebetween and concurrently urging the respective frame pieces toward each other along the stationary jaws and tightly engaging the mitered ends 55a,55a with each other, whereupon the operator hammers in the securing nails 77,77 (FIG. 1). It will be noted that the guide block as well as the mounting plate are provided with vertically aligned holes 78,79 through which extends a securing bolt 80 which is threaded at its free upper end as at 81 upon which there is threaded a wing nut 84 which is adapted to seat against the top side 85 of the mounting plate and tightly engage the bottom side of the plate with the top side of the block. The lower end of bolt 80 is provided with an eye block 86 which is vertically slidable in a guide slot 87 in the lower end of the guide block and open through the lower side thereof. The eye block 86 has a transverse horizontal aperture 87a therein which aligns with fore and aft extending apertures 88,89 in front and rear portions 90,91 of the guide block flanking the guide slot 87.
A push rod 92 extends through apertures 87,88 and 89 and is tightly held to the guide block upon the wing nut being tightened. This mechanism provides an easy adjustment of the movable jaw assembly along the push rod within the longitudinal guide slot to accommodate frames of different widths.
The forward end 93 of the push rod is piloted in a horizontal pilot opening 94 provided in the front wall 4 of the housing. The rear end of the push rod is guided in a horizontal aperture 95 provided in a vertical lug 96, depending from the top wall of the housing at the inner end of the guide slot 5. The rear extremity 97 of the push rod is pivoted by a horizontally extending pin 98 to the elbow 99a of a bell crank lever 99 which has a rearwardly extending horizontal leg 100 provided at its distal end 101 with a roller 102 rotatable on a journal pin 103 on a generally horizontal axis, and guided between a pair of vertical opposing front and rear guide tracks 105,106 which depend from the top wall or table 3 of the housing.
The lower end of leg 107 of the lever arm 99 is provided with horizontal front and rear parallel pivots 110,112; the front pivot 110 is connected to the core 114 of a solenoid 115 and extends from a coil 116 thereof, which is mounted in a shell 117. The shell 117 is connected to a hinge arm 118, which is pivoted forwardly of the solenoid 115 on a horizontal pin 119 from the lower end 120 of an anchor 122 which at its upper end is suitably connected to the underside of the table 3, preferably by welding.
The rear pivot 112 is connected to the outer end of the core 124 of the rear solenoid 125, the core extending into the coil 126 which is mounted in a shell 127. The shell 127 is connected to arm 128 which is pivoted on horizontal pivot 129 therebehind from the lower end of anchor 130, which is formed as part of bracket 131 mounted beneath table 3 and which provides the rear guide track 106.
The front and rear solenoids are interconnected via the adjacent ends of the arms 118 and 128 by a tension spring 134 which biases the solenoids toward each other to a position aligning the pivots 110,112 in aligned position, said solenoids serving as a toggle linkage.
A combination control switch operator and manual cam assembly 135 (FIGS. 7 and 8) is provided comprising a horizontal cylindrical rod portion 136 which is journaled in aligned opening in laterally spaced depending flanges 138,139 of bracket 140 fastened to the underside of table 3. The inner end of said rod 136 has a tangentially extending cam element 140a which is adapted to ride upon the top of roller 102.
Inwardly of the inner end of the rod and cam element 141 there is provided on the rod a detent 142 which rides over the lobe 144 of a spring cam 145 to one side or the other thereof. The cam 145 is carried from the flange 138 of bracket 140. The extent of pivotal movement of rod 136 is limited by an adjusting screw 145 which is threaded through the table 3 in position for engagement with a radially extending stop 146 provided on rod 136. Rod 136 also has an actuating finger 147 thereon which is vertically aligned with a switch button 148 of cut-off switch 149 mounted on flange 139 of bracket 140.
The outer end of rod 131 is journaled at 150 from the adjacent side wall 4 of the housing and is connected to an operating handle 151 which parallels the adjacent side wall and is spaced outwardly thereof.
In operation, starting with the handle 151 being in "off" position as seen in phantom lines in FIGS. 4a and 8, and in full lines in FIGS. 6 and 7, the cam element 140 is swung down and presses upon the roller 102 swinging the lever 99 in a clockwise direction from the position of FIG. 4b to that shown in FIG. 4c. This shifts the jaw-actuating push rod 94 rearwardly to the right (FIGS. 4b, 4c) retracting the movable jaws 35,36 with its mounting and connecting assembly.
In this condition the mounting assembly, namely the block 6, plate 16, and locking screw mechanism 80 are adapted to be unlocked and the jaw assembly slid along the push rod and locked at an adjusted position defining sufficient space to accommodate easy insertion and withdrawal of the frame pieces to be nailed together.
Then the handle 151 is placed in "on" position (see FIGS. 1, 5, and 8). The equipment now is conditioned to be operated by a two-position foot switch 155 which in its released position closes switching contacts 156,157 (FIG. 5) connecting one line 158 of the supply source through the coil 116 solenoid 115 to line 159 of the supply source. The energized coil 116 draws the core 114 forwardly into the coil and moves the lever 99 from position 4b to 4c stretching the assist return spring 160 which is connected between core 124 of the rear solenoid and the upstanding portion 161 of arm 128, core 124 being extended and the pivots 110,112 being vertically offset from one another, the jaws being retracted.
When the foot switch 155 is depressed the contacts 162,163 are bridged or closed by switch element 164 and current then flows from power supply line 158 through line 165 through closed switch 149 through coil 126 of solenoid 125 and through the second line 159, it being understood that the main switch 170 in line 159 is closed. Upon energizing of the coil 126, the core 124 is retracted, the lever 99 assumes the position of FIG. 4b, the pivots 110,112 align and the rush rod 94 moving forwardly with the movable jaws clamps, the frames against the stationary jaws. Release of the font switch automatically retracts the jaws.
It will now be appreciated that a novel effective and fully operative mechanism has been disclosed in a preferred embodiment, and that various modification will become apparent within the scope of the appended claims.
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A novel holder for work pieces, particularly for holding picture frame pieces in which the adjoining mitered ends of the frame pieces are brought together. The inventive concept resides in providing a mechanism which permits primary adjustment of the jaws in such manner that the pieces are easy to insert and wherein as the last increment of movement of the jaws they tightly clamp the pieces and move them endwise toward each other in perfect alignment and after nailing; the mechanism also quickly releases the joined frame pieces because of the electrical toggle linkage employed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of displaying a knit fabric and stitched structure on a screen in a knit design system. More particularly this invention relates to a displaying method of a knit fabric and its structure which includes a plating stitch such that when planning the knitting process of the knitting machine in accordance with a knit design, one can easily recognize a knitting structure through a displayed image on the screen.
2. Description of the Prior Art
In designing this type of a knit fabric, a so-called knit fabric design system has sprung into wide use, by which a process for designing the knit fabric can be saved by displaying it on the screen of a display unit in various colors and further all the knit control information necessary to knit the designed knit fabric by a knitting machine can be automatically created (for example, Japanese Examined Patent Publication No. 3-21661, Japanese Unexamined Patent Publication No. 5-78960).
This system permits the finished design of a knit fabric to be easily observed by intuition and readily understood in such a manner that a type of a thread such as its color forming each stitch as a unit constituting a knit fabric is classified by a different color and displayed on the screen of a display unit as well as a type of the stitch based on the knitting method of each stitch is displayed on the screen by a different color. For example, when a type of a thread forming each stitch is discriminated and displayed, the designed color arrangement of a knit fabric can be understood at the first glance and when a type of each stitch is classified by color and displayed, how special stitches such as a cable stitch, a stitch with transfer of wales and the like are disposed in a knit fabric can be understood by intuition.
According to the above mentioned prior art, since a type of a thread is displayed by a single color corresponding to the type of the thread in each display area divided for each stitch, when a plating stitch is contained in a knit fabric, there cannot be avoided a problem that the designed color arrangement of the knit fabric cannot be correctly understood. Thus misunderstanding is liable to arise. The plating stitch forms a single stitch using two types of threads, but the designed color arrangement of a knit fabric is completely changed by which of the threads is positioned on the surface of the knit fabric depending upon a type of the stitch. However, the conventional knitting method is disadvantageous in that it cannot exhibit the difference of such a designed color arrangement.
SUMMARY OF THE INVENTION
An object of the present application is to provide a displaying method of knit fabric and stitched structure in a knit fabric design system for allowing the design of a knit fabric to be exhibited in an understandable form especially in a knit fabric containing a plating stitch by classifying the displayed area of each stitch to a ground yarn display area and a plating yarn display area.
A method of displaying a stitched structure of the present invention for achieving the above object when a type of a thread for each stitch of a knit fabric is displayed on the screen of a display unit as a stitched structure classified by a different color, such method comprises the steps of dividing the display area of each stitch into a ground yarn display area and an plating yarn display area as to a stitch composed of a plating stitch, allocating a ground yarn in one of the divided areas, and allocating an plating yarn in the other of the divided areas.
In the above display method, the ground yarn display area can be disposed to the lower portion of the display area and the plating yarn display area can be disposed to the upper portion of the display area.
Further, the area ratio of the respective divided areas can be changed in accordance with a type of a thread of the ground yarn and the plating yarn.
According to the above display method, since the display area of each stitch is divided into the ground yarn display area and the plating yarn display area, the ground yarn corresponding to the first side thread is displayed in one of the areas and the plating yarn is displayed in the other one of the areas. Thus the actual colored design of the knit fabric can be expressed with respect to the plating stitch taking the color of the plating yarn into consideration so that it can be easily understood.
It should be noted that the ground yarn referred to here is a thread to be fed through a preceding yarn carrier against two types of threads which form a single stitch and the plating yarn is a thread to be fed through a yarn carrier following the above yarn carrier feeding the ground yarn. Further, the corresponding relationship between the ground yarn, the plating yarn and the ground yarn display area and the plating yarn display area is such that when a plating stitch is knitted by the needle of a front bed, the ground yarn is caused to correspond to the ground yarn display area and the plating yarn is caused to correspond to the plating yarn display area. Whereas when the plating stitch is formed by the needle of a rear bed, they are caused to correspond to each other in a reverse fashion. However, it is supposed that a knitting machine at this case is a V-bed type flat knitting machine having a plurality of independently operable yarn carriers and front and rear needle beds.
It is preferable that the display area of each stitch is formed to a rectangle generally having a long side in the course direction and a short side in the wale direction and the plating yarn display area is formed by partitioning a portion of the display area by a straight line or a curved line and the remaining area is allocated to the ground yarn display area. At the time, the ground yarn display area and the plating yarn display area may be discriminated by displaying one or a plurality of figures in the ground yarn display area and the plating yarn display area, respectively, and changing a type of the figures in addition to that they are displayed by a different color depending upon a type of a thread of the ground yarn and the plating yarn. That is, the discrimination referred to in the present invention includes the discrimination of the display using same area and different figures.
Further, the plating yarn display area may be displayed by a one, two or more of horizontal lines or oblique lines displayed in the display area or a half-tone dot meshing composed of a number of dots entirely or partially dispersed in the display area. At the time, however, all the display areas except the plating yarn display area are caused to correspond to the ground yarn display area.
When the ground yarn display area is disposed in the lower portion of the display area and the plating yarn display area is disposed in the upper portion of the display area, the plating yarn display area is displayed to the upper portion of the ground yarn display area in each display area for each stitch, thus the fact that the ground yarn display area is the base of a color scheme can be properly expressed. However, the upper portion and the lower portion referred to here may arbitrarily classify each display area in such a manner, for example, that the position corresponding to the center of gravity of the ground yarn display area is located in the lower portion of the position corresponding to the center of gravity of the plating yarn display area i.e., the latter is located above the former in addition to the horizontally separated groups between the upper portion and the lower portion.
Further, although the area ratio of the ground yarn display area and the plating yarn display area may be suitably determined previously, it may be automatically or manually set so that it can be arbitrarily changed depending upon a type of a thread of the ground yarn and the plating yarn.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view showing the basic arrangement of an apparatus used to a stitched structure display method of the present invention;
FIG. 2 is a schematic view showing a stitch image of displayed on a display unit;
FIG. 3 is a flowchart explaining control operation;
FIG. 4A is a schematic view showing how a displaying area is divided, corresponding to a knit symbol A of FIG. 2;
FIG. 4B is another schematic view showing how a displaying area is divided, corresponding to a knit symbol B of FIG. 2;
FIG. 4C is still another schematic view showing how a displaying area is divided, corresponding to a knit symbol C in FIG. 2; and
FIG. 5 is a partial flowchart showing the changed portion of the control operation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, a method of displaying the stitched structure of the present invention will be described. In FIG. 1, a knit fabric design system 10 used in the stitched structure display method of the present invention processes data input from a data input unit 11 by an arithmetic processing unit 12 and outputs a processed result to a display unit 13.
More specifically, the data input unit 11 is composed of a single unit or a combination of two or more of, for example, a keyboard, a mouse, a joy stick, a scanner, a digitizer and the like and inputs various types of information as to the design of a knit fabric to the arithmetic processing unit 12. The arithmetic processing unit 12 is composed by the use of a known computer system or a workstation system and displays a type of a thread forming each stitch as a unit for constituting a knit fabric being designed as well as a type of a stitch in each stitch by classifying them by a different color on the screen of the display unit 13.
Further, the arithmetic processing unit 12 can automatically create a series of knitting control information D necessary to knit a knit fabric specified by the stitch images and output it to an external knitting machine M as a whole. Note, the knitting control information D may transmitted on-line as suitable electric signal data through a data bus line Mb for connecting the arithmetic processing unit 12 to the controller Ma of the knitting machine M. Further, it is also possible to record the information D once to a recording media such as a floppy disk or the like, set the recording media to the controller Ma of the knitting machine M and read out the information from the information media by the controller Ma.
A case that a type of a thread for forming each stitch as a unit of the knit fabric is displayed on the display unit 13 as a stitch image K will be described in FIG. 2 as an example. The stitch image K displays m courses of the knit fabric in a longitudinal direction and n wales of the knit fabric in a lateral direction and thus has mn pieces of display areas Kij (i=1, 2 . . . m, j=1, 2 . . . n). Therefore, when each of the display areas Kij is caused to correspond to each stitch of the knit fabric, the stitch image K can display a type of a thread forming each stitch by classifying it by a different color. Note that it is assumed that the arithmetic processing unit 12 can designate any arbitrary portion of the knit fabric and display the stitch image K on the screen of the display unit 13 in a size enlarged or reduced at a desired magnification.
Next, how the arithmetic processing unit 12 executes control operation will be described according to the flowchart of FIG. 3. However, it is assumed that information as to a type of a stitch based on a knitting method of each stitch and a type of a thread for forming each stitch is input and stored to the internal memory of the arithmetic processing unit 12 for each stitch constituting a knit fabric prior to the execution of the program shown in FIG. 3.
First, as to a specific stitch, information as to a type of a thread which forms the stitch is read out from the internal memory (step S1). Next, whether two or more types of threads are designated or not is determined, that is, whether the stitch is a plating stitch or not is determined (step S2). When the stitch is not the plating stitch, a color corresponding to the designated type of the thread (one type) is displayed over the entire display area Kij corresponding to the stitch in the stitch image K (step S3) and the same procedure is continued until the display of the types of the threads for all the stitches is completed (steps S3→S10→S1→S3).
Whereas, when it is determined at step S2 that two types of threads are designated and the stitch is the plating stitch, the corresponding display area Kij is divided into a ground yarn display area Ka and an plating yarn display area Kb as shown in FIG. 4A (step S4). At the time, however, the display area Kij may be divided into any arbitrary form so long as the position corresponding to the center of gravity of the ground yarn Ka is located to the lower portion of the display area Kij and the position corresponding to the center of gravity of the plating yarn Kb is located to the upper portion of the display area Kij.
Next, at step S5, it is determined whether the stitch is knitted by the needle of a front bed or not. Note, the determination at the time is carried out based on the information as to a type of a stitch based on the knitting method of each stitch.
When the stitch is knitted by the needle of the front bed, the ground yarn a is displayed in correspondence to the ground yarn display area Ka (step 16) and then the plating yarn b is displayed in correspondence to the plating yarn display area Kb (step S7). Whereas, when it is determined that the stitch is knitted by the needle of a rear bed (step S5), the plating yarn b is caused to correspond to the ground yarn display area Ka (step S8) and the ground yarn a is caused to correspond to the plating yarn display area Kb (step S9). That is, when the stitch is knitted by the needle of the front bed, the ground yarn display area Ka in the lower portion of the display area Kij is displayed by the color corresponding to the ground yarn a and the plating yarn display area Kb in the upper portion is displayed by the color corresponding to the plating yarn b.
Whereas, when the stitch is knitted by the needle of the rear bed, the above display is reversed in the display pattern opposite to that shown in FIG. 4A(I)-(III) and FIG. 4B(I)-(III). Next, the process goes to step S10 to check whether the display of the types of the threads as to all the stitches is completed and the similar procedure is repeated until the display is completed (steps S10→S1→S2→S10).
For example, a stitch in which the ground yarn "a" and the plating yarn "b" are knitted to a plating stitch by the needle of the front bed is denoted by a symbol A, a stitch in which the ground yarn a and the plating yarn b are knitted by the needle of the rear bed is denoted by a symbol B and a stitch in which a ground yarn "b" and an plating yarn "d" are knitted to a plating stitch by the needle of the rear bed is denoted by a symbol C in FIG. 2, the respective display areas Kij shown by the symbols A, B, C in the drawing can be expressed by the display areas Kij shown in FIGS. 4A(I-III), 4B(I-III),and 4C(I-III) respectively. That is, the stitch image K at the time can properly express the colored design of the knit fabric where the plating stitch exists.
In FIG. 4A to FIG. 4C, it is preferable that the area ratio of the ground yarn display area Ka and the plating yarn display area Kb obtained by dividing the display area Kij is set to the ratio of about 1:1 to 10:1 as shown in (I)-(III) of the respective drawings FIGS. 4A-4C. In particular, when the display area Kij is horizontally divided ((I) in the respective drawings FIGS. 4A-4C), the division of the area ratio thereof to 2:1 permits a visually excellent recognizing property.
Further, the plating yarn display area Kb may be expressed by one, two or more of simple horizontal lines or oblique lines or by a half-tone dot meshing composed of a number of dots dispersed in the display area Kij. Further, when a plating stitch is knitted by the single ground yarn a and the two or more plating yarns b1, b2 . . . by the employment of three or more yarn carriers, it is preferable to display the plating yarn display area Kb by further classifying it to two or more plating yarn display areas Kb1, Kb2 . . . by a different color.
Note that how the ground yarn a and the plating yarn b appear on the knit fabric may be greatly changed depending upon the thickness, bulkiness and the like of the ground yarn a and the plating yarn b to be used in addition to a type of each stitch. To cope with this problem, programming may be made so as to set the area ratio of the ground yarn display area Ka and the plating yarn display area Kb in each display area Kij variable in accordance with a type of a thread of the ground yarn a and the plating yarn b as shown in the partial flowchart of FIG. 5. However, FIG. 5 is prepared by adding the processing of step S11 in front of step S10 of FIG. 3 and this step (processing at step S11) shows that a predetermined area ratio can be automatically set to the ground yarn display area Ka and the plating yarn display area Kb in accordance with a type of a thread of the ground yarn and the plating yarn b. Further, the area ratio of ground yarn display area ka and the plating yarn display area Kb in each display area Kij may be manually set to a suitable area ratio in accordance with a type of a thread of the ground yarn a and the plating yarn b after the completion of a series of the processing in FIG. 3 or FIG. 5 in addition to the automatic setting.
As described above, according to the present invention, since the display area corresponding to the stitch of the stitch image is divided into the ground yarn display area and the plating yarn display area, even if a knit fabric contains a plating stitch, the colored design of the knit fabric in which a type of a thread of an plating yarn is taken into consideration can be properly displayed. As a result, there can be obtained an excellent advantage that the design of the knit fabric can be easily examined and expressed so as to be readily understood by intuition.
Although the present invention has been fully described by way of examples with reference to the accompanied drawings, it is to be understood various changes and modifications will be apparent to those skilled in the art without departing from the spirit and the scope of the invention. Accordingly, the invention should not be limited by the foregoing description but rather should be defined only by the following claims.
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A method of displaying a stitching image particularly for a plating stitch. A screen of a display unit displays a stitch structure including a type of thread for each stitch of a knit fabric. The display area of each stitch is divided into a ground yarn display area and a plating yarn display area based on the type of stitch. The ground yarn is allocated to one of the divided areas while the plating yarn is allocated to the other of the divided areas.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to electronic record access and retrieval systems, and in particular relates to patient access to personal electronic medical or healthcare records (EMRs or EHRs) via a mobile communication device such as a smartphone.
[0002] MyChart by Epic Systems Corporation is an integrated patient health record (PHR) system that gives patients controlled access to their medical records through an internet browser. MyChart provides a number of functions, such as allowing patients to view test results, view upcoming and past medical appointments, fill out pre-visit questionnaires, schedule appointments, view paperless statements and pay bills online, upload photos, update medications and allergies, connect to home devices, refill prescriptions, message securely with providers, view a child's records and print growth charts, manage the care of elderly parents, and view education topics triggered by EHR data.
[0003] While MyChart also provides a mobile application, privacy and security concerns require pre-authentication and authorization of a patient's smartphone before the patient is able to use the mobile application. Also, many functions of the MyChart application are not available on the mobile application version. What is needed is a method for secure activation of a patient account from a smartphone, wherein a patient may establish a web portal account and download a mobile PHR application directly from their smartphone or other mobile communication device.
SUMMARY OF THE INVENTION
[0004] In accordance with the invention, a method, system and computer program product are provided to authenticate a user and create an account for a web-based portal. An electronic medical record system generates a unique activation code and uses SMS gateways to send an encrypted activation code in an embedded URL to a user's mobile device. The user then authenticates with a custom web application on their healthcare provider's server, and creates an account on a patient portal. The user then may download a mobile PHR application to obtain access to their personal health and medical records from their healthcare provider.
[0005] In particular, in accordance with one aspect of the invention, a method is provided for activating a mobile communication device of a patient to have access to electronic medical records of the patient, comprising: receiving a request for activation of a mobile communication device of a patient, said request being initiated through a link in a medical report of said patient; in response to said request, creating an activation code and associating said activation code with a telephone number of said mobile communication device; sending said activation code to said mobile communication device using said telephone number; receiving a communication from said mobile communication device in response to sending said activation code; and in response to verification of the validity of said response, creating a user account for said patient and associating the user account with said mobile communication device; whereby said patient is provided with access to said patient's electronic medical records through said mobile communication device.
[0006] In accordance with another aspect of the invention, a system is provided for activating a mobile communication device of a patient to have access to electronic medical records of the patient, comprising: an electronic medical record application server, configured to receive a request for activation of a mobile communication device of a patient, said request being initiated through a link in a medical report of said patient; an electronic medical record database configured to generate, in response to a query from said application server, activation code data and associate said activation code with a telephone number of said mobile communication device; a message gateway server configured to send said activation code to said mobile communication device using said telephone number; a Web server configured to receive a communication from said mobile communication device in response to sending said activation code; and a Web Services gateway server configured to create a user account for said patient and associate the user account with said mobile communication device; whereby said patient is provided with access to said patient's electronic medical records through said mobile communication device.
[0007] In accordance with yet another aspect of the invention, a non-transitory computer-readable medium is provided having stored thereon computer-executable instructions for activating a mobile communication device of a patient to have access to electronic medical records of the patient, comprising instructions for causing a computer to: receive a request for activation of a mobile communication device of a patient, said request being initiated through a link in a medical report of said patient; generate, in response to a query from said application server, activation code data and associate said activation code with a telephone number of said mobile communication device; send said activation code to said mobile communication device using said telephone number; receive a communication from said mobile communication device in response to sending said activation code; and create a user account for said patient and associate the user account with said mobile communication device; whereby said patient is provided with access to said patient's electronic medical records through said mobile communication device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic diagram illustrating one example of a process flow for smartphone activation of a patient health record account and smartphone authentication in accordance with one aspect of the invention;
[0009] FIG. 2 is a screenshot of a user's smartphone display, showing a text message with embedded link for smartphone activation in accordance with the invention;
[0010] FIG. 3 is a screenshot of a user's smartphone display, showing a patient activation window for creation of a patient PHR account in accordance with the invention;
[0011] FIG. 4 is a schematic diagram of an example system structure in accordance with another aspect of the invention; and
[0012] FIG. 5 is a flow diagram illustrating a workflow process for patient account establishment and smartphone authentication in accordance with another aspect of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0013] FIG. 1 illustrates a process flow for PHR smartphone authentication and activation in accordance with one aspect of the invention. A user initiates a smartphone activation request for the smartphone of a patient 11 , from within an EMR in a PHR system 12 (such as Epic for example), at step 1 . The request redirects to a custom ASP page on a PHR server 13 (such as e.g. MyChart). The custom ASP page then generates an activation code and a creation time for the activation code, encrypts the activation code (using, for example, BASE64), and sends it to an SMS gateway such as Nexmo Gateway 14 , at step 2 . The SMS gateway then sends to the smartphone of the patient 11 a text message containing a link, and the encoded activation code and creation time, to the user's smartphone. An example of the text message is shown in FIG. 2 .
[0014] The patient 11 then clicks on the link in the text message displayed on the patient's smartphone, and is thereby redirected to the custom ASP page on the server 13 , at step 3 . The patient is then directed on the custom ASP page to enter authentication information, such as the last four digits of the patient's Social Security Number (SSN), the patient's date of birth (DOB), or other secure information. If the patient's access to the server 13 is within a predefined period of time after the creation time (such as, for example, 3 hours), at step 4 the ASP sends the patient's credentials via a CreatePatientAccount web service to an Interconnect server 15 . The web service submits an XML object containing the activation code and the patient's authentication data to the server. The Interconnect server 15 returns to the ASP on server 13 a validation response if all the information is valid. All communications with the Interconnect server are done via reverse proxy server such as Coyote Point LB. At step 5 , the custom ASP page collects a user name and password from the patient 11 via the patient's smartphone as shown in FIG. 3 , and sends this information back to the Interconnect server 15 via an ActivateAccount web service. The service then establishes a patient account with the user name and password and associates the account with the telephone number of the patient's smartphone. The patient may then open or download a mobile application providing access to the patient's personal medical records directly from the PHR server.
[0015] FIG. 4 shows an example system structure in accordance with another aspect of the invention. A staff member initiates a request from a patient's electronic medical record in EMR server 41 to send a message to the patient. A query (A) is sent to the database 42 for an activation code and the telephone number(s) of the patient's mobile communication device(s). The database 42 returns a unique activation code (B) specific to the patient as well as any mobile numbers on file, to the application server 41 . The application server 41 then generates a JavaScript Object Notation (JSON) message containing the unique activation code, a link to a Web server 45 , and the time that the message was generated, encoded in BASE64, and sends it to the Web short message service (SMS) gateway 43 via HTTP post using secure socket layers (SSL).
[0016] The web SMS gateway 43 then sends an SMS message (D) to a telephone number of a patient's mobile communication device 44 as returned from the EMR database 42 . The patient then taps the touch-sensitive phone display to open the link. This generates a request (E) to the Web server 45 , which contains the unique activation code and the time of generation. The Web server 45 validates the code if it is not expired according to the received creation time. The Web server 45 then forwards the activation code (F) to the reverse proxy server 47 as an XML SOAP request. The reverse proxy server 47 then forwards the SOAP request (G) to Web services gateway server 46 (behind the firewall). The Web services gateway server 46 then forwards the activation code (H) to the electronic medical record database server 42 . The database 42 then checks the code and returns either an “invalid” message or a patient ID (I) to the Web services gateway server 46 . The Web services gateway server 46 then creates an XML SOAP response containing either the invalid error message or patient ID (J) and forwards it to the reverse proxy server 47 .
[0017] The reverse proxy server 47 then forwards the XML SOAP response (K) to a JSON object on Web server 45 and returns it to the patient's smartphone 44 (L). The smartphone 44 shows either the error message or a screen (see FIG. 3 ) to create a username and password. The patient's inputted username, password, and security questions are then sent as JSON (M) to Web server 45 . Web server 45 then creates an XML SOAP request containing the patient's inputted username, password and security questions and sends it (N) to the reverse proxy server 47 . The reverse proxy server 47 then forwards the XML SOAP request (O) to the Web services gateway server 46 behind the firewall. The Web services gateway server 46 then forwards the patient's requested username, password and security questions (P) to the database 42 . The database 42 attempts to create a patient account and returns either an error or an account successful message (Q) and forwards it to the EMR Web services server 46 , which forwards it to the reverse proxy server 47 (R). Reverse proxy server 47 then forwards the XML SOAP response to the web server 45 (S). Web server 45 then creates a JSON object containing the error message or activation successful message and returns it (T) to the patient's smartphone 44 . If activation was successful, the patient is redirected to the EMR server 41 and prompted to either open or download the PHR mobile application.
[0018] FIG. 5 shows a flow diagram according to another aspect of the invention. The steps are self-explanatory and analogous to the procedures explained above with respect to FIG. 4 .
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To authenticate a user and create an account for a web-based portal, an electronic medical record system generates a unique activation code and uses SMS gateways to send encrypted an activation code in an embedded URL to a user's mobile communication device. The user then authenticates with a custom web application and creates account on a patient web portal to the EMR system.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage patent application of PCT/2006/002385, filed Jun. 28, 2006 and designating the United States, which claims priority to European Patent Application No. 0514680, filed Jul. 16, 2005.
BACKGROUND
In a Passive Optical Network (PON), optical fibers are deployed in a central split or dual split branch arrangement in order to distribute signals from the OLT (Optical Line Transmitters) in the central office towards a plurality of ONU's at the subscriber's residence. In order to identify failures in the network that need to be restored when a subscriber lacks service, optical time domain reflectometry (OTDR) is used. For a distributed split PON, this method is inappropriate since OTDR measurements carried out from the central office cannot distinguish between the superpostition of the back reflected signals from the splitter branches. Consequently, it is not possible to locate the fault after the split branch. As a result, field technicians (technicians that have to go into the field equipped with an OTDR) are necessary to do measurements after the split branch to identify possible failures.
The negative drawbacks of this approach are (1) that it is a very expensive method that cannot be used to measure the network pro-actively on a regular basis; and (2) that for field technician measurements, connectors are needed in the outside plant in order to allow for connecting the OTDR equipment to the cable infrastructure. This can lead to connector failures over time in case cleaning precautions have not been taken into account by the field technician crews. In addition, the lifetime of the network elements where the monitoring has to be carried out is fairly reduced due to a substantial number of re-entrances in the network element. Known systems are described, for example, in U.S. Pat. No. 6,396,575 of W. R. Holland (Lucent), U.S. Pat. No. 6,771,358 of M. Shigeghara and H. Kanomori (Sumitomo), and U.S. Reissue Pat. 36471 of L. G. Cohen (Lucent).
SUMMARY
A scalable optical printed circuit board is disclosed that allows for optical monitoring in a Passive Optical Network (PON), keeping its passive optical character. The concept of the optical pcb incorporates a planar waveguide optical splitter, a detector, a CMOS transistor chip, a rechargeable battery, and a Vertical Cavity Surface Emitting Laser (VCSEL) array. A distinction can be made between a solution for a split PON where the splitters are already deployed in a splitter node and a solution for a new ‘green field’ PON that still needs to be deployed. For the former, a separate VCSEL transmitter device can be spliced between the splitter output port and the fiber of the distribution cable. For the latter, an integrated module can be spliced to the feeder cable from the Central Office (CO) and the distribution cable protruding to the Optical Network Units (ONUs). By means of a trigger signal that can be recognized by each VCSEL separately and that is multiplexed at the central office to the downstream traffic, a test pulse is generated at the splitter node by the VCSEL. The back reflections of this signal can be measured by an Optical Time Delay Reflectometer (OTDR) at the central office. This OTDR device can be shared for measurement of different PON's by means of fiber optic switches. By appropriate software analysing and reworking the OTDR data, operators can make a map of the loss evolution of their PON over time.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description of the drawings particularly refers to the accompanying figures in which:
FIG. 1 is a diagram of a monitoring solution implemented with a dual port device according to an embodiment of the present disclosure;
FIG. 2 a is a diagram of a WDM device spliced into a feeder fiber and a splitter output port according to an embodiment of the present disclosure;
FIG. 2 b is a diagram showing the internal configuration of the device depicted in exemplary FIG. 2 a;
FIG. 3 a is a diagram showing an integrated splitter on board solution for a green field situation according to an embodiment of the present disclosure;
FIG. 3 b is a diagram showing a planar waveguide device where the splitting of the signal and the multiplexing of the output of the VCSEL arrays is performed in the same waveguide according to an embodiment of the present disclosure;
FIG. 4 a is a signal diagram showing data and clock signals according to an embodiment of the present disclosure;
FIG. 4 b is a diagram showing functional blocks of a CMOS chip according to an embodiment of the present disclosure shown in FIGS. 1 , 2 a , 3 a , and 3 b;
FIG. 4 c is a functional block diagram of an exemplary μ-controller and inputs for a μ-controller showing battery charging functionality according to an embodiment of the present disclosure;
FIG. 5 a is a diagrammatic view of exemplary monitoring where a planar splitter is active in the splitter node according to an embodiment of the present disclosure; and
FIG. 5 b is a diagrammatic view of exemplary monitoring where a planar splitter is not deployed and a planar splitter on board solution can be integrated in an outside plant network element according to an embodiment of the present disclosure.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the disclosure and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.
DESCRIPTION OF THE INVENTION
A scalable solution for PON monitoring is presented. For a PON that is already deployed, the monitoring solution can be implemented by splicing a dual port device (see FIG. 1 ) or a multiple port device (see FIG. 2 ) into the port(s) of a splitter branch and a fiber(s) of the distribution cable (situation A).
For a green field PON that still needs to be deployed the solution consists of an optical pcb, where the planar splitter is mounted on the board. The connection between the optical devices on the board is done via optical fibers and fiber coupling devices. These fiber coupling devices can consist of alignment grooves and refractive micro lenses. The integrated module has an input port that can be spliced or connectorised to the feeder fiber and a multiple output port that can be spliced to the fibers of the distribution cable going to the ONU's. (situation B).
A schematic lay out of the concept that is needed for situation A is depicted in FIG. 1 .
Port 1 is the input port of the device that is spliced or connected to an output port of the planar splitter. That can be a 250 μm coated fiber, a 900 μm coated fiber, a 3 mm cable, or a connectorised pigtail with different connectors. The same applies to the output port 2 . The add/drop coupler device 3 demultiplexes a trigger (pump) signal for activating the VCSEL from the input port. For this optical device a filter WDM 10 (wavelength demultiplexer) can be used or a diffractive (binary diffractive or Fresnel diffractive) lens system like that described in U.S. Pat. No. 6,243,513 B1 can be used to decouple the pump from the input fiber. These micro optic components can if necessary be mounted on the pcb or chip via flip chip bonding techniques. The light from the pump signal impinges on the detector 4 . Depending on the wavelength of the pump signal used, this can be a Si-based detector or a GaAs detector. A CMOS transistor-chip 5 collects the optical signal and boosts the power into a charge collector 7 that is rechargeable each time a VCSEL needs to be activated by a triggering signal from the Central Office. When an appropriate digital sequence is received, (intelligence that via the CMOS circuit can be built into the system) a dedicated VCSEL starts to emit a short intense pulse. The VCSEL output is collected by microlenses or other coupling optics into the add port of the add/drop coupler devices 3 . As a result, the VCSEL signal is coupled in the output fiber of the transmitter device 6 . This creates an OTDR pulse that starts in the selected branch and which will only propagate to one dedicated ONU. The optical sensor (of an OTDR system) at the CO will consequently receive an OTDR trace of the only selected branch.
It is clear that for this situation the pump signal to trigger the VCSELs is attenuated by the coupler. This solution can be adopted when the take rates are low and all the splitter ports are not already connected to an ONU. This should be considered as a grow-as-you-go method which is of course more expensive than the other options.
When the splitter has however no output ports available (in a “parking lot”), a filter WDM 10 can demultiplex the pump signal from the splitter port (see FIG. 2 a ). The configuration of the device depicted in FIG. 1 is then also different. It basically has N+1 input ports and N output ports. The N+1 input ports need to be spliced to the N output branches of the splitter 203 and the extra input port 1 ′ needs to spliced to the pump demultiplexer branch of the WDM device 10 that decouples the pump light from the downstream traffic.
FIG. 2 a shows the configuration when an extra WDM device 10 is spliced into the feeder fiber and the splitter output port. The demultiplexer port of the WDM 10 is spliced to the VCSEL array device. The output ports of the planar splitter 203 are also spliced to the VCSEL array component of the device 200 .
FIG. 2 b shows the internal configuration of the device 200 depicted in FIG. 2 a . An optical waveguide board with multiple couplers 3 that couple light from a transmitter array (preferably a VCSEL array).
For a green field situation however, the solution would look like the solution depicted in FIGS. 3 a and 3 b . For this situation there are more options possible. FIG. 3 a shows an integrated splitter 301 on board solution. FIG. 3 b shows an integrated splitter on board solution where the multiplexing of the VCSELs output is accomplished by the planar waveguide 351 .
When integrating the planar splitter on the board one can opt for a planar waveguide device 351 where the splitting of the signal and the multiplexing of the output of the VCSEL arrays 6 is performed in the same waveguide (see FIG. 3 b ). In that case the splitter has N+1 input ports and N output ports. For N+1 inputs, one port is used to distribute the power to the N output channels. This input is spliced to the feeder cable of the CO. The other N inputs are multiplexed to the output ports and will carry the OTDR pulses from the transmitter array. The N output ports need to be spliced to the distribution cable.
Description of the Design of the Electronic Board
The electronic interface consists of four main parts. First of all we have the detector (or photovoltaic cell) that can consist of one or more series of connected photodiodes. The material system (InP, GaAs or Si) depends on the operating wavelength of the trigger signal sent from the CO. The function of the photodiode stack is twofold. First, power will be provided via the pump wavelength to boot up the circuit or to sufficiently recharge the battery. Then, in a second phase, the power of the pump will be modulated to provide an identification tag which will select which transmitter needs to fire up and generate a pulse for the OTDR trace. Further elements include an ASIC CMOS chip 5 , a rechargeable battery 25 and an optical transmitter bank 26 (preferably consisting of a VCSEL array).
The functional blocks of the CMOS chip 5 that control the electronics are depicted in FIG. 4 . b . It contains a DC/DC regulator 15 which will convert energy from the diode into a suitable voltage to recharge the battery of the module. This can be done by switching (pulse width modulation) the energy stored inside an inductor. The next element of the chip is an optical receiver 16 . This is not a conventional trans-impedance receiver as it should consume minimal power and is required to operate next to the voltage regulator 15 . A possible scheme is to use the state of the voltage regulator 15 itself to sense to the modulation of the pump signal. Indeed, when little light is impinging on the photodiodes, the regulator will switch more slowly than when abundant light is falling on the detectors. It is clear that in this way the data-transfer rate can only be low (smaller than the PMW rate) but high transfer rates are not imperative for the application. Another possibility is the use of an extra dedicated photodiode that is only sensed for receiving the data-signals.
The signal from the optical receiver 16 is then transferred to a local shift register 18 . The clocking is deduced following an asynchronous serial UART regime 20 (see FIG. 4 a ). This requires an additional local oscillator (crystal to be included on the electronic board). Another possibility for clocking is to synchronize the local clock by receiving alternating one's and zero's which are sent at the beginning of each triggering.
When the shift register 18 is filled up, the content is compared with a predetermined bit-pattern. This bit pattern is used to determine whether the communication is really intended for the module. After the receiving of the fixed bit pattern, the Finite State Machine (FSM) 22 changes state and the shift register 18 starts now to receive a new pattern which will uniquely identify one of the optical transmitters. The FSM controller 22 then checks if the indicated transmitter number is one of the transmitters for which the module is responsible. If so, it will power up the driver 26 and generate an OTDR pulse on the required channel. The module knows which channels it should respond to since it was pre-programmed during fabrication. The data can be either provided via a DIP-switch or via a programmable EEPROM. The μ-controller compares the incoming binary data with a internal memory array which is stored in the μ-controller, so that the μ-controller activates the correct VCSEL in the VCSEL array.
In FIG. 4 b below the principle is illustrated. To power the three building parts the detector, the μ-controller and the VCSEL array, a lithium ion battery can be used or a rechargeable battery. The battery that can be used is a single cell lithium ion that produces just enough power to drive the three building parts used on the board. The recharging of the battery can be done based on two principles: the first is based on the fact that the μ-controller can function as the Li-ion battery charger. For this approach the principle of a stand alone charging Integrated Circuit (IC) is used, and this is build in an internal charging program that is active within the μ-controller and we use a Mosfet component and a sense line to sense the voltage over the battery. This is already done with a trickle charge system to correctly charge the battery. The second option is that we use external IC, a lithium ion battery charger. This IC uses an external power PMOS device to form a two chip, low cost, low dropout linear battery charger. The charge current can be set by an external resistor.
These two principles are further illustrated in the functional block diagram 401 FIG. 4 c of an exemplary μ-controller 403 . The recharge of the lithium ion battery is accomplished when there is no signal on the UART of the μ-controller, or we can receive a specific code on the UART that triggers the μ-controller to recharge the lithium ion battery.
FIG. 5 a . shows how monitoring can be done in situation A where the planar splitter is already active in the splitter node. FIG. 5 b . shows how monitoring is accomplished in situation B where the planar splitter is not deployed yet and a planar splitter on board solution can be integrated in an outside plant network element. By means of a pump signal that can trigger one particular VCSEL transmitter in a separate device or in an integrated solution on board, the VCSEL sends out a pulse. This signal is back reflected and can be demultiplexed in the Central office and measured by an OTDR. Due to the fact that one particular VCSEL sending a signal to one of the N ONU's can be triggered, the problem that for conventional OTDR measurements from the central office the OTDR signals after the splitter branch are superimposed is overcome.
In FIG. 5 a it is shown that in the Central Office 100 voice and data traffic is multiplexed with video traffic and connected with the feeder cable 120 , that runs to the splitter node 104 where the splitting is done at once (centralised) or can be done over two branches (not shown). An OTDR set up 102 is placed in the central office and connected to the demultiplexed test signals from the VCSELs that are placed into the field. For situation A as described above the transmitter devices 105 that remotely can be triggered are spliced into the network. Two options are feasible or N separate devices can be spliced to the splitter output port and the fibers of the distribution cable (grow as you go option). Or a WDM device 10 is spliced just before the splitter demultiplexing the pump triggering signal. The output ports of the splitter and the demultiplexer port of the WDM 10 can be spliced to the N+1 input ports of the optical pcb board device housing electronic components and the VCSEL array 105 . Upon triggering a VCSEL the back reflections can be measured by the OTDR in the central office. The back reflected signals can provide loss and fault information of the traject from the splitter node to the tap terminal 106 and the last drop to the subscriber's residence 107 . In FIG. 5 b the green field situation is depicted allowing for a connector loss solution in the outside plant. The monitoring procedure is just the same as in FIG. 5 a.
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A network monitoring module for deployment in a branched optical network at a split location where the network splits into a plurality of branches, the network monitoring module is disclosed, comprising an array of transmitters for generating optical test signals, an output of each transmitter in the array being optically connected to a respective branch, a detector for receiving a remotely generated optical trigger signal which identifies a particular one of the transmitters, and a CMOS circuit for selectively triggering the transmitter identified in the optical trigger signal to transmit an optical test signal into the branch connected to that transmitter.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] None.
ABSTRACT
[0002] A modified dental implant fixture designed with a multiple of three or more thread or groove patterns such that the threads or grooves transition from smaller to larger moving in the apical direction along the long axis of the dental implant body. Such a modified implant maintains adequate wall thickness for a deep conical connection.
BACKGROUND OF THE INVENTION
[0003] The present disclosure relates generally to dental implants, and more specifically to a dental implant having a deep female conical connection which can result in limited wall thickness. By combining an innovative thread or combination of thread and groove patterns that transition from smaller coronal to larger and deeper apical threads, which are helpful in providing greater primary stability, a dental implant that maintains adequate wall thickness, when a deep conical connection is utilized, is achieved.
[0004] Dental implants are used in place of missing natural teeth to provide a base of support for single or multiple teeth prosthetics. These implants generally include two components, the implant itself and the prosthetic mounting component referred to as an abutment upon which the final prosthesis is installed. The implant has apical and coronal ends, whereby the coronal end accepts the base of the prosthetic abutment using connection mechanisms of different designs. One such mechanism is a deep female conical receptor with an internal alignment or anti-rotational component such as a hex, double hex, spline or other single/multi-sided arrangement used for prosthetic alignment and anti-rotation stability. Deep female conical connections have been shown to prevent micro movement between the implant body and the abutment when loaded but can have the disadvantage of limited wall thickness especially if the implant is of a tapered design.
[0005] In practice, the implant body is surgically inserted in the patients jaw and becomes integrated with the bone. More specifically, the implant body is screwed or pressed into holes drilled in the respective bone. The surface of the implant body is characterized by macroscopic and microscopic features that aid in the process of osseointegration. Once the implant is fully integrated with the jaw bone, the abutment is ready to be mounted. For two-stage implant designs, the abutment passes through the soft tissue that covers the coronal end of the implant after healing and acts as the mounting feature for the prosthetic device to be used to restore oral function. Implants of the single-stage design extend at least partially through the soft tissue at the time of surgical insertion. The coronal end of the implant body acts as part of a built-in abutment design with the margin of the coronal collar usually being employed as the margin of attachment for the prosthesis used to restore oral function.
[0006] Both single and two stage implants are characterized by a central bore hole at their coronal ends that is generally threaded to accept a central screw to hold the abutment securely to the implant body. The exception would be some implants where the abutment is friction fit into the central bore hole and no screw is required. In any event, the implant, abutment, and screw are typically fabricated from titanium or a titanium alloy. Some implants are zirconia based, alumina based or sapphire based ceramics, and, in regions of high esthetic demands, the abutments are zirconia based. In some instances, ceramics and metals are combined to make a single component, though this is usually limited to the abutment component of the implant system. There is also promising research on the use of titanium zirconia alloys as well.
[0007] One of the original implant designs was the so-called Branemark type implant characterized by an external hex. The hex was originally used to insert the implant and later utilized as an external anti-rotational and alignment element. This design usually displays a bone loss pattern described as a cupping of the bone at the coronal end of the implant once loaded with occlusal forces. This cupping pattern usually stabilizes after about one year of function with vertical bone loss of approximately 2 mm. By that time, loss of bone critical to the predictable support of overlying soft tissue is lost. As implant designs evolved internal connections utilizing an internal hex became much more common. For example, Astra Tech Inc. (“Astra”) was one of the first companies to introduce a deep conical design and use a double hex as their internal orientation element.
[0008] In addition to having a more stable implant connection (deep female conical connection), Astra has also addressed the coronal bone loss by introducing micro threads at the coronal aspect of the implant body. This further modification is designed to distribute and transfer forces to the surrounding bone. However, clinicians are increasingly demanding dental implants with macro designs that achieve higher insertion torque values that generally translate to high initial implant stability. Prior Astra implants with a coronal flair had a single lead micro thread of 0.185 mm combined with a single lead apical thread of about 0.6 mm. To increase primary stability the micro threads were increased to 0.22 mm and made triple lead so as to be timed, together with having the same pitch, as the apical threads. This dramatically increased the required insertion torque and primary stability. Accordingly, in order to have more aggressive/deeper apical threads with wider spacing in combination with coronal micro threads of a similar dimension and still allow for adequate wall thickness for the deep female conical connection, an additional transitional thread pattern(s) of intermediate thread size(s) between the coronal micro threads and the larger apical threads is disclosed herein. However, the same thread pattern with inherent advantages can be utilized with any implant and is not limited to one with a deep conical connection.
[0009] Another advantage to a larger apical thread, in addition to increasing primary stability, is to increase surface area particularly on larger diameter implants when wall thickness is less of an issue. While apical threads in the size range of 0.6 to 0.66 may be ideal for implants in the 3.0 to 4.5 mm diameter, larger diameter implants have adequate distance between the central bore hole and the outer wall to allow for deeper apical threads. The resulting increase in surface area is particularly beneficial for large diameter, shorter implants which, depending on the clinical circumstances, would allow surgeons to avoid the maxillary sinus in the upper posterior region of the mouth.
[0010] More recent Astra implants have moved away from using an untimed micro thread of approximately 0.185 mm paired to a single lead apical thread of 0.6 mm, and now use a triple lead micro threads of about 0.22 mm timed to a single apical thread of approximately 0.66 mm. Meanwhile, U.S. Pat. No. 7,677,891 to Niznick (incorporated herein by reference) proposes quadruple lead (i.e.4X) coronal threads spaced 0.3 mm apart and timed to double lead (i.e. 2X) apical threads spaced 0.6 mm apart with the 4X coronal threads being spaced considerably greater than 0.22 mm. Referring to FIG. 1 , the implant 10 , includes a tapered body 12 with two externally-threaded regions 14 and 16 . Proximal, externally-threaded region 14 includes V-shaped X 4 lead threads all of which have the same pitch. Distal portion 16 includes V-shaped X 2 lead threads. This type of implant design has a couple of disadvantages. First, in soft bone, the apical threads are limited to approximately 0.6 mm because coronal micro threads cannot be any larger than 0.3 mm and maintain crestal bone. Perhaps more critical, is the fact that a 2X apical thread increases the insertion speed. Specifically, if a sloped topped (e.g. U.S. Pat. No. 6,655,961) or asymmetric (e.g. copending application U.S. Ser. No. 12/494,510) coronal configuration is utilized, controlling the speed of the implant advancement into the host bone is essential. Accordingly, and as disclosed herein, the most apical thread should be a single thread (i.e. X 1 ).
[0011] There is considerable prejudice among dentists and manufactures as to the benefits of tapered or straight walled implant designs. Some, like Astra, even combine a tapered coronal aspect with a parallel walled apical portion of the implant. Most now agree that some type of tapered apical cutting end, even on the parallel walled design, is desirable. This is demonstrated on Astra's recently introduced TX (tapered apex) design. Referring to FIG. 2 in particular, the implant 20 , includes a straight walled body 22 with two externally-threaded regions 24 (proximal) and 26 (distal). The tapered apex 28 has been added to make initial installation, into holes drilled in the respective bone, easier.
[0012] However, both straight, tapered or a combination of tapered and straight bodied dental implants have their place in the field of implant dentistry depending on bone type and clinical application. For example, in the upper arch the bone is softer and the apical ends of adjacent teeth are closer together than in the lower arch. Therefore, a tapered design (that with a smaller apical end) fits between the roots of adjacent teeth more suitably while the tapered design compresses the softer maxillary bone upon insertion thus increasing implant primary stability at the time of placement. In the lower arch the bone is denser and root proximity is less of an issue so implants with parallel walls are considered more suitable by many clinicians.
[0013] A tapered implant with a truly more concave profile has not been utilized in the dental implant field. While Astra does transition from a straight apical end to a 6 degree flared coronal design, the transition is abrupt. What is proposed herein is a 2 and then a 5 degree concave flare (or any like progressive) transition be utilized. Besides allowing adequate wall thickness, another advantage, when combined with the proposed herein combination of thread sizes, is to increase implant primary stability as measured by resonance frequency analysis while possibly lowering the amount of torque required to seat the implant.
[0014] Accordingly, it is a general object of this dosclosure to provide a series of thread or a combination of groove and thread patterns that transition in spacing, size, pitch and depth such that adequate wall thickness for a deep internal female conical connection is maintained while allowing for an apical macro tread design that will result in greater primary stability for the dental implant while still keeping the rate of insertion within the limits that allow for either a sloped or asymmetric coronal configuration.
[0015] It is a another object of this disclosure to enable implants with a tapered implant body to maintain adequate wall thickness when utilizing a deep female internal conical connection and still allow for a macro tread design that will result in greater primary stability while still keeping the rate of insertion within the limits that allow for either a sloped or asymmetric coronal configuration to be aligned with the surrounding bony topography.
[0016] It is a further object of this disclosure to enable implants with a concave tapered implant body profile to maintain adequate wall thickness when utilizing a deep female internal conical connection and still allow for a macro thread design that will result in greater primary stability while still keeping the rate of insertion within the limits that allow of either a sloped or asymmetric coronal configuration to be aligned with the surrounding bony topography.
[0017] It is a more specific object of this disclosure to enable a large diameter, shorter length implants with deeper apical threads with increased surface area while maintaining adequate wall thickness for a deep conical connection and coronal micro threads.
[0018] These and other objects, features and advantages of this disclosure will be clearly understood through a consideration of the following detailed description.
SUMMARY OF THE INVENTION
[0019] According to an embodiment of the present invention, there is provided a dental implant for implanting within a human jawbone having an implant body with an outer surface, a longitudinal axis, a coronal end and an apical end. The coronal end includes a deep female conical receptor that creates a wall thickness between the outer surface of the implant body and the receptor. At least three differently sized threaded regions are positioned on the outer surface of the implant body with each region transitioning from smaller to larger in the apical direction along the axis.
[0020] There is also provided a dental implant for implanting within the human jawbone having a longitudinal implant body with an outer surface, an apical end and a coronal end. A series of three or more thread patterns that start near the coronal end are in series with each one becoming progressively larger, deeper and/or wider in size when moving in the apical direction along the implant body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a side elevational view of a prior art implant.
[0022] FIG. 2 is a side elevated view of a prior art implant having a tapered apex.
[0023] FIG. 3 is a cross-sectionals side elevated view of a prior art implant without thread timing or a tapered apex.
[0024] FIG. 4 is a cross-sectional side elevational view a prior art implant with thread timing and a tapered apex.
[0025] FIG. 5 is a cross-sectional side elevational view of an implant according to the principles of an embodiment of the present invention.
[0026] FIG. 6 is a cross-sectional side elevational view of an alternate embodiment of an implant.
[0027] FIG. 7 is a cross-sectional side elevational view of an alternate embodiment of an implant.
[0028] FIG. 8 is a cross-sectional side elevational view of an alternate embodiment of an implant.
[0029] FIG. 9 is a cross-sectional side elevational view of an alternate embodiment of an implant.
[0030] FIG. 10 is a cross-sectional side elevational view of an implant.
[0031] FIG. 11 is a side elevated view of an implant according to the principles of an embodiment of the present invention.
[0032] FIG. 12 is a side elevated view of an alternate embodiment of an implant.
[0033] FIG. 13 a is a side elevated view of an alternate embodiment of an implant.
[0034] FIG. 13 b is a cross-sectional side elevational view of the implant of FIG. 13 a.
[0035] FIG. 13 c is a top plan view of the implant of FIG. 13 a.
[0036] FIG. 13 d is a perspective view of the implant of FIG. 13 a.
[0037] FIG. 13 e is a detailed view of the variable thread form detail of FIG. 13 a.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] An embodiment of the subject invention will now be described with the aid of numerous drawings and included measurement designations. Unless otherwise indicated, such measurements are used for explanatory purposes only and they are not deemed to be limiting of the disclosed embodiments herein. The purpose of describing these measurements is to illustrate that the concept of using three or more thread or groove patterns while maintaining adequate wall thickness for a deep conical connection can be utilized for a wide variety of implant sizes and designs.
[0039] In any event, turning now to the Figures, and in particular FIG. 3 , a prior art dental implant 30 is illustrated. This implant 30 is 11 mm long and has a step-wise diameter taper from 4.5 mm at its coronal end to 3 mm at its apical end. Two 60° thread patterns, at 1X to 1X are used on this implant 30 . The coronal threads 32 are 0.185 mm apart with grooves 0.1 mm deep, while the apical threads 34 are 0.6 mm apart with grooves 0.325 mm deep. The deep female conical connection 36 is the space within the implant 30 denoted by the dotted lines. This design provides for an upper wall thickness 38 of 0.303 mm and a lower wall thickness 40 of 0.440 mm.
[0040] The prior art implant 50 of FIG. 4 is the next generation Astra design of FIG. 3 and is again 11 mm long, but instead of having a step-wise diameter taper from 4.5 mm to 3 mm ( FIG. 3 ), it utilizes a tapered apex (similar to FIG. 2 ) going down to 2 mm. While such a tapered apex makes installation of the implant easier, the thread pattern needed to be adjusted in an attempt to increase wall thickness for the deep conical connection. Specifically, two 80° thread patterns, at 1X to 3X, are used on this implant 50 . With 80°, the resulting reduced thread depth will increase the wall thickness. The coronal threads 52 are 0.22 mm apart with grooves 0.082 mm deep, while the apical threads 54 are 0.66 mm apart with grooves 0.246 mm deep. The deep conical connection 56 has an upper wall thickness 58 of 0.321 mm and a lower wall thickness of 0.519 mm. The change to 0.22 mm 3X coronal thread timing dramatically increases implant primary stability while the change to 80 degree threads increases all thickness for both the coronal threads 52 and the apical threads 54 .
[0041] It has become apparent that an implant having a deep female conical connection is preferred to prevent micro movement between the implant and the abutment. In order to have both deeper apical threads that increase primary stability and coronal micro threads or grooves that better distribute force to the surrounding bone, an embodiment of the present invention adds at least one intermediate or middle thread to the pattern. This additional thread provides the necessary wall thickness to prevent implant breakage during function.
[0042] There have been studies claiming that certain thread timing patterns are more ideal than others. Specifically, that a 2X to 4X combination allows for the micro threads to follow partially in the path of the major apical thread with only a new middle thread being cut. However, Astra's 1X to 3X thread does much the same thing where the transition to 3X from 1X merely adds one smaller thread above and one below the major thread which itself transitions to a micro thread following the prior path of the major thread. While the 2X to 4X pattern avoids cross cutting the major apical threads, the 1X to 3X Astra pattern does essentially the same thing. Accordingly, in one of the solutions disclosed herein, a 1X to 2X to 3X thread pattern, there would be cross cutting for the 2X apical threads but not for the most coronal 3X micro thread. However, as long as the same thread pitch is maintained in a tapered implant design or one with a slightly concave coronal profile cross cutting is inconsequential as the bone is being compressed and expanded outward.
[0043] Cross cutting may be avoided for either a straight walled or tapered body implant using a 1X to 2X to 4X combination. However, bone gap jumping of up to 0.5 mm is clinically proven upon the immediate implant placement and therefore the only possible benefit might be for the ease of implant insertion as bone healing will fill in any cross threaded area in the bone. Taken to the extreme, and taking a 1X to 3X to 5X combination as an example, only the 5X portion would start to cross cut the 3X threads and only for the most coronal 20-25% or less. Furthermore, with a 1X to 2X to 4X, or a 1X to 3X to 6X no cross cutting would take place. For those knowledgeable in multiple lead thread timing this is well understood.
[0044] The utilization of a middle thread to the pattern will now be described. An example thereof is first shown in FIG. 5 . In particular, this implant 70 is 11 mm long and has a step-wise diameter taper from 4.5 mm at its crown to 2 mm at its apex and is shown with 5° of coronal taper 72 and 2° of mid wall taper 74 . Three thread patterns, 80° at 1X to 80° at 2X to 80° at 4X, are used on this implant 70 . The coronal threads 76 are 0.22 mm apart with grooves 0.082 mm deep, the middle threads 78 are 0.44 mm apart with grooves 0.164 mm deep and the apical threads 80 are 0.88 mm apart with grooves 0.476 mm deep. The deep conical connection 82 has a mid wall thickness 84 of 0.372 mm and a lower wall thickness 86 of 0.607 mm, both of which exceed the parameters for prior art FIGS. 3 and 4 .
[0045] While the straight walled apical diameter 88 has increased to 3.868 mm due to the increased thread depth in that region, the implant will go into the same diameter bone site as the prior art implant of FIG. 4 . Further, since the apical wall thickness has been increased to 0.607 mm, the parallel walled region could become slightly tapered with a minimal apical wall thickness equal to or greater than 0.519 mm shown in FIG. 4 . It should be noted that the implant of FIG. 4 does not allow the parallel walled section to become tapered because the apical threads were changed from 60° to 80° from the prior art of FIG. 3 in order to increase wall thickness for additional strength.
[0046] It will be appreciated that merely adding an intermediate or middle or transitional thread to any implant will not create the acceptable wall thickness. For example, implant 90 of FIG. 6 differs from FIG. 5 by using 6° of coronal and 3° of mid wall taper and again all three thread patterns are at 80° and the apical thread 92 depth is 0.328 mm. This allows a mid wall thickness 94 of only 0.304 mm and a lower wall thickness 96 of 0.518 mm. The lower wall thickness is acceptable but the middle wall thickness is less than prior art FIG. 4 and the parallel wall section could not become slightly tapered as for the implant shown in FIG. 5 as it is already 0.001 mm below minimum dimension per FIG. 4 . Accordingly, the implant described in FIG. 5 is preferable to the implant of FIG. 6 .
[0047] Three or more thread patterns can also be used on larger implants. For example, 11 mm long with step-wise diameter taper from 5 mm to 2.5 mm implants are shown in FIGS. 7 and 8 . Referring first to FIG. 7 , the implant 100 has a thread pattern of 60° at 1X to 80° at 3X to 80° at 5X. The coronal threads 102 are 0.2 mm apart with grooves 0.074 mm deep, the middle threads 104 are 0.33 mm apart with grooves 0.123 mm deep and the apical threads 106 are 1 mm apart with grooves 0.541 mm deep. The deep conical connection 108 has a mid wall thickness 110 of 0.595 mm and a lower wall thickness 112 of 0.553 mm.
[0048] The implant 120 of FIG. 8 has all three thread patterns at 80° with a 1X to 3X to 6X pitch. The coronal threads 122 are 0.2 mm apart with grooves 0.074 mm deep, the middle threads 124 are 0.4 mm apart with grooves 0.149 mm deep and the apical threads 126 are 1.2 mm apart with grooves 0.447 mm deep. The deep conical connection 128 has a mid wall thickness 130 of 0.569 mm and a lower all thickness 132 of 0.647 mm.
[0049] Referring now to FIG. 9 , this implant 140 is 11 mm long and has a step-wise diameter taper from 4.5 mm at its crown to 2 mm at its apex. Three thread patterns, 80° at 1X to 80° at 2X to 80° at 3X, are used on this implant 140 . The coronal threads 142 are 0.22 mm apart with grooves 0.082 mm deep, the middle threads 144 are 0.44 mm apart with grooves 0.164 mm deep and the apical threads 146 are 0.66 mm apart with grooves 0.246 mm deep. The deep conical connection 148 has a mid wall thickness 150 of 0.372 mm and a lower wall thickness 152 of 0.689 mm.
[0050] The slightly more tapered implant 160 of FIG. 10 has the same thread pattern and measurements of FIG. 9 . However, as discussed with regard to FIG. 6 , and due to the implant 160 dimensions, acceptable wall thickness is not created. While the deep conical connection 162 has a lower wall thickness 164 of 0.599 mm, the mid wall thickness 166 is merely 0.304 mm. Accordingly, the implant described in FIG. 9 is preferable to the implant of FIG. 10 .
[0051] FIG. 11 shows a dental implant 170 with multiple thread patterns in profile. In this case, the deep apical threads 172 are followed by middle threads 174 and then coronal threads 176 up to the unthreaded portion 178 and top surface 180 .
[0052] FIG. 12 shows a dental implant 190 with an addition set of threads. In particular, the deep apical threads 192 are followed by middle threads 194 and coronal threads 196 leading to parallel groove threads 198 before reaching the unthreaded portion 200 and the top surface 202 . It will be appreciated that two or more parallel groove patterns may be employed.
[0053] One of the more advantageous uses for the present invention is to allow for wider diameter dental implants; the same can be said of shorter and wider diameter implants. For example, FIG. 13 a shows an implant 210 that is 6.50 mm long and has a diameter taper from 5.50 mm at its crown to 4.75 mm at its apex. Three thread patterns, a 1X to 2X to 3X all at 60°, are used on this implant 210 . The coronal threads 212 are 0.25 mm apart with grooves 0:14 mm deep and the middle threads 214 are 0.375 mm apart with grooves 0.20 mm deep. As for the apical threads 216 , they are shown with the apical minor diameters progressively being lowered, which results in the most apical thread having a more aggressive cutting profile (see FIG. 13 e ). Conversely, allowing the minor diameter to migrate coronally will result in a most apical buttress thread. The deep conical connection 218 of this shorter implant 210 is shown in FIG. 13 b - d . The combination multiple thread pattern of this design maintains the necessary wall thickness 220 between the deep conical connection 218 and the grooves of the thread patterns.
[0054] Alternatively, 60° 1X, 2X, 4X threads could be used with the coronal threads 212 being 0.22 mm apart and 0.12 mm deep and the middle threads 214 being 0.44 mm and 0.24 mm while the apical threads would be spaced 0.88 mm apart and be variable or of consistent depth.
[0055] The present disclosure addresses the issue of limited wall thickness associated with a deep conical connection. However, there are other advantages inherent in the design that could equally be applied to the implant with a different abutment connection Accordingly, while particular embodiments of the invention have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made therein without departing from the invention if its broader aspects, and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the present invention.
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A modified dental implant fixture designed with a multiple of three or more thread or groove patterns which provide adequate wall thickness for a deep female conical connection such that the threads or grooves transition from smaller to larger moving in the apical direction along the long axis of the dental implant.
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BACKGROUND
[0001] Field of the Invention
[0002] The present invention generally relates to pumps, which could be in various configurations, such as in the form of rotodynamic or centrifugal pumps, or positive-displacement pumps, and which may be magnetically driven or may have dynamic seals.
[0003] Description of the Related Art
[0004] Many pumps utilize dynamic seals, which are mechanical seals between rotating parts. However, in some pumping applications, it is desirable to try to avoid potential seal leakage by not using seals in conjunction with rotating parts. Accordingly, in some instances, it is becoming more common in the pump arts to employ a magnetic drive system to eliminate the need for seals along rotating surfaces. The present disclosure addresses numerous shortcomings in prior art equipment, such as pumps, some of which utilize a magnetic coupling, while others of which may be employed with pumps having seals along rotating surfaces. The pumps also may employ rotodynamic or positive-displacement pumping principles. The following are several of the shortcomings recognized and sought to be addressed in the present disclosure.
[0005] Prior art systems for supporting a rotor assembly within a magnetically driven pump may be of different constructions but tend to provide radial and axial (thrust) bearing support for the rotor assembly that does not rely on the canister that separates the fluid pumping chamber from the drive portion of the pump. This results in a disadvantage of causing magnetically driven pumps to have greater axial length and weight, because the bearing support is located forward and/or rearward of the pumping portion of the rotor assembly. For example, bearings providing radial support and forward and rearward thrust or axial bearings that restrict forward or rearward motion typically are located forward and/or rearward of the pumping elements of a rotor assembly.
[0006] Almost all magnetically coupled pumps have a recirculation path that allows a small percentage of the pump fluid flow to recirculate from the pump outlet or discharge side, back to the inlet or suction side. This recirculation is used mostly for lubrication and cooling of bushings and for cooling of the canister, which may get hot due to electrical eddy currents generated by the magnetic coupling. Prior art recirculation paths include one or more segments where the path is essentially a hole thru a single part, such as a hole thru a single stationary part of the pump casing or thru a single piece rotating impeller. The downside of a hole thru a single part is that it is prone to causing clogging of the recirculation path.
[0007] In the chemical processing industry, the standard ASME B73.1 is a very popular specification for most centrifugal dynamically sealed pumps. In this standard and in the ISO 5199 standard, one of the main features of the specification is the establishment of a common mounting footprint, including the sizes and locations of the outlet or discharge port, the inlet port, the mounting foot and the shaft of the pump. The industry also sells magnetically coupled pumps but they utilize a different rear end mechanical drive portion or power end in comparison to the dynamically sealed pumps. There are far fewer magnetically coupled pumps, so the power ends for magnetically driven pumps tend to be more costly. Also, due to overall size and especially axial length, no magnetically coupled pumps known to the inventors have been able to utilize the power end that is commonly used with the dynamically sealed pumps while meeting either of the standards for the location of the stated features involved in mounting such pumps.
[0008] When a rotor assembly of a pump includes an impeller, the pump generally is most efficient and has the best suction capability when the center starting ends of the vanes have a relatively small diameter. However, in a magnetically driven rotodynamic pump, a front nose cap that holds a front axial bearing is most beneficial if it has a relatively large outer diameter, so that the axial bearing can be large. In a typical design, a nose cap must be assembled from the front of the impeller, so the center of the forward ends of the impeller vanes must start at a diameter at least as large as the diameter of the nose cap. This requires a disadvantageous tradeoff pitting a desired small diameter for the front end of the impeller vanes against a desired large diameter of a front axial bearing.
[0009] As noted above, it is common for pumps to have separate radial and axial bushings or bearings. This tends to add undesirable complexity and length to a pump.
[0010] The above are some of the shortcomings of prior art pumps that are sought to be addressed by the teachings and examples provided in the present disclosure.
SUMMARY
[0011] In a first aspect, the present disclosure provides a magnetically driven pump having a compact advantageous design that overcomes the above discussed disadvantages associated with having radial and axial bearing surfaces well forward or rearward of the pumping area of a rotor assembly. The disclosure provides a magnetically driven pump that includes a casing, a rotor assembly, an inner magnet assembly and a canister assembly. The casing has a front portion, a rear portion, a discharge port and an inlet port. The rotor assembly includes a rear cylindrical opening having an inner wall surface and having a plurality of magnet segments connected to the inner wall surface, a front cylindrical opening having an inner wall surface that provides a radial bearing surface, and a first axial bearing surface. The canister assembly includes a cylindrical portion disposed within a radial gap between magnet segments of the inner magnet assembly and magnet segments of the rotor assembly, and a front portion extending from the cylindrical portion and having a radial bearing surface and a first axial bearing surface. In this design, the radial bearing surface of the rotor assembly and the radial bearing surface of the canister assembly front portion restrict radial motion of the rotor assembly, and the first axial bearing surface of the rotor assembly and the first axial bearing surface of the canister assembly front portion restrict forward motion of the rotor assembly.
[0012] In a second aspect, the present disclosure addresses the disadvantageous structures of prior art magnetically driven pumps having a recirculation path through a single part or through stationary segment. The disclosure provides a magnetically driven pump that includes a stationary casing, a rotatable rotor assembly, a rotatable drive magnet assembly, a stationary canister assembly, and a recirculation path. The stationary casing has a front portion, a rear portion, a discharge port and an inlet port. The rotatable rotor assembly includes a rotor, at least one radial bearing surface, at least one axial bearing surface and a plurality of magnet segments. The rotatable drive magnet assembly includes a plurality of magnet segments in axial alignment with the magnet segments of the rotor assembly. The stationary canister assembly includes a cylindrical portion disposed within a radial gap between the magnet segments of the rotor assembly and the magnet segments of the drive magnet assembly. The recirculation path extends from the casing discharge port, across the at least one radial bearing surface of the rotor assembly, across the at least one axial bearing surface of the rotor assembly, across the cylindrical portion of the canister assembly, and to the casing inlet port, wherein when the rotor assembly rotates within the casing and relative to the canister assembly, all portions of the recirculation path include at least one stationary surface of the casing or canister assembly that is opposed to at least one surface of the rotor assembly.
[0013] In a third aspect, the present disclosure also addresses the lack of magnetically driven pumps able to meet the industry standards ASME B73.1 and/or ISO 5199 for mounting locations of key features and able to utilize the rear end mechanical drive portion commonly used with dynamically sealed pumps that meet the standard. The disclosure provides a magnetically driven rotodynamic pump that includes a stationary casing, an inner magnet assembly, and an impeller assembly. The stationary casing includes a discharge port, an inlet port, a mounting foot and a rear mounting flange. The inner magnet assembly has an inner ring and a plurality of magnet segment. The casing, inner magnet assembly and impeller assembly are configured and dimensioned to be assembled to a power end and adapter of a commercially available non-magnetically driven rotodynamic pump having a dynamic seal that is designed in accordance with dimensions specified in a pump industry standard, such that when assembled, the sizes and locations of the casing discharge port, the casing inlet port, the casing mounting foot, and the power end and adapter all meet the dimensions specified in the standard. The unique, axially compact design of a pump of the present disclosure is capable of utilizing the rear end mechanical drive components or power end normally in place for such centrifugal dynamically sealed pumps. Thus, the pump may be installed without needing to remove the power end that is connected to the electric drive motor, and therefore, without disturbing the electric motor and its mounting and electrical connections, and without disturbing the shaft alignment between the electric motor and the power end. Also, the new pump advantageously may be connected to existing power end and adaptor structures. This can be particularly beneficial to manufacturers that already make the power end and adapter components for the centrifugal dynamically sealed pumps. Moreover, it permits utilization of the less expensive power ends normally used with dynamically sealed pumps, and provides an opportunity for field retrofits that can be achieved by leaving in place the existing power end and only changing out the pump, while also gaining the advantages of a magnetically driven pump.
[0014] In a fourth aspect, the present disclosure addresses the previously noted issue that typical magnetically driven rotodynamic pumps having a front axial bearing at a nose cap must balance the benefit of having a small diameter at the center starting portion of the impeller vanes against the benefit of having a large diameter canister nose cap for the front axial bearing. The disclosure provides a magnetically driven rotodynamic pump having a stationary casing, a stationary canister assembly, and a rotatable rotor assembly. The stationary casing has a front portion, a rear portion, a discharge port and an inlet port. The stationary canister assembly is connected to the stationary casing. The stationary canister assembly further includes a canister and a stationary nose cap is connected to the canister and has an outer diameter, a rear axial bearing surface and a front surface. The rotatable rotor assembly includes an impeller having a plurality of front vanes, wherein a portion of the impeller front vanes extend forward of the nose cap front surface and inward to an inner diameter that is smaller than the outer diameter of the nose cap. Thus, the design includes the benefits of both a smaller diameter at the center starting portion of the impeller vanes and a large diameter canister nose cap having a front axial bearing. In this design, the stationary front surface of the nose cap is positioned where there would otherwise be an impeller base surface and the forward extending portions of the impeller vanes extend forward of the surface of the base of the impeller. This results in an advantageous relatively small diameter of the center starting ends of the impeller vanes combined with an advantageous relatively large outer diameter of the axial bearing at the nose cap of the canister assembly.
[0015] In a fifth aspect, the present disclosure provides a pump that includes a stationary casing having a front portion, a rear portion, a discharge port and an inlet port, and further includes a rotor assembly having a bushing wherein the bushing is of single piece construction and includes a radial bearing surface that restricts radial motion of the rotor assembly, a front axial bearing surface that restricts forward motion of the rotor assembly, and a rear axial bearing surface that restricts rearward motion of the rotor assembly. This design is believed to provide the first instance of a pump having a bushing for a rotor assembly that is of single piece construction while providing radial and front and rear axial bearing surfaces. This provides a particularly compact rotor assembly design.
[0016] In an sixth aspect, the present disclosure provides a pump that includes a stationary casing having a front portion, a rear portion, a discharge port and an inlet port, and further includes a rotor assembly having a rotor that includes a central opening extending axially through the rotor and having a step proximate one end of the central opening, a rotor ring, and a bushing, wherein the bushing fits inside the rotor central opening and is held in place between the rotor ring and the step in the central opening of the rotor. This design provides a uniquely compact and efficient bushing design and construction for a rotor assembly wherein a bushing extends through a portion of and is held within the rotor assembly by a fastening means at one end of the rotor assembly. This also enables the use of advantageous longer bearing surfaces.
[0017] It is to be understood that both the foregoing general description and the following detailed description are exemplary and provided for purposes of explanation only, and are not restrictive of the subject matter claimed. Further features and objects of the present disclosure will become more fully apparent in the following description of the preferred embodiments and from the appended claims. Indeed, it is contemplated that certain aspects of the present disclosure pertain to pumps that may be dynamically sealed and/or magnetically driven and considered to be sealless, while certain aspects also pertain to rotodynamic pumps and/or positive-displacement pumps. It also will be appreciated that, if magnetically driven, some aspects may be applied to pumps having an inner magnet drive assembly and/or an outer magnet drive assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In describing the preferred embodiments, references are made to the accompanying drawing figures wherein like parts have like reference numerals, and wherein:
[0019] FIG. 1 provides a side view and a front view of a first example pump connected to a motor using an adapter and shaft extension in a close-coupled fashion.
[0020] FIG. 2 provides a quarter-sectioned perspective view of the first example pump of FIG. 1 .
[0021] FIG. 3 provides an enlarged closer perspective view of the quarter-sectioned area of FIG. 2 .
[0022] FIG. 4 provides a perspective view of the first example pump of FIG. 1 with a sectioned front portion of the casing.
[0023] FIG. 5 provides a front view of the first example pump of FIG. 1 with a sectioned front portion of the casing.
[0024] FIGS. 6 a and 6 b provide quarter-sectioned rear and front perspective views of the rotor assembly of the first example pump of FIG. 1 .
[0025] FIG. 7 provides a quarter-sectioned perspective partially exploded view of the inner portion of the first example pump of FIG. 1 .
[0026] FIG. 8 provides a partially quarter-sectioned perspective partially exploded view of the rotor assembly of the first example pump of FIG. 1 .
[0027] FIG. 9 provides a perspective exploded view of the center portion of the first example pump of FIG. 1 .
[0028] FIG. 10 provides a portion of a quarter-sectioned plan view of the first example pump of FIG. 1 showing a recirculation path and without the power end drive components.
[0029] FIG. 11 provides a side view and a front view of a second example pump connected to a power end that is suitable for another pump meeting ASME B73.1 or ISO 5199 dimensional standards.
[0030] FIG. 12 provides a quarter-sectioned perspective view of the second example pump of FIG. 11 .
[0031] FIG. 13 provides a quarter-sectioned perspective partially exploded view of the second example pump of FIG. 11 .
[0032] FIG. 14 provides a front perspective view of a third example pump.
[0033] FIG. 15 provides a cross-sectioned view of the third example pump of FIG. 14 .
[0034] FIG. 16 provides a front perspective partially exploded view of the third example pump of FIG. 14 .
[0035] FIG. 17 provides a rear perspective partially exploded view of the third example pump of FIG. 14 .
[0036] FIG. 18 provides a front perspective exploded view of the rotor assembly of the third example pump of FIG. 14 .
[0037] FIG. 19 provides a front perspective exploded view of the drive magnet assembly of the third example pump of FIG. 14 .
[0038] FIG. 20 provides a quarter-sectioned perspective partially exploded view of the drive magnet assembly, canister and rotor assembly of the third example pump of FIG. 14 .
[0039] FIG. 21 provides a portion of a quarter-sectioned plan view of the pump of FIG. 14 showing a recirculation path and without the power end drive components.
[0040] It should be understood that the drawings are not to scale. While some mechanical details of the example pumps, including details of fastening means and other plan and section views of the particular components, have not been shown, such details are considered to be within the comprehension of those skilled in the art in light of the present disclosure. It also should be understood that the present disclosure and claims are not limited to the preferred embodiments illustrated.
DETAILED DESCRIPTION
[0041] Referring generally to FIGS. 1-21 , it will be appreciated that pumps devices of the present disclosure generally may be embodied within numerous configurations. Indeed, the teachings within this disclosure may pertain to dynamically sealed pumps, whether of the rotodynamic or positive-displacement types, and/or to magnetically driven or sealless pumps, whether of the rotodynamic or positive-displacement types. If of the magnetically driven type, the pumps may be of the inner magnet drive and/or outer magnet drive types.
[0042] Referring to a preferred first example embodiment, in FIGS. 1-10 , and particularly to FIGS. 1 and 2 , an example pump 2 is shown connected to a motor adapter 4 that, in turn, is connected to a standard C-face electric motor 6 . The configuration of pump 2 happens to be a magnetically driven rotodynamic pump. More particularly, a first flange 5 of the adapter 4 is connected to the motor 6 by use of a plurality of fasteners 8 , such as threaded screws or other suitable means of connection. In this first example, the motor 6 includes a motor shaft 22 to which is connected a shaft extension 620 , and it will be appreciated that in combination with the adapter 4 , these components provide the rear end mechanical drive portion or power end that is connected to the pump 2 .
[0043] The pump 2 includes a casing 100 that is intended to be mounted in place, so as to be stationary. The casing 100 includes a front portion 100 a and a rear portion 100 b . The casing 100 also has an outlet or discharge port 102 and an inlet port 104 . In this first example, the discharge port 102 is radially facing, while the inlet port 104 is axially facing, although alternative configurations may be utilized. The casing 100 includes a rear face 106 that is connected to a second flange 7 of the adapter 4 by use of a plurality of fasteners 10 that pass through apertures in the second flange 7 and engage threaded holes in the casing rear face 106 . The casing 100 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like.
[0044] As may be seen in FIGS. 2 and 9 , the pump 2 also includes a backplate 200 that has an outer flange 202 . The backplate outer flange 202 is clamped between the casing 100 and the adapter 4 when connecting the pump 2 to the adapter 4 by installing the fasteners 10 . Sealing is provided between the casing 100 and the backplate 200 by an O-ring 13 , although other methods of sealing may be employed, such as use of a gasket, liquid sealant or the like. The pump 2 also includes a rear cover 300 that has an outer flange 302 . The rear cover 300 is connected to the backplate 200 by use of a plurality of fasteners 14 , such as threaded screws that pass through apertures 304 in the rear cover 300 and engage threaded holes in a rear face of the backplate 200 .
[0045] The pump 2 also includes a canister assembly 400 that includes a canister 400 a that has an outer flange 402 . The canister outer flange 402 is clamped between the backplate 200 and the rear cover 300 when connecting the rear cover 300 to the backplate 200 by installing the fasteners 14 . Sealing is provided between backplate 200 and the canister assembly 400 by an O-ring 16 , although other methods of sealing may be employed, such as use of a gasket, liquid sealant or the like. The canister assembly 400 also includes a front portion 404 that includes a front face 406 having a front cavity 408 and an aperture 410 that passes through the front portion 404 . The canister assembly 400 may be constructed of rigid materials. It will be appreciated that common materials may be used, such as stainless steel, or low conductivity metals, such as alloy C-22 or alloy C-276, and it could be advantageous to use materials having very low electrical conductivity, such as silicon carbide, ceramic, polymers or the like.
[0046] In addition, the canister assembly 400 includes a nose cap 500 , which has a threaded hole 502 , a rear face 504 and a rear extended portion 506 . The nose cap 500 is attached to the canister assembly front portion 404 by a fastener 18 , such as a threaded screw that passes through the aperture 410 in the front portion 404 and engages the threaded hole 502 in the rear of the nose cap 500 . In this first example embodiment, there is just one fastener 18 securing the nose cap 500 , but it will be appreciated by one of skill in the art that a plurality of fasteners or other suitable fastening means may be employed in assembling the components of the canister assembly 400 . Also, in this first example pump 2 , the front portion 404 and nose cap 500 of the canister assembly 400 are spaced from the front portion 100 a of the casing 100 , such that they do not receive support from the front portion 100 a . The nose cap 500 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like.
[0047] The shape of the front cavity 408 is not cylindrical, and it corresponds to a non-cylindrical shape of the nose cap extended portion 506 , so as to prevent relative rotation between the nose cap 500 and canister 400 a when connected by the fastener 18 , and to ensure that the canister assembly will remain stationary. Throughout this disclosure, it will be appreciated that alternative ways of preventing relative rotation between components may be used, such as by use of one or more fasteners, welding or other suitable alternatives. Sealing between the canister 400 a and the nose cap 500 is provided by an O-ring 20 , although other methods of sealing may be employed, such as use of a gasket, liquid sealant or the like.
[0048] The pump 2 further includes a drive magnet assembly, such as an inner magnet assembly 600 that includes an inner ring 640 which may be connected directly to a motor shaft, or in this example, to the shaft extension 620 . The inner ring 640 has a central threaded aperture 642 and the shaft extension 620 has a mating externally threaded front portion 622 , which is used to connect the inner ring 640 to the shaft extension 620 . In this first example embodiment, the shaft extension 620 and inner ring 640 are separate pieces, but it will be appreciated that they could be combined, so as to be a single piece, or a different method of connection may be used. The inner ring 640 may be constructed of rigid materials, but is preferably constructed of a material with high magnetic permeability, such as iron, carbon steel or the like.
[0049] The shaft extension 620 of this example includes an inner opening 624 that slidably receives a shaft 22 of the motor 6 . The shaft extension 620 also includes a keyway 626 and one or more threaded apertures 628 . A key 24 is positioned in the shaft extension keyway 626 and engages with a keyway 26 of the motor shaft 22 , to provide a positive rotational connection between the shaft extension 620 and the motor shaft 22 . One or more setscrews 28 are positioned in the shaft extension threaded apertures 628 and are tightened against the keyway 26 of the motor shaft 22 , to provide a positive axial connection between the shaft extension 620 and the motor shaft 22 .
[0050] The inner ring 640 of the drive magnet assembly, such as inner magnet assembly 600 includes an outer surface 644 to which are connected twenty-four magnet segments 646 , although it will be appreciated that one may have an embodiment with a different quantity of magnet segments. The magnet segments 646 are radially charged and are positioned with alternating polarity. The magnet segments 646 are rigidly connected to the inner ring 640 using an adhesive, although alternative suitable means of connection may be used, such as use of fasteners or the like. Although not required, this example embodiment includes an inner magnet sleeve 648 having a thin cylindrical portion 650 that closely fits over the outer surfaces of the magnet segments 646 .
[0051] The pump 2 also includes a rotatable rotor assembly, such as a rotatable impeller assembly 700 that includes a rotor, such as an impeller 702 . The impeller 702 includes a rear opening 704 , which receives a driven magnet assembly, such as an outer magnet assembly 705 . The outer magnet assembly 705 includes an outer ring 706 having an inner wall surface 708 to which are connected twenty-four magnet segments 710 , which corresponds to the number connected to the inner ring 640 , although it will be appreciated that one may have an embodiment with a greater or lesser quantity of magnet segments. The magnet segments 710 are radially charged and are positioned with alternating polarity. The magnet segments 710 are rigidly connected to the outer ring 706 using an adhesive, although alternative suitable means of connection may be used, such as use of fasteners or the like. An impeller magnet sleeve 712 is included having a thin cylindrical portion 714 that closely fits along the inner surfaces of the magnet segments 710 . The impeller magnet sleeve 712 also includes a rear flange 718 . The impeller magnet sleeve 712 is sealingly connected to the impeller 702 by continuous weld joints located at an outer end 720 of the rear flange 718 and at a front end 722 of the cylindrical portion 714 . It will be appreciated by one of skill in the art that other methods of connection may be used, such as liquid adhesive, gaskets, O-rings or the like. The rotor or impeller 702 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. The outer ring 706 may be constructed of rigid materials, but preferably is constructed of a material with high magnetic permeability, such as iron, carbon steel or the like.
[0052] Referring to FIGS. 6 a and 6 b , the rotatable rotor assembly or impeller assembly 700 includes a rotor or impeller 702 having a central opening 724 that includes one or more grooves 726 . A bushing 800 is received in the central opening 724 of the rotor or impeller 702 , and one or more O-rings 30 are positioned between an outer surface 802 of the bushing 800 and the grooves 726 in the central opening 724 of the impeller 702 . The bushing 800 is held in a forward direction against a step 727 in the central opening 724 proximate an end of the central opening 724 of the impeller 702 , where there is a transition from a first inner surface 727 a to a second inner surface 727 b having a smaller diameter. The bushing outer surface 802 is slightly smaller than the rotor or impeller central opening 724 , and the O-rings 30 are not intended to provide sealing between the two surfaces. Rather, in the event that the operating temperature may vary, and the bushing 800 and the impeller 702 may be made of materials with different rates of thermal expansion, then the size or extent of the clearance between the bushing 800 and impeller 702 will change and the compression of the O-rings 30 of this example embodiment will accommodate this clearance change and will maintain a concentric relationship between the bushing 800 and the impeller 702 .
[0053] The rotor or impeller 702 further includes a rear surface 728 that includes one or more threaded holes 730 . An impeller rear cap, such as rotor ring 732 having a central opening 736 is connected to the impeller rear surface 728 by at least one fastener 32 , such as by a plurality of screws that pass through apertures 734 in the rotor ring 732 and engage the threaded holes 730 in the impeller 702 . The bushing 800 includes a rear portion 804 with a shape that is not cylindrical, and it corresponds to a non-cylindrical shape of the central opening 736 in the rotor ring 732 to prevent relative rotation between the bushing 800 , rotor ring 732 and impeller 702 , although as previously noted, alternative ways of preventing relative rotation may be utilized. Thus, the bushing 800 fits inside the central opening 736 extending axially through the rotor or impeller 702 and is held in place between the rotor ring 732 and the step 727 in the central opening 736 of the impeller 702 .
[0054] As will be further described and more fully appreciated, within this first example pump 2 , the bushing 800 provides the rotatable rotor assembly or impeller assembly 700 a radial bearing surface, a first or front axial bearing surface, and a second or rear axial bearing surface. In this example, these bearing surfaces engage respective bearing surfaces of the canister assembly 400 , which as will be described further herein more particularly include a radial bearing surface provided by a bearing sleeve 806 , a first or front axial bearing surface provided by a front thrust washer 818 , and a second or rear axial bearing surface provided by a rear thrust washer 814 .
[0055] Thus, the canister assembly 400 of the first example pump 2 also includes a stationary bearing sleeve 806 that has a cylindrical shape. The front portion 404 of the canister 400 a includes an outer surface 412 having at least one groove 414 . The bearing sleeve 806 is positioned over the outer surface 412 of the front portion 404 , and at least one O-ring 34 is positioned between the outer surface groove 414 of the front portion 404 and an inner surface 808 of the bearing sleeve 806 . In this example embodiment, two O-rings 34 are received in two grooves 414 . The outer surface 412 of the front portion 404 of the canister 400 a is slightly smaller than the inner surface 808 of the bearing sleeve 806 . In the event that the operating temperature may vary and the canister 400 a and the bearing sleeve 806 may be made of materials with different rates of thermal expansion, then the size or extent of the clearance between the canister 400 a and the bearing sleeve 806 will change. The O-rings 34 are not intended to seal, but the compression of the O-rings 34 will accommodate this clearance change and will maintain a concentric relationship between the canister 400 a and the bearing sleeve 806 . In this manner, the bearing sleeve 806 provides the canister assembly 400 with a radial bearing surface for rotational engagement with the bushing 800 of the rotor assembly 700 .
[0056] The outer surface 810 of the stationary bearing sleeve 806 provides the canister assembly 400 a radial bearing surface at the front portion 404 of the canister 400 a , which is slightly smaller than an inner wall surface 812 of the bushing 800 . The inner wall surface 812 serves as a central cylindrical opening for the rotor assembly, such as impeller assembly 700 , and provides a radial bearing surface for the impeller assembly 700 . Thus, the rotatable rotor assembly, such as impeller assembly 700 , has a bushing 800 having a radial bearing surface 812 that rotates in engagement with and is supported by the outer surface 810 of the stationary bearing sleeve 806 of the canister assembly 400 .
[0057] The canister assembly 400 of pump 2 of this first example embodiment also includes a stationary rear thrust washer 814 having a central opening 816 with a shape that is not cylindrical. The canister 400 a includes a center portion 416 having a non-cylindrical shape that corresponds to the shape of the central opening 816 of the rear thrust washer 814 , to prevent relative rotation between the canister 400 and rear thrust washer 814 , although suitable alternative ways of preventing relative rotation may be utilized. The canister 400 a includes a center wall 418 that has a front surface 420 . The rear thrust washer 814 is positioned over the canister center portion 416 and against the front surface 420 of the canister center wall 418 .
[0058] The canister assembly 400 of pump 2 further includes a stationary front thrust washer 818 with a central opening 820 having a shape that is not cylindrical. The nose cap 500 includes a center portion 508 having a non-cylindrical shape that corresponds to the shape of the central opening 820 of the front thrust washer 818 to prevent relative rotation between the nose cap 500 and front thrust washer 818 , although suitable alternative ways of preventing relative rotation between the components of the canister assembly 400 may be utilized. The nose cap 500 has a front surface 509 that includes a front flange 510 . The front flange 510 also has a rear surface 512 . The front thrust washer 818 is positioned over the center portion 508 of the nose cap 500 and against the rear surface 512 of the front flange 510 of the nose cap 500 .
[0059] It will be appreciated that while the bearing sleeve 806 provides the canister assembly 400 a radial bearing surface 810 , the front thrust washer 818 has a rear surface 828 that provides the canister assembly 400 a first or front axial bearing surface and the rear thrust washer 814 has a front surface 826 that provides the canister assembly 400 a second or rear axial bearing surface, these bearing surfaces alternatively could be integral with the front portion 404 of the canister assembly 400 .
[0060] The bushing 800 of the rotor assembly or impeller assembly 700 has a length that is slightly shorter than the length of the bearing sleeve 806 of the canister assembly 400 . The bearing sleeve 806 is positioned between the rear thrust washer 814 and the front thrust washer 818 of the canister assembly 400 , creating a gap equal to the length of the bearing sleeve 806 . The impeller assembly 700 is positioned such that the bushing 800 is in the gap between the rear thrust washer 814 and the front thrust washer 818 . The bushing 800 also has a front surface 822 and a rear surface 824 . The front surface 822 provides the impeller assembly 700 a first or front axial bearing surface. Similarly, the rear surface 824 provides the impeller assembly 700 a second or rear axial bearing surface. Thus, the pump 2 includes a rotatable rotor assembly 700 that includes a bushing 800 wherein the bushing 800 is of single piece construction and includes a radial bearing surface 812 that restricts radial motion of the rotor assembly, a front axial bearing surface 822 that restricts forward motion of the rotor assembly 700 , and a rear axial bearing surface 824 that restricts rearward motion of the rotor assembly 700 .
[0061] Under some pump operating conditions, the impeller assembly 700 may experience a rear thrust force, pushing the impeller assembly 700 rearward and causing the rear surface 824 of the bushing 800 to rotatably engage the front surface 826 of the rear thrust washer 814 . Under other pump operating conditions, the impeller assembly 700 may experience a forward thrust force, pushing the impeller assembly 700 forward and causing the front surface 822 of the bushing 800 to rotatably engage the rear surface 828 of the front thrust washer 818 . The bushing 800 also includes one or more grooves 830 on the front face 822 , rear face 824 and inner surface 812 , which are connected. The radial bearing surface 812 of the rotor assembly 700 and the radial bearing surface 810 of the canister assembly front portion restrict radial motion of the rotor assembly 700 , and the first axial bearing surface 822 of the rotor assembly 700 and the first axial bearing surface 828 of the canister assembly front portion 404 restrict forward motion of the rotor assembly 700 . In addition, the rotor assembly 700 further comprises a second axial bearing surface 824 , the canister assembly front portion further comprises a second axial bearing surface 826 , and the second axial bearing surface of the rotor assembly 824 and the second axial bearing surface 826 of the canister assembly front portion 404 restrict rearward motion of the rotor assembly 700 .
[0062] The canister 400 a includes a thin cylindrical portion 422 having an inner surface 424 that is slightly larger than the outer surface 652 of the inner magnet assembly 600 , and having an outer surface 426 that is slightly smaller than the inner surface 738 along the thin cylindrical portion 714 of the impeller magnet sleeve 712 . The casing 100 , backplate 200 , and canister assembly 400 , with its canister 400 a and nose cap 500 , all remain stationary, are sealingly connected, and together form a sealed fluid chamber rearward of the canister assembly 400 .
[0063] The magnet segments 646 of the drive magnet assembly or inner magnet assembly 600 are in axial alignment with the magnet segments 710 of the outer magnet assembly 705 of the rotatable rotor assembly or impeller assembly 700 . The stationary cylindrical portion 422 of the canister assembly 400 is located in a radial gap between the magnet segments 646 of the inner magnet assembly 600 and the magnet segments 710 of the outer magnet assembly 705 of the rotor assembly 700 . The alternating polarity of the magnet segments 646 creates an inner magnetic field, and the alternating polarity of the magnet segments 710 creates an outer magnetic field. These two magnetic fields synchronize together to provide a strong magnetic coupling torque between the inner magnet assembly 600 and the impeller assembly 700 , such that when the motor 6 is energized, it rotates the motor shaft 22 , which rotates the inner magnet assembly 600 , which in turn, rotates the impeller assembly 700 .
[0064] Referring to FIGS. 4 and 5 , the impeller 702 includes a plurality of vanes 740 . The casing 100 includes a discharge collector cavity 108 that is fluidly connected to the casing discharge port 102 . The rotation of the impeller vanes 740 causes a pumping action that moves liquid into the pump through the casing inlet port 104 , radially outward to the discharge collector cavity 108 , and out of the pump through the discharge port 102 . A portion of the vanes 740 of the rotor or impeller 702 extend forward in front of the front surface 509 of the nose cap 500 and inward to an inner diameter 744 that is smaller than an outer diameter 514 of the nose cap 500 of the canister assembly 400 .
[0065] Referring to FIG. 6 a , the impeller 702 includes a rear wall 746 having a plurality of optional rear vanes 748 . As seen in FIG. 3 , the casing 100 includes a rear cavity 110 that is partially blocked from the discharge collector cavity 108 by the impeller rear wall 746 . During pump operation, rotation of the impeller 702 rotates the fluid within the rear cavity 110 . The optional rear vanes 748 enhance or increase the speed of rotation of the fluid within the rear cavity 110 of the casing 100 which experiences centrifugal force. The centrifugal force will tend to create a radial pressure gradient in the rear cavity 110 , where the pressure is somewhat proportional to the radius. This gradient will partially resist the pressure differential that promotes the recirculation path P, and will reduce the overall pressure within the rear cavity 110 , to that the net forward thrust on the rotor assembly or impeller assembly 700 is reduced.
[0066] When pump 2 is operating, the pumping action of the impeller vanes 740 creates a pressure differential within the pump 2 , such that the pressure at the inlet port 104 and in front of the nose cap 500 at the suction end of the pump 2 is lower than the pressure in the discharge collector cavity 108 and at the discharge port 102 .
[0067] As may be seen in FIG. 10 in a simplified view of the pump 2 without the drive magnet assembly or inner magnet assembly 600 and the power end drive components, the pump 2 includes a rather complex recirculation path P behind the impeller assembly 700 . The recirculation path P begins at the discharge collector cavity 108 , where the pressure is high, extends between stationary and rotating surfaces, and ends in front of the nose cap 500 , where the pressure is low. The recirculation path P is uniquely dynamic, because every portion of the path is bounded by a combination of a stationary surface and a rotating surface. This helps to avoid stagnation and clogging of the recirculation path P, which is used for lubrication and cooling of the pump components, such as the bushings and the canister assembly. The stationary surfaces are on the casing 100 , backplate 200 , and components of the canister assembly 400 , including the canister 400 a , rear thrust washer 814 , bearing sleeve 806 , front thrust washer 818 and nose cap 500 . The rotating surfaces are on the rotatable rotor assembly or impeller assembly 700 . The recirculation path P includes a radial gap between the canister 400 a and the sleeve 712 of the rotor assembly or impeller assembly 700 . The one or more grooves 830 on the front face 822 , rear face 824 and inner surface 812 of the bushing 800 also facilitate fluid passage.
[0068] The recirculation path P includes flow from the discharge collector cavity 108 past the outer edge of the impeller 702 . The fluid moves radially inward behind the impeller 702 and then further rearward behind the outer magnet assembly 705 . The fluid then moves forward along the canister portion extending through the radial gap between the canister and the outer magnet assembly 705 , and then the fluid passes radially inward over the canister to the bushing 800 . The fluid then passes through the grooves 830 that extend across the rear surface, inner surface and front surface of the bushing 800 . This example pump 2 includes four grooves 830 in the bushing 800 , and as a result, the fluid splits into four separate streams corresponding to the four grooves 830 . The four parallel paths continue through the grooves 830 to the front surface of the bushing 800 . The four flow paths come together at the front surface of the bushing 800 and then the fluid passes through a gap formed by the inner surface 727 b of the impeller and both the outer surface of the front thrust washer 818 and the outer edges of the nose cap 500 , and to the low pressure area proximate the inlet port 104 .
[0069] Referring to FIGS. 11-13 , the same pump 2 of the first example is shown in a second example but connected to a different a rear end mechanical drive portion or power end and an adaptor. In this second example, the pump 2 is connected to a power end 900 and adapter 904 of a commercially available non-magnetically driven rotodynamic pump having a dynamic seal that is designed in accordance with dimensions specified in a pump industry standard, such as, for example, a Goulds 3196 Pump, made by ITT Goulds Pumps of Seneca Falls, N.Y., which is designed to meet the dimensioned required in industry standard ASME B73.1. This also applies to industry standard ISO 5199. The casing 100 is configured to be mounted in a stationary position and includes a rear face 106 that is connected to a flange 907 of the adapter 904 by use of a plurality of fasteners 10 that pass through apertures 912 in the flange 907 and engage threaded holes in the casing rear face 106 .
[0070] In this second example, however, the pump 2 further includes an inner magnet assembly 600 that includes an inner ring 640 which is connected directly to a shaft 902 of the power end 900 . The inner ring 640 has a central threaded aperture 642 and the power end shaft 902 has a mating externally threaded front portion 922 , which is used to connect the inner ring 640 to the power end shaft 902 . Thus, the example magnetically driven pump 2 can be substituted in place for a dynamically sealed pump and will provide or accommodate the same mounting dimensions that are shown in FIG. 11 as including: the horizontal distance F between the front and rear mounting feet; the vertical distance D from the bottom of the front mounting feet to the center of the motor shaft 902 and center of the flange for the inlet port 104 at the front of the pump 2 ; the vertical distance X from the center of the motor shaft 902 and center of the flange for the inlet port 104 at the front of the pump 2 to the top surface of the flange for the discharge port 102 ; the horizontal distance from the center of the discharge port 102 to the front of the flange for the inlet port 104 ; the horizontal distances E 1 from the center of the inlet port 104 to the center of the mounting holes of the front mounting feet; the diameter H of the mounting holes in the front mounting feet; and the overall length CP of the pump 2 and power end.
[0071] Turning to FIGS. 14-21 , a third example pump 1002 is shown. The third example pump 1002 happens to be a magnetically driven, positive-displacement gear pump. The third example pump 1002 includes a casing 1100 that includes a front portion 1100 a and a rear portion 1100 b and a central portion 1100 c . The casing portions may be separate components that are connected together or portions may be formed integrally, such as by casting. The casing 1100 is configured to be mounted in a stationary position via mounting feet on the central portion 1100 c . The casing 1100 also has a discharge port 1102 and an inlet port 1104 . In this third example, the discharge port 1102 and inlet port 1104 both are radially facing, although alternative configurations may be utilized. The casing 1100 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like.
[0072] The rear portion 1100 b of the casing 1100 includes an opening 1107 that receives one or more bushings or bearings 1120 , shown in the present example in the form of bearings. Also within the rear portion 1100 b is a shaft 1130 . The shaft 1130 has a drive end 1132 that may be coupled to a driver (not shown), such as an electric motor or the like, that causes the shaft 1130 to rotate. As such, the example shaft 1130 is supported by the bushings or bearings 1120 and is free to rotate within the opening 1107 of the rear portion 1100 b of the casing 1100 .
[0073] The shaft 1130 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. The shaft 1130 also may have a magnet receiving end 1134 that may include one or more holes 1136 , which in this example are threaded, but it will be understood that other configurations may be used for connecting components to the magnet receiving end 1134 .
[0074] An example rotatable drive magnet assembly or inner magnet assembly 1200 is attached to the magnet receiving end 1134 of the shaft 1130 . The inner magnet assembly 1200 may include an inner ring 1210 having a generally cylindrical shape, one or more fasteners 1220 for connection to the receiving end 1134 , a plurality of (two or more) inner magnet segments 1230 and an optional inner magnet sleeve 1240 . The optional inner magnet sleeve 1240 may provide additional attachment force to hold the inner magnet segments 1230 to an outer surface 1211 of the inner ring 1210 and may provide protection of the inner magnet segments 1230 from corrosion or damage. The inner magnet sleeve 1240 may be constructed of rigid materials, but preferably is constructed of a material with very low magnetic permeability, such as stainless steel or the like. The method of connection for the inner magnet segments 1230 may be via adhesive, mechanical fasteners or other suitable means of connection. The magnet segments 1230 are radially charged and are positioned with alternating polarity, so as to create a magnetic field directed radially outward.
[0075] The example inner ring 1210 may have a web 1250 that in this example engages the magnet receiving end 1134 of the shaft 1130 , and one or more holes 1260 that align with holes 1136 in the magnet receiving end 1134 of the shaft 1130 and receive the fasteners 1220 . In the present example, the inner ring 1210 may be connected to and rotate with the magnet receiving end 1134 of the shaft 1130 . The inner ring 1210 may be constructed of rigid materials, but is preferably constructed of a material with high magnetic permeability, such as iron, carbon steel or the like. It also will be understood that the inner ring 1210 may be connected to the shaft 1130 in alternative ways.
[0076] The casing 1100 includes an opening 1109 , which in this example is in the central portion 1100 c . The opening 1109 receives a canister assembly 1300 that is intended to be stationary. The canister assembly 1300 may be constructed of multiple pieces or may be of an integral, one-piece construction. The canister assembly 1300 may be constructed of rigid materials. It will be appreciated that common materials may be used, such as stainless steel, or low conductivity metals, such as alloy C-22 or alloy C-276, and it could be advantageous to use materials having very low electrical conductivity, such as silicon carbide, ceramic, polymers or the like. The stationary canister assembly 1300 includes a canister 1301 having a rear flange 1302 that extends radially outward and is held between the connection of the rear portion 1100 b to the central portion 1100 c of the casing 1100 . A rear canister seal 1310 creates a leak-tight connection between the radial rear flange 1302 of the canister 1301 and the central portion 1100 c of the casing 1100 . The rear canister seal 1310 , may be in the form of static seal having a resilient O-ring shape, or a preformed or liquid gasket or the like, and preferably is constructed of an elastomeric material such as rubber or the like.
[0077] The canister 1301 of the canister assembly 1300 also includes a first cylindrical portion 1303 extending forward from the rear flange 1302 to a central radially extending portion 1304 that extends outward from the first cylindrical portion 1303 to a second cylindrical portion 1305 that extends further forward and is closed at the forward end by an end wall 1306 . The end wall 1306 is set back from the front end of the second cylindrical portion 1305 , forming a recess 1307 at the front of the canister 1301 .
[0078] The canister assembly 1300 also includes a nose cap 1330 having a rear portion 1331 that engages the recess 1307 at the front of the canister 1301 . The nose cap 1330 of the canister assembly 1300 also has a flange 1332 that extends radially outward. A rear surface 1334 of the flange 1332 provides a first or forward axial bearing surface of the canister assembly 1300 . The central radially extending portion 1304 of the canister 1301 has a front surface 1308 that provides a second or rearward axial bearing surface of the canister assembly 1300 . The nose cap 1330 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. A front canister seal 1320 , such as in the form of static seal having a resilient O-ring shape, or a preformed or liquid gasket or the like, creates a leak-tight connection between the canister 1301 and the nose cap 1330 , and may be constructed of similar materials to those mentioned with respect to the rear seal 1310 . The stationary canister assembly 1300 separates an internal fluid chamber within the pump 1002 from the inner magnet assembly 1200 . It also will be appreciated that any of the bearing surfaces of the canister assembly 1300 , such as the radial bearing surface provided by the second cylindrical portion 1305 , the first or forward axial bearing surface provided by the rear surface 1334 of the flange 1332 of the nose cap 1330 , and the second or rearward axial bearing surface provided by the front surface 1308 of the central radially extending portion 1304 of the canister 1301 alternatively could be provided by separate pieces, such as in the first example pump 2 .
[0079] The front portion 1100 a of the casing 1100 has a rear face that is sealed by a gasket 1108 to a front face of the central portion 1100 c and closes the opening 1109 in the central portion 1100 c . The gasket 1108 may be in the form of a static seal, such as a preformed or liquid gasket or the like, or an O-ring, and creates a leak-tight connection between the front portion 1100 a and central portion 1100 c , and may be constructed of similar materials to those mentioned with respect to the other seals. In this example, the front portion 1100 a also has an inner surface 1109 a that generally is aligned with the opening 1109 of the central portion 1100 c of the casing 1100 . The front portion 1100 a may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like.
[0080] The front end of the central portion 1100 c has one or more holes 1113 , which in this example are threaded. The front portion 1100 a is connected to the central portion 1100 c by one or more fasteners 1360 . In the present example, an elongated shaft portion of the one or more fasteners 1360 , which in this example is threaded, is assembled through one or more holes 1106 in the front portion 1100 a and is installed in the one or more holes 1113 in the front of the central portion 1100 c of the casing 1100 . It also will be understood that the front portion 1100 a may be connected to other portions of the casing 1100 in alternative ways.
[0081] The nose cap 1330 of the canister assembly 1300 includes a front face 1333 that engages the front portion 1100 a . The nose cap 1330 also includes a front gear support extension 1336 , from which a further nose cap support extension 1338 extends. At least a portion of the nose cap support extension 1338 is received by an opening 1112 in the front portion 1100 a . The front nose cap support extension 1338 of the canister nose cap 1330 may include an alignment surface or shape that engages with a complementary surface or shape within the front portion 1100 a , such that when the nose cap support extension 1338 is received in the opening 1112 of the front portion 1100 a , the canister assembly 1300 is supported at its front end by the front portion 1100 a of the casing 1100 and the engagement of the alignment surface or shape prevents relative rotation between nose cap 1330 and the front portion 1100 a . It will be understood that alternative methods and configurations may be used to prevent relative rotation between the respective components, so that the canister assembly 1300 remains stationary. Although not required, an optional seal, such as in the form of static seal having a resilient O-ring shape, or a preformed or liquid gasket or the like, may be located between the nose cap front portion 1100 a to prevent pumped fluids from entering the opening 1112 in the front portion 1100 a . Such a seal may be constructed of similar materials to those mentioned with respect to the other seals.
[0082] A rotatable rotor assembly or outer gear assembly 1500 includes a rotor 1501 having an outer gear 1510 at a forward end and an opening 1520 at the rearward end that receives an outer ring 1530 , a plurality of (two or more) outer magnet segments 1540 , and an optional inner magnet sleeve 1550 . In this way, the rotor assembly 1500 includes a rear opening 1520 having an inner wall surface 1521 to which a plurality of magnet segments 1540 is connected. The rotor 1501 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. The outer ring 1530 may be constructed of rigid materials, but preferably is constructed of a material with high magnetic permeability, such as iron, carbon steel or the like. The outer ring 1530 is connected in the opening 1520 , which may be accomplished by various means, including by interference fit, adhesive, welding, the use of fasteners or the like.
[0083] The outer ring 1530 includes an inner surface to which a plurality of (two or more) outer magnet segments 1540 are connected. It will be appreciated that the quantity of outer magnet segments 1540 should be equal to the quantity of the inner magnet segments 1230 that are connected to the inner ring 1210 . The method of connection for the outer magnet segments 1540 may be via adhesive (preferred), mechanical fasteners or other suitable means of connection. The outer magnet segments 1540 are magnetically radially charged and are positioned with alternating polarity, so as to create a magnetic field directed radially inward. The optional inner magnet sleeve 1550 may provide additional attachment force to hold the outer magnet segments 1540 to the outer ring 1530 and may provide protection of the outer magnet segments 1540 from corrosion or damage.
[0084] The stationary first cylindrical portion 1303 of the canister assembly 1300 is located in a radial gap between the magnet segments 1230 of the inner magnet assembly 1200 and the magnet segments 1540 of the rotatable rotor assembly or outer magnet assembly 1500 . The magnet segments 1230 of the inner magnet assembly 1200 also are in axial alignment with the magnet segments 1540 of the rotor assembly or outer magnet assembly 1500 . The stationary first cylindrical portion 1303 of the canister assembly 1300 is located in a radial gap between the magnet segments 1230 of the inner magnet assembly 1200 and the magnet segments 1540 of the outer magnet assembly of the rotor assembly 1500 . The alternating polarity of the magnet segments 1230 creates an inner magnetic field, and the alternating polarity of the magnet segments 1540 creates an outer magnetic field. These two magnetic fields synchronize together to provide a strong magnetic coupling torque between the inner magnet assembly 1200 and the rotating rotor assembly 1500 . In addition, the canister assembly 1300 includes a front portion extending from the first cylindrical portion, which in this example also includes a second cylindrical portion 1305 which essentially extends from the first cylindrical portion and includes a radial bearing surface, as well as a nose cap 1330 , which includes a first axial bearing surface 1334 on the rear of the flange 1332 .
[0085] The rotatable rotor assembly 1500 is positioned within the central portion 1100 c and front portion 1100 a of the casing 1100 and includes a rotor bushing 1560 . The rotor 1501 having the outer gear 1510 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. The rotor bushing 1560 includes a front surface 1562 that provides a first or forward axial bearing surface and a rear surface 1564 that provides a second or rearward axial bearing surface. The rotor bushing 1560 further includes an inner wall surface 1566 that serves as a central cylindrical opening for the rotor assembly 1500 and provides a radial bearing surface for the rotor assembly 1500 .
[0086] The inner surface 1566 of the bushing 1560 of the rotor assembly or outer gear assembly 1500 provides a radial bearing surface that slidingly rotates on and is supported by the second cylindrical portion 1305 of the canister 1301 of the canister assembly 1300 . The first or forward axial bearing surface provided by the front surface 1562 of the bushing 1560 slidingly rotates against or engages the first or forward axial bearing surface provided by the rear surface 1334 of the flange 1332 of the canister assembly 1300 . The second or rearward axial bearing surface provided by the rear surface 1564 of the bushing 1560 slidingly rotates against or engages the second or rearward axial bearing surface provided by the front surface 1308 of the central radially extending portion 1304 of the canister 1301 of the canister assembly 1300 . Thus, the bushing 1560 is of single piece construction and provides all of the bearing surfaces for the rotor assembly 1500 .
[0087] Indeed, the radial bearing surface 1566 of the rotatable rotor assembly 1500 and the radial bearing surface provided by the outer surface of the second cylindrical portion 1305 of the canister assembly front portion restrict radial motion of the rotor assembly 1500 , and the first axial bearing surface 1562 of the rotor assembly 1500 and the first axial bearing surface 1334 of the nose cap 1330 restrict forward motion of the rotor assembly 1500 . In addition, the rotor assembly 1500 further comprises a second axial bearing surface 1564 , the canister assembly front portion further comprises a second axial bearing surface 1308 , and the second axial bearing surface of the rotor assembly 1564 and the second axial bearing surface 1308 of the front portion of the canister assembly 1300 restrict rearward motion of the rotor assembly 1500 .
[0088] A rotatable drive magnet assembly or inner gear assembly 1600 includes inner gear 1610 that is positioned within the front portion 1100 a of the casing 1100 . The inner gear 1610 may be constructed of rigid materials, such as steel, stainless steel, cast iron or other metallic materials, or structural plastics or the like. Although not required, the inner gear assembly 1600 also may include an optional inner gear bushing 1620 , which has an outer surface 1622 that may be connected to an inner surface 1612 of the inner gear 1610 by various means, including by interference fit, adhesive, welding, the use of fasteners or the like. The inner gear bushing 1620 also has an inner surface 1624 that provides a radial bearing surface for the inner gear 1610 as it slidingly rotates on the front gear support extension 1336 of the nose cap 1330 of the canister assembly 1300 .
[0089] Pump operation comes from rotational energy that is supplied by a driver (not shown), such as an electric motor or the like, that is connected to the drive end drive end 1132 of the shaft 1130 . Thus, rotation of a driver or motor that is connected to the drive end 1132 causes the shaft 1130 to rotate. The inner magnet assembly 1200 is connected to, and therefore, rotated by the shaft 1130 . The radially outward magnetic field of the inner magnet segments 1230 rotates along with inner magnet assembly 1200 . In turn, the radially outward magnetic field of the inner magnet segments 1230 interacts with the radially inward magnetic field of the outer magnet segments 1540 , such that it drives the rotor assembly or outer gear assembly 1500 to rotate synchronously with inner magnet assembly 1200 , even though there is no physical contact between the outer gear assembly 1500 and the inner magnet assembly 1200 .
[0090] The outer gear 1510 includes a plurality of (in this instance three or more) teeth 1517 that mesh with a plurality of teeth 1613 of the inner gear 1610 . Rotation of the outer gear assembly 1500 causes engagement of the surfaces of the outer gear teeth 1517 with the surfaces of the inner gear teeth 1613 , thereby causing the inner gear assembly 1600 to rotate.
[0091] The front portion 1100 a of the casing 1100 provides a pumping cavity that is connected to a discharge port 1102 and an inlet port 1104 . As the outer gear assembly 1500 and inner gear assembly 1600 rotate, the unmeshing of their teeth 1517 and 1613 , respectively, causes an expanding first pumping pocket that pulls fluid into it from the inlet port 1104 . As the outer gear assembly 1500 and inner gear assembly 1600 rotate further, the first pumping pocket moves clockwise until the teeth 1517 and 1613 , respectively, begin to remesh, which causes the pumping pocket to collapse, forcing the fluid to be discharged out of the pump 1002 through discharge port 1102 .
[0092] When pump 1002 is operating, the pumping action creates a pressure differential within the pump 1002 , such that the pressure at the inlet port 1104 proximate the inner gear 1610 and nose cap 1330 at the suction end of the pump 1002 is lower than the pressure in the discharged fluid at the discharge port 1102 . As may be seen in FIG. 21 in a simplified view of the pump 1002 without the inner magnet assembly 1200 , the rear portion 1100 b of the casing 1100 , or the power end drive components, the pump 1002 includes a rather complex recirculation path P′ that extends behind the rotor assembly or outer gear assembly 1500 . The recirculation path P′ begins at the discharge portion of the casing 1100 that forms the discharge port 1102 , where the pressure is high, extends between stationary and rotating surfaces, and ends in front of the nose cap 1300 , where the pressure is low.
[0093] The recirculation path P′ is uniquely dynamic, because every portion of the path is bounded by a combination of a stationary surface and a rotating surface. This helps to avoid stagnation and clogging of the recirculation path P′, which is used for lubrication and cooling of the pump components, such as the bushings and the canister assembly. The stationary surfaces are on the casing 1100 and components of the canister assembly 1300 , including the radial rear flange 1302 , the first cylindrical portion 1303 , the central radially extending portion 1304 , the second cylindrical portion 1305 , and the nose cap 1330 . The rotating surfaces are on the rotor assembly or outer gear assembly 1500 and the inner gear assembly 1600 .
[0094] The recirculation path P′ includes a longitudinal groove 1122 in the discharge side of the front portion 1100 a of the casing that allows fluid to pass around a forward portion of the rotor assembly or outer gear assembly 1500 , which otherwise has a close clearance fit with the front portion 1100 a . The outer diameter of the rotor assembly 1500 is reduced rearward of the front portion, increasing the clearance between the rotor assembly 1500 and the central portion 1100 c of the casing 1100 . When the fluid from the groove 1122 in the front portion 1100 a enters this area of greater clearance, it spreads out all the way around the rotor 1501 and into a cylindrical gap between the rotor assembly 1500 and the central portion 1100 c of the casing 1100 , and continues to move rearward. The recirculation path P′ continues behind the rotor assembly 1500 and along the radial rear flange 1302 of the canister 1301 , then moving forward along the first cylindrical portion 1303 and radially inward along the central radially extending portion 1304 of the canister 1301 and the rear surface 1564 of the bushing 1560 that provides the second or rearward axial bearing surface of the rotor assembly 1500 . The rear surface 1564 of the bushing 1560 has a close clearance fit to the rear flange 1302 , but the rear surface 1564 also includes a plurality of grooves 1570 that extend across surfaces of the bushing 1560 , including the rear surface 1564 that provides a second or rearward axial bearing surface, inner surface 1566 that provides a radial bearing surface, and front surface 1562 that provides a first or forward axial bearing surface of the bushing 1560 . This example pump 1002 includes four grooves 1570 in the bushing 1560 , and as a result, the fluid splits into four separate streams corresponding to the four grooves 1570 as it passes over the axial and radial bearing surfaces of the bushing 1560 . The four parallel paths continue through the grooves 1570 to the front surface 1562 of the bushing 1560 . The four flow paths from the grooves 1570 come together at the front surface 1562 and meet an outer corner of the flange 1332 of the nose cap 1330 , where a small donut shaped cavity 1574 is formed by a circumferential groove 1576 in the inner surface 1572 of the rotor 1501 , a circumferential groove on the outer rear corner of the flange 1332 of the nose cap 1330 , and a circumferential groove 1578 on the outer front edge of the bushing 1560 . Continuing in the path P′, the radial flange 1332 of the nose cap 1330 has a close clearance fit with the inner surface 1572 of the rotor, but fluid is permitted to pass through a groove 1340 that extends longitudinally along the outer edge of the flange 1332 and then radially inward across the front face 1333 of the nose cap 1330 . The groove 1340 leads the fluid flow to a flat surface 1342 in the front gear support extension 1336 , which permits fluid to flow forward between the front gear support extension 1336 and the inner gear bushing 1620 , to a groove 1124 in the front portion 1100 a of the casing 1100 . This further groove 1124 allows the fluid to flow through to the suction side at the inlet port 1104 , completing the recirculation path P′ of the pump 1100 .
[0095] From the above disclosure, it will be apparent that pumps constructed in accordance with this disclosure may include a number of structural aspects that provide advantages over conventional constructions, depending upon the specific design chosen.
[0096] It will be appreciated that pumps constructed in accordance with the present disclosure may be provided in various configurations. Any variety of suitable materials of construction, configurations, shapes and sizes for the components and methods of connecting the components may be utilized to meet the particular needs and requirements of an end user. Indeed, pumps in accordance with the present disclosure may include interior surfaces that are constructed of specific materials and/or have particular surface finishes wherein the interior surfaces permit use of the pumps in hygienic applications where microbial growth must be prevented. It will be apparent to those skilled in the art that various modifications can be made in the design and construction of such pumps without departing from the scope or spirit of the claimed subject matter, and that the claims are not limited to the preferred embodiment illustrated herein. It also will be appreciated that some aspects of the example embodiment are discussed in a simplified manner and the aspects may be capable of being implemented in rotodynamic pumps, positive-displacement pumps, and whether such pumps include dynamic seals between rotating parts or are magnetically driven.
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The disclosure provides pumps that include improvements in construction, which involve bearing surfaces, recirculation paths, mounting footprints, impeller vane starting diameters, canister assemblies, and rotor assembly bushing configurations.
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FIELD OF THE INVENTION
[0001] The present invention relates to pins and in particular to pins that mount equipment that must be removed from time to time.
BACKGROUND OF THE INVENTION
[0002] Pins are often used to mount elements of equipment which must be removed from time to time. For example there are many applications in the oil and gas industry where pins are used to mount hydraulic cylinders. Hydraulic cylinders must be serviced regularly in order for them to perform reliably.
[0003] Where machines are used in harsh conditions they suffer from corrosion. It is often the case that due to corrosion pins are difficult to remove when they have been in service for only a modest period. In the off-shore oil and gas industry it is common practice for hydraulic cylinders to be removed from service and taken away for repair. Typically, hydraulic cylinders are removed every six years. Off-shore oil rigs are exposed to the most extreme environments, and it is common for pins to be so corroded that a machine such as an oxy-acetylene torch, spark eroder, hydraulic press or in line borer is required to remove the pin. In most areas of off-shore oil/gas rigs health and safety regulations forbid the use of equipment generating in excess of 240 C. As such, normal practice is for pins to be pressed or bored out. The equipment required for either pressing or boring out a pin is substantial, requiring transport to and from the rig by vessel and a team of four men for its operation who would be transported by helicopter.
[0004] The requirement to bring in specialist equipment to remove a pin is not desirable. It is expensive in terms of manpower, equipment requirements and plant downtime (for example when a pin must be removed at a non-scheduled time).
[0005] An example of a device for removing pins that have been working in harsh environments can be found in U.S. Pat. No. 4,870,739 which describes a device for forcing the pins out of links in chains that have been used to secure anchors or buoys.
[0006] As well as being a problem in the oil and gas and marine industries, corrosion of pins is a problem in other areas. For example in the construction and agricultural industries machines work outside and are subjected to dust, debris, extremes of temperature, rain, etc, all resulting in corrosion. In the chemical industries elements of machines may be located in environments which cause corrosion.
[0007] It would therefore be desirable to provide an improved pin.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the invention there is provided a pin as specified in Claim 1 .
[0009] According to another aspect of the invention there is provided mounting arrangement as specified in Claim 14 .
[0010] According to another aspect of the invention there is provided a method of mounting an object as specified in Claim 15 .
[0011] The pin of the invention provides for much easier removal of parts of machines secured in position by pins. Using the pin of the invention the job of removing a hydraulic cylinder (or other part) becomes a one man job requiring only a spanner and a grease gun or a hammer and chisel, instead of being a four man job requiring specialist equipment that must be transported to the site.
[0012] Releasing the pin of the invention does not require heat making the pin particularly suitable for use on oil and gas installations. In fact, the pin of the invention will find application in any scenario involving uncoated pins used in harsh environments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In the drawings, which illustrate a preferred embodiment of the invention, and are by way of example:
[0014] FIG. 1 is a schematic representation of a pin according to the invention;
[0015] FIG. 2 is a cross-sectional elevation of the pin illustrated in FIG. 1 ;
[0016] FIG. 3 a is a side view of a mounting arrangement according to the invention; and
[0017] FIG. 3 b is a plan view of the mounting arrangement illustrated in FIG. 3 a.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] Referring now to FIGS. 1 and 2 , there is shown a pin 1 comprising an inner element 2 having a first end 4 and a second end 4 a and an elongate portion 2 a extending between the said first and second ends. The elongate portion 2 a is tapered between the first and second ends 4 , 4 a , the cross-section of the portion 2 a being greater at the first end 4 than at the second 4 a . A seal 5 adjacent the first end 4 sits in a seal housing 5 a . The taper terminates at a seal 6 located in a seal housing 6 a , the second end 4 a including portion 7 having parallel sides. The second end 4 a further includes a stub 8 including a threaded portion 10 . A seal 9 is mounted on the stub 8 .
[0019] The inner element 2 is housed in a sleeve 3 , the inner element 2 and the sleeve 3 forming a substantially cylindrical pin, the external diameter of the sleeve 3 being substantially the same as the external diameter of the first end 4 of the inner element 2 .
[0020] The sleeve 3 includes an opening 12 through which the stub 8 passes, the threaded portion 10 extending beyond the outer end of the sleeve 3 . A seal 9 sits in a seal housing 9 a in the form of a groove in the sleeve 3 . An internally threaded nut 11 is fastened onto the threaded portion 10 of the stub 8 to secure together the inner element 2 and the sleeve 3 to form the pin 1 .
[0021] The stub 8 may be unthreaded and lockable cap screws used to hold the inner element 2 in place.
[0022] The end wall of the sleeve 3 includes a bore 13 of a first diameter and extending therefrom a second bore that communicates with the chamber formed between the inner surface of the sleeve 3 and the outer surface of the parallel sided portion of the elongate element 2 . The second bore is threaded, in use receiving either grub screw 15 which covers the grease nipple 14 , the function of which is described in greater detail below.
[0023] To remove the pin 1 , first the lock nut 11 is slackened and removed, then the grub screw 15 is removed allowing access to the grease nipple 14 . A grease gun is attached to the grease nipple and is operated to force grease into the cavity 16 . The cavity 16 is bounded by a face of the ‘O’ ring 9 , the internal surface 17 of the sleeve 3 , the outer surface 7 of the inner element 2 and one face of the seal 6 . The build up of pressurised grease in the cavity 16 causes the inner element to move in the direction X. Due to the taper of the elongate section 2 a and the inner surface of the sleeve 3 , a relatively small amount of movement of the inner element 2 in the direction X results in the two parts of the pin being free of each other.
[0024] Referring now to FIGS. 3 a and 3 b , a mounting arrangement comprises a levis 50 including bores 51 in each of the bifurcations 52 of levis 50 . A piston rod 53 of a hydraulic cylinder terminates in a bracket 54 including a bore 55 . The pin 1 passes through aligned bores 51 and 55 and the lock nut 11 is fastened onto the threaded portion 10 of the stub 8 . A lip 17 of the end 4 engages with the outer surface of one of the bifurcations 52 and the lock nut 11 engages with a washer 18 , which may be a spring washer or an unsprung washer, to secure the pin 1 in a working position.
[0025] The method of assembling the arrangement illustrated in FIG. 3 comprises the steps of:
i) aligning the bores 51 , 55 ; ii) removing the lock nut 11 from a pin 1 as illustrated in FIG. 1 ; iii) passing the pin 1 through the bores 51 , 55 ; iv) presenting a washer 18 up to an outer face of one of the bifurcations 52 over the stub 8 ; and v) fastening lock nut 11 onto the stub 8 and tightening the same.
[0031] The method of disassembling the arrangement illustrated in FIG. 3 comprises the steps of:
i) slackening off the lock nut 11 ; ii) removing the washer 18 ; iii) removing the grub screw 15 ; iv) attaching a grease gun to the grease nipple 14 ; v) filling the cavity 16 with grease until the inner element 18 is force sufficiently far in the X direction to release the inner element 2 from the sleeve 3 ; vi) removing the inner element 2 from the sleeve 3 ; vii) removing the sleeve 3 or the remains thereof from the aligned bores 51 , 55 .
[0039] Where the mounting arrangement illustrated in FIGS. 3 a and 3 b has been located in a very harsh environment, such as an off-shore oil rig, the corrosion of the sleeve is usually such that when the inner element 2 is released the sleeve collapses, allowing the bracket 54 of piston rod 53 to be removed.
[0040] In a simplified embodiment of the invention instead of using a hydraulic system to separate the inner element from the sleeve a hammer, or hammer and chisel are employed. A fitter removes the lock nut 11 and taps on the end of the stub 8 with a hammer, or hammer and chisel. In such an embodiment there is no need for the seals 5 , 6 and 9 .
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A pin comprises an inner element and an outer sleeve. The inner element is insertable into and removable from the outer sleeve, and the outer surface of the inner element and the inner surface of the outer sleeve are tapered along at least a part of their lengths.
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APPLICATION DATA
[0001] This application is a divisional application of U.S. application Ser. No. 11/284,836 filed Nov. 22, 2005 which claims priority to German application DE 10 2004 058 337 filed Dec. 2, 2004, both of which are incorporated herein in their entirety by reference.
[0002] The invention relates to a process for preparing fused piperazin-2-one derivatives of general formula (I)
wherein the groups R 1 to R 5 have the meanings given in the claims and specification, particularly a process for preparing 7,8-dihydro-5H-pteridin-6-one derivatives.
BACKGROUND TO THE INVENTION
[0003] Pteridinone derivatives are known from the prior art as active substances with an antiproliferative activity. WO 03/020722 describes the use of dihydropteridinone derivatives for the treatment of tumoral diseases and processes for preparing them.
[0004] 7,8-Dihydro-5H-pteridin-6-one derivatives of formula (I) are important intermediate products in the synthesis of these active substances. Up till now they have been prepared using methods involving reduction of nitro compounds of formula (II) below, which led to strongly coloured product mixtures and required laborious working up and purification processes.
[0005] WO 96/36597 describes the catalytic hydrogenation of nitro compounds using noble metal catalysts with the addition of a vanadium compound, while disclosing as end products free amines, but no lactams.
[0006] The aim of the present invention is to provide an improved process for preparing compounds of formula (I), particularly 7,8-dihydro-5H-pteridin-6-one derivatives.
DETAILED DESCRIPTION OF THE INVENTION
[0007] The present invention solves the problem outlined above by the method of synthesising compounds of formula (I) described hereinafter.
[0008] The invention thus relates to a process for preparing compounds of general formula I
wherein
R 1 denotes a group selected from the group consisting of chlorine, fluorine, bromine, methanesulphonyl, ethanesulphonyl, trifluoromethanesulphonyl, para-toluenesulphonyl, CH 3 S(═O)— and phenylS(═O)— R 2 denotes hydrogen or C 1 -C 3 -alkyl, R 3 denotes hydrogen or a group selected from the group consisting of optionally substituted C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, C 2 -C 12 -alkynyl and C 6 -C 14 -aryl, or a group selected from the group consisting of optionally substituted and/or bridged C 3 -C 12 -cycloalkyl, C 3 -C 12 -cycloalkenyl, C 7 -C 12 -polycycloalkyl, C 7 -C 12 -polycycloalkenyl, C 5 -C 12 -spirocycloalkyl and saturated or unsaturated C 3 -C 12 -heterocycloalkyl, which contains 1 to 2 heteroatoms, R 4 , R 5 which may be identical or different denote hydrogen or optionally substituted C 1 -C 6 -alkyl, or R 4 and R 5 together denote a 2- to 5-membered alkyl bridge which may contain 1 to 2 heteroatoms, or R 4 and R 3 or R 5 and R 3 together denote a saturated or unsaturated C 3 -C 4 -alkyl bridge, which may optionally contain 1 heteroatom, and A 1 and A 2 which may be identical or different represent —CH═ or —N═, preferably —N═, in which a compound of formula II
wherein
R 1 -R 5 and A 1 , A 2 have the stated meaning and R 6 denotes C 1 -C 4 -alkyl, a) is hydrogenated with hydrogen in the presence of a hydrogenation catalyst and b) a copper, iron or vanadium compound is added,
in which steps a) and b) may take place simultaneously or successively.
[0020] In a preferred process, the hydrogenation of the compound of formula II is carried out directly in the presence of the hydrogenation catalyst and the copper, iron or vanadium compound to form the compound of formula I.
[0021] In a particularly preferred process, after the first hydrogenation step a), first of all the intermediate product of formula III is obtained, which may optionally be isolated,
and is then further reduced in the presence of a hydrogenation catalyst and a copper, iron or vanadium compound to form a compound of formula I
[0022] Also preferred is a process in which the hydrogenation catalyst is selected from the group consisting of rhodium, ruthenium, iridium, platinum, palladium and nickel, preferably platinum, palladium and Raney nickel. Platinum is particularly preferred. Platinum may be used in metallic form or oxidised form as platinum oxide on carriers such as e.g. activated charcoal, silicon dioxide, aluminium oxide, calcium carbonate, calcium phosphate, calcium sulphate, barium sulphate, titanium dioxide, magnesium oxide, iron oxide, lead oxide, lead sulphate or lead carbonate and optionally additionally doped with sulphur or lead. The preferred carrier material is activated charcoal, silicon dioxide or aluminium oxide.
[0023] Preferred copper compounds are compounds in which copper assumes oxidation states I or II, for example the halides of copper such as e.g. CuCl, CuCl 2 , CuBr, CuBr 2 , CuI or CuSO 4 . Preferred iron compounds are compounds wherein iron assumes oxidation states II or III, for example the halides of iron such as e.g. FeCl 2 , FeCl 3 , FeBr 2 , FeBr 3 , FeF 2 or other iron compounds such as e.g. FeSO 4 , FePO 4 or Fe(acac) 2 .
[0024] Preferred vanadium compounds are compounds wherein vanadium assumes the oxidation states 0, II, III, IV or V, for example inorganic or organic compounds or complexes such as e.g. V 2 O 3 , V 2 O 5 , V 2 O 4 , Na 4 VO 4 , NaVO 3 , NH 4 VO 3 , VOCl 2 , VOCl 3 , VOSO 4 , VCl 2 , VCl 3 , vanadium oxobis(1-phenyl-1,3-butanedionate), vanadium oxotriisopropoxide, vanadium(III) acetylacetonate [V(acac) 3 ] or vanadium(IV) oxyacetylacetonate [VO(acac) 2 ]. Vanadium(IV) oxyacetylacetonate [VO(acac) 2 ] is particularly preferred
[0025] The copper, iron or vanadium compound may be used either directly at the start of the hydrogenation or after the formation of the intermediate of formula (III), as preferred.
[0026] Also preferred is a process wherein the amount of added hydrogenation catalyst is between 0.1 and 10 wt.-% based on the compound of formula (II) used.
[0027] Also preferred is a process wherein the amount of copper, iron or vanadium compound used is between 0.01 and 10 wt.-% based on the compound of formula (II) used.
[0028] Also preferred is a process wherein the reaction is carried out in a solvent selected from the group consisting of dipolar, aprotic solvents, for example dimethylformamide, dimethylacetamide, N-methylpyrrolidinone, dimethylsulphoxide or sulpholane; alcohols, for example methanol, ethanol, 1-propanol, 2-propanol, the various isomeric alcohols of butane and pentane; ethers, for example diethyl ether, methyl-tert.-butylether, tetrahydrofuran, 2-methyltetrahydrofuran, dioxane or dimethoxyethane; esters, for example ethyl acetate, 2-propylacetate or 1-butylacetate; ketones, for example acetone, methylethylketone or methylisobutylketone; carboxylic acids, for example acetic acid; apolar solvents, for example toluene, xylene, cyclohexane or methylcyclohexane, as well as acetonitrile, methylene chloride and water. The solvents may also be used as mixtures.
[0029] Also preferred is a process wherein the reaction temperature is between 0° C. and 150° C., preferably between 20° C. and 100° C.
[0030] Also preferred is a process wherein the hydrogen pressure is 1 bar to 100 bar.
[0031] The invention further relates to a compound of formula (III)
wherein R 1 to R 5 may have the stated meaning.
[0032] Preferred compounds of formula (III) are those wherein A 1 and A 2 are identical and denote —N═.
[0033] The reactions are worked up by conventional methods e.g. by extractive purification steps or precipitation and crystallisation methods.
[0034] The compounds according to the invention may be present in the form of the individual optical isomers, mixtures of the individual enantiomers, diastereomers or racemates, in the form of the tautomers as well as in the form of the free bases or the corresponding acid addition salts with acids—such as for example acid addition salts with hydrohalic acids, for example hydrochloric or hydrobromic acid, or organic acids, such as for example oxalic, fumaric, diglycolic or methanesulphonic acid.
[0035] Examples of alkyl groups, including those which are part of other groups, are branched and unbranched alkyl groups with 1 to 12 carbon atoms, preferably 1-6, particularly preferably 1-4 carbon atoms, such as for example: methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl and dodecyl. Unless otherwise stated, the above-mentioned designations propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl and dodecyl include all the possible isomeric forms. For example the term propyl includes the two isomeric groups n-propyl and iso-propyl, the term butyl includes n-butyl, iso-butyl, sec. butyl and tert.-butyl, the term pentyl includes isopentyl, neopentyl etc.
[0036] In the above-mentioned alkyl groups one or more hydrogen atoms may optionally be replaced by other groups. For example these alkyl groups may be substituted by fluorine. It is also possible for all the hydrogen atoms of the alkyl group to be replaced.
[0037] Examples of alkyl bridges, unless otherwise stated, are branched and unbranched alkyl groups with 2 to 5 carbon atoms, for example ethylene, propylene, isopropylene, n-butylene, iso-butyl, sec. butyl and tert.-butyl etc. bridges. Particularly preferred are ethylene, propylene and butylene bridges. In the above-mentioned alkyl bridges 1 to 2 C atoms may optionally be replaced by one or more heteroatoms selected from among oxygen, nitrogen or sulphur.
[0038] Examples of alkenyl groups (including those which are part of other groups) are branched and unbranched alkylene groups with 2 to 12 carbon atoms, preferably 2-6 carbon atoms, particularly preferably 2-3 carbon atoms, provided that they have at least one double bond. The following are mentioned by way of example: ethenyl, propenyl, butenyl, pentenyl etc. Unless otherwise stated, the above-mentioned designations propenyl, butenyl etc. include all the possible isomeric forms. For example the term butenyl includes 1-butenyl, 2-butenyl, 3-butenyl, 1-methyl-1-propenyl, 1-methyl-2-propenyl, 2-methyl-1-propenyl, 2-methyl-2-propenyl and 1-ethyl-1-ethenyl.
[0039] In the above-mentioned alkenyl groups, unless otherwise described, one or more hydrogen atoms may optionally be replaced by other groups. For example these alkyl groups may be substituted by the halogen atom fluorine. It is also possible for all the hydrogen atoms of the alkenyl group to be replaced.
[0040] Examples of alkynyl groups (including those which are part of other groups) are branched and unbranched alkynyl groups with 2 to 12 carbon atoms, provided that they have at least one triple bond, for example ethynyl, propargyl, butynyl, pentynyl, hexynyl etc., preferably ethynyl or propynyl.
[0041] In the above-mentioned alkynyl groups, unless otherwise described, one or more hydrogen atoms may optionally be replaced by other groups. For example these alkyl groups may be fluorosubstituted. It is also possible for all the hydrogen atoms of the alkynyl group to be replaced.
[0042] The term aryl denotes an aromatic ring system with 6 to 14 carbon atoms, preferably 6 or 10 carbon atoms, preferably phenyl, which, unless otherwise described, may for example carry one or more of the following substituents: OH, NO 2 , CN, OMe, —OCHF 2 , —OCF 3 , halogen, preferably fluorine or chlorine, C 1 -C 10 -alkyl, preferably C 1 -C 5 -alkyl, preferably C 1 -C 3 -alkyl, particularly preferably methyl or ethyl, —O—C 1 -C 3 -alkyl, preferably —O-methyl or —O-ethyl, —COOH, —COO—C 1 -C 4 -alkyl, preferably —O-methyl or —O-ethyl, —CONH 2 .
[0043] Examples of cycloalkyl groups are cycloalkyl groups with 3-12 carbon atoms, for example cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl, preferably cyclopropyl, cyclopentyl or cyclohexyl, while each of the above-mentioned cycloalkyl groups may optionally also carry one or more substituents, for example: OH, NO 2 , CN, OMe, —OCHF 2 , —OCF 3 or halogen, preferably fluorine or chlorine, C 1 -C 10 -alkyl, preferably C 1 -C 5 -alkyl, preferably C 1 -C 3 -alkyl, particularly preferably methyl or ethyl, —O—C 1 -C 3 -alkyl, preferably —O-methyl or —O-ethyl, —COOH, —COO—C 1 -C 4 -alkyl, preferably —COO-methyl or —COO-ethyl or —CONH 2 . Particularly preferred substituents of the cycloalkyl groups are ═O, OH, methyl or F.
[0044] Examples of cycloalkenyl groups are cycloalkyl groups with 3-12 carbon atoms, which have at least one double bond, for example cyclopropenyl, cyclobutenyl, cyclopentenyl, cyclohexenyl or cycloheptenyl, preferably cyclopropenyl, cyclopentenyl or cyclohexenyl, while each of the above-mentioned cycloalkenyl groups may optionally also carry one or more substituents.
[0045] “═O” denotes an oxygen atom linked by a double bond.
[0046] Examples of heterocycloalkyl groups are, unless otherwise described in the definitions, 3- to 12-membered, preferably 5-, 6- or 7-membered, saturated or unsaturated heterocycles, which may contain nitrogen, oxygen or sulphur as heteroatoms, for example tetrahydrofuran, tetrahydrofuranone, γ-butyrolactone, α-pyran, γ-pyran, dioxolane, tetrahydropyran, dioxane, dihydrothiophene, thiolane, dithiolane, pyrroline, pyrrolidine, pyrazoline, pyrazolidine, imidazoline, imidazolidine, tetrazole, piperidine, pyridazine, pyrimidine, pyrazine, piperazine, triazine, tetrazine, morpholine, thiomorpholine, diazepan, oxazine, tetrahydro-oxazinyl, isothiazole and pyrazolidine, preferably morpholine, pyrrolidine, piperidine or piperazine, while the heterocycle may optionally carry substituents, for example C 1 -C 4 -alkyl, preferably methyl, ethyl or propyl.
[0047] Examples of polycycloalkyl groups are optionally substituted, bi-, tri-, tetra- or pentacyclic cycloalkyl groups, for example pinane, 2,2,2-octane, 2,2,1-heptane or adamantane. Examples of polycycloalkenyl groups are optionally bridged and/or substituted, 8-membered bi-, tri-, tetra- or pentacyclic cycloalkenyl groups, preferably bicycloalkenyl or tricycloalkenyl groups, if they contain at least one double bond, for example norbornene.
[0048] Examples of spiroalkyl groups are optionally substituted spirocyclic C 5 -C 12 alkyl groups.
[0049] Halogen generally denotes fluorine, chlorine, bromine or iodine, preferably fluorine, chlorine or bromine, particularly preferably chlorine.
[0050] The substituent R 1 may represent a group selected from the group consisting of chlorine, fluorine, bromine, methanesulphonyl, ethanesulphonyl, trifluoromethanesulphonyl and para-toluenesulphonyl, preferably chlorine.
[0051] The substituent R 2 may represent hydrogen or C 1 -C 3 -alkyl, preferably hydrogen.
[0052] The substituent R 3 may represent hydrogen,
or a group selected from the group consisting of optionally substituted C 1 -C 12 -alkyl, C 2 -C 12 -alkenyl, C 2 -C 12 -alkynyl, and C 6 -C 14 -aryl, preferably phenyl, or a group selected from the group consisting of optionally substituted and/or bridged C 3 -C 12 -cycloalkyl, preferably cyclopentyl, C 3 -C 12 -cycloalkenyl, C 7 -C 12 -polycycloalkyl, C 7 -C 12 -polycycloalkenyl, C 5 -C 12 -spirocycloalkyl and saturated or unsaturated C 3 -C 12 -heterocycloalkyl, which contains 1 to 2 heteroatoms.
[0054] The substituents R 4 , R 5 may be identical or different and may represent hydrogen,
or optionally substituted C 1 -C 6 -alkyl, or R 4 and R 5 together represent a 2- to 5-membered alkyl bridge which may contain 1 to 2 heteroatoms, or R 4 and R 3 or R 5 and R 3 together represent a saturated or unsaturated C 3 -C 4 -alkyl bridge, which may optionally contain 1 heteroatom.
[0058] A 1 and A 2 which may be identical or different represent —CH═ or —N═, preferably —N═.
[0059] R 6 may represent a C 1 -C 4 -alkyl, preferably methyl or ethyl.
[0060] The compound of formula (II) may be prepared according to methods known from the literature, for example analogously to the syntheses described in WO 03/020722.
[0061] The compounds of general formula (I) may be prepared inter alia analogously to the following examples of synthesis. These Examples are, however, intended only as examples of procedures to illustrate the invention, without restricting it to their content. The general synthesis is shown in Scheme (1).
Synthesis of (7R)-2-chloro-8-cyclopentyl-7-ethyl-5-hydroxy-7,8-dihydro-5H-pteridin-6-one
[0062]
[0063] 30 g (84.2 mmol) of 1 are dissolved in 300 ml of tetrahydrofuran and 3 g Pt/C (5%) are added. The reaction mixture is hydrogenated for 5 h at 35° C. and a hydrogen pressure of 4 bar. The catalyst is filtered off and washed with approx. 30 ml of tetrahydrofuran. The filtrate is concentrated by evaporation under reduced pressure. 25.6 g of product 2 are obtained as a yellow solid.
[0064] 1 H-NMR (400 MHZ) (DMSO d6 ): δ 11.05 (bs 1H); 7.85 (s 1H); 4.47-4.45 (dd 1H); 4.16-4.08 (t 1H); 1.95-1.67 (m 10H); 0.80-0.73 (t 3H)
Synthesis of (7R)-2-chloro-8-cyclopentyl-7-ethyl-7,8-dihydro-5H-pteridin-6-one
[0065]
[0066] 5.22 g (17.6 mmol) of 2 are dissolved in 55 ml of tetrahydrofuran. 520 mg Pt-C (5%) and 250 mg vanadium(IV) oxyacetylacetonate are added. The reaction mixture is hydrogenated for 6 hours at 20° C. and a hydrogen pressure of 4 bar. The catalyst is filtered off and washed with approx. 15 ml of tetrahydrofuran. The filtrate is concentrated by evaporation under reduced pressure.
[0067] 5.0 g of product 3 are obtained as a yellow powder.
[0068] 1 H-NMR (400 MHz) (DMSO d6 ): δ 11.82 (bs 1H); 7.57 (s 1H); 4.24-4.21 (dd 1H); 4.17-4.08 (m 1H); 1.97-1.48 (m 10H); 0.80-0.77 (t 3H).
Synthesis of: (7R)-2-chloro-8-cyclopentyl-7-ethyl-7,8-dihydro-5H-pteridin-6-one
[0069] 70 g Pt/C (5%) are added to a solution of 700 g (1.96 mol) of 1 in 700 ml of tetrahydrofuran. The reaction mixture is hydrogenated for 2.5 hours at 35° C. and a hydrogen pressure of 4 bar until the hydrogen uptake has stopped. The autoclave is opened and 35 g vanadium(IV) oxyacetylacetonate are added. The mixture is hydrogenated for a further 2.5 hours at 35° C. and a hydrogen pressure of 4 bar. It is filtered and the residue is washed with tetrahydrofuran. The filtrate is concentrated by evaporation under reduced pressure. The residue is dissolved in 2.75 L acetone and precipitated by the addition of an equal amount of demineralised water. The solid is suction filtered and washed with an acetone/water mixture (1:1), then with tert.-butylmethylether. After drying 551 g of product 3 are obtained.
Synthesis of: (7R)-2-chloro-8-cyclopentyl-7-ethyl-7,8-dihydro-5H-pteridin-6-one
[0070] 30 g (84 mmol) of 1 are dissolved in 300 ml of tetrahydrofuran. 3 g Pt/C (5%) and 1.5 g vanadium(IV) oxyacetylacetonate are added. The reaction mixture is hydrogenated for 24 hours at 35° C. and a hydrogen pressure of 4 bar until the reaction is complete. It is filtered, the residue is washed with tetrahydrofuran and the filtrate is concentrated by evaporation under reduced pressure. The residue is dissolved in 118 ml acetone and precipitated by the addition of an equal amount of demineralised water. The solid is suction filtered and washed with an acetone/water mixture (1:1) and then with tert.-butylmethylether. After drying 18 g of product 3 are obtained.
Synthesis of: (7R)-2-chloro-7-ethyl-8-isopropyl-7,8-dihydro-5H-pteridin-6-one
[0071]
[0072] 10 g (316 mmol) of 4 are dissolved in 800 ml of tetrahydrofuran and 200 ml isopropanol. 10 g Pt/C (5%) and 5 g vanadium(IV) oxyacetylacetonate are added. The reaction mixture is hydrogenated for 24 hours at 35° C. and a hydrogen pressure of 4 bar until the reaction is complete. It is filtered and the filtrate is evaporated down until crystallisation sets in. 150 ml isopropanol are added and the suspension is heated to 70-80° C. until fully dissolved. After the addition of 600 ml demineralised water the product is brought to crystallisation. It is suction filtered and washed with demineralised water. After drying 68 g of product 5 are obtained.
[0073] 1 H-NMR (400 MHz) (DMSO d6 ): δ 10.81 (bs 1H); 7.56 (s 1H); 4.37-4.24 (m 2H); 1.89-1.65 (m 2H); 1.34-1.31 (m 6H); 0.80-0.73 (t 3H)
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Disclosed are processes for the preparation of fused piperazin-2-one derivatives of general formula (I)
wherein the groups R 1 to R 5 , A 1 and A 2 have the meanings given in the claims and in the description, particularly the preparation of 7,8-dihydro-5H-pteridin-6-one derivatives and intermediates thereof.
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RELATED APPLICATIONS
The present invention is a continuation-in-part of, was first described in, and claims the benefit of U.S. Provisional Application No. 61/948,913, filed Mar. 6, 2014, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a wash tray with a rail brush assembly to improve and expedite the preparation of foodstuffs in a kitchen.
BACKGROUND OF THE INVENTION
Root vegetables, such as potatoes, are used in almost every kind of food and from every nationality. They can be found at lunches, dinners, and even breakfasts. As a natural food, they are very healthy. Such root vegetables are a good source of potassium, iron, vitamin C, fiber, protein while containing no fat or cholesterol, and only a small amount of sodium. However, because they grow in the ground, they do suffer from the fact that they must be rigorously cleaned as the first part of their preparation. While cleaning a few root vegetables for dinner at home is not a big burden, it is a significant task for those who prepare many root vegetables in a restaurant, commercial, or institutional environment. Such a prep cook may spend hours cleaning hundreds of root vegetables while hunched over a sink in a position that can cause pain in the lower back. Additionally, the labor associated with such cleaning drives up the cost of food for everyone. Accordingly, there exists a need for a means by which a large amount of root vegetables can be easily cleaned. The development of the present invention fulfills this need.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide such a vegetable washing device that has a tray formed as a inclined plane and defining a loading area and an exit area, a scrub brush array attached to the tray, a rail brush assembly slidable motionable along a longitudinal axis of the tray, and a water pan affixed to a bottom of the tray. The device is designed to cleanse a root vegetable loaded at the loading area and agitated by the rail brush assembly along the scrub brush array, and convey the root vegetable to the exit area. The water pan acts as a sump to receive water introduced at the loading area such that the scrub brush array can use water to scrub the root vegetable. In a preferred embodiment, the device is capable and sized to be secured to and utilize a conventional three-basin sink assembly.
Another object of the present invention is to provide such a tray that has a pair of parallel side frames, each with a leg portion deflected off at an angle. A feed plate is affixed to an upper portion of the side frames adjacent to the legs. At least one (1) embodiment of the feed plate has angled ridges on the upper surface to direct the flow of water towards the scrub brush array. At least one (1) embodiment of the feed plate has a plurality of ribs on a lower surface to provide rigidity.
Yet another object of the present invention provides for at least one (1) groove to extend inward from distal ends of the leg portions of the side frames. The grooves enable the device to securely rest on a perimeter rim of a sink.
Yet another object of the present invention provides for a backsplash to be affixed to an upper surface of the face plate above the leg portions.
Still yet another object of the present invention is to provide a scrub brush array that is attached to a lower portion of the side frames. The array includes a rectangular frame having a loading member, an exit member, and a pair of parallel members having a longitudinal split portion enabling attachment of a plurality of axles. Each axle extends outward from a shaft that in at least one (1) embodiment is cylindrical. A plurality of bristles are attached to the outer surface of each shaft. A key plate, attached to a lower surface of the feed plate, receives tabs located on the loading member. An adjustable clamp attached to the exit plate receives tabs located on the exit member.
Yet another object of the present invention provides for the rail brush assembly to include pair of parallel guide rails, each attached to a respective side frame, to receive a rail brush housing. The guide rails extend from the backsplash to the exit end. In at least one (1) embodiment, the guide rails extend beyond the exit end of the device. The rail brush housing has a handle on an upper surface, a rail brush head on a first area of a lower surface, a soaking brush on a second area of the lower surface, and an outwardly extending extender bar adjacent to the soaking brush. In at least one (1) embodiment the rail brush head is a plurality of uniformly-shaped pieces. In at least one (1) embodiment the soaking brush is a semi-circular shape.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is an isometric view of a root vegetable washer 10 , in accordance with the preferred embodiment of the present invention;
FIG. 2 is a section view along line A-A as seen in FIG. 1 of the root vegetable washer 10 , in accordance with the preferred embodiment of the present invention;
FIG. 3 is a section view along line B-B as seen in FIG. 1 of the root vegetable washer 10 in accordance with the preferred embodiment of the present invention;
FIG. 4 is an isolated isometric view of a scrub brush array 50 of the root vegetable washer 10 in accordance with the preferred embodiment of the present invention;
FIG. 5 a is an isolated view of a key plate 42 in a tray 20 of the root vegetable washer 10 in accordance with the preferred embodiment of the present invention; and,
FIG. 5 b is an isolated view of an adjustable clamp 46 in the tray 20 of the root vegetable washer 10 in accordance with the preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 vegetable washer
15 vegetable
20 tray
22 a first side frame
22 b second side frame
24 leg
26 bar member
27 exit end
28 a first leg groove
28 b second leg groove
30 rail brush assembly
32 brush housing
35 backsplash
38 undercut
42 key plate
44 socket
46 adjustable clamp
50 scrub brush array
55 sop brush
60 loading area
70 handle
75 cylindrical brush
80 brush shaft
85 brush bristles
87 axle
90 forward end
110 feed plate
112 top face
115 ridge
120 guide rail
130 brush frame
132 first end member
134 second end member
136 a first split member
136 b second split member
138 axle aperture
142 tab
144 fastener
145 protrusion
150 channel groove
170 water pan
180 lateral member
190 upper brush head
195 upper brush bristles
200 longitudinal motion
210 upper surface
220 incline
225 exit plate
230 extender arm
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 b . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one (1) of the referenced items.
The present invention describes a vegetable washer (herein referred to as the “device”) 10 , being equipped with a tray 20 and a rail brush assembly 30 to improve and expedite the preparation of foodstuffs, such as vegetable 15 , in a kitchen, by quickly washing the vegetable 15 via a scrub brush array 50 of the device 10 . The invention is particularly suitable for washing dirt and grime from root vegetables which grown in the ground.
Referring now to FIG. 1 , an isometric view, FIG. 2 , a section view along line A-A as seen in FIG. 1 , and FIG. 3 , a section view along line B-B as seen in FIG. 1 , of the device 10 , in accordance with the preferred embodiment of the present invention, are disclosed. The device 10 provides a tray 20 , a rail brush assembly 30 , a scrub brush array 50 , and a water pan 170 , which collectively act as a cleaning and conveyance system to direct the vegetables 15 through the device 10 and into a third basin of an existing washtub or sink. The tray 20 includes a first side frame 22 a and a mirrored second side frame 22 b . The side frames 22 a , and 22 b are each be composed of an extruded square, or rectangular, thermoplastic shape formed having a vertical leg 24 and a bar member 26 disposed at an acute included angle so as to fall upon a negative incline 220 . Other shapes, such as a hollow square, or rectangular tube, or other materials, such as some metals, or wood, may be utilized without limiting the scope of the device 10 . The side frames 22 a , 22 b occupy a horizontal distance of approximately forty two inches (42 in.) from the leg 24 to the exit end 27 . The legs 24 are configured to result in a total height of the side frames 22 a and 22 b of approximately seven inches (7 in.).
Disposed in each leg 24 of the side frames 22 a , 22 b are a first leg groove 28 a and a deeper second leg groove 28 b . The leg grooves 28 a , 28 b are vertical slots cut, or formed, into the legs 24 in a perpendicular orientation to the longitudinal axis of the bar member 26 . As previously stated, the second leg groove 28 b is cut more deeply into the legs 24 than the first leg groove 28 a . The purpose of the leg grooves 28 a and 28 b is to accommodate the insertion of the material of the sink separator therein so as to secure the positional placement of the device 10 relative to the sink. The deeper second leg groove 28 b will permit a placement of the device 10 at a smaller incline 220 than the engagement of the sink separator into the first leg groove 28 a by virtue of a geometric relationship. The device 10 is envisioned to be made available in various sizes for commercial and private applications, and as such the dimensions provided in this preferred embodiment should not be interpreted as a limitation of scope. The previous dimensions are envisioned to be suitable for positioning of the device 10 upon an existing three-compartment sink as is found in many restaurants or commercial kitchens.
The side frames 22 a and 22 b are connected at a first end, in proximity to the legs 24 , by a planar feed plate 110 . The feed plate 110 is a rigid thermoplastic plate attached to interior faces of the side frames 22 a , 22 b , either permanently, by some thermoforming process, or removably, by means of threaded fasteners or other similar securement means. The utilization of threaded fasteners, or other interlocking features, to attach the feed plate 110 to the side frames 22 a , 22 b may require the additional incorporation of shaped apertures or other formed projections; however, it is understood that any such eventualities do not modify the scope, or the intent, of the present device 10 , and this preferred embodiment does not preclude other embodiments. Other materials, such as certain metals, wood, or composites, may be utilized, with the previously stated qualifications, without limiting the scope of the device 10 . The feed plate 110 may be provided with any type of projections on a lower surface, such as ribs, or the like, to provide additional flexural rigidity thereto in order to withstand the forces induced during use. The feed plate 110 is attached to the side frames 22 a , 22 b having a top face 112 in a parallel disposition to the bar members 26 so as to be placed at an equal incline 220 . The combined width across the side frames 22 a , 22 b , and the feed plate 110 will be approximately twelve inches (12 in.). Disposed upon the top face 112 of the feed plate 110 is a plurality of angled ridges 115 configured to spread a flow of water from a faucet, or other convenient source, impinging on that top face 112 generally evenly across the feed plate 110 .
A key plate 42 is attached along a lower face of the feed plate 110 between the first side frame 22 a and the second side frame 22 b as more clearly illustrated in FIG. 5 a . The purpose of the key plate 42 will be explained at a later point in this narrative.
A backsplash 35 is also attached along the feed plate 110 spanning the distance of the first side frame 22 a and the second side frame 22 b . The backsplash 35 is a rigid thermoplastic plate oriented perpendicular, or nearly perpendicular, to the feed plate 110 . The backsplash 35 is configured to obviate a flow of water over a first end of the side frames 22 a , 22 b . The feed plate 110 and the backsplash 35 comprise a loading area for the vegetables 15 to be cleaned within the device.
The tray 20 includes a scrub brush array 50 incorporating a plurality of cylindrical brushes 75 mounted upon axles 87 about which a rotating motion can be achieved. The cylindrical brushes 75 are configured to be a cylindrical brush shaft 80 , preferably composed of an extruded thermoplastic with brush bristles 85 projecting radially therefrom. Other materials, such as wood, or composites, may be utilized without limiting the scope of the device 10 . The brush bristles 75 are composed of nylon or other suitable natural or synthetic material. The cylindrical brushes 80 are envisioned to be confined within a brush frame 130 which will be explained in greater detail elsewhere in this narrative.
An exit plate 255 is attached between the first side frame 22 a and the second side frame 22 b at the exit end 27 of the bar members 26 . The exit plate 255 is a planar rigid thermoplastic plate similar to the feed plate 110 provided with a smooth upper face. The feed plate 255 is configured to be attached to the side frames 22 a , 22 b longitudinally parallel to the bar members 26 so as to be at an equal incline 220 . An adjustable clamp 46 is slidingly attached to a lower face of the exit plate 225 as depicted in FIG. 5 b.
A water pan 170 is removably attached to a lower side of the tray 20 . The water pan 170 is a thermoplastic tray having a planar bottom attached to short encircling sidewalls along abutting edges. Other materials, such as certain corrosion resistant metals, may be utilized without limiting the scope of the device 10 . The water pan 170 may be provided with a perpendicular flange along part, or all, of the sidewall. The water pan 170 may be attached to the side frames 22 a , 22 b , and other portions tray 20 as well, by means of removable fasteners or by means of the retention of keyhole slots slidingly received upon headed pins permanently fixed to appropriate locations on the tray 20 . In use, the water pan 170 provides a sump, subjacent to the scrub brush array 50 , for the retention of some water which is envisioned to be flowing from a faucet and striking the feed plate 110 . The water retained within a least some portion of the water pan 170 is held in contact with some of the partially submerged cylindrical brushes 75 of the scrub brush array 50 to assist with the removal of any undesirable material from the vegetable 15 .
A pair of guide rails 120 is attached to an upper surface of the side frames 22 a , 22 b by means of a plurality of threaded fasteners. The guide rails 120 are configured to be rectangular thermoplastic bars with a square-cut channel groove 150 along a majority of the length of an inner face thereof. The guide rails 120 extend from the backsplash 35 at a first end to just beyond the exit plate 225 at a second end. An outer face of the guide rails 120 is intended to be flush with the outer face of the bar member 26 of each side frame 22 a , 22 b while not spanning the entire width of the bar member 26 .
A rail brush assembly 30 is configured to be placed between the guide rails 120 to be activated in a longitudinal motion 200 for the purpose of imparting a reciprocating scrubbing action to the vegetable 15 . The rail brush assembly 30 consists of an upper brush head 190 affixed within a brush housing 32 . The brush housing 32 is generally “U” shaped with a horizontal planar member formed with a pair of down-turned vertical lateral members 180 . The lateral members 180 are formed with a generally square protrusion 145 extending from each outside face. The protrusion 145 is configured to be inserted into the channel groove 150 of each guide rail 120 to constrain the movement of the rail brush assembly 30 to the longitudinal motion 200 . The upper brush head 190 may be composed of a single piece, or a plurality of uniformly shaped pieces into which upper brush bristles 195 are embedded. The upper brush bristles 195 , also preferably nylon, are configured to be angled away from the loading area 60 at approximately forty five degrees (45°). This configuration results in a longitudinal motion 200 in the direction of the exit plate 225 will tend move the vegetable 15 along the scrub brush array 50 in the same direction, whereas the longitudinal motion 200 in an opposite direction will preferably result in the upper brush bristles 195 scrubbing over a stationary vegetable 15 to cleanse the vegetable 15 .
A semi-circular sop brush 55 is affixed to a projecting portion of the brush housing 32 on that side in closest proximity to the feed plate 110 . The soaking brush is configured to extend onto the feed plate 110 to define an extent of the longitudinal motion 200 toward the loading area 60 . The sop brush 55 is composed of a highly absorbent material, such as a textile mop or an open-cell foam, or the like, to accumulate water coursing over the top face 112 of the feed plate 110 and apply that water liberally to the surface of the vegetable 15 and down onto the scrub brush array 50 .
An extender arm 230 is permanently affixed to a side portion of the brush housing 32 near the sop brush 55 . The extender arm 230 provides a confined space which serves as a rake or grappler to entrain each vegetable 15 at the feed plate 110 and convey the vegetable 15 into the rail brush assembly 30 and the scrub brush array 50 . When the rail brush assembly 30 is displaced toward the exit plate 225 , a vegetable 15 is incrementally advanced through the scrub brush array 50 .
Extending from an upper surface 210 of the rail brush assembly 30 is an inverted “U”-shaped handle 70 . The handle 70 is affixed to the upper surface 210 using fasteners such as screws, rivets, or the like, and enables a user to grasp the rail brush assembly 30 and force it to be displaced reciprocally in a longitudinal direction 200 along the tray 20 . Preferably, the handle 70 is orientated parallel with a longitudinal center axis of the tray 20 .
The device 10 is built upon a declining plane, indicated here as an incline 220 , as previously stated to assist the transfer of the vegetable 15 through the device 10 . The device 10 is envisioned to utilize moving water from at least one (1) existing faucet of the sink to wash the vegetable 15 . The configuration of the preferred embodiment of the device 10 , shown here, enables the cleansing of a plurality of vegetables 15 simultaneously. In use, the rail brush assembly 30 is moved to the loading area 60 with the extender arm 230 projecting over the feed plate 110 . At least one (1) vegetable 15 is placed upon the loading area 60 of the device 10 within the reach of the extender arm 230 . A user then moves the rail brush assembly 30 toward the exit plate 225 using the handle 70 to pull the vegetable 15 , within the extender arm 230 , into the scrub brush array 50 . The longitudinal motion 200 is then reversed and the sop brush 55 is swabbed across the vegetable 15 and the now wetted vegetable 15 becomes engulfed by the rail brush assembly 30 . Each successive reciprocating longitudinal motion 200 displaces the vegetable 15 across the subjacent scrub brush array 50 and through the rail brush assembly 30 . Due to the natural curved shape of the vegetable 15 , a vegetable 15 is transported down the incline 220 as it is assisted by gravity, the angled upper brush bristles 195 , and the longitudinal motion 200 of the rail brush assembly 30 , being applied by the user. Any released dirt, sand, or other foreign material will fall between the cylindrical brushes 75 of the scrub brush array 50 and into the water pan 170 and then ultimately into the sink upon which the device 10 is positioned. At this point, the vegetables 15 will exit from the device 10 over an exit plate 225 , where it is envisioned the vegetable 15 will fall into the third compartment of the sink, being cleaned and ready for further preparation.
Referring now to FIG. 4 , an isolated isometric view of the scrub brush array 50 , and FIG. 5 a , an isolated view of the key plate 42 , and 5 b , an isolated view of the adjustable clamp 46 , of the device 10 , in accordance with the preferred embodiment of the present invention, are disclosed. Each of the first side frame 22 a and the second side frame 22 b is provided with an undercut 38 along a lower, inner corner of the bar member 26 . The undercut 38 is configured to be a void into which the first split members 136 a of a brush frame 130 can be inserted. The scrub brush array 50 includes the brush frame 130 configured to support the previously described cylindrical brushes 75 . The brush frame 130 is a rectangular framework consisting of a rectangular first end member 132 and a similar second end member 134 fastened to a pair of first split members 136 a and a pair of second split members 136 b with a plurality of fasteners 144 . The brush frame 130 is comprised of extruded rigid thermoplastic pieces formed with the requisite features, including axle apertures 138 , to accomplish the intended task of retaining a plurality of cylindrical brushes 75 . Other materials, such as corrosion resistant metals, may be utilized without limiting the scope of the device 10 . A first split member 136 a is attached to a second split member 136 , having the halves of the axle apertures 138 in alignment, by means of a plurality of evenly spaced fasteners 144 . The end members 132 , 134 are provided with a pair of tabs 142 extending from an exterior side surface. A preferred method of assembly for the brush frame 130 is to support a pair of second split members 136 b upon an appropriate surface having the axle apertures 138 facing upwardly and aligned so that the axles 87 of each assembled cylindrical brush 75 can be placed therein. A pair of first split members 136 a is then placed atop the corresponding second split member 136 b with the axle apertures 138 faced downward and aligned with each axle 87 . The split members 136 a , 136 b are then fastened together with the fasteners 144 , thus clamping the axles 87 of each cylindrical brush 75 . The end members 132 , 134 are then fastened to the split members 136 a , 136 b by means of fasteners 144 , ensuring that the tabs 142 are facing outward, away from the cylindrical brushes 75 .
The key plate 42 is provided with a pair of sockets 44 conforming to the profile of the tabs 142 as seen in FIG. 5 a . Similarly the adjustable clamp 46 is provided with a pair of sockets 44 as depicted in FIG. 5 b . The tabs 142 of the first end member of the brush frame 130 are inserted into the sockets 44 of the key plate 42 located under the feed plate 110 . The brush frame is then rotated to fit the first split members 136 a into the undercuts 38 in the side frames 22 a , 22 b . It is envisioned that the adjustable clamp 46 under the exit plate 225 may be adapted in some sliding manner so as to secure the tabs 142 of the second end member 134 into the sockets 44 thereof so as to retain the scrub brush array 50 within the tray 20 .
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the device 10 , it would be installed as indicated in FIG. 1 . The method of utilizing the device 10 may be achieved by performing the following steps: acquiring a model of the device 10 of a desired length and width; placing the tray 20 upon dividing basin wall portions of an existing multi-basin sink; allowing an upper edge of a divider wall between the first sink basin and the second sink basin to protrude into either a first leg groove 22 a , or a second leg groove 22 b in order to correctly position and orient the forward end 90 ; slidingly inserting the rail brush assembly 30 between the guide rails 120 ; utilizing a flow of water upon the top face 115 and the ridges 115 of the feed plate 110 and the scrub brush array 50 to pre-soak or wash the vegetable 15 , as desired, using an existing faucet; allowing the water to run across the top face 112 into the water pan 170 through the gap 118 ; placing a vegetable 15 , or several vegetables 15 , onto the feed plate 110 while having the extender arm 230 of the rail brush assembly 30 positioned over the feed plate 110 ; grasping the handle 70 and moving the rail brush assembly 30 away from the feed plate 110 to engage the vegetable 15 within the sop brush 55 ; continuing to grasp the handle 70 to oscillate the rail brush assembly 30 in a reciprocating longitudinal direction 200 , thereby entraining the vegetable 15 between the rail brush assembly 30 and the scrub brush array 50 ; allowing the angled upper brush bristles 195 to displace the vegetable 15 to traverse the scrub brush array 50 ; allowing dirt and debris to fall from the vegetable 15 through the scrub brush array 50 as the vegetable 15 makes its way down the tray 20 ; allowing the vegetable 15 to exit the device 10 and into the sink; repeating the aforementioned steps to scrub additional vegetables 15 ; and, benefiting from effective scrubbing of vegetables 15 afforded a user of the present invention 10 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.
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An apparatus adapted to provide a washing and cleaning system for vegetables in a restaurant environment includes a stationary lower frame having a plurality of cylindrical scrub brushes, and an operable and manually movable upper brushing assembly. Vegetables progress between the upper and lower brushes resulting in the removal of dirt and debris.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an integrated coal gasification combined cycle plant for combined power generation using coal as fuel, and in particular, to an increase in the plant efficiency in a flue-gas-desulfurization-type integrated coal gasification combined cycle plant.
[0003] This application is based on Japanese Patent Application No. 2004-188886, the content of which is incorporated herein by reference.
[0004] 2. Description of Related Art
[0005] Heretofore, a flue-gas-desulfurization-type integrated coal gasification combined cycle (hereinafter referred to as “IGCC”) plant has been known. In such a flue-gas-desulfurization-type IGCC plant, an exhaust gas in a gas turbine contains a large amount of a sulfur component. However, since a heat recovery steam generator (HRSG) provided at the downstream side of the gas turbine includes a carbon steel heat exchanger therein, sulfuric acid produced from the sulfur component causes a corrosion problem.
[0006] In order to prevent this corrosion, the gas temperature at the outlet of the heat recovery steam generator must be set at a value (for example, about 150° C.) higher than the dew point (130° C.) of sulfuric acid. However, when the gas temperature at the outlet of the heat recovery steam generator is set at a high value, thermal energy of a gas recovered from the exhaust gas of the gas turbine at the heat recovery steam generator is decreased. Consequently, the output of a steam turbine which utilizes steam generated by heat recovery steam generator is decreased, thereby decreasing the plant efficiency.
[0007] According to a proposed example measure for the above-described corrosion caused by sulfuric acid, by adjusting the amount of recirculation in a deaerator, the gas temperature at the outlet of the, heat recovery steam generator is controlled to a value equal to or higher than the dew point of sulfuric acid. In this method, the corrosion can be prevented by increasing the temperature of a metal at the heat transfer surface which is in contact with the gas, but the gas temperature also increases at the same time. Consequently, the amount of heat recovery is decreased, resulting in a problem of reduced power generation efficiency (see, for example, Japanese Unexamined Patent Application, Publication No. Hei-11-148603).
[0008] In the above flue-gas-desulfurization-type IGCC plant, the plant efficiency is desirably increased by recovering the maximum amount of thermal energy from the exhaust gas (combustion exhaust gas) of the gas turbine. Therefore, preferably, by increasing the thermal energy recovered from the combustion exhaust gas of the gas turbine, even when the gas temperature at the outlet of the heat recovery steam generator is lower than the dew point of sulfuric acid, the corrosion problem of the heat recovery steam generator can be solved, thus realizing an IGCC plant with high efficiency.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention has been conceived in view of the above situation, and an object of the present invention is to provide an integrated coal gasification combined cycle plant in which, when, the gas temperature at the, outlet of a heat recovery steam generator is set to a value equal to or lower than the dew point of sulfuric acid, the corrosion problem of a heat exchanger can be solved and high efficiency can be realized.
[0010] To solve the above problem, the present invention provides the following solutions.
[0011] An integrated coal gasification combined cycle plant of the present invention includes a gasifier configured to convert pulverized coal to a gas fuel; a heat recovery steam generator configured to generate steam; a gas turbine which is operated by the gas fuel and which supplies a combustion exhaust gas to the heat recovery steam generator; a steam turbine which is operated by the steam generated by the heat recovery steam generator; a power generator connected to at end of the gas turbine and the steam turbine; a desulfurization equipment configured to desulfurize the combustion exhaust gas discharged from the heat recovery steam generator, the desulfurized exhaust gas being exhausted into the atmosphere; and an acid-resistant feedwater heater configured to preheat boiler feedwater, the acid-resistant feedwater heater being provided at a downstream side of the heat recovery steam generator.
[0012] According to the integrated coal gasification combined cycle plant of the present invention, the acid-resistant feedwater heater for preheating boiler feedwater is provided at the downstream side of the heat recovery steam generator. Accordingly, steam can be generated by maximally utilizing thermal energy possessed by the combustion exhaust gas without being concerned with the corrosion problem caused by sulfuric acid.
[0013] In this case, the acid-resistant feedwater heater is preferably disposed at an area where the temperature of the combustion exhaust gas is lower than the dew point of sulfuric acid. Consequently, thermal energy possessed by the combustion exhaust gas can be effectively utilized while minimizing the use of the expensive acid-resistant feedwater heater.
[0014] In the above integrated coal gasification combined cycle plant, preferably, a cleaning water spray device is provided at an upstream side of the acid-resistant feedwater heater, and the flow direction of the combustion exhaust gas is the downward direction. Consequently, even during the operation of the power generation plant, the acid-resistant feedwater heater and the like can be cleaned by spraying a cleaning fluid in the downward direction, which is the same as the flow direction of the combustion exhaust gas.
[0015] That is, when the gas flow direction of the part to be cleaned is the downward direction, the acid-resistant feedwater heater and the like can be cleaned during operation. Since the water, after being used in the cleaning, flows into the downstream flue-gas-desulfurization equipment, a special waste water treatment system need not be added.
[0016] According to the above integrated coal gasification combined cycle plant of the present invention, the heat recovery steam generator includes the acid-resistant feedwater heater for preheating the boiler feedwater at the downstream side thereof. Therefore, steam can be generated by maximally utilizing thermal energy possessed by the combustion exhaust gas without being concerned with the corrosion problem of a heat exchanger caused by sulfuric acid produced from a sulfur component contained in the combustion exhaust gas. Consequently, significant advantages can be achieved, namely, realizing an integrated coal gasification combined cycle plant with high efficiency and improving the durability of the plant. In particular, when the acid-resistant feedwater heater is disposed at an area where the temperature of the combustion exhaust gas is lower than the dew point of sulfuric acid, and preheating of the boiler feedwater is performed, an integrated coal gasification combined cycle plant with high efficiency can be realized at low cost.
[0017] Furthermore, when the cleaning water spray device is provided at the upstream side of the acid-resistant feedwater heater, the cleaning fluid can be sprayed in the same direction as the flow direction of the combustion exhaust gas. Consequently, the acid-resistant feedwater heater and some equipments disposed at the downstream side thereof etc. can be cleaned without stopping the operation of the power generation plant.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] FIG. 1 is a schematic diagram showing the outline of an integrated coal gasification combined cycle plant.
[0019] FIG. 2 is a schematic diagram showing the relevant part of the integrated coal gasification combined cycle plant according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] An embodiment of an integrated coal gasification combined cycle plant according to the present invention will now be described with reference to the drawings.
[0021] As shown in FIG. 1 , an integrated coal gasification combined cycle (hereinafter referred to as “IGCC”) plant 1 , using coal as fuel, primarily includes a gasifier 3 , a gas turbine 5 , and a steam turbine 7 .
[0022] A coal supply system 10 for supplying pulverized coal to the gasifier 3 is provided at an upstream side thereof. This coal supply system 10 has a pulverizer (not shown) which pulverizes raw coal into pulverized coal having a particle size of several to several hundreds of micrometers and is designed so that the pulverized coal is stored in the pulverized coal bin 11 a.
[0023] The pulverized coal stored in the bin 11 a is fed at a constant flow rate to the gasifier 3 together with nitrogen gas supplied from an air separation unit 15 .
[0024] The gasifier 3 has a coal gasification section 3 a which is designed so that a gas flows from the lower side to the upper side and a heat exchange section 3 b which is connected to the downstream side of the coal gasification section 3 a and which is designed so that a gas flows from the upper side to the lower side.
[0025] In the coal gasification section 3 a , a combustor 13 and a reductor 14 are provided in that order from the lower side. The combustor 13 is a portion in which the pulverized coal and char are partially burned, and the rest is pyrolyzed into volatile components (CO, H 2 , and lower hydrocarbons). In the combustor 13 , an entrained bed is used. Alternatively, a fluidized bed or a fixed bed may also be used.
[0026] The combustor 13 and the reductor 14 are provided with a combustor burner 13 a and a reductor burner 14 a , respectively, and the pulverized coal is supplied thereto from the coal supply system 10 .
[0027] The combustor burner 13 a is designed so that air from an air booster 17 is supplied thereto together with oxygen separated in the air separation unit 15 . As described above, the configuration is designed so that air containing oxygen at a controlled concentration is supplied to the combustor burner 13 a.
[0028] In the reductor 14 , the pulverized coal is gasified by a high-temperature combustion gas supplied from the combustor 13 . Consequently, flammable gases such as CO and H 2 are produced from the coal. The coal gasification reaction is an endothermic reaction in which carbon atoms in the pulverized coal and char are allowed to react with CO 2 and H 2 O in a high-temperature gas to produce CO and H 2 .
[0029] In the heat exchange section 3 b of the gasifier 3 , a plurality of heat exchangers is provided and is designed to generate steam using the sensible heat obtained from the gas fed from the reductor 14 . The steam generated in the heat exchangers is primarily used to drive a steam turbine 7 b.
[0030] The gas passing through the heat exchange section 3 b is fed to a char recovery equipment 20 . This char recovery equipment 20 has porous filters, and when the gas is made to pass therethrough, char contained in the gas is trapped and recovered. This char is returned to the combustor burner 13 a of the gasifier 3 , together with the nitrogen gas separated by the air separation unit 15 , for recycling.
[0031] The gas passing through the char recovery equipment 20 is then supplied as a fuel gas to a combustor 5 a of the gas turbine 5 .
[0032] A branching path 22 is provided between the char recovery equipment 20 and the combustor 5 a of the gas turbine 5 , and a flare system 24 is provided downstream of this branching path 22 , with a valve 23 interposed therebetween. The flare system 24 is a system for processing a gas having a small calorific value by combustion, which is produced during a startup stage of the gasifier 3 .
[0033] The gas turbine 5 has the combustor 5 a in which the gas obtained by gasification is burned, a gas turbine 5 b driven by the combustion gas, and a turbo compressor 5 c feeding high-pressure air to the combustor 5 a . The gas turbine 5 b and the turbo compressor 5 c are connected to each other by a rotating shaft 5 d . The air compressed by the turbo compressor 5 c is supplied to the air booster 17 in addition to the combustor 5 a.
[0034] A combustion exhaust gas (gas-turbine exhaust gas) passing through the gas turbine 5 b is supplied to an heat recovery steam generator (HRSG) 30 .
[0035] The steam turbine 7 b of the steam turbine system 7 is connected to the same rotating shaft 5 d as that of the gas turbine 5 , so that a so-called single-shaft combined system is formed. High-pressured steam is supplied to the steam turbine 7 b from the gasifier 3 and the heat recovery steam generator 30 . In addition to the single-shaft combined system, a multi-shaft combined system may also be used.
[0036] A power generator G which outputs electricity from the rotating shaft 5 d driven by the gas turbine 5 b and the steam turbine 7 b is provided at one side of the steam turbine 7 opposite to that of the gas turbine 5 . However, the position of the power generator G is not limited to that described above, and the power generator G may be disposed at any position so long as an electrical output can be obtained from the rotating shaft 5 d.
[0037] The heat recovery steam generator 30 generates steam by the combustion exhaust gas from the gas turbine 5 b , and a flue gas desulfurization (FGD) equipment 32 is provided downstream of the combustion exhaust gas flow of the heat recovery steam generator 30 . This flue gas desulfurization equipment 32 is designed to remove a sulfur component in the exhaust gas.
[0038] The gas passing through the desulfurization equipment 32 is allowed to pass through a wet-type electric precipitator (wet-EP) 34 and an induction fan (i.e., boost-up fan (BUF)) 36 and is then exhausted into the atmosphere via a stack 38 .
[0039] Next, the structures of the heat recovery steam generator 30 and the periphery thereof will now be described in detail with reference to FIG. 2 .
[0040] The heat recovery steam generator 30 receives the combustion exhaust gas which has done its work in the gas turbine 5 b and heats boiler feedwater to produce steam. In a boiler-water piping system 40 through which the boiler feedwater is circulated, a feedwater pump 41 , an acid-resistant feedwater heater 42 , a main heat exchanger 43 , the steam turbine 7 b , and a steam condenser 44 form a closed circuit connected by piping 45 .
[0041] The feedwater pump 41 is a delivery device of the boiler feedwater which circulates in the boiler-water piping system 40 and whose state is repeatedly changed in the order: feedwater, steam, and condensed water.
[0042] The acid-resistant feedwater heater 42 performs heat exchange between the combustion exhaust gas and the boiler feedwater in the heat recovery steam generator 30 . The acid-resistant feedwater heater 42 functions as a preheater that preliminarily heats the boiler feedwater by effectively utilizing the exhaust heat of the combustion exhaust gas through this heat exchange.
[0043] In the acid-resistant feedwater heater 42 used in this embodiment, an acid-resistant film is provided on all surfaces that are in contact with the combustion exhaust gas. Examples of the acid-resistant film which is effective against sulfuric acid produced from a sulfur component contained in the combustion exhaust gas include a film of a fluorocarbon resin (polytetrafluoroethylene) such as Teflon (registered trademark), a chromium (Cr) film formed by thermal spraying, and a composite film including an undercoat composed of Cr or a Ni—Cr alloy and a topcoat composed of the ceramic Cr 2 O 3 .
[0044] In the heat recovery steam generator 30 , the main heat exchanger 43 is disposed at the upstream side of the acid-resistant feedwater heater 42 in the flow direction of the combustion exhaust gas. The main heat exchanger 43 heats the boiler feedwater by heat exchange with the high-temperature combustion exhaust gas to generate steam.
[0045] The steam condenser 44 is a heat exchanger that cools the steam which has done its work in the steam turbine 7 b to convert it back to water.
[0046] A heat absorber 51 of a gas-gas heat exchanger 50 is disposed at the downstream side of the acid-resistant feedwater heater 42 in the flow direction of the combustion exhaust gas. In the gas-gas heat exchanger 50 , the heat absorber 51 , a radiator 52 , and a heat-medium circulation unit 53 form a closed circuit connected by piping 54 . A heat medium which absorbs heat at the heat absorber 51 transfers the thermal energy to the radiator 52 by the operation of the heat-medium circulation unit 53 . The radiator 52 is disposed at the downstream side of the wet-type electric precipitator 34 and functions as a gas reheater which heats the combustion exhaust gas, before exhausting it into the atmosphere via the stack 38 , to a temperature at which white smoke is not produced.
[0047] In addition, at the upstream side of the acid-resistant feedwater heater 42 , spray nozzles 61 are provided in a cleaning water line 60 as a cleaning water spray device which sprays cleaning water in the same direction as the combustion exhaust gas flowing downward. Cleaning water is supplied to the cleaning water line 60 as required. The acid-resistant feedwater heater 42 and the equipments disposed at the downstream side thereof etc. can be cleaned by spraying the cleaning water from the spray nozzle 61 .
[0048] Additionally, in FIG. 2 , reference numeral 70 indicates an sulfur-absorbing-liquid circulating pump, and reference numeral 71 indicates a nozzle.
[0049] Next, the operation of the IGCC plant 1 having the above structure will be described.
[0050] Raw coal is pulverized with a pulverizer (not shown) and is then fed to the pulverized coal bin 11 a for storage. The pulverized coal stored in the bin 11 a is fed into pulverized coal supply hoppers 11 , and supplied to the reductor burner 14 a and the combustor burner 13 a together with nitrogen gas separated by the air separation unit 15 . Furthermore, in addition to the pulverized coal, the char recovered by the char recovery equipment 20 is also supplied to the combustor burner 13 a.
[0051] As combustion air for the combustor burner 13 a , air which is prepared by adding oxygen separated by the air separation unit 15 to compressed air obtained by further increasing the pressure of compressed air extracted from the turbo compressor 5 c using the air booster 17 is used. In the combustor 13 , the pulverized coal and the char are partially burned with the combustion air, and the rest is pyrolyzed to generate volatile components (CO, H 2 , and lower hydrocarbons).
[0052] In the reductor 14 , the pulverized coal supplied via the reductor burner 14 a and the char from which the volatile components are discharged in the combustor 13 are gasified by a high-temperature gas rising from the combustor 13 to produce flammable gases such as CO and H 2 .
[0053] The gases passing through the reductor 14 transfer their sensible heat to the hear exchangers while passing through the heat exchange section 3 b of the gasifier 3 , so that steam is generated. The steam generated in the heat exchange section 3 b is primarily used to drive the steam turbine 7 b.
[0054] The gasses passing through the heat exchange section 3 b are fed to the char recovery equipment 20 , so that char is recovered. The char is returned to the gasifier 3 .
[0055] The gases passing through the char recovery equipment 20 are fed to the combustor 5 a of the gas turbine 5 and are then burned together with the compressed air supplied from the turbo compressor 5 c . The gas turbine 5 b is rotated by this combustion gas, and the rotating shaft 5 d is driven.
[0056] During the startup stage of the gasifier 3 , it is not possible to obtain a gas which has a calorific value suitable for use as fuel supplied to the combustor 5 a of the gas turbine 5 . Therefore, a gas having a low calorific value is fed to the flare system 24 by opening the valve 23 so as to be processed by combustion.
[0057] The combustion exhaust gas passing through the gas turbine 5 b is fed to the heat recovery steam generator 30 , and by using the sensible heat of this combustion exhaust gas, steam is generated. The steam generated in the heat recovery steam generator 30 is primarily used to drive the steam turbine 7 b . During this exhaust heat recovery of the combustion exhaust gas, at the upstream side of the combustion exhaust gas introduced into the heat recovery steam generator 30 , the boiler feedwater flowing through the main heat exchanger 43 is heated by the high-temperature combustion exhaust gas and is converted to steam. The combustion exhaust gas whose temperature has been decreased by this heat exchange passes through the acid-resistant feedwater heater 42 disposed at the downstream side and preheats the low-temperature boiler feedwater by heating.
[0058] That is, in order to efficiently utilize the thermal energy possessed by the combustion exhaust gas, the high-temperature combustion exhaust gas and the preheated boiler feedwater are subjected to heat exchange in the main heat exchanger 43 to efficiently generate steam, and in addition, the combustion exhaust gas whose temperature has been decreased preheats the low-temperature boiler feedwater in the acid-resistant feedwater heater 42 . This two-stage heating enables effective use of the thermal energy.
[0059] Furthermore, even when the temperature of the combustion exhaust gas is decreased in preheating the boiler feedwater by the acid-resistant feedwater heater 42 , and the ambient temperature is decreased to the dew point of sulfuric acid or lower, that is, 130° C. or lower, corrosion by sulfuric acid does not occur because a heat exchanger in which an acid-resistant film is provided on all surfaces in contact with the combustion exhaust gas is used. That is, even when the exhaust heat possessed by the combustion exhaust gas is maximally recovered by the acid-resistant feedwater heater 42 without consideration of the dew point of sulfuric acid, and the boiler feedwater is maximally preheated, the corrosion problem does not occur. Consequently, the efficiency of the IGCC plant 1 can be increased.
[0060] The steam turbine 7 b is rotated by the steam from the gasifier 3 and the steam from the heat recovery steam generator 30 to drive the rotating shaft 5 d of the gas turbine 5 . The torque of the rotating shaft 5 d is then converted to an electrical output by the power generator G.
[0061] The combustion exhaust gas passing through the heat recovery steam generator 30 is fed to the desulfurization equipment 32 , and the sulfur component is removed thereby. Subsequently, the combustion exhaust gas sucked by the induction fan 36 passes, through the, wet-type electric precipitator 34 so as to remove ash dust and sulfuric acid mist in the combustion exhaust gas. Furthermore, the combustion exhaust gas then passes through the radiator 52 to be heated to a temperature at which white smoke is not produced, and is then exhausted into the atmosphere via the stack 38 .
[0062] When cleaning of the acid-resistant feedwater heater 42 is required during the above operation, cleaning can be performed by spraying cleaning water from the spray nozzle 61 without stopping the operation of the IGCC plant 1 . This is because the flow direction of the combustion exhaust gas in the heat recovery steam generator 30 is the same as the flow direction of the cleaning water. Accordingly, the operation of the system need not be interrupted by stopping for cleaning.
[0063] The present invention is not limited to the above embodiment, and modifications may be optionally made without departing from the scope and the spirit of the present invention.
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The problem of a heat exchanger of a heat recovery steam generator being corroded by sulfuric acid is solved, and the gas temperature at the outlet of the heat recovery steam generator is set at a value equal to or lower than the dew point of sulfuric acid, thereby realizing an integrated coal gasification combined cycle plant with high efficiency. A flue-gas-desulfurization-type integrated coal gasification combined cycle plant includes a gasifier configured to convert pulverized coal to a gas fuel; an heat recovery steam generator configured to generate steam; a gas turbine which is operated by the gas fuel and which supplies a combustion exhaust gas to the heat recovery steam generator; a steam turbine which is operated by the steam generated by the heat recovery steam generator; a power generator connected to at least one of the gas turbine and the steam turbine; and a desulfurization equipment configured to desulfurize the combustion exhaust gas discharged from the heat recovery steam generator, the desulfurized combustion exhaust gas being exhausted into the atmosphere, wherein the heat recovery steam generator includes an acid-resistant feedwater heater which preheats boiler feedwater and which is provided at the downstream side of a main heat exchanger.
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TECHNICAL FIELD
[0001] The technical field generally relates to fan blades for use in turbofan gas turbine engines.
BACKGROUND
[0002] Rotor disks used in some turbofan engines can have blades removably mounted in circumferentially-disposed blade retention slots provided at their periphery. These blades have blade roots that are somewhat loose in their corresponding blade retention slots when the engine is shut down. However, when the engine is running rotor disk rotates at high speeds and the centrifugal force pushes the blades radially outwardly for a firm connection between the blade roots and the respective blade retention slots.
[0003] Windmilling is the passive rotation of an engine spool at very low speeds when the gas turbine engine is not operating (i.e. on the ground) in response to environmental wind blowing on the engine. The clearance between a blade root and its blade retention slot can cause the blade root to flop around in the blade retention slot. After many hours of windmilling, the mating surfaces on the blade root and the blade retention slot will be subject to wear. This wear can have a detrimental impact on the low cycle fatigue life of the rotor disk and of the blades.
[0004] It is known to provide devices to bias the blades outwardly so as to reduce blade friction wear while windmilling, but known devices are often relatively complex to assemble. Room for improvements thus exists.
SUMMARY
[0005] In one aspect, there is provided a fan blade assembly for a turbofan engine, comprising a plurality of fan blades each having a root at one end thereof, the root having a lengthwise direction and a widthwise direction, a rotor disk having a plurality of retention slots each with a lengthwise and widthwise direction corresponding to and for retaining the root of the fan blade; an elongated resilient first member extending within the retention slot in the lengthwise direction between the root of the fan blade and the bottom of the retention slot, and a second member extending lengthwise between the root of the fan blade and the first member while compressing the first member to provide a radial preload to the root of the fan blade.
[0006] In a second aspect, there is provided a fan blade assembly of a turbofan engine, comprising a fan blade having a root having a longitudinal axis and a lateral axis, a rotor disk which has a retention slot corresponding to the root of the fan blade, an elongated resilient first member insertable in the retention slot between the root of the fan blade and the bottom of the retention slot and a second member insertable between the root and the first member in a manner that the second member compresses the first member for radially preloading the fan blade in the rotor disk.
[0007] In a third aspect, there is provided a method of assembling an assembly of fan blades and a rotor disk of a turbofan engine, wherein the fan blades each include a root having a longitudinal axis and a lateral axis and the rotor disk has retention slots corresponding to the root of the fan blades, the method comprising the steps of: inserting the fan blades into the slots, inserting a first elongated member longitudinally into each retaining slot between the root of the fan blade and the bottom of the retention slot; and inserting a second elongated member between the root and the first elongated member to compress the first member in a direction of the fan blade to thereby preload the fan blade in the rotor disk in a radial outward direction.
DESCRIPTION OF THE DRAWINGS
[0008] Reference is now made to the accompanying figures, in which:
[0009] FIG. 1 is a schematic cross-sectional view of a turbofan gas turbine engine;
[0010] FIG. 2 is a fragmentary axial cross section showing a detail of an embodiment of the preload device;
[0011] FIG. 3 is a fragmentary radial cross section showing the detail of FIG. 2 ;
[0012] FIG. 4 is a fragmentary perspective view of the fan blade and root showing the embodiment of FIG. 2 ;
[0013] FIG. 5 is a fragmentary perspective view of the detail shown in FIG. 4 but taken from below;
[0014] FIG. 6 is a fragmentary rear elevation of the detail shown in FIG. 4 ;
[0015] FIG. 7 a is a perspective view of a further detail of FIG. 4 ;
[0016] FIG. 7 b is a perspective view of a still further detail of FIG. 4 ; and
[0017] FIG. 7 c is a view similar to FIG. 7 a showing a set of strips of different lengths and weights that can be used to balance the fan rotor in addition of providing assistance in pre-loading the fan blades around the fan hub.
DETAILED DESCRIPTION
[0018] FIG. 1 illustrates a turbofan gas turbine engine 10 of a type preferably provided for use in subsonic flight, generally comprising in serial flow communication a fan 12 through which ambient air is propelled, a multistage compressor 14 for pressurizing the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating an annular stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. Fan assembly 12 includes a plurality of blades 36 , each with a root 42 inserted into a corresponding slot (not indicated) on a hub 20 . A blade pre-loading apparatus 54 / 64 is also provided, as described further below.
[0019] Referring now to FIGS. 2 to 7 there is shown a portion of the rotor disk or hub 20 in which retention slots 22 are disposed somewhat axially and spaced apart circumferentially. FIGS. 2 and 3 show the retention slot 22 as having a bottom groove 24 and side walls 26 and 28 . Referring to FIG. 2 there is an axial rim 30 that is concentric with the rotor disk 20 . The rim 30 includes a radial flange 32 and a rim extension 34 . The purpose of the rim 30 and the radial flange 32 is for anchoring weights in order to balance the rotor disk 20 with the assembled fan blades 36 . The rim extension 34 acts as a support rim for the rotor disk when it is being serviced and laid on a flat surface.
[0020] The fan blade 36 is shown in FIG. 4 . The fan blade 36 includes an airfoil 38 with a leading edge 39 extending above a land or platfolin 40 . Below the land 40 is a root 42 adapted to be inserted in the retention slot 22 of the rotor disk 20 . The root 42 includes a groove 44 extending longitudinally thereof. The root 42 also includes side walls 46 and 48 as well as stoppers 50 and 52 at the front end. These stoppers 50 and 52 prevent the root from sliding beyond the rear end of the retention slot 22 .
[0021] Since the root 42 fits somewhat loosely in the retention slot 22 there is a need to preload the fan blade 36 so that it does not slop around in the rotor when the engine is stopped with the aircraft on the ground. The preloading device in one embodiment includes a resilient strip which can, for instance, be made of an elastomeric material such as rubber. The strip 54 as shown in FIG. 7B includes a downward hook portion 55 at the front end thereof and a groove 60 on the top surface 56 . The bottom surface 58 is at least contoured to fit in the groove 24 of the retention slot 22 . The top surface of the strip 54 includes parallel lobes 62 on either side of the groove 60 . The purpose of the hook portion 55 , at the front end of the strip 54 , is to retain the strip 54 within the groove 22 and to prevent it from sliding beyond the rear face of the rotor 22 . The strip 54 is prevented from moving forwardly in the groove 22 by a retaining ring (not shown) which will eventually be bolted to the front of the rotor disk 20 when all the blades 36 have been loaded on the rotor 20 . The ring will encompass the root 32 as well as the strip 54 .
[0022] A further separate strip 64 is provided to function with the strip 54 . The strip 64 , shown in FIG. 7 a , is metallic and can be produced from titanium in order to minimize corrosion. The strip 64 also has a front bend in the shape of a hook 66 for the purposes of preventing the strip 64 from moving rearwardly and also to allow a tool to grab onto the strip so that it can be removed. The retaining ring, as previously discussed, will prevent the strip 64 from moving forwardly.
[0023] Once the fan blade 36 has been mounted on the rotor disk 20 with the root 32 inserted into the retention slot 22 , the strip 54 will be inserted in the clearance between the groove 44 shaped in the root 42 and the groove 24 formed in the bottom of the retention slot 22 . The metal strip 64 is then inserted between the rubber strip 54 and the groove 44 of the root 42 . By inserting the metal strip 64 , the rubber strip 54 is compressed thereby providing radial pressure on the strip 64 and the root 42 .
[0024] This provides the necessary preloading of the fan blade 36 on the rotor.
[0025] The metal strip 64 (or the resilient strips 54 ) can serve the further purpose of balancing the rotor disk 20 c when the fan blades 36 are mounted thereon. For instance, as shown in FIG. 7 c , a set of different metal strips 64 ′ can be provided to enable the operator to place strips 64 ′ of different weights from one fan blade to the next and thus ensure a uniform distribution of the weight around the fan rotor. These strips 64 ′ could be of different lengths (i.e. from one blade to the next) so that the different strips have different weights and can therefore be used to balance the fan rotor assembly, thereby providing for selective balancing within the retention slot 22 .
[0026] It is assumed that the rear extension 30 may be all but eliminated since the rear rim 30 and the radial flange 32 are for the purposes balancing rotor disk 20 and blades 36 . All that would be retained would be a short rim extension 34 for the purpose of laying the rotor disk on a flat surface for servicing. This would eliminate weight which compensates to a certain extent to the added weight of the strips 54 and 64 .
[0027] Little or no modification may need to be done to the root 42 or the retention slot 22 to implement the present approach, relative to a traditional root/slot design. The rubber strip 54 may be made of any elastomeric or other suitably resilient material, and the density, composition, shape, etc. thereof can be selected to obtain the proper preload on the fan blade 36 . The strip 64 may be made of any suitable material. The strip 64 may be flexible but its main purpose is to apply pressure on the rubber strip 54 and therefore should have enough rigidity to perform this function and allow it to be forced in after the resilient piece 54 is in place. The strip 64 could for instance be of the same material as the strip 54 , but with a metal rod down its core or simply of a greater density to make it more rigid. The rigidity of the strip 64 in the longitudinal direction is selected so that it can be forced in the slot after the resilient piece is in place.
[0028] The above description is meant to be exemplary only, and one skilled in the art will recognize that changes may be made to the embodiments described without departing from the scope of the invention disclosed. Still other modifications will be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims.
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A removable fan blade of a turbofan engine includes a blade root at one end thereof. A rotor disk has a retention slot having dimensions corresponding for receiving the root of the fan blade in the slot. An elongated resilient member extends within the retention slot in a lengthwise direction between the root of the fan blade and the bottom of the retention slot and an elongated member extends lengthwise between the root of the fan blade and the elastomeric member to compress the resilient member and provide a radial preload to the fan blade.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/127,336 filed Apr. 1, 1999, which is herein incorporated by reference and this application contains subject matter that is related to the disclosure in U.S. patent application Ser. No. 09/459,215 now U.S. Pat. No. 6,639,896 filed simultaneously herewith, which is herein incorporated by reference.
BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The invention relates to digital information distribution systems and, more particularly, the invention relates to a data packet structure for routing digital information through a multi-user network.
2. Description of the Background Art
Digital information, including digital video, can be distributed through networks that utilize asynchronous transfer mode (ATM) and packet over SONET. However, both of these types of data distribution systems are not cost effective for providing digital video distribution and require significant bandwidth overhead for each respective packet format plus configuration and control overhead for the network. A more efficient network solution for simplex, point-to-point transmission and delivery of Moving Pictures Experts Group (MPEG) packets is known as DVB-ASI (Digital Video Broadcast/Asynchronous Serial Interface). DVB-ASI is described in European Standard EN 50083 entitled “Cable Distribution System for Television, Sound, and Interactive Multimedia Signals”, March 1997. This specification defines a protocol for distributing digital video in the form of MPEG packets at a rate of 270 Mbps. The actual data carriage under this protocol is 216 Mbps. Although the DVB-ASI protocol is well suited for simplex, point-to-point communications, a system based on this protocol is not capable of supporting high speed data transmissions that are necessary for multi-user digital video distribution systems. Furthermore, because of the limited data carrying capability, the DVB-ASI protocol does not efficiently utilize the bandwidth that is available for optical fiber based systems, i.e., a bandwidth that exceed 1 Gbps.
Therefore, there is a need in the art for a protocol for multi-user, digital information distribution system that provides high speed transmissions, e.g., more than a gigabit per second, in conjunction with a low overhead.
SUMMARY OF THE INVENTION
The disadvantages associated with the prior art are overcome by a data packet structure capable of efficiently propagating a payload through a multiple source, multiple sink digital information distribution system. The system is capable of delivering multimedia data (video and audio information) using the Moving Picture Expert Group (MPEG-2) transport packets as payload within a unique packet structure. This same packet structure is used to carry data, such as internet protocol data. The packet structure enables routing of the packets through a variety of network topologies. Specifically, the packet structure comprises a packet header, a destination address field, a private data field, digital information payload, and an error correction code field. Such a packet structure enables the network to deliver digital information through a point-to-point, star, ring, dual ring, and other network topologies to a user that is identified in the routine information field.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a packet structure of the present invention;
FIG. 2 depicts the packet header field of the packet structure of FIG. 1;
FIG. 3 depicts the destination address field of the packet structure of FIG. 1; and
FIG. 4 depicts an illustrative switched network capable of routing digital video information to users using the packet structure of FIG. 1 .
To facilitate understanding, identical reference numerals have been used, where possible to designate identical elements that are common to the figures.
DETAILED DESCRIPTION
The present invention extends the existing DVB-ASI protocol to improve the transmission bit rate, support duplex communications, support multipoint-to-multipoint communications, provide a flexible packet structure that can support packet routing or packet switching network architectures, and enable a variety of network topologies to be used for multiple source, multiple sink data distribution. The present invention comprises a packet structure 100 as shown in FIGS. 1, 2 and 3 and a multi-user video data distribution network as shown in FIG. 4 .
This packet structure facilitates high bandwidth data streaming of constant bit rate (CBR), variable bit rate (VBR) and undefined bit rate (UBR) data. CBR data is typically used for audio and video, VBR data can be used for video to to take advantage of the compression of movies such that certain scenes are compressed more or less than other scenes, and UBR data is used for internet protocol (IP) data. For each of these data types, the packet structure can be used to implement quality of service such that the network can simultaneously handle various types of services and adapt the services in response to network congestion. For example, if the network is congested to a point where CBR can not be guaranteed to each user, the packet structure can be used to send data in a UBR manner and video in a CBR manner. As such, using a quality of service technique, certain services can be guaranteed a particular bandwidth for a particular connection.
The packet structure is typically transmitted through a network in a serial format, then the packet is converted into a parallel format upon being received at a network node. The two formats have identical fields; however, in the parallel format an IDLE character field 101 is removed from the serial packet format.
The packet structure 100 of both the serial and parallel formatted packets comprises a payload portion 102 , a header portion 104 and a trailer portion 106 . The payload portion 102 is 188 bytes in length to accommodate an MPEG-2 transport packet. Within the 188 bytes are 4 bytes of header information 116 and 184 bytes of MPEG data 118 . There are 12 bytes of information in the header portion 104 and 4 bytes that are placed as an extended trailer portion 120 . To handle errors in transmission the trailer portion 120 comprises a 4 byte cyclical redundant code (CRC) field. The CRC value is used for error detection and correction.
An IDLE or comma character (defined as the K28.5 character according to the 8B/10B encoding specification) appears in the IDLE field 101 in front of every packet. The field is only present in the serial packet format. These comma characters are used by the network nodes to obtain the frame boundary locations of the packets. A minimum of two comma characters is required by the DVB-ASI specification. At least four comma characters are transmitted between each packet initially because hardware requires four consecutive comma characters to obtain initial synchronization. In the event that synchronizaton is lost (due to a cable being temporarily disconnected for example), the use of four comma characters allows resynchronization to occur within one packet time. More efficient use of bandwidth can occur by inserting comma codes less frequently than before each packet. The cost of less frequent comma codes is that, upon synchronization loss, the network will require more MPEG packets to be lost (not routed properly) while the network nodes await enough comma codes to resynchronize.
The header portion 104 comprises a 1 byte sync field 108 , a 3 byte packet header 110 , a 4 byte destination address field 112 , and a 4 byte private data field 114 . The sync field 108 is one byte in length and has a value that facilitates packet synchronization.
The packet header 110 provides synchronization information that is used by routing switches in the network nodes to route the packet and by a depacketizer at a user's location to extract the payload information from the packet 100 . The packet header field 110 is composed of three bytes as shown in FIG. 2 . The header 110 provides packet type information 200 to identify the type of packet which will be used to determine how the bytes in the packet should be interpreted. There are eight undefined bits in the reserved sub-field 202 that can be used for future enhancements since this sub-field is not used at the current time. The continuity counter sub-field 204 is similar in function to the continuity counter field defined in the MPEG-2 specification in that sequential packets within a stream (comprising audio, video and program specific information data) have this value incremented by one.
The packet type sub-field 200 is used to distinguish between different types of payload contained with the packet 100 . The types of packets include data packets carrying real-time MPEG data, data packets carrying MPEG data using flow control, IP packets, in-band message packets, and reserved values.
The data packets for real-time MPEG data contain MPEG data for real-time streams. No flow control or throttling of the data is defined in the protocol for real-time MPEG streams, thus any errors in transmission will result in a packet being dropped at the user equipment. This is deemed necessary for streaming video and audio. The packet type field equals 16(0x10).
The data packets carrying MPEG data with flow control contain MPEG data being routed through the network using some type of flow control performed by software at a higher level. This is performed for content introduction or content migration (i.e., movement of video content from one video server to another). In these situations it is very important to be able to recognize if a packet(s) has been dropped somewhere in the network. Since this data is being written to disk, e.g., for many iterations of subsequent playing of this locally stored movie, the network must be able to guarantee that all the data actually arrived at the destination.
Internet protocol (IP) data that is formatted into the payload portion 102 is identified because some nodes might process these packets differently. For instance, a routing switch has the ability to transfer IP packets through the in-band port when bandwidth is available on the port, i.e., no data packets are being transferred. In one embodiment of the invention, the IP packet is contained within the 184 byte data field 118 of the MPEG data packet while an MPEG header 116 remains before the data. This form of payload, an MPEG header plus IP data is referred to as IP over MPEG. In alternative embodiment of the invention, the entire payload portion 104 carries IP data, i.e., 188 bytes of IP data. Within the routing switch the switch controller processor will be responsible for formatting a single IP packet into multiple payload portions 102 . For IP packet transmission, the IP packets are encapsulated using LLC/SNAP encapsulation and the encapsulated packets are than segmented into payload portion sized packets for insertion into the payload portion 118 of the MPEG packet 102 . The packet type field will equal 18 (0x12).
Special messages that require low latency between nodes are sent through an in-band connection. Examples are user migration messages, timestamp synchronization messages, “ping” messages, etc. These are used when a message does not need to incur the overhead or processing power required for IP messages. The packet type field is in the range between 128(0x80) and 191(0xBF).
Packets with a packet type sub-field between 0 and 15 and from 192 to 254 are reserved for future use.
The private data field 114 (a reserved vendor specific field) contains application specific data that facilitates payload handling. For example, in a video distribution system, the private data identifies the title identification codes (TIC) that are associated with specific programs being transported in the payload portion 104 . The title identification code (TIC) field 114 is used to perform stream integrity checking on a packet-by-packet basis for data packets only. At some nodes within the system, when a data packet is received, the received TIC is compared to the expected TIC to verify that the correct content is being received. The expected TIC is stored in a lookup table that is indexed by the destination address from the received packet. When the TIC stored in the table matches the received TIC, then the packet has been received correctly, otherwise, an error has occurred and the packet needs to be removed from the stream. For non-data packets such as IP packets or in-band messages, this field will be reserved for future use. A possible use would be to store the source address of the packet.
FIG. 3 depicts the destination address field 112 . The destination address field 112 is used to route the packet 100 to the proper destination node. This field is also used by the destination endpoint node to identify the packet so that it can be processed correctly. Every destination node in the network must have a unique address and the stream going to that particular address must be uniquely identified. The field 112 is 32 bits long and comprises a 4 bit reserved sub-field 300 , a 12 bit stream number sub-field 302 and a 16 bit node ID sub-field 304 . The reserved sub-field is preserved for future use.
The node ID sub-field 304 is a 16-bit identifier that provides unique address for every node in the system. This allows for a maximum of 65,536 different nodes to exist within a network. A packet's node ID will be examined by a node in the network to determine if the received packet is intended to be processed by that node. If the node ID field in the packet does not match the board's own node ID contained in memory then the packet needs to be routed to another node. When this is the case, the received node ID accesses a lookup table that provides the routing information and any other associated data for that packet.
When the received node ID field does match the node's own node ID, then the packet is intended to be removed from the network and processed by that node. The stream number sub-field 302 , which is described below, is then used to index a table to provide information specific to that particular stream.
The node ID for a particular node in the network is assigned when the node initially logs onto the system. When a device is first powered up, it must make its presence known to the network so that the device can receive a node ID. Once it receives its node ID, the device can then communicate with other devices on the network.
The stream number subfield 302 is a 12-bit identifier that is assigned by the destination node to uniquely identify a data stream being sent to that node. This allows for a maximum of 4096 streams to be processed by any individual node. This field is used in conjunction with the node ID to uniquely identify a packet in the network.
When using the packet structure 100 in a switched network, such as an ATM-like network, the destination address field 112 carries information that is used to define a virtual path identifier and/or a virtual channel identifier. As such, the destination address field information facilitates routing of the packet through a plurality of switches that form the network.
The MPEG data field 118 contains the encoded MPEG-2 transport stream that is being delivered to the destination node. For non-data packets such as IP packets, the IP packets are encapsulated and divided into multiple payload portions 102 .
For IP packet transmission, the IP packets are encapsulated using LLC/SNAP encapsulation and the encapsulated packets are then segmented into payload portion sized packets for insertion into the payload portion 102 of the packet 100 . These reformatted IP packets are inserted at the origination switch in place of null packets. The destination field information used for these packets is used to route the IP data through the network. At the destination end, the last switch extracts the data carrying packets and reassembles them back to IP packets. A virtual LAN concept is supported by IP packets that are routed through the network in this manner.
In one embodiment of the inventive packet structure, the CRC-32 field 120 protects against bit errors being introduced within the network. A standard 32-bit Ethernet polynomial is used. The CRC is computed on all 200 bytes of the packet preceding the CRC. In alternative embodiments of the inventive packet structure, the trailing 4 byte field 120 forms a vendor specific field that may contain information used to support particular vendor equipment.
FIG. 4 depicts a multi-user (subscriber) video distribution network 400 . To illustrate the flexibility of the invention, FIG. 4 depicts both a dual ring network 402 and a star network 404 that illustratively carry digital video to various users (subscribers) from a network manager 406 . The network manager 406 controls the content server 408 . Specificially, the manager 406 controls the access and transmission of digital video that is stored on a central content server 408 . The content server 408 is coupled to a number of distributed neighborhood servers 412 1 , 412 2 . . . 412 n through a ring network 402 . The rings are counter rotating such that data on ring 418 flows in the clockwise direction, while data on ring 420 flows in a counter clockwise direction. The data is routed from distributed server to distributed server and through the content server based upon the destination address in each packet. The content server 408 addresses the packets to each of the distributed servers 412 such that the content server 408 can propagate digital video to the distributed servers 412 in each of the neighborhoods. The distributed server receiving the packets can save or store the information and/or distribute it directly to the subscriber equipment. e.g., a set top box 422 for decoding and display to a user. The counter rotating ring network 402 operates such that if a link to the distributed server 412 should fail, then distributed server 412 1 will route the information that would have been passed on the ring 420 to distributed server 412 2 back through its internal switch and return the packet to server 408 . As such, the dual, counter-rotating ring 402 becomes a single ring.
The low overhead MPEG-based transport packets and fixed length packets enable a very high data rate to be transmitted through such a dual, counter-rotating ring network 402 . The data rates for such a system are greater than 1 gigabit per second.
The packet structure of FIG. 1 is also useful in routing packets through a “star” network 404 . The network manager 406 controls the addressing of packets to a user via the destination address field. The star network 404 comprises at least one distribution node 414 and a plurality of neighborhood servers 416 1 , 416 2 . . . 416 n . The distribution node and the servers contain network switches that properly route the packets in accordance with destination address. Additional star networks can be coupled to from distribution node 414 to distribution node 414 via one or more “legs” 424 to form a “daisy chained” network of nodes.
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings.
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A data packet structure capable of efficiently propagating a payload through a multi-user, digital video distribution system. The system is capable of delivering multimedia data (video and audio information) using the Moving Picture Expert Group (MPEG) packets as payload within a unique packet structure. The packet structure enables routing of the packets through a variety of network topologies. Specifically, the packet structure comprises a packet header, a routing information field, a private data field, digital data payload, and an error correction code field. Such a packet structure enables the network to deliver digital video through a point-to-point, star, ring, dual ring, and other network topologies to a user that is identified in the routine information field.
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BACKGROUND OF THE INVENTION
This invention relates to a semiconductor device such as SRAM (Static Random Access Memory), and a method of manufacturing the same.
Conventionally, a soft error (hereinafter, may be abbreviated as SER) caused by an α-ray often takes place with high-integration of a SRAM device in a semiconductor device of the type as described.
More specifically, when a memory cell is reduced in size in order to highly integrate the SRAM device, a current per a unit memory cell is reduced. On the other hand, the α-ray emitted from natural uranium or the like is irradiated into a semiconductor memory device.
Herein, it is noted that the natural uranium is slightly contained in a ceramic package or a cover for sealing the semiconductor memory device.
Thereby, a large number of electron-hole pairs are generated in a substrate. Consequently, the electron being generated moves in the substrate and destroys information (namely, electric charge) stored in the memory cell. This results to an error operation of the semiconductor memory cell.
Referring to FIG. 1, description will be made about a basic structure of a high-resistance load type memory cell serving as a main part of the related SRAM device.
The SRAM device includes a pair of transfer transistors ST 1 and ST 2 , a pair of driving transistors DT 1 and DT 2 , and a pair of load resistors L 1 and L 2 .
In the transfer transistor ST 1 , one terminal (source or drain) is connected to a bit line BL 1 while the other terminal (source or drain) is connected to a node N 1 . Further, the gate electrode terminal is connected to a word line WL 1 .
In the transfer transistor ST 2 , one terminal (source or drain) is connected to a bit line BL 2 while the other terminal (source or drain) is connected to a node N 2 . Further, the gate electrode terminal is connected to a word line WL 2 .
In the driving transistor DT 1 , one terminal (source or drain) is connected to a reference voltage Vss while the other terminal (source or drain) is connected to the node N 1 . Further, the gate electrode terminal is connected to the node N 2 .
In the driving transistor DT 2 , one terminal (source or drain) is connected to a reference voltage Vss while the other terminal (source or drain) is connected to the node N 2 . Further, the gate electrode terminal is connected to the node N 1 .
In the load resistor L 1 , one terminal is connected to a power supply voltage Vcc while the other terminal is connected to the node N 1 .
In the load resistor L 2 , one terminal is connected to the power supply voltage Vcc while the other terminal is connected to the node N 2 .
Further, a capacitor C 1 is coupled to the node N 1 while a capacitor C 2 is coupled to the node N 2 .
For example, a NMOS may be used as each of the transfer transistors ST 1 , ST 2 , and the driving transistors DT 1 , DT 2 .
Subsequently description will be made about a SER resistance in such high-resistance load type memory cell.
In the case of the resistance load type memory cell, the SER resistance is generally determined in dependence upon a current IL flowing through the load resistor L 1 , L 2 and node capacitance C 1 , C 2 .
When the node N 1 is put into a high state and a voltage is equal to V 1 h in the memory cell, the current IL flowing through the load resistor L 1 and the node capacitance C 1 has the following relationship with the SER resistance.
Namely, in the case where the bit line BL 1 is put into the power supply voltage Vcc, when the transfer transistor ST 1 is turned on, the voltage V 1 h of the node N 1 is reduced with about a threshold voltage Vt of the transfer transistor ST 1 from the power supply voltage Vcc to become Vcc−Vt.
Under this circumstance, if the current sufficiently flows through the load resistor L 1 from the power supply voltage Vcc, the voltage V 1 h is more increased to the power supply voltage Vcc.
In such a memory cell, when the transfer transistor ST 1 is turned on and the voltage V 1 h is reduced from the power supply voltage Vcc to Vcc−Vt, the probability of the occurrence of the decrease in the voltage V 1 h, in which the voltage is reduced from the power supply voltage Vcc to the Vc−Vt, may be lowered as the node capacitance C 1 becomes higher.
In addition, such a time that the voltage V 1 h further restores to the power supply voltage Vcc by the power supply voltage Vcc of the power supply becomes rapider, as the current IL flowing through the load resistor L 1 is higher and as the node capacitance C 1 is higher.
Hereinafter, description will be made about a method of manufacturing the high resistance load memory cell with reference to FIGS. 2 through 7.
Herein, only a region around the node N 1 of the memory cell in FIG. 1 is illustrated in FIGS. 2 through 7, and the illustration of the peripheral circuit portion is omitted.
Referring to FIG. 2, a thick device isolation silicon oxide film 2 is formed to a thickness of 400 nm by the use of Local Oxidation of Silicon (LOCOS) method on a principal surface of a silicon substrate 1 .
Thereafter, only region for forming a memory cell region, a transfer transistor, and a driving transistor (namely, NMOS) are opened by the use of the photolithography technique.
Subsequently, impurity (boron) is implanted so as to form a P-type well region 21 by the ion-implanting technique.
In this event, the ions are implanted within a concentration range between 1×10 13 and 2×10 13 [cm −2 ] and within an accelerating voltage range between 250 and 350 [Kev].
Although not illustrated, the ions are implanted to form the device isolation region at the same time, and a P-type impurity region is formed under the device isolation silicon oxide film 2 . Further, the ions are also implanted so as to control the voltage Vt.
Thereafter, the silicon substrate 1 is thermally oxidized to form a gate silicon oxide film 3 to a thickness of about 8 nm. Successively, a polysilicon film is deposited to a thickness of about 100 nm of the gate silicon oxide film 3 by the use of CVD technique.
Subsequently, compound (namely, silicide) between Ti or W serving vas a high-melting point metal and silicon is deposited to a thickness of about 100 nm by thermally diffusing phosphorus to form a polyside.
Further, the gate electrode 4 is patterned by the use of the photolithography technique.
Referring to FIG. 3, only a region for forming the memory cell region, the transfer transistor and the driving transistor (namely, NMOS) is opened by the use of the photolithography technique.
Thereafter, impurity (phosphorus) is implanted in a self-alignment. manner using the gate electrode 4 as a mask by the ion implanting technique to form an N-type low concentration impurity region 5 .
In this case, the ions are implanted within the concentration range between 1×10 13 and 3×10 13 [cm −2 ] and within the accelerating voltage range between 15 and 25 [Kev].
Next, the silicon oxide film 6 is formed within the thickness range between 100 and 150 nm on the device isolation silicon oxide film 2 , the gate silicon oxide film 3 , and the gate electrode 4 by the use of the CVD technique.
Successively, referring to FIG. 4, the silicon oxide film 6 is etched-back by the use of the etching technique to form a sidewall silicon oxide film 7 at the sidewall of the gate electrode 4 .
Thereafter, only a region for forming the memory cell region, the transfer transistor and the driving transistor (namely, NMOS) is opened by the use of the photolithography technique.
Subsequently, impurity (phosphorus) is implanted in a self-alignment manner using the gate electrode 4 and the sidewall silicon oxide film 7 as a mask by the ion implanting technique to form a N-type high concentration impurity region 8 .
In this case, the ions are implanted within the concentration range between 1×10 15 and 5×10 15 [cm −2 ] and within the accelerating voltage range between 30 and 40 [Kev].
Next, the silicon oxide film 9 is formed within the thickness range between 100 and 150 nm on the device isolation silicon oxide film 2 , the gate silicon oxide film 3 , and the gate electrode 4 by the use of the CVD technique.
Further, a TEOS.BPSG film 10 having excellent reflow characteristic is deposited to a thickness of about 500 nm on the silicon oxide film 9 by the use of the CVD technique.
Thereafter, a reflow is performed for about 30 to 60 minutes within the temperature range between 800 and 900° C., and the surface of the TEOS.BPSG film 10 is flattened. In this event, the flattening process is carried out such that a wiring layer of a polysilicon film 14 (will be formed later) is not short-circuited.
Subsequently, referring to FIG. 5, a contact hole 11 is opened for the silicon oxide film 9 and the TEOS.BPSG film 10 by the etching technique. Thereinafter, impurity (phosphorus) is partially implanted into the N-type high concentration impurity region 8 under the contact hole 11 by the use of the ion implanting technique to form the N-type high impurity region 12 .
In this case, the ions are implanted within the concentration range between 1×10 14 and 1×10 15 [cm −2 ] and within the accelerating voltage range between 40 and 60 [Kev].
Through the contact hole 11 , the diffusion layers of the driving transistor DT 1 and the transfer transistor ST 1 , the load resistor L 1 , and the gate electrode of the driving transistor DT 2 illustrated in FIG. 1 are connected to each other.
Herein, the ions are implanted so as to reduce contact resistance between the load resistor L 1 , the diffusion layers of the driving transistor DT 1 and the transfer transistor ST 1 and the gate electrode of the driving transistor DT 2 .
Further, referring to FIG. 6, the polysilicon film 14 is deposited to a thickness within the range between 100 and 150 nm on the N-type high concentration impurity region 12 and the TEOS.BPSG film 10 by the CVD technique.
Thereafter, impurity (phosphorus) is implanted for the entire surface of the polysilicon film 14 by the use of the ion implanting technique.
In this case, the ions are implanted within the concentration range between 5×10 12 and 3×10 13 [cm −2 ] and within the accelerating voltage range between 50 and 70 [Kev].
The ion implantation serves to determine the resistance value of the load resistor L 1 illustrated in FIG. 1 . This implanting condition is important for manufacturing the SRAM device because the resistance value of the load resistor L 1 is a factor for determining consuming current during a standby mode in the SRAM device.
Thereafter, the polysilicon film 14 is patterned by the photolithography technique. Successively, impurity (phosphorus) is implanted onto the polysilicon film 14 and the TEOS.BPSG film 10 patterned by the photolithography technique and the ion implanting technique.
In this case, the ions are implanted within the concentration range between 1×10 15 and 1×10 18 [cm −2 ] and within the accelerating voltage range between 50 and 70 [Kev].
Herein, the polysilicon film 14 serves as the load resistor L 1 illustrated in FIG. 1 while the ion implantation serves to form the wiring pattern for the power supply voltage Vcc in FIG. 1 .
Further, a silicon oxide film 15 is deposited to a thickness within the range between 100 and 150 nm on the TEOS.BPSG film 10 and the polysilicon film 14 by the CVD technique.
Thereafter, the TEOS.BPSG film 16 is deposited to a thickness within the range between 500 and 1500 nm by the CVD technique.
In addition, the TEOS.BPSG film 16 is polished by the Chemical Mechanical Polishing (CMP) technique in order to flatten the surface. The flattening process is conducted so that the wiring layer is not short-circuited.
Finally, referring to FIG. 7, a contact hole 17 is opened for the silicon oxide film 9 , the TEOS.BPSG film 10 , the silicon oxide film 15 , and the TEOS.BPSG film 16 by the use of the etching technique.
Thereafter, the contact hole 17 is buried with W (tungsten) serving as the high-melting point metal by sequentially depositing a titanium film and a titanium nitride serving as the high-melting point metal.
Subsequently, W serving as the high-melting point metal is etched-back by the etch-back technique to deposit Al (aluminum).
At the same time, an Al wiring layer 18 is patterned by the use of the photolithography technique.
Through the above-mentioned steps, the main part of the high-resistance load type memory cell for the SRAM device is completed.
The related technique with respect to such a semiconductor device is, for example, disclosed in Japanese Unexamined Patent Publication (JPA) No. Sho. 62-31155 and Japanese Unexamined Patent Publication (JPA) No. Hei. 8-23037.
In the high-resistance load type memory cell of the SRAM device, when the memory is reduced in size to realize the high-integration, the node capacitance is reduced also.
Thereby, the ratio, in which the voltage V 1 h is reduced to Vcc−Vt by the power supply voltage Vcc, becomes high. Further, the time, in which the voltage V 1 h restores to the power supply voltage Vcc by the power supply voltage Vcc, also become slow. As a result, the SER resistance is deteriorated.
To avoid the deterioration of the SER resistance, a P-type impurity region having higher concentration than the P-well region may be formed on the entire surface of the memory cell region.
However, this method deteriorates substrate bias characteristic of the transfer transistor. Consequently, it is difficult to actually apply this method for the SRAM device because the high-speed of the SRAM device can not be readily realized.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a semiconductor device in which substrate bias characteristic is not deteriorated in a transfer transistor even when a memory is reduced in size.
It is another object of this invention to provide a semiconductor device which is capable of enhancing a SER resistance by increasing node capacitance of a memory cell.
According to this invention, a SRAM device includes at least a transfer transistor, a driving transistor and a load resistor which are commonly connected to a node.
With this structure, a well has a first conductive type, and is placed on a substrate.
Further, a first impurity region has a second conductive type opposite to the first conductive type, and is placed in the well.
Moreover, a second impurity region has the first conductive type and has higher impurity concentration than impurity concentration of the well, and is placed at a lower portion of the first impurity region.
Herein, the node is composed of at least the first impurity region and the second impurity region.
For example, the first conductive type is a P-type while the second conductive type is an N-type.
The SRAM device further comprises a bit line and a word line. The transfer transistor includes a first terminal, a second terminal and a third terminal.
In this condition, the first terminal is connected to the bit line, the second terminal is connected to the node, and the third terminal is connected to the word line.
More specifically, the transfer transistor includes a source, a drain and a gate, the first terminal and the second terminal is any one of the source and the drain, and the third terminal is the gate.
Further, the SRAM device comprises a reference voltage terminal. The driving transistor includes a first terminal and a second terminal, the first terminal is connected to the node, and the second terminal is coupled to the reference voltage terminal.
More specifically, the driving transistor includes a source and a drain, and the first terminal and the second terminal is any one of the source and the drain.
Moreover, the SRAM device comprises a power supply voltage terminal. The load resistor includes a first terminal and a second terminal, the first terminal is connected to the node, and the second terminal is coupled to the power supply voltage terminal.
Further, a node capacitor is coupled to the node. In this event, the node capacitor has a capacitance, and the transfer transistor has a substrate bias characteristic.
Under this circumstance, the second impurity region serves to increase the capacitance without deterioration of the substrate bias characteristic.
In addition, the SRAM device has a soft error resistance, and the second impurity region serves to enhance the soft error resistance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing a basic structure of a high-resistance load type memory cell serving as a main part of a related SRAM device;
FIG. 2 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 1;
FIG. 3 is cross sectional side view showing a method of manufacturing the high resistance load type memory cell around one node in FIG. 1;
FIG. 4 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 1;
FIG. 5 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 1;
FIG. 6 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 1;
FIG. 7 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 1;
FIG. 8 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node according to an embodiment of this invention;
FIG. 9 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 8; and
FIG. 10 is cross sectional side view showing a method of manufacturing the high-resistance load type memory cell around one node in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 8 through 10, description will be made about a method of manufacturing a high-resistance load memory according to an embodiment of this invention.
In this embodiment, only the manufacturing steps illustrated in FIGS. 5 through 7 have been improved in the manufacturing steps illustrated in FIGS. 2 through 7 with respect to the above-mentioned related SRAM device.
In other words, the initial manufacturing steps illustrated in FIGS. 2 through 4 are substantially equivalent to the manufacturing steps in this embodiment. Therefore, description thereof will be omitted in this embodiment.
Herein, only a region around the node N 1 of the memory cell in FIG. 1 is illustrated in FIGS. 8 through 10, and the illustration of the peripheral circuit portion is omitted.
Referring to FIG. 8, a contact hole 11 is opened for the silicon oxide film 9 and the TEOS.BPSG film 10 by the etching technique.
Thereinafter, impurity (phosphorus) is partially implanted into the N-type high concentration impurity region 8 under the contact hole 11 by the use of the ion implanting technique to form the N-type high impurity region 12 .
In this case, the ions are implanted within the concentration range between 1×10 14 and 1×10 15 [cm −2 ] and within the accelerating voltage range between 40 and 60 [Kev].
Through the contact hole 11 , the diffusion layers of the driving transistor DT 1 and the transfer transistor ST 1 , the load resistor L 1 , and the gate electrode of the driving transistor DT 2 illustrated in FIG. 1 are connected to each other.
Herein, the ions are implanted so as to reduce contact resistance between the load resistor L 1 , the diffusion layers of the driving transistor DT 1 and the transfer transistor ST 1 and the gate electrode of the driving transistor DT 2 .
Subsequently, a P-type impurity region 13 is formed so as to contact with the lower portion of the N-type high concentration impurity region 12 by injecting impurity (boron) using the ion-implanting technique.
In this case, the ions are implanted within the concentration range between 1×10 12 and 1×10 13 [cm −2 ] and within the accelerating voltage range between 60 and 80 [Kev].
Further, referring to FIG. 9, the polysilicon film 14 is deposited to a thickness within the range between 100 and 150 nm on the N-type high concentration impurity region 12 and the TEOS.BPSG film 10 by the CVD technique.
Thereafter, impurity (phosphorus) is injected for the entire surface of the polysilicon film 14 by the use of the ion implanting technique.
In this case, the ions are implanted within the concentration range between 5×10 12 and 3×10 13 [cm −2 ] and within the accelerating voltage range between 50 and 70 [Kev].
The ion implantation serves to determine the resistance value of the load resistor L 1 illustrated in FIG. 1 . This implanting condition is important for manufacturing the SRAM device because the resistance value of the load resistor L 1 is a factor for determining consuming current during a standby mode in the SRAM device.
Thereafter, the polysilicon film 14 is patterned by the photolithography technique. Successively, impurity (phosphorus) is injected onto the polysilicon film 14 and the TEOS.BPSG film 10 patterned by the photolithography technique and the ion implanting technique.
In this case, the ions are implanted within the concentration range between 1×10 15 and 1×10 16 [cm −2 ] and within the accelerating voltage range between 50 and 70 [Kev].
Herein, the polysilicon film 14 serves as the load resistor L 1 illustrated in FIG. 1 while the ion implantation serves to form the wiring pattern for the power supply voltage Vcc in FIG. 1 .
Further, the silicon oxide film 15 is deposited to a thickness within the range between 100 and 150 nm on the TEOS.BPSG film 10 and the polysilicon film 14 by the CVD technique.
Thereafter, the TEOS.BPSG film 16 is deposited to a thickness within the range between 500 and 1500 nm by the CVD technique.
In addition, the TEOS.BPSG film 16 is polished by the Chemical Mechanical Polishing (CMP) technique in order to flatten the surface. The flattening process is conducted so that the wiring layer is not short-circuited.
Finally, referring to FIG. 10, the contact hole 17 is opened for the silicon oxide film 9 ; the TEOS.BPSG film 10 , the silicon oxide film 15 , and the TEOS.BPSG film 16 by the use of the etching technique.
Thereafter, the contact hole 17 is buried with W (tungsten) serving as the high-melting point metal by sequentially depositing a titanium film and a titanium nitride serving as the high melting point metal.
Subsequently, W serving as the high melting point metal is etched-back by the etch-back technique to deposit Al (aluminum).
Further, the Al wiring layer 18 is patterned by the use of the photolithography technique.
Through the above-mentioned steps, the main part of the high-resistance load type memory cell for the SRAM device is completed.
In the above-mentioned method of the high-resistance load type memory of the SRAM device, the first contact hole 11 is opened for the second silicon oxide film 9 and the first TEOS.BPSG film 10 by the use of the etching technique in order to connect the diffusion layers of the first driving transistor DT 1 and the first transfer transistor ST 1 , the first load resistor L 1 , and the gate electrode of the second driving transistor DT 2 .
Thereafter, the second N-type high impurity region 12 is formed by injecting impurity (phosphorus) for a part of the first N-type high impurity region 8 under the first contact hole 11 .
Subsequently, the P-type impurity region 13 having higher concentration than the P-type well region 21 is formed by injecting impurity (boron) with suitable energy so as to contact with the lower portion of the second N-type high impurity region 12 .
Actually, the node N 2 is simultaneously formed in addition to the node N 1 illustrated in FIG. 1 . In consequence, the node N 2 has the same structure as the node N 1 illustrated in FIG. 1 .
In such a high-resistance load memory cell, the P-type high concentration region 13 having the higher concentration than the P-type well region 21 is formed so as to contact with the second N-type high impurity region 12 only at the lower portion of the first contact hole 11 .
Consequently, even when the memory cell is reduced in size to realize the high-integration, the transistor characteristics of the first driving transistor DT 1 , the second driving transistor DT 2 , the first transfer transistor ST 1 , and the second transfer transistor ST 2 are not deteriorated.
Further, the node capacitance of the node N 1 and the node capacitance C 2 of the node N 2 in the memory cell can be increased, and the SER resistance can be enhanced without the deterioration of the substrate bias characteristic of the transfer transistor ST 1 , ST 2 .
Moreover, if impurity (boron) injecting concentration for forming the P-type impurity region 13 positioned at the lower portion of the second N-type high impurity region 12 is suitably selected, the SER resistance can be improved with 2˜5 times in comparison with the high-resistance load type memory cell produced by the above-mentioned related manufacturing method.
As described above, in the manufacturing method according to this invention, the P-type impurity region having higher concentration than the P-type well region is formed at the lower portion of the node of the memory cell in order to increase the node capacitance.
As a result, even when the memory is reduced in size to realize the high-integration, the substrate bias characteristic of the transfer transistor is not degraded, and the SER resistance can be enhanced also.
Therefore, the node capacitance in the semiconductor device produced by such a manufacturing method is increased as compared with the conventional case.
Further, the SER resistance is excellent, and the highly integrated semiconductor device can be obtained with high-performance and high quality.
While this invention has been thus far been disclosed in conjunction with an embodiment thereof, it will be readily possible for those skilled in the art to put this invention into practice in various other manners.
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A Static Random Access Memory (SRAM) device includes at least a transfer transistor, a driving transistor and a load resistor which are commonly connected to a node. A well has a first conductive type, and is placed on a substrate. A first impurity region has a second conductive type opposite to the first conductive type, and is placed in the well. A second impurity region has the first conductive type and has higher impurity concentration than the well, and is placed at a lower portion of the first impurity region. The node is composed of at least the first impurity region and the second impurity region.
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[0001] This application is a continuation of U.S. patent application Ser. No. 13/669,809, filed on Nov. 6, 2012 (now U.S. Pat. No. 8,561,717), which in turn is a divisional of U.S. patent application Ser. No. 11/592,603, filed on Nov. 3, 2006 (now U.S. Pat. No. 8,322,456), which claims the benefit of provisional U.S. Patent Application No. 60/733,546, filed on Nov. 4, 2005, the disclosure of each of which are hereby totally incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an electric hand tool and more particularly to an articulating power hand tool.
BACKGROUND
[0003] Power tools including battery operated tools are well-known. These tools typically include an electric motor having an output shaft that is coupled to a spindle for holding a tool. The tool may be a drill bit, sanding disc, a de-burring implement, or the like. The power source may be a battery source such as a Ni-Cad or other rechargeable battery that may be de-coupled from the tool to charge the battery and coupled to the tool to provide power.
[0004] The power source is coupled to the electric motor through a power switch. The switch includes input electrical contacts for coupling the switch to the power source. Within the switch housing, a moveable member, sometimes called a switch, is coupled to the input electrical contacts and to a wiper of a potentiometer. As the moveable member is pressed against the biasing component of the switch, it causes the input electrical contacts to close and provide current to one terminal of the electric motor and to the wiper of the potentiometer. The moveable member is biased so that the biasing force returns the moveable member to the position where the input electrical contacts are open when the moveable member is released. The current is coupled to a timing signal generator, such as a “555” circuit, through the potentiometer. As the member or trigger continues to be pulled against the biasing force so that the wiper reduces the resistance of the potentiometer from an open circuit to a low resistance or short circuit condition, the level of the current supplied to the timing signal generator increases.
[0005] The output of the timing signal generator is coupled to the gate of a solid state device, such as a MOSFET. The source and drain of the solid state device are coupled between a second terminal of the electric motor and electrical ground. In response to the timing signal turning the solid state device on and off, the motor is selectively coupled to electrical ground through the solid state device. Thus, as the timing signal enables the solid state device to couple the motor to electrical ground for longer and longer intervals, the current flows through the motor for longer intervals. The longer the motor is coupled to power, the faster the electric motor rotates the output shaft of the motor. Consequently, the tool operator is able to vary the speed of the motor and, correspondingly, the rotational speed of the tool in the spindle by manipulating the trigger for the power switch.
[0006] The timing signal generated by the timing circuit selectively couples the motor to the power source because it alternates between a logically on-state and a logically off-state. During the logically off-state, the motor is no longer coupled to the power source. The windings in the motor, however, still have current in them. To provide a path for this current, a freewheeling diode is provided across the terminals of the motor.
[0007] The trigger of the power switch is also coupled to two sets of contacts.
[0008] One of these contact sets is called the bypass contact set. When the trigger reaches the stop position of its travel against the biasing component, it causes the bypass contacts to close. The closing of the bypass contacts causes the current through the motor to bypass the solid state device and be shunted to electrical ground. This action enables the motor to remain continuously coupled to the power source and reach its maximum speed.
[0009] The other set of electrical contacts controlled by the switch trigger are the brake contacts. These contacts are closed when the trigger is at the fully biased off position. As the trigger is moved against the biasing force, the brake contacts open. The brake contacts couple one terminal of the electric motor to the other terminal of the motor. In response to the trigger being released from a position that enables power to be supplied to the motor, the brake contacts close to provide a current path through the motor for dynamic braking of the motor. This enables the motor to stop more quickly than if the motor simply coasted to a stop under the effects of friction.
[0010] While the power switch described above is effective for tool speed control, it suffers from some limitations. Known power switches are limited because of the effect of carrying the battery current through the switch. When the battery current is first applied to the contacts, the current level may be sufficient to cause arcing. Arcing may cause the contacts to become pitted or otherwise damaged. Additionally, large currents also tend to heat the components within the switch. Consequently, the switch may require a heat sink or a larger volume to dissipate heat within the switch. The larger size of the housing for the switch may also impact the design of the tool housing to accommodate the switch geometry. Another factor affecting the geometry or size of the switch housing is the potentiometer that generates the variable speed signal. Typically, the distance traveled by the wiper of the potentiometer is approximately the same as the distance traveled by the trigger. In many cases, this distance is approximately 7 mm and this distance must be accommodated by the potentiometer and the housing in which the potentiometer is mounted.
[0011] The direction of motor rotation depends upon whether the battery current flows through the motor from the first terminal to the second terminal or vice versa. Because bidirectional rotation of battery operated tools is desirable, most tools are provided with a two position switch that determines the direction of battery current through the electric motor. In some previously known switches for battery operated tools, this two position switch is incorporated in its own housing that is mounted to the switch housing. The additional two position switch housing may exacerbate the space issues already noted. In other known switches, the two position switch may be integrated within the switch housing. This arrangement, while perhaps smaller than the two housing construction, adds another set of contacts to the switch with the attendant heat or contact deterioration concerns that arise from the motor current flowing through these contacts.
[0012] Another limitation of known power switches relates to the torque control for power tools. In some battery operated tools, mechanical clutches are used to set a torque limit for the tool. When the resistance to the rotation of the tool causes the torque generated by the tool to increase to the torque limit, the clutch slips to reduce the torque. The torque may then build again until it reaches the limit and the clutch slips again. The iterating action of clutch slippage followed by renewed torque buildup is sensed by the operator as vibration. This vibration informs the operator that the tool is operating at the set torque limit. This slippage also causes wear of the mechanical components from friction and impact.
[0013] Electric drills suffer the foregoing limitations. Moreover, electric drills are usually constructed as straight-drilling machines in which the drill spindle extends parallel to the motor shaft and axis of the housing and, for specific purposes, as angular-drilling machines in which the drill spindle is aligned at a right angle to the motor shaft and housing axis. In certain applications in which both straight and angular drilling must be carried out, as is the case in installations in wooden house construction, the two machines must be at hand for continuous alternation.
[0014] What is needed is an articulating power hand tool which does not require a large housing for mechanical switches. What is further needed is an articulating power hand tool with a reduced forward section and a compact articulating system to allow for use of the tool in confined areas.
SUMMARY
[0015] The present invention is an articulating hand power tool. In one embodiment, the tool includes an articulating hand power tool with a main housing having a longitudinal axis, a head portion rotatably engaged with the main housing for placement at a plurality of angles with respect to the longitudinal axis of the main housing, an integrated circuit board located within the main housing and at least one controller accessible from outside of the main housing for controlling the integrated circuit board.
[0016] In another embodiment, a hand power tool includes a longitudinally extending main housing, a head portion configured to be engaged with the main housing at a plurality of angles with respect to the longitudinal axis of the main housing, each of the plurality of angles within a single plane, an articulation gear system for providing motive force to a bit holder in the head portion including a motor side pinion gear having an axis of rotation generally parallel to a longitudinal axis of the housing and an output pinion gear having an axis of rotation generally parallel to a longitudinal axis of the head portion, wherein the motor side pinion gear is operatively connected to the output side pinion gear through a bevel gear, a controller operable from outside of the main housing and located generally on the plane and an integrated circuit located within the main housing and responsive to the controller.
[0017] One method in accordance with the invention includes rotating a head portion of a power tool to one of a plurality of angles with respect to the longitudinal axis of a main housing of the power tool, moving a variable speed trigger switch located outside of the main hosing, generating a variable speed signal with an integrated circuit located within the main housing in response to the movement of the variable speed trigger, controlling the speed of a motor located within the main housing based upon the variable speed signal and transferring motive force from the motor to a component within the head portion.
[0018] These and other advantages and features of the present invention may be discerned from reviewing the accompanying drawings and the detailed description of the preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present invention may take form in various system and method components and arrangement of system and method components. The drawings are only for purposes of illustrating exemplary embodiments and are not to be construed as limiting the invention.
[0020] FIG. 1 shows a perspective view of an articulating drill incorporating features of the present invention;
[0021] FIG. 2 shows a side elevational view of the articulating drill of FIG. 1 with the rechargeable battery pack removed;
[0022] FIG. 3 shows a perspective view of the articulating drill of FIG. 1 with the battery pack, a portion of the main housing cover, and a portion of the head housing removed and a bit in the bit holder;
[0023] FIG. 4 shows a cross-sectional view of the head portion, the articulating gear system and the planetary gear system of the articulating drill of FIG. 1 ;
[0024] FIG. 5 shows an exploded perspective view of the head portion, including an automatic spindle lock system, of the articulating drill of FIG. 1 ;
[0025] FIG. 6 shows a top plan view of the head portion of the drill of FIG. 1 with some components located within bays in the head housing;
[0026] FIG. 7 shows a top plan view of a bracket used to support an output pinion shaft in the articulating drill of FIG. 1 ;
[0027] FIG. 8 shows a side plan view of the bracket of FIG. 7 ;
[0028] FIG. 9 shows a top elevational view of the planetary gear section, articulating section and head portion of the articulating drill of FIG. 1 with the main housing and a portion of the head housing removed;
[0029] FIG. 10 shows a side elevational view of the articulating gear system of the articulating drill of FIG. 1 including a bevel gear and two pinion gears;
[0030] FIG. 11 is a perspective view of a portion of the head housing of the drill of FIG. 1 with a plurality of teeth in a well which are formed complimentary to teeth on the articulation button;
[0031] FIG. 12 shows a perspective view of the articulating button of the articulating drill of FIG. 1 ;
[0032] FIG. 13 shows a perspective view of the bottom of the articulating button of FIG. 12 ;
[0033] FIG. 14 shows a partial top elevational view of the inner surface of the outer housing of the articulating drill of FIG. 1 with teeth formed complimentary to the teeth on the articulation button and a hole for receiving a raised portion of the articulating button;
[0034] FIG. 15 shows a top elevational view of the inner surface of the outer housing of the articulating drill of FIG. 1 ;
[0035] FIG. 16 shows a partial plan view of the articulating drill of FIG. 1 with the head portion aligned with the main housing portion and without a dust lid;
[0036] FIG. 17 shows a partial plan view of the articulating drill of FIG. 1 with the head portion aligned with the main housing portion with a dust lid;
[0037] FIG. 18 shows a side elevational view of the articulating drill of FIG. 18 with the head portion rotated to an angle of 90 degrees from the main housing portion of the drill and a portion of the main housing portion removed to show the position of the dust lid of FIG. 17 ;
[0038] FIG. 19 shows a side elevational view of the articulating drill of FIG. 18 with the head portion rotated to an angle of 180 degrees from the main housing portion of the drill and a portion of the main housing portion removed to show the position of the dust lid of FIG. 17 ;
[0039] FIG. 20 shows a detail view of the dust lid of FIG. 19 ;
[0040] FIG. 21 shows a perspective view of the articulating drill of FIG. 1 with the variable speed trigger switch, clutch control and a portion of the main housing removed;
[0041] FIGS. 22 a , 22 b and 22 c show various views of a printed circuit board of the articulating drill of FIG. 1 in accordance with principles of the invention;
[0042] FIG. 23 shows a perspective view of the articulating drill of FIG. 21 with a collapsible boot with an internal reflective surface installed over a light generator and a light sensor;
[0043] FIG. 24 shows a schematic/block diagram of the drill of FIG. 1 incorporating an optical switch for motor speed control;
[0044] FIG. 25 shows a side elevational view of a drill bit in the form of a screw driver bit that may be used with the articulating drill of FIG. 1 ;
[0045] FIG. 26 shows a cross-sectional view of the drill bit of FIG. 25 being inserted into the articulating drill of FIG. 1 ;
[0046] FIG. 27 shows a cross-sectional view of the drill bit of FIG. 25 inserted into the articulating drill of FIG. 1 ;
[0047] FIG. 28 shows a partial top elevational view of a bevel gear in accordance with principles of the invention with two pinion gears at a 90 degree spacing;
[0048] FIG. 29 shows a partial top elevational view of the bevel gear of FIG. 28 with the two pinion gears at a 180 degree spacing;
[0049] FIG. 30 shows an electrical diagram/schematic of a powered tool that dynamically brakes the tool motor using a motor interface circuit having a half bridge to provide vibratory feedback to the operator that the torque limit has been reached;
[0050] FIG. 31 shows an electrical diagram/schematic of a circuit that may be used with the drill of FIG. 1 which dynamically brakes the drill motor using a motor interface circuit having a full H-bridge circuit to provide vibratory feedback to the operator that the torque limit has been reached; and
[0051] FIGS. 32A and 32B show an electrical diagram/schematic of a powered tool that provides solid state motor speed control in correspondence with a variable speed signal from an optical switch and that dynamically brakes the motor to indicate a torque limit has been reached.
DESCRIPTION
[0052] An articulating drill generally designated 100 is shown in FIG. 1 . In the embodiment of FIG. 1 , the drill 100 includes a main housing portion 102 and a head portion 104 . The main housing portion 102 houses a motor and associated electronics for control of the drill 100 . The main housing portion 102 includes a battery receptacle for receiving a rechargeable battery pack 106 as is known in the art. In one embodiment, the rechargeable battery pack 106 comprises a lithium-ion battery. The battery pack 106 is removed by depression of the battery release tabs 108 . FIG. 2 shows the drill 100 with the battery pack 106 removed. The drill 100 may alternatively be powered by an external power source such as an external battery or a power cord.
[0053] A variable speed trigger switch 110 controls the speed at which the motor rotates. The direction of rotation of the motor is controlled by a reversing button 112 which slides within a finger platform 114 . Ventilation openings 116 allow for cooling air to be circulated around the motor inside of the main housing 102 . A clutch control 118 sets the maximum torque that may be generated when using the drill 100 . At the position shown in FIG. 1 , the clutch control 118 is at the highest setting or drill mode. At the highest setting, the clutch is disabled to provide maximum torque. By sliding the clutch control 118 downwardly from the position shown in FIG. 1 , a user may set a desired torque limit that is allowed to be generated by the drill 100 as discussed in more detail below. Accordingly, at settings other than the highest setting, a torque above the setting of the clutch control 118 causes the clutch to activate.
[0054] The main housing portion 102 also includes an articulation button 120 and a plurality of angle reference indicators 122 molded onto the outer surface 124 of the main housing 102 . In the embodiment of FIG. 1 , there are five angle reference indicators 122 used to identify five angular positions in which the head portion 104 may be placed.
[0055] The head portion 104 includes a collet locking device 126 and an angle indicator 128 . The angle at which the head portion 104 is positioned is indicated by the angle reference indicator 122 with which the angle indicator 128 is aligned. As shown in FIG. 1 , the head portion 104 is at a 90 degree angle with respect to the main housing portion 102 . In FIG. 2 , the head portion 104 is axially aligned with the main housing portion 102 . Although the embodiment of FIGS. 1 and 2 has five angle reference indicators 122 , there may be additional or fewer angle reference indicators 122 and corresponding angles at which the head portion 104 may be placed with respect to the main housing portion 102 .
[0056] Referring now to FIGS. 3-6 , the collet locking device 126 is located around a bit holder 130 which is in turn supported by a ball bearing 132 that is fixed within a bearing pocket 134 of the head housing 136 . The collet locking device 126 includes a sleeve 138 with recesses 140 . A spring 142 is positioned about the bit holder 130 . The bit holder 130 includes a hole 144 which receives a cylinder pin 146 and recesses 148 which receive steel balls 150 .
[0057] The bearing 132 abuts the head housing 136 of the head portion 104 at the outer rear periphery of the bearing 132 . More specifically, the bearing 132 abuts a flange 152 . In this embodiment, the flange 152 is continuous about the housing 136 , although a flange may alternatively be in the form of a plurality of fins located about the inner portion of the housing 136 .
[0058] The bit holder 130 is operably coupled to a drive collet 154 which is in turn connected to an output pinion shaft 156 through a drive plate 158 which is fixedly attached to the output pinion shaft 156 . A lock ring 160 surrounds the drive collet 154 and three locking pins 162 . The lock ring 160 , the drive collet 154 , the drive plate 158 , and the locking pins 162 all comprise an automatic spindle lock system such that the output bit holder 130 can only be driven from the pinion side as known in the art. When driven from the bit side, i.e., when the tool 100 is used as a manual screwdriver, the spindle lock system keeps the output pinion shaft 156 from rotating thus facilitating use of the tool 100 as a manual screwdriver. In an alternative embodiment, a manually manipulated locking device may be used.
[0059] A pinion gear 164 is located at the opposite end of the output pinion shaft 156 from the drive plate 158 . One end of the output pinion shaft 156 is maintained in axial alignment by a bearing 166 which fits within bearing pocket 168 . The opposite end of the output pinion shaft 156 is supported by a sleeve 170 . The sleeve 170 is supported on one side by a flange 172 on the head housing 136 . On the opposite side, the sleeve 170 is supported by a bracket 174 also shown in FIGS. 7 and 8 .
[0060] The bracket 174 includes a support area 176 configured complimentary to a portion of the sleeve 170 . Two connection arms 178 are configured to be attached to the head housing 136 as shown in FIG. 9 . The bracket 174 eliminates the need to provide a matching flange for flange 172 molded into the opposite side of the head housing 136 . The elimination of the need for an opposing flange allows for a significant increase in design freedom as the space requirements for the support structure for the sleeve 170 are reduced. The bracket 174 may be stamped from W108 steel to provide the needed rigidity and strength.
[0061] Referring now to FIG. 10 , the pinion gear 164 forms a portion of an articulating gear system 180 . The articulating gear system 180 further includes a bevel gear 182 which is engaged at the output portion of the articulating gear system 180 with the pinion gear 164 and further engaged on the motor portion by pinion gear 184 . The shaft 186 of the bevel gear 182 is supported at one end within a hole 188 (see FIG. 4 ) of the frame 190 . The frame 190 is made from a zinc and aluminum alloy ZA-8. This material provides a sufficiently low coefficient of friction to ensure relatively small frictional forces exist between the shaft 186 and the frame 190 .
[0062] The shaft 186 is radially and axially supported at the opposite end by a ball bearing 192 supported by the frame 190 . At this end of the shaft 186 , however, comparatively larger forces are generated than at the end of the shaft 186 inserted within the hole 188 . More specifically, as shown in FIG. 10 , both pinion gear 164 and pinion gear 184 are located on the same side of the bevel gear 182 . Accordingly, as the articulating gear system 180 rotates, a force is generated on the bevel gear 182 in the direction of the arrow 194 toward the base 196 of the bevel gear 182 . This force acts to disengage the bevel gear 182 from the pinion gear 164 and the pinion gear 184 . With this increased force acting upon the bevel gear 182 , an unacceptable amount of axial force would be transmitted to the bearing 192 . Accordingly, a thrust bearing 198 is provided to protect the ball bearing 192 and to provide a low friction support for the base 196 of the bevel gear 182 . The thrust bearing 198 is made of a material with an acceptably low coefficient of friction such as oil impregnated bronze commercially available from McMaster Carr of Chicago, Ill. Accordingly, the friction generated at the base 196 of the bevel gear 182 is maintained within acceptable levels.
[0063] Referring again to FIG. 4 , the pinion gear 184 is fixedly attached to a planetary gearbox shaft 200 which receives torque from a planetary gear system generally indicated as reference numeral 202 . The planetary gear system 202 receives torque from a motor as is known in the art. The planetary gear system 202 is located within a planetary gear housing 204 which is inserted partially within the frame 190 . This arrangement allows for the planetary gear system 202 to be separately manufactured from the other components while simplifying assembly of the planetary gear system 202 with the other components. This modularity further allows for alternative gearings to be provided in the planetary gear system 202 while ensuring a proper fit with the other components.
[0064] Generally, it may be desired to provide a simple friction fit between the planetary gear housing 204 and the frame 190 . In the embodiment of FIG. 4 , however, the articulating gear system 180 generates an axial force along the planetary gearbox shaft 200 . This axial force acts to disengage the planetary gear housing 204 from the frame 190 . Accordingly, pins 206 and 208 which extend through both the planetary gear housing 204 and the frame 190 are provided. The pins 206 and 208 ensure the planetary gear housing 204 does not become detached from the frame 190 during operation of the drill 100 . Alternatively, the planetary gear housing 204 and the frame 190 may be formed as an integral unit.
[0065] Continuing with FIG. 4 , the frame 190 is configured to slidingly mate with the head housing 136 . To this end, the head housing 136 includes a shroud portion 210 which is complimentarily formed to the frame 190 about the ball bearing 192 . The head housing 136 further includes a recess 212 which is configured to receive the portion of the frame 190 which defines the hole 188 . Also shown in FIG. 4 is a well 214 which includes a plurality of teeth 216 shown in FIG. 11 .
[0066] With further reference to FIGS. 12-14 , the well teeth 216 are formed complimentary to a plurality of teeth 218 which are formed in the articulation button 120 . The articulation button 120 includes a raised center portion 220 which is configured to fit within a hole 222 in the main housing portion 102 . The teeth 218 of the articulation button 120 are further configured to mesh with a plurality of teeth 224 formed on the inner side of the main housing portion 102 around the hole 222 . The articulation button 120 also includes a spring receiving well 226 on the side of the articulation button 120 facing the well 214 . When assembled, a spring (not shown) is located within the well 214 and extends into the spring receiving well 226 forcing the raised center portion 220 of the articulation button 120 toward a position wherein the articulation button 120 projects into the hole 222 .
[0067] Referring to FIGS. 4 and 15 , the frame 190 is supported axially in the main housing portion 102 , which in this embodiment is made of plastic, by a rib 228 . The rib 228 lies beneath a fin 230 of the frame 190 when the frame 190 is installed in the main housing portion 102 as shown in FIG. 3 . The planetary gear system 202 is mechanically secured to a motor 232 which is itself electrically connected to a printed circuit board 234 which in turn is electrically connected to a battery contact holder 236 . The contact holder 236 mates with battery pack receptacles on the battery pack 106 and transmits battery power to the electronic circuit board 234 through lead wires (not shown). Another pair of lead wires (not shown) extend from the circuit board 234 to the motor terminals 238 to deliver the required voltage level to the motor 232 .
[0068] Referring now to FIG. 5 , a gap 240 is provided in the portion of the head housing 136 surrounding the bevel gear 182 which allows the head housing 136 to be rotated with respect to the main housing portion 102 while the pinion gear 164 remains engaged with the bevel gear 182 . When the head portion 104 is axially aligned with the main housing portion 102 , however, the gap 240 is exposed as shown in FIG. 16 . The articulating gear system 180 is thus exposed allowing contaminants access to the articulating gear system 180 which could foul the articulating gear system as well as presenting a safety concern since clothing, fingers or hair could become enmeshed in the articulating gear system 180 . Accordingly, a floating dust lid 242 shown in FIG. 17 is used to prevent contamination of the articulating gear system 180 and to avoid exposure of moving gears to an operator through the gap 240 , particularly when the head housing 136 is axially aligned with the main housing portion 102 as shown in FIG. 17 .
[0069] The dust lid 242 is located in a channel 244 defined by the main housing portion 102 and the head housing 136 as shown in FIGS. 18-20 . The position of the dust lid 242 at the lower portion (as depicted in FIGS. 18 and 19 ) of the channel 244 is constrained either by a movable dust lid travel limiter 246 positioned on the head housing 136 , shown most clearly in FIGS. 11 and 20 , or by a portion 248 of the frame 190 . The position of the dust lid 242 at the upper portion of the channel 244 is constrained either by a neck portion 250 of the head housing 136 or by a lip 252 in the main housing portion 102 .
[0070] Referring now to FIGS. 3 , and 21 - 23 , the clutch control 118 is mechanically interfaced with a linear potentiometer 254 on the circuit board 234 . Also located on the circuit board 234 is a light sensor 256 which is covered by a collapsible rubber boot 258 which is in turn mechanically fastened to the variable speed trigger 110 . A reflective surface 260 (see FIG. 24 ) is located on the inside of the rubber boot 258 . A plastic spring locating member 262 which is mechanically secured to the circuit board 234 serves to locate and support a spring 264 which is mechanically fastened to the variable speed trigger 110 . The spring 264 biases the variable speed trigger 110 in a direction away from the circuit board 234 about a pivot 266 . The circuit board 234 also contains a two position slide switch 268 which is mechanically interfaced to the reversing button 112 .
[0071] Manipulation of the variable speed trigger 110 about the pivot 266 changes the position of the reflective surface 260 relative to the light sensor 256 to produce a variable speed control signal. While the embodiment of tool 100 incorporates an optical signal generator and receiver for provision of a variable speed control signal, such a tool may alternatively use a pressure transducer, a capacitive proximity sensor, or an inductive proximity sensor. In these alternative embodiments, a pressure sensing switch for generating the variable motor speed control signal may include a pressure transducer for generating a variable speed control signal that corresponds to a pressure applied to the pressure transducer directly by the operator or through an intermediate member such as a moveable member that traverses the distance between the stop position and the full speed position.
[0072] An embodiment of the variable motor speed control signal implemented with a capacitive proximity sensor may include a capacitive sensor that generates a variable speed control signal that corresponds to an electrical capacitance generated by the proximity of an operator's finger or moveable member's surface to the capacitive sensor. An embodiment implemented with an inductive proximity sensor generates a variable speed control signal that corresponds to an electrical inductance generated by the proximity of an operator's finger or moveable member's surface to the inductive sensor.
[0073] Referring to FIG. 24 , the variable speed control circuit 270 of the tool 100 is schematically shown. The variable speed control circuit 270 includes a power contact 272 which is operably connected to the variable speed trigger switch 110 . An optical signal generator 274 is coupled to the battery 106 and arranged on the circuit board 232 such that light emitted from the optical signal generator 274 is directed toward the reflective surface 260 of the variable speed trigger switch 110 and directed toward the light sensor 256 .
[0074] The light sensor 256 and the optical signal generator 274 may be located in the same housing or each may be within a separate housing. When the two components are located in the same housing, the light generator and sensor may emit and receive light through a single sight glass in the housing. Alternatively, each component may have a separate sight glass. An integrated component having the light generator and sensor in a single housing is a QRD1114 Reflective Object Sensor available from Fairchild Semiconductor of Sunnyvale, Calif. Such a housing is substantially smaller than a potentiometer that has a wiper, which traverses approximately the same distance as the trigger traverses from the stop to the full speed position.
[0075] The optical signal generator 274 and the light sensor 256 may be an infrared light emitter and an infrared light receiver. In an alternative embodiment, an IR transceiver may be contained within a flexible dust cover that is mechanically fastened to the back of the variable speed trigger switch. In such an embodiment, the inside of the cover in the vicinity of the moveable trigger reflects the optical signal to the receiver for generating the speed control signal.
[0076] Control of a tool incorporating the light sensor 256 may be adversely affected by external energy sources such as the sun. Accordingly, in one embodiment, the collapsible boot or dust cover 258 is made from an opaque material or coated with an opaque material such that energy from the sun which may leak past the housing and trigger arrangement does not affect the signal received by the light sensor 256 . Alternatively, a light sensor that is sensitive to a specific frequency band may be used with a device which shields the light sensor from only that specific frequency band. In further embodiments, other circuitry or coding which uniquely identifies the energy from the reflected signal from interfering energy may be used.
[0077] The light sensor 256 is an optical transistor having a collector 276 coupled to the battery pack 106 through the contact 272 and an emitter 278 coupled to electrical ground though a voltage divider 280 and a capacitor 282 . A timing signal generator 284 receives voltage from the voltage divider 280 . In the tool 100 , the timing signal generator 264 is a commonly known “555” timer, although other timing signal generators may be used.
[0078] The output of the timing signal generator 264 is coupled to a gate 286 of a MOSFET 288 that has a drain 290 coupled to one of the motor terminals 238 and a source 292 coupled to electrical ground. The other motor terminal 238 is coupled to the battery pack 106 through the contact 272 . A freewheeling diode 294 is coupled across the motor terminals 238 . A bypass contact 296 , which is operatively connected to the variable speed trigger switch 110 , is located in parallel to the MOSFET 288 between the motor terminal 238 and electrical ground and a brake contact 298 is in parallel with the freewheeling diode 294 .
[0079] Operation of the drill 100 is explained with initial reference to FIGS. 24-26 . The collet locking device 126 is configured to operate with bits such as the screw driver bit 300 shown in FIG. 24 . The screw driver bit 300 and the bit holder 130 are complimentarily shaped. In this example, both the screw driver bit 300 and the bit holder 130 are generally hexagonal in shape, although alternative shapes may be used. The screw driver bit 300 has a diameter slightly less than the bit holder 130 so that it may fit within the bit holder 130 . The screw driver bit 300 includes a notched area 302 and a tail portion 304 .
[0080] Initially, the sleeve 138 is moved to the right from the position shown in FIG. 4 to the position shown in FIG. 26 thereby compressing the spring 142 . As the sleeve 138 moves, recesses 140 in the sleeve 138 are positioned adjacent to the recesses 148 in the bit holder 130 . Then, as the screw driver bit 300 is moved into the bit holder 130 , the tail portion 304 forces the steel balls 150 toward the recesses 140 and out of the channel of the bit holder 130 , allowing the tail portion 304 to move completely past the steel balls 150 .
[0081] At this point, the notched area 302 is aligned with the recesses 148 . The sleeve 138 is then released, allowing the spring 142 to bias the sleeve 138 onto the bit holder 130 which is to the left from the position shown in FIG. 27 . As the sleeve 138 moves, the recesses 140 are moved away from the recesses 148 thereby forcing the steel balls 150 partially into the channel of the bit holder 130 as shown in FIG. 27 . Movement of the steel balls 150 into the channel of the bit holder 130 is allowed since the notched area 302 is aligned with the recesses 148 . At this point, the bit 300 is firmly held within the bit holder 130 .
[0082] The head housing 136 is then articulated to a desired angle with respect to the main housing portion 102 . Initially, the spring (not shown) in the spring receiving well 226 forces the articulation button 120 to extend into the hole 222 . Accordingly, the teeth 218 of the articulation button 120 are meshed with the teeth 224 in the main housing portion 102 as well as the teeth 216 in the well 214 of the head housing 136 , thereby angularly locking the articulation button 120 (and the head housing 136 ) with the main housing portion 102 . Additionally, the dust lid 242 is constrained at the upper portion of the channel 244 by the neck portion 250 of the head housing 136 and at the lower portion of the channel 244 by the portion 248 of the frame 190 as shown in FIG. 18 .
[0083] The operator then applies force to the articulation button 120 causing the spring (not shown) to be depressed thereby disengaging the teeth 218 from the teeth 224 . Thus, even though the teeth 218 remain engaged with the teeth 216 , the head portion 104 is allowed to pivot with respect to the main housing portion 102 . As the head portion 104 is articulated, for example, from the position shown in FIG. 1 to the position shown in FIG. 2 , the pinion gear 164 articulates about the bevel gear 182 . By way of example, FIG. 28 shows the positions of the pinion gears 164 and 184 with respect to the bevel gear 182 when the drill 100 is in the configuration shown in FIG. 1 . In this configuration, the pinion gear 164 is approximately 90 degrees away from the pinion gear 184 about the perimeter of the bevel gear 182 . As the head portion 104 is articulated in the direction of the arrow 306 , the pinion gear 164 articulates about the bevel gear 182 in the same direction. Thus, when the head portion 104 is aligned with the main housing portion 102 , the pinion gear 164 is positioned on the bevel gear 182 at a location 180 degrees away from the pinion gear 184 as shown in FIG. 29 .
[0084] Throughout this articulation, the pinion gears 164 and 184 remain engaged with the bevel gear 182 . Accordingly, the bit holder 130 may be rotated by the motor 232 as the head housing 136 is articulated. Additionally, the articulation of the head housing 136 causes the movable dust lid travel limiter 246 to contact the dust lid 242 and push the dust lid 242 along the channel 244 . Thus, the dust lid 242 , which is configured to be wider than the gap 240 as shown in FIG. 17 , restricts access from outside of the drill 100 to the articulating gear system 180 .
[0085] When the articulating drill 100 is rotated to the desired location, the operator reduces the force applied to the articulating button 120 . The spring (not shown) in the spring receiving well 226 is then allowed to force the articulation button 120 away from the well 214 until the articulation button 120 extends through the hole 222 . Accordingly, the teeth 218 of the articulation button 120 are meshed with the teeth 224 in the main housing portion 102 as well as the teeth 216 in the well 214 of the head housing 136 , thereby angularly locking the articulation button 120 (and the head housing 136 ) with the main housing portion 102 .
[0086] The desired direction of rotation for the bit 300 is then established by placing the reversing button 112 in the position corresponding to the desired direction of rotation in a known manner. Rotation is accomplished by moving the variable speed trigger switch 110 about the pivot 266 to close the power contact 272 . The closing of the contact 272 completes a circuit allowing current to flow to the optical signal generator 274 causing light to be emitted.
[0087] The emitted light strikes the reflective surface 260 and a portion of the light is reflected toward the light sensor 256 . The amount of light reflected by the reflective surface 260 increases as the reflective surface 260 is moved closer to the light sensor 256 . The increased light sensed by the light sensor 256 causes increased current to be conducted by the light sensor 256 and the flow of current through the light sensor 256 causes current to flow from the collector 276 to the emitter 278 . Thus, as the intensity of the light impinging on the light sensor 256 increases, the current conducted by the light sensor 256 increases. This increase in current causes the voltage level presented by the voltage divider 280 to the timing signal generator 284 to increase. The increased signal is the variable speed signal and it causes the timing signal generator 284 to generate a timing signal in a known manner. In the depicted drill 100 , the timing signal generator 284 is a commonly known “555” timer, although other timing signal generators may be used.
[0088] The timing signal generator 284 generates a timing pulse having a logical on-state that corresponds to the level of the variable speed signal. This signal is presented to the gate 286 of the MOSFET 288 . When the signal present at the gate 286 is a logical on-state, the MOSFET 288 couples one of the motor terminals 238 to ground while the other motor terminal 238 is coupled to battery power through the main contact 272 . Thus, when the variable speed trigger switch 110 reaches a position where the light sensor 256 begins to detect reflected light and generate a variable speed signal, the timing signal generator 284 begins to generate a signal that causes the MOSFET 288 to couple one of the motor terminals 238 to ground. Once this occurs, current begins to flow through the MOSFET 288 and the motor 232 begins to rotate in the direction selected by the reversing button 112 .
[0089] The freewheeling diode 294 causes appropriate half-cycles of the current in the windings of the motor 232 to flow out of the motor 232 , through the diode 294 , and back into the motor 232 when the MOSFET 288 does not conduct in response to the timing signal being in the off-state. This action is known as freewheeling and is well known.
[0090] When the variable speed trigger 110 is in the full speed position, the timing signal is predominantly in the on-state and the bypass contact 296 closes. The closing of the bypass contact 296 enables the battery current to continuously flow through the motor 232 so that the motor 232 rotates at the highest speed.
[0091] When rotation is no longer desired, the operator releases the variable speed trigger switch 110 and the spring 264 causes the variable speed trigger switch 110 to rotate about the pivot 266 causing the bypass contact 296 to open. Additionally, the brake contact 298 closes thereby coupling the motor terminals 238 . The coupling of the two motor terminals 238 to one another through the brake contact 298 enables dynamic braking of the motor.
[0092] The electronic control of the tool 100 thus requires less space for the components that generate the variable speed signal than prior art control systems. Because the distance traveled by the variable speed trigger switch 110 does not have to be matched by the light signal generator 274 and the light sensor 256 , considerable space efficiency is gained. Additionally, the light signal generator 274 and the light sensor 256 do not require moving parts, so reliability is improved as well. Advantageously, the light signal generator 274 and the light sensor 256 may be mounted on the same printed circuit board 234 on which the timing signal generator 284 is mounted.
[0093] As the drill 100 is operated, the bit 300 is subjected to axial forces. The axial forces may result from, for example, pressure applied by the operator or by an impact on the bit. In either instance, the articulating gear system 180 is protected from damage without increasing the bulk of the components within the articulating gear system 180 . This is accomplished by directing axial forces from the bit 300 to the main housing portion 102 of the drill 100 while bypassing the articulating gear system. With initial reference to FIG. 27 , an impact on the bit 300 tends to move the bit 300 further into the drill 100 , or to the left as depicted in FIG. 27 . In prior art designs, not only could such a force damage the gear system, but the steel balls used to retain the bit within the bit holder would frequently jam necessitating replacement of the collet locking device.
[0094] As shown in FIG. 27 , however, the cylinder pin 146 is positioned such that the tail portion 304 of the bit 300 will contact the cylinder pin 146 before the wall of the notched area 302 contacts the steel balls 150 . Thus, an axial impact will not cause the steel balls 150 to jam. Of course, the cylinder pin 146 must be made from a material sufficient to withstand the axial impact. In accordance with one embodiment, the cylinder pin 146 is made of AISI 4135 steel.
[0095] Referring now to FIG. 4 , in the event of an axial impact, the force is transferred from the cylinder pin 146 to the to the bit holder 130 . The axial force is transmitted from the bit holder 130 to the bearing 132 which is located within the bearing pocket 134 . Accordingly, the axial force is transferred into the flange 152 (see also FIG. 5 ) of the head housing 136 . The head housing 136 in this embodiment is made from aluminum alloy A380 so as to be capable of receiving the force transmitted by the bearing 132 . The force is subsequently transferred to the frame 190 and into the rib 228 of the main housing portion 102 .
[0096] More specifically, two paths for the transfer of axial forces are provided around the articulating gear system 180 . The first path predominantly transfers axial forces when the head housing 136 is axially aligned with the main housing portion 102 . In this configuration, axial forces pass from head housing 136 to the frame 190 primarily through the recess 212 where the head housing 136 engages the frame 190 about the hole 188 (see FIG. 4 ) and at the shroud portion 210 where the head housing 136 engages the frame 190 outwardly of the base of the bevel gear 196 .
[0097] The second path predominantly passes axial forces when the head housing 136 is at a ninety degree angle with respect to the main housing portion 102 . In this configuration, axial forces are again transferred from the cylinder pin 146 to the to the bit holder 130 . The axial forces then pass primarily from the teeth 216 in the well 214 of the head housing 136 to the teeth 218 on the articulation button 120 and then to the teeth 224 in the main housing portion 102 .
[0098] When the head housing 136 is neither completely aligned with the main housing portion 102 or at a ninety degree angle with respect to the main housing portion 102 , axial forces generally pass through both of the foregoing pathways. Accordingly, the effect of axial forces on the articulating gear system 180 of the drill 100 are reduced.
[0099] Because the articulating gear system 180 is thus protected, the articulating gear system 180 may be constructed to be lighter than other articulating gear systems.
[0100] In one embodiment, a printed circuit board which may be used in the drill 100 or another power tool includes a circuit that provides vibratory feedback to the operator as shown in FIG. 30 . The vibratory feedback circuit 308 includes a microcontroller 310 , a driver circuit 312 , and motor interface circuit 314 . The driver circuit 312 in this embodiment is an integrated circuit that generates driving signals for a half-bridge circuit from a single pulse width modulated (PWM) signal, a torque limit indicating signal, which may be the same signal as the PWM signal, and a motor direction control signal. The driver circuit 312 may be a half bridge driver, such as an Allegro 3946 , which is available from Allegro Microsystems, Inc. of Worcester, Massachusetts.
[0101] The output of the driver circuit 312 is connected to a motor 316 through two transistors 318 and 320 which may be MOSFETs, although other types of transistors may be used. The transistor 318 may be connected to either terminal of the motor 316 through switches 322 and 324 while the transistor 320 may be connected to either terminal of the motor 316 through switches 326 and 328 . A shunt resistor 330 is coupled between the transistor 320 and electrical ground. The high potential side of the resistor 330 is coupled to the microcontroller 310 through an amplifier 332 . A power source 334 is also provided in the vibratory feedback circuit 308 and a maximum torque reference signal is provided from a torque reference source 336 which may be a linear potentiometer such as the linear potentiometer 254 .
[0102] The half-bridge control of the motor 316 eliminates the need for a freewheeling diode because the driver circuit 312 generates motor interface circuit signals for selectively operating the motor interface circuit 314 to control the rotational speed of the motor 316 . More specifically, a variable speed control signal 338 , which may be from a trigger potentiometer or the like, is provided to the microcontroller 310 for regulation of the rotation of the motor 316 by the microcontroller 310 . Based upon the variable speed control signal 338 , the microcontroller 310 generates a PWM signal that is provided to the driver circuit 312 . In response to the PWM signal, the driver circuit 312 turns transistors 318 and 320 on and off.
[0103] During typical operations, the transistor 318 is the complement of the transistor 320 such that when the transistor 320 is on, the transistor 318 is off. The rate at which the transistor 320 is turned on and off determines the speed of motor 316 . The direction of rotation of the motor 316 is determined by the position of the switches 322 , 324 , 326 and 328 under the control, for example, of a reversing switch.
[0104] The current through the motor 316 is provided through the transistor 320 and the resistor 330 to electrical ground when the transistor 320 is in the on-state. This current is related to the torque at which the motor 316 is operating. Thus, the voltage at the high potential side of the resistor 330 is related to the torque on the motor 316 . This motor torque signal is amplified by the amplifier 332 and provided to the microcontroller 310 . The microcontroller 310 compares the amplified motor torque signal to the torque limit signal established by the torque reference source 336 . The torque limit signal, which may alternatively be provided by a different type of torque limit signal generator, provides a reference signal to the microcontroller 310 that corresponds to a current through the motor 316 that represents a maximum torque setting for the motor 316 .
[0105] In response to the microcontroller 310 receiving a motor torque signal that exceeds the maximum torque setting for the motor 316 , the microcontroller 310 generates a braking signal that is provided to the driver circuit 312 . In response to the braking signal, the driver circuit 312 turns transistor 320 to the off-state and leaves transistor 318 in the on-state. This enables regenerative current to dynamically brake the rotation of the motor 316 .
[0106] As dynamic braking occurs, the torque experienced by the motor 316 decreases until the sensed torque is less than the maximum torque setting for the motor 316 . The microcontroller 310 then returns the transistor 320 to the on-state, thereby rotating the motor 316 and increasing the torque experienced by the motor 316 . In this manner, the motor 316 alternates between rotating and dynamically braking which causes the tool to vibrate and alert the operator that the torque limit has been reached. An effective frequency for providing this vibratory feedback is 30 Hz. The torque limit indicating signal that results in this operation continues as long as the trigger remains depressed. Alternatively, the microcontroller may be programmed to generate the torque limit indicating signal for a fixed duration and then to stop to reduce the likelihood that the motor will be overpulsed.
[0107] In one embodiment, vibratory feedback is provided for the drill 100 with the circuit shown in FIG. 31 . The vibratory feedback circuit 340 includes a microprocessor 342 , an H-bridge driver circuit 344 and a motor interface circuit 346 . Four MOSFETs 348 , 350 , 352 and 354 control power to the motor 232 from the rechargeable battery pack 106 under the control of the H-bridge driver circuit 344 . A shunt resistor 356 is provided between the MOSFETs 352 and 354 and electrical ground. The signal at the high potential side of the resistor 356 corresponds to the torque being generated by the motor 232 . This motor torque signal is amplified by an amplifier circuit 358 , which may be implemented with an operational amplifier as shown in FIG. 31 , and provided to the microcontroller 342 . The microcontroller 342 compares the motor torque signal to the torque limit signal and generates a torque limit indicating signal in response to the motor torque signal being equal to or greater than the torque limit signal. The torque limit indicating signal may have a rectangular waveform.
[0108] In one embodiment, the microcontroller 342 provides a torque limit indicating signal that is a rectangular signal having an off-state of at least 200 μseconds at a frequency of approximately 30 Hz. This torque limit indicating signal causes the driver circuit 344 to generate motor interface control signals that disconnect power from the motor 232 and couple the MOSFETs 348 , 350 , 352 and 354 together so the current within the windings of the motor 232 flows back through the motor 232 to dynamically brake the motor 232 .
[0109] The dynamic braking causes the motor 232 to stop. Before application of the next on-state pulse, the microcontroller inverts the signal to the direction control input of the H-bridge driver 344 . Thus, the subsequent on-state of the rectangular pulse causes the H-bridge driver circuit 344 to operate the H-bridge to couple the motor 232 to the rechargeable battery pack 106 with a polarity that is the reverse of the one used to couple the motor 232 and the rechargeable battery pack 106 prior to braking This brake/reverse/start operation of the motor at the 30 Hz frequency causes the tool to vibrate in a manner that alerts the operator that the torque limit has been reached while preventing the bit from continuing to rotate during the clutching operation. The dynamic braking may also be used without inverting the signal.
[0110] In yet another embodiment, the rectangular waveform may be generated for a fixed duration, for example, 10 to 20 pulses, so the motor is not over-pulsed. Also, the microcontroller 342 may invert the direction control signal to the H-bridge driver 344 during the off-time of the rectangular waveform so that the motor 232 starts in the opposite direction each time. This action results in the net output rotation being zero during the clutching duration. Additionally, the microcontroller 342 may disable the clutching function in response to the motor direction control signal indicating reverse, rather than forward, operation of the motor 232 .
[0111] FIGS. 32A and 32B show an embodiment of a circuit used in a tool that eliminates the need for mechanical contacts. The circuit 360 includes an optical speed control switch 362 , a two position forward/reverse switch 364 , a microcontroller 366 , a driver circuit 368 , an H-bridge circuit 370 , a motor 372 , a shunt resistor 374 , a motor torque signal amplifier 376 , and a torque limit signal generator 378 . In this embodiment, power is coupled to the motor 372 through the H-bridge circuit 370 , but the main contact, brake contact, and bypass contact are no longer required. Thus, this embodiment significantly reduces the number of components that are subject to mechanical wear and degradation. Because the optical control switch 362 , microcontroller 366 , driver circuit 368 , H-bridge circuit 370 , and torque signal amplifier 376 may all be implemented with integrated circuits, then ICs may be mounted on a common printed circuit and the space previously occupied by the mechanical contacts and variable signal potentiometer are gained. This construction further enables the tool components to be arranged in more efficient geometries.
[0112] In the circuit 360 , the optical speed control switch 362 operates as described above to generate a variable control signal from the reflection of an optical signal directed at the reflective surface of a pivoting trigger. The variable speed control signal is provided to the microcontroller 366 for processing. The microcontroller 366 , which may be a microcontroller available from Texas Instruments and designated by part number MSP430, is programmed with instructions to generate a PWM pulse with an on-state that corresponds to the level of the variable speed signal. The microcontroller 366 provides the PWM signal to the driver circuit 368 for generation of the four motor interface control signals used to couple battery power to the motor 372 . The direction in which the motor 372 is driven is determined by the contacts in the two position forward/reverse switch 364 through which a signal is provided to the microcontroller 366 . In the circuit 360 , the contacts of the two position forward/reverse switch 364 do not need to carry the current provided to the motor 372 so the contacts of the two position forward/reverse switch 364 may be smaller than contacts in other systems. The directional signal is also provided by the microcontroller 366 to the driver circuit 368 so the driver circuit 368 is capable of two directional control of current in the H-bridge circuit 370 .
[0113] The motor torque signal amplifier 376 provides the torque signal from the high potential side of the shunt resistor 374 to the microcontroller 366 . The torque limit signal generator 378 may be implemented with a potentiometer as described above to provide a reference signal for the microcontroller 366 . When the microcontroller 366 determines that the motor torque signal equals or exceeds the motor torque limit, the microcontroller 366 generates a torque limit indicating signal so the driver circuit 368 generates the motor interface control signals that operate the motor 372 in a manner that causes vibration. For the TD340 driver circuit, the torque limit indicating signal generated by the microcontroller 366 is a rectangular signal having an off-state of at least about 200 μseconds at a frequency of about 30 Hz.
[0114] While the present invention has been illustrated by the description of exemplary processes and system components, and while the various processes and components have been described in considerable detail, applicant does not intend to restrict or in any limit the scope of the appended claims to such detail. Additional advantages and modifications will also readily appear to those skilled in the art. The invention in its broadest aspects is therefore not limited to the specific details, implementations, or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicant's general inventive concept.
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The present invention is an articulating hand power tool with a main housing having a longitudinal axis, a head portion rotatably engaged with the main housing for placement at a plurality of angles with respect to the longitudinal axis of the main housing, an integrated circuit board located within the main housing and at least one controller accessible from outside of the main housing for controlling the integrated circuit board.
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FIELD OF THE INVENTION
[0001] The present invention relates to a semiconductor structure and a method of fabricating the same. More particularly, the present invention relates to a hybrid interconnect structure that exhibits improved performance as well as enhanced reliability.
BACKGROUND OF THE INVENTION
[0002] Generally, semiconductor devices include a plurality of circuits that form an integrated circuit (IC) fabricated on a semiconductor substrate. A complex network of signal paths will normally be routed to connect the circuit elements distributed on the surface of the substrate. Efficient routing of these signals across the device requires formation of multilevel or multilayered schemes, such as, for example, single or dual damascene wiring structures. The wiring structure typically includes copper, Cu, since Cu based interconnects provide higher speed signal transmission between large numbers of transistors on a complex semiconductor chip as compared with aluminum, Al, based interconnects.
[0003] Within a typical interconnect structure, metal vias run perpendicular to the semiconductor substrate and metal lines run parallel to the semiconductor substrate. Further enhancement of the signal speed and reduction of signals in adjacent metal lines (known as “crosstalk”) are achieved in today's IC product chips by embedding the metal lines and metal vias (e.g., conductive features) in a dielectric material having a dielectric constant of less than 4.0.
[0004] That is, in order to reduce the interconnect portion of circuit delay, conventional dielectric materials having a dielectric constant of about 4.0 or greater such as, for example, silicon dioxide, have been replaced with dense lower-k dielectric materials having a dielectric constant of less than 4.0, preferably less than 3.5. It is noted that all dielectric constants mentioned throughout this application are relative to vacuum. For further performance improvement, more dielectric capacitance reduction is required for advanced devices.
[0005] Capacitance improvements can be made by replacing the dense low-k dielectric materials with porous low-k dielectric materials, Despite the improvement in capacitance, porous low-k dielectric materials have relatively weak mechanical properties as compared to dense dielectrics. Additionally, it is a significant challenge for current interconnects processing to integrate porous low-k dielectric materials with other module processes.
[0006] For example, the conventional chemical mechanical polishing (CMP) process has difficulty in planarizing a low mechanical-module porous dielectric, and the conventional physical vapor deposition (PVD) diffusion barrier deposition technology cannot offer reasonable coverage on the surface of the porous low-k dielectric material. That is, the conventional PVD process provides a discontinuous PVD liner on the exposed surfaces of the porous low-k dielectric material. It is noted that the presence of a discontinuous PVD liner around the conductive feature embedded in a porous low k dielectric material is a sever circuit reliability concern.
[0007] Referring back to dense low-k dielectric materials, the applicants have observed that an undercut profile, such as shown, in FIG. 1A , exists because of the etching rate difference between the dense low-k dielectric material and the oxide-containing hard mask material. A similar result may exist with some porous low-dielectric materials as well. Specifically, FIG. 1A shows a partially formed prior art interconnect structure 10 which includes a lower interconnect level 12 A and an upper interconnect level 12 B which are separated by a dielectric capping layer 20 . The lower interconnect level 12 A includes a first dielectric material 14 A having at least one conductive feature represented by conductive material 18 A embedded therein. A diffusion barrier 16 A separates the conductive material 18 A from the first dielectric material 14 A. Atop the dielectric capping layer 20 , is the upper interconnect level 12 B which, at this stage of the prior art process, includes a patterned dense low-k dielectric material 14 B and a patterned oxide-containing hard mask 22 located on a surface of the low-k dielectric material 14 B. The undercut region is labeled as 24 in FIG. 1A .
[0008] This undercut profile results in poor conductor fill property in the final interconnect structure and leaves voids between the diffusion barrier and the interconnect conductive material. This is clearly seen in FIGS. 1B (actual cross sectional photograph of a prior art interconnect structure) and 1 C (actual top down view). The term ILD denotes the second dielectric material 14 B mentioned above, barrier represents a second diffusion barrier that is formed in the opening of the patterned ILD, Cu represents the conductive material used in filling the openings. Reliability related issues may be caused by having the voids present inside the interconnect structure.
[0009] In view of the above, there is a need for providing a new and improved interconnect structure which overcomes all of the drawbacks mentioned above. That is, there is a need for providing a new and improved interconnect structure that has improved performance as well as enhanced reliability without changing the existing materials or the process flow significantly.
SUMMARY OF THE INVENTION
[0010] The present invention provides an interconnect structure (of the single or dual damascene type) and a method of forming the same, in which a dense (i.e., non-porous) dielectric spacer is present on the sidewalls of a dielectric material. The presence of the dense dielectric spacer results in a hybrid interconnect structure that has improved reliability and performance as compared with existing prior art interconnect structures which do not include such dense dielectric spacers. Moreover, the inventive hybrid interconnect structure provides for better process control which leads to the potential for high volume manufacturing.
[0011] It is noted that by ‘improved reliability’ it is meant that the inventive hybrid interconnect structure has improved barrier coverage and improved conductor/barrier adhesion. The improved barrier coverage means less leakage concerns within the inventive interconnect structure, while improved adhesion means less electromigration within the inventive interconnect structure.
[0012] The present invention provides a hybrid interconnect structure that contains a dense dielectric spacer located on patterned sidewalls of an interconnect dielectric material which avoids maintaining an undercut region within the final interconnect structure. The present invention also provides, in some embodiments, an embedded air gap within the interconnect structure which helps to reduce the overall interconnect capacitance and to enhance the circuit performance.
[0013] In one embodiment, the present invention provides a hybrid interconnect structure that comprises:
[0000] a dielectric material having a conductive material embedded within at least one opening in said dielectric material, wherein said conductive material is laterally spaced apart from said dielectric material by a diffusion barrier and a dense dielectric spacer, said diffusion barrier is in contact with said conductive material.
[0014] In another embodiment, the present invention provides a hybrid interconnect structure that comprises:
[0000] a dielectric material having a conductive material embedded within at least one opening in said dielectric material, wherein said conductive material is laterally spaced apart from said dielectric material by a diffusion barrier, a dense dielectric spacer and an air gap, said diffusion barrier is in contact with said conductive material.
[0015] In yet another embodiment of the present invention, an interconnect structure is provided that includes:
[0000] a lower interconnect level comprising a first dielectric material having a first conductive material embedded therein; and
an upper interconnect level comprising a second dielectric material having at least one opening that is in contact with said first conductive material of the lower interconnect level, wherein said second dielectric material has a second conductive material embedded within said at least one opening that is laterally spaced apart from said second dielectric material by a diffusion barrier and a dense dielectric spacer, said diffusion barrier is in contact with at least said second conductive material.
[0016] In some embodiments, an optional air gap may also be present in the upper interconnect level.
[0017] In any of the embodiments mentioned above, the dielectric material includes any dielectric level of an interconnect structure. The dielectric material may be dense or porous, with porous being highly preferred. The dielectric material employed in any of the embodiments has a dielectric constant of about 4.0 or less. Examples of some dielectric materials that can be employed include SiO 2 , silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H), thermosetting polyarylene ethers, or multilayers thereof. Preferably, a dielectric material having a dielectric constant of less than silicon dioxide is employed.
[0018] The dielectric spacer employed in the present invention comprises any dielectric material whose composition is typically, but not necessarily always, different from that of the dielectric material including the embedded conductive material. Examples of dielectric spacers that can be used in the present invention include, but are not limited to: SiO 2 , Si 3 N 4 , SiC, silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H) or thermosetting polyarylene ethers. Multilayered dense dielectric spacers are also within the scope of the present invention.
[0019] In addition to the hybrid interconnect structure mentioned above, the present invention also relates to a method of fabricating such a hybrid interconnect structure. The inventive method is compatible within current interconnect processing and, as such, no significant cost increase is associated with the fabrication thereof. Additionally, the inventive method (as well as the interconnect structure) does not put any limitations on the possible choices for the ILD material which means that the inventive method (as well as interconnect structure) provides for better technology extendibility.
[0020] In general terms, the method of the present invention comprises:
[0000] forming at least one opening in a dielectric material utilizing a patterned hard mask located on a surface of said dielectric material as a mask, wherein an undercut is present beneath said patterned hard mask;
forming a dense dielectric spacer in said at least one opening on exposed sidewalls of said dielectric material;
forming a diffusion barrier within said at least one opening on at least said dense dielectric spacer; and
forming a conductive material within said at least one opening on said diffusion barrier.
[0021] In some embodiments of the inventive method, an air gap remains between the dense dielectric spacer and the dielectric material. The air gap is typically located near the undercut region mentioned above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1A is a pictorial representation (through a cross sectional view) of a partially formed prior art interconnect structure which includes undercuts between an oxide-containing hard mask and a low-k dielectric material.
[0023] FIG. 1B is a cross sectional photograph of an actual prior art interconnect structure which includes voids created from the undercuts shown in FIG. 1A .
[0024] FIG. 1C is a top-down photograph of the prior art interconnect structure whose cross sectional view is shown in FIG. 1B .
[0025] FIGS. 2A-2B are pictorial representations (through cross sectional views) illustrating the inventive hybrid interconnect structure in accordance with a first embodiment and a second embodiment of the present invention.
[0026] FIGS. 3A-3F are pictorial representations (through cross sectional views) depicting the basic processing steps employed in the present invention for fabricating the inventive interconnect structure shown in FIG. 2A .
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention, which provides a hybrid interconnect structure including a dense dielectric spacer on sidewalls of a patterned dielectric material as well as a method of fabricating the same, will now be described in greater detail by referring to the following discussion and drawings that accompany the present application. The drawings of the present invention, which are referred to in the present application, are provided for illustrative purposes and, as such, they are not drawn to scale.
[0028] In the following description, numerous specific details are set forth, such as particular structures, components, materials, dimensions, processing steps and techniques, in order to provide a thorough understanding of the present invention. However, it will be appreciated by one of ordinary skill in the art that the invention may be practiced without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the invention.
[0029] It will be understood that when an element as a layer, region or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “connected” or “coupled” to another element, it can be directly connected or coupled to the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly connected” or “directly coupled” to another element, there are no intervening elements present.
[0030] Generally, the present invention provides a hybrid interconnect structure (see, for example, FIGS. 2A-2B ) which includes a dielectric material 56 B having a conductive material 60 B embedded within at least one opening in the dielectric material 56 B, wherein the conductive material 60 B is laterally spaced apart from the dielectric material 56 B by a diffusion barrier 58 B, a dense dielectric spacer 66 ′ and, optionally, an air gap 68 .
[0031] More particularly, FIGS. 2A and 2B illustrates various embodiments of the present invention. FIG. 2A is an embodiment including an air gap, while FIG. 2B is an embodiment which does not include an air gap. Both embodiments shown include the following elements: a lower interconnect level 52 A comprising a first dielectric material 56 A having a first conductive material 60 A embedded therein. An upper interconnect level 52 B is also present in the two illustrated embodiments. Specifically, the upper interconnect level 52 B includes a second dielectric material 56 B having at least one opening that is in contact with the first conductive material 60 A of the lower interconnect level 52 A. The second dielectric material 56 B has a second conductive material 60 B embedded within said at least one opening and the conductive material 60 B is laterally spaced apart from the second dielectric material 56 B by a diffusion barrier 58 B, a dense dielectric spacer 66 ′ and, optionally, an air gap 68 . If present, the air gap 68 is located in an undercut region that was created beneath the hard mask that was used in patterning the second dielectric material 56 B.
[0032] The other elements illustrated and referenced in FIGS. 2A-2B will be described in detail in the process flow that follows.
[0033] Reference is now made to FIGS. 3A-3F which illustrate the basic processing steps that are employed in the present invention for fabricating the inventive structure shown in FIG. 2A . Although the basic processing steps can be used in forming the inventive interconnect structure shown in FIG. 2A , the same can also be used in forming the inventive interconnect structure shown in FIG. 2B except that during the formation of the dense dielectric liner 66 a better conformal deposition technique is employed to completely fill in the undercut feature 64 . An alternative method to create more volume of air gap 68 is to exaggerate the undercut feature 64 intentionally post/during the etching process.
[0034] In accordance with the present invention, the process flow begins with providing the initial interconnect structure 50 shown in FIG. 3A . Specifically, the initial interconnect structure 50 shown in FIG. 3A comprises a multilevel interconnect including a lower interconnect level 52 A and an upper interconnect level 52 B that are typically, but not necessarily always, separated by dielectric capping layer 54 . The lower interconnect level 52 A, which may be located above a semiconductor substrate including one or more semiconductor devices, comprises a first dielectric material 56 A having at least one conductive feature (represented by a first conductive material 60 A) that is separated from the first dielectric material 56 A by a first diffusion barrier 58 A. The upper interconnect level 52 B comprises a second dielectric material 56 B that has at least one opening located therein. FIG. 3A also shows a patterned hard mask 62 located atop the second dielectric material and an undercut region 64 located beneath the patterned hard mask 62 .
[0035] In FIG. 3A , two openings are shown; reference number 106 denotes a line opening for a single damascene structure, and reference numeral 108 denotes a combined via and a line opening for a dual damascene structure. Although such a structure is shown, the present application is not limited to such a structure. Instead, the present application contemplates structures that include at least one opening to the underlying conductive feature, i.e., the first conductive material 60 A. Typically, that at least one opening is a via opening located beneath a line opening.
[0036] The initial interconnect structure 50 shown in FIG. 3A is made utilizing standard interconnect processing which is well known in the art. For example, the initial interconnect structure 50 can be formed by first applying the first dielectric material 56 A to a surface of a substrate (not shown). The substrate, which is not shown, may comprise a semiconducting material, an insulating material, a conductive material or any combination thereof. When the substrate is comprised of a semiconducting material, any semiconductor such as Si, SiGe, SiGeC, SiC, Ge alloys, GaAs, InAs, InP and other III/V or II/VI compound semiconductors may be used. In addition to these listed types of semiconducting materials, the present invention also contemplates cases in which the semiconductor substrate is a layered semiconductor such as, for example, Si/SiGe, Si/SiC, silicon-on-insulators (SOIs) or silicon germanium-on-insulators (SGOIs).
[0037] When the substrate is an insulating material, the insulating material can be an organic insulator, an inorganic insulator or a combination thereof including multilayers. When the substrate is a conducting material, the substrate may include, for example, polySi, an elemental metal, alloys of elemental metals, a metal silicide, a metal nitride or combinations thereof including multilayers. When the substrate comprises a semiconducting material, one or more semiconductor devices such as, for example, complementary metal oxide semiconductor (CMOS) devices can be fabricated thereon.
[0038] The first dielectric material 56 A of the lower interconnect level 52 A may comprise any interlevel or intralevel dielectric including inorganic dielectrics or organic dielectrics. The first dielectric material 56 A may be porous or non-porous. Some examples of suitable dielectrics that can be used as the first dielectric material 56 A include, but are not limited to SiO 2 , silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H, SiC(N,H), thermosetting polyarylene ethers, or multilayers thereof. The term “polyarylene” is used in this application to denote aryl moieties or inertly substituted aryl moieties which are linked together by bonds, fused rings, or inert linking groups such as, for example, oxygen, sulfur, sulfone, sulfoxide, carbonyl and the like.
[0039] The first dielectric material 56 A typically has a dielectric constant that is about 4.0 or less, with a dielectric constant of about 2.8 or less being even more typical. It is noted that the low-k dielectrics (less than 4.0) generally have a lower parasitic crosstalk as compared with dielectric materials that have a higher dielectric constant than 4.0. The thickness of the first dielectric material 56 A may vary depending upon the dielectric material used as well as the exact number of dielectrics within the lower interconnect level 52 A. Typically, and for normal interconnect structures, the first dielectric material 52 A has a thickness from about 200 to about 450 nm.
[0040] The lower interconnect level 52 A also has at least one conductive feature that is embedded in (i.e., located within) the first dielectric material 56 A. The conductive feature comprises a first conductive material 60 A, which is separated from the first dielectric material 56 A by a first diffusion barrier 58 A. The conductive feature is formed by lithography (i.e., applying a photoresist to the surface of the first dielectric material 56 A, exposing the photoresist to a desired pattern of radiation, and developing the exposed resist utilizing a conventional resist developer), etching (dry etching or wet etching) an opening in the first dielectric material 56 A and filling the etched region with the first diffusion barrier 58 A and then with a first conductive material 60 A forming the conductive region. The first diffusion barrier 58 A, which may comprise Ta, TaN, Ti, TiN, Ru, Ir(Ta), Ir(TaN), Ru(Ta), Ru(TaN), W, WN or any other material that can serve as a barrier to prevent conductive material from diffusing there through, is formed by a deposition process such as, for example, atomic layer deposition (ALLD), chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), physical vapor deposition (PVD), sputtering, chemical solution deposition, or plating.
[0041] The thickness of the first diffusion barrier 58 A may vary depending on the exact means of the deposition process as well as the material employed. Typically, the first diffusion barrier 58 A has a thickness from about 4 to about 40 nm, with a thickness from about 7 to about 20 nm being more typical.
[0042] Following the formation of the first diffusion barrier 58 A, the remaining region of the opening within the first dielectric material 56 A is filled with a first conductive material 60 A. The conductive material 60 A includes, for example, polySi, a conductive metal, an alloy comprising at least one conductive metal, a conductive metal silicide or combinations thereof. Preferably, the conductive material 60 A is a conductive metal such as Cu, W or Al, with Cu or a Cu alloy (such as AlCu) being highly preferred in the present invention. The conductive material 60 A is filled into the remaining opening in the first dielectric material 56 A utilizing a conventional deposition process including, but not limited to: CVD, PECVD, sputtering, chemical solution deposition or plating. After deposition, a conventional planarization process such as, for example, chemical mechanical polishing (CMP) can be used to provide a structure in which the first diffusion barrier 58 A and the conductive material 60 A each have an upper surface that is substantially coplanar with the upper surface of the first dielectric material 56 A.
[0043] It should be noted that the inventive dielectric spacer 66 ′ to be described in greater detail herein below may be formed in the lower interconnect level 52 A. If present, the dielectric spacer 66 ′ would line the sidewalls of the at least one opening including first conductive material 60 A.
[0044] After forming the at least one conductive feature 60 A, the dielectric capping layer 54 is formed on the surface of the lower interconnect level 52 A utilizing a conventional deposition process such as, for example, CVD, PECVD, chemical solution deposition, or evaporation. It is noted that the dielectric capping layer is not necessarily required in all circumstances. The dielectric capping layer 54 comprises any suitable dielectric capping material such as, for example, SiC, Si 4 NH 3 , SiO 2 , Si 3 N 4 , a carbon doped oxide, a nitrogen and hydrogen doped silicon carbide SiC(N,H) or multilayers thereof The thickness of the dielectric capping layer 54 may vary depending on the technique used to form the same as well as the material make-up of the layer. Typically, the dielectric capping layer 54 has a thickness from about 15 to about 55 nm, with a thickness from about 25 to about 45 nm being more typical.
[0045] Next, the upper interconnect level 52 B is formed by applying the second dielectric material 56 B to the upper exposed surface of the dielectric capping layer 54 . The second dielectric material 56 B may comprise the same or different, preferably the same, dielectric material as that of the first dielectric material 56 A of the lower interconnect level 52 A. In one embodiment, it is highly preferred to utilize a dielectric material whose dielectric constant is less than 4.0 as the second dielectric material 56 B. Porous and non-porous dielectrics, with porous dielectrics being highly preferred, can be used, The processing techniques and thickness ranges for the first dielectric material 56 A are also applicable here for the second dielectric material 56 B.
[0046] A blanket layer of hard mask material such as an oxide-containing material is then formed atop the second dielectric material 56 B utilizing a standard deposition process including, for example, chemical vapor deposition, plasma enhanced chemical vapor deposition, chemical solution deposition and atomic layer deposition. Alternatively, the hard mask material can be formed by a thermal process such as, for example, oxidation.
[0047] Next, at least one opening is formed into the second dielectric material 56 B utilizing lithography, as described above, and etching. The hard mask material is used as a patterned mask during the etching step. The lithographic step includes applying a photoresist atop the hard mask material, exposing the photoresist to a pattern of radiation and developing the exposed resist. After resist development, the pattern is transferred first into the hard mask material (forming patterned hard mask 62 ) and then into the second dielectric material 56 B. The lithographically patterned resist is typically, but not necessarily always, removed after transferring the pattern into the hard mask material. The etching may comprise a dry etching process, a wet chemical etching process or a combination thereof. The term “dry etching” is used herein to denote an etching technique such as reactive-ion etching, ion beam etching, plasma etching or laser ablation.
[0048] It should be noted that during the above described etching step and because of the different etching rates between the hard mask material and the second dielectric material 56 B, an undercut region 64 forms beneath the patterned hard mask 62 .
[0049] After providing the initial interconnect structure 50 shown in FIG. 3A , the exposed surfaces of the structure, i.e., the patterned hard mask 62 , the exposed sidewalls of the second dielectric material 56 B, and the dielectric capping layer 54 , are lined with a dielectric liner 66 . The resultant structure including dielectric liner 66 is shown, for example, in FIG. 3B .
[0050] The dielectric liner 66 is any dense dielectric material including, for example, any of the dielectrics mentioned above for the first and second dielectric materials. The dielectric liner 66 typically, but not necessarily always, has a different composition than the second dielectric material 56 B. Example of dielectric materials that can be used as liner 66 include silsesquioxanes, C doped oxides (i.e., organosilicates) that include atoms of Si, C, O and H. thermosetting polyarylene ethers, SiO 2 , Si 3 N 4 , SiC(N,H), SiC or multilayers thereof.
[0051] The dielectric liner 66 is formed utilizing any deposition process including, for example, chemical vapor deposition and plasma enhanced chemical vapor deposition. The thickness of the dielectric liner 66 that is deposited is typically from about 100 to about 2000 Å, with a thickness from about 300 to about 800 Å being even more typical.
[0052] It is noted that under normal deposition conditions, an air gap 68 remains in the structure after deposition of the dielectric liner 66 . The presence of the air gap 68 is advantageous since it lowers the overall capacitance of the interconnect structure. As shown, the air gap 68 is located beneath the patterned hard mask 62 and between the liner 66 and the patterned second dielectric material 56 B.
[0053] The dielectric liner 66 shown in FIG. 3B is then subjected to an anisotropic etching process which provides a dielectric spacer 66 ′ (see, for example, FIG. 3C ) which is present on the exposed sidewall portions of the patterned second dielectric material 56 B; the anisotropic etching removes the dielectric material that is present on all horizontal surfaces within the structure. The resultant structure including dielectric spacer 66 ′ is shown, for example, in FIG. 3C .
[0054] It is emphasized that during the above mentioned anisotropic etch, a portion of the dielectric capping layer 54 is typically removed. If the etching used in forming the dielectric spacer 66 ′ does not remove the underlying dielectric capping layer 54 , a separate etching process can be used to selectively remove the exposed portion of the dielectric capping layer 54 .
[0055] Next, a second diffusion barrier 58 B is provided by forming the second diffusion barrier 58 B on exposed surfaces including the previously formed dielectric spacer 66 ′. The resultant structure is shown, for example, in FIG. 3D . The second diffusion barrier 58 B comprises at least one of TaN, Ta, TiN, TiN, Ir(Ta), Ir( TaN), Ru(Ta), Ru(TaN), W and WN. The second diffusion barrier 58 B is formed utilizing a deposition process such as, for example, atomic layer deposition (ALD), chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), physical vapor deposition (PVD), sputtering, chemical solution deposition, or plating.
[0056] The thickness of the second diffusion barrier 58 B may vary depending on the number of material layers, the technique used in forming the same as well as the material of the second diffusion barrier 58 B itself. Typically, the second diffusion barrier 58 B has a thickness from about 4 to about 40 nm, with a thickness from about 7 to about 20 nm being even more typical.
[0057] It is noted that the presence of the dense dielectric spacer 66 ′ aids in providing a second diffusion barrier 58 B that is continuous.
[0058] At this point of the present invention, an optional plating seed layer (not shown) can be formed at least within the openings atop the second diffusion barrier 58 B. Although optional, it is preferred to include a plating seed layer within the structure to aid in growth of the conductive material. This is especially the case when a conductive metal or metal alloy is to be subsequently formed within the at least one opening. When present, the plating seed layer may comprise a conductive metal or metal alloy such as that used in forming the conductive material to be described in greater detail herein below. Typically, and when the conductive material comprises Cu, the plating seed layer comprises Cu, CuAl, CuIr, CuTa, CuRh, Ru, Ir, CuRu, or other alloys of Cu, i.e., Cu-containing alloys.
[0059] The plating seed layer is formed by a conventional deposition process including, for example, ALL), CVD, PECVD, PVD, chemical solution deposition and other like deposition processes. The thickness of the plating seed layer may vary and it is within ranges that are well known to those skilled in the art. Typically, the plating seed layer has a thickness from about 2 to about 80 nm.
[0060] Next, a second conductive material 60 B which is the same or different from that of the first conductive material 60 A is formed within the at least one opening. The second conductive material 60 B forms a second conductive feature within the structure. Preferably, Cu, Al, W or alloys thereof are used, with Cu or AlCu being most preferred, The second conductive material 60 B is formed utilizing the same deposition processing as described above in forming the first conductive material 60 A and following deposition of the second conductive material 60 B, the structure is subjected to planarization. FIG. 3E shows the interconnect structure after conductive material 60 B deposition, while FIG. 3F shows the interconnect structure after planarization. The planarization process, which includes grinding and/or chemical mechanical polishing (CMP) removes the patterned hard mask 62 from the structure.
[0061] Following the planarization process, a second dielectric capping layer 54 B can be formed as described above providing the structure illustrated in FIG. 2A .
[0062] It is again noted that the same basic processing steps as described above can be used in forming the structure shown, in FIG. 2B except that a better conformal deposition of the dielectric liner 66 is performed such that no air gap is present in the structure. An alternative method to create more volume of air gap 68 is to exaggerate the undercut feature 24 intentionally post/during the etching process.
[0063] It is noted that the embodiment depicted above is for a closed via-bottom structure. In another embodiment of the present invention, an open-via bottom structure can be provided. In the open-via bottom structure, the second conductive material 60 B is in direct contact with a surface of the first conductive material 60 A. The open-via bottom structure is formed by removing the second diffusion barrier from the bottom of via utilizing ion bombardment or another like directional etching process. The present invention also contemplates an anchored-via bottom structure. The anchored-via bottom structure is formed by first etching a recess into the conductive feature in the first dielectric material 56 A utilizing a selective etching process. After formation of the second diffusion barrier, the second diffusion barrier is typically removed from the bottom portion of the via and recess by a directional etching process. The second conductive material is then formed as described above.
[0064] While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims.
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The present invention provides an interconnect structure (of the single or dual damascene type) and a method of forming the same, in which a dense (i.e., non-porous) dielectric spacer is present on the sidewalls of a dielectric material. More specifically, the inventive structure includes a dielectric material having a conductive material embedded within at least one opening in the dielectric material, wherein the conductive material is laterally spaced apart from the dielectric material by a diffusion barrier, a dense dielectric spacer and, optionally, an air gap. The presence of the dense dielectric spacer results in a hybrid interconnect structure that has improved reliability and performance as compared with existing prior art interconnect structures which do not include such dense dielectric spacers. Moreover, the inventive hybrid interconnect structure provides for better process control which leads to the potential for high volume manufacturing.
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BACKGROUND OF THE INVENTION
The present invention relates to a construction for positioning a magnetic head of a magnetic disk drive.
To increase a recording density of a magnetic disk drive, it is effective to reduce errors in positioning a read/write head on a disk so as to allow information to be stored in a narrower area. For a positioning operation of a magnetic head relative to a magnetic disk surface, it has been common to use a swing type carriage, on which the magnetic head is mounted, and a voice coil motor (VCM) for driving the carriage. The swinging carriage is provided to be pivotable about a pivot shaft and carries the magnetic head at an end thereof on one side of this shaft. Further, between the magnetic head and the pivot shaft are provided a suspension, to which the magnetic head is mounted, and a carriage arm, to which a base portion of the suspension is attached. The suspension supports the magnetic head while urging it toward the magnetic disk surface. On the other side of the pivot shaft opposite the magnetic head, there are a coil of the voice coil motor and a coil bobbin attached with the coil.
With this construction, an electromagnetic force is generated by an electric field acting on the coil supported inside the coil bobbin, and it causes the carriage to rotate about the pivot shaft so as to move in a plane almost perpendicular to the axis of the pivot shaft. This causes the magnetic head, which is mounted on a slider at a front end of the suspension to be moved and positioned above the disk surface.
The force applied to the carriage when driven about the pivot shaft acts as a vibration force that causes vibration in the carriage. Among resonance modes of the carriage, a resonance mode, in which the carriage as a whole deforms and vibrates in the direction of a head movement about a target position on the disk where the head is to be positioned or about an imaginary line connecting the pivot shaft and the magnetic head (hereinafter referred to as a main resonance mode), constitutes a factor in limiting a servo band of a positioning control system. So, for the carriage main resonance mode, it is required that a resonance frequency of the carriage be set as high as possible.
This main resonance mode is a vibration mode that can be modeled by a carriage mass and an overall spring rigidity, which is a combination of a rigidity of a bearing (pivot bearing) supporting the carriage for swing motion and a flexural rigidity of the carriage against its entire bending. From this, to increase the main resonance frequency, it is necessary to improve the flexural rigidity of the carriage.
A means for joining the coil to the bobbin formed integral with the carriage includes bonding or insert-molding using resin such as liquid crystal polymer. The former requires a jig when applying and hardening an adhesive, whereas the latter is advantageous in that it requires only performing injection molding with a mold. Whichever assembling method is selected, the rigidity of the coil and the bobbin needs to be increased. In the main resonance mode described above, the substantially annular-shaped coil and the bobbin joined thereto with adhesive or resin are deformed within a plane of the coil in a manner of collapsing the annulation.
As a conventional art for increasing the rigidity of the coil and the bobbin, a technique has been described in JP-A-63-277458 (prior art 1 ). This involves bonding the coil to the coil bobbin of a ceramic material and fastening the bobbin to the carriage.
This prior art 1 requires fastening the ceramic bobbin to the carriage body made from aluminum or the like, increasing the number of assembling steps and therefore the cost. Further, ceramic materials easily produce dust particles which may adversely affect the reliability of the magnetic disk drive.
The prior art 1 , although it can improve the rigidity as ceramics have a high specific rigidity, has a drawback that the ceramics are difficult to handle because of the dust particle problem. For example, using a ceramic in the disk drive with its surface exposed is troublesome from the standpoint of securing the reliability.
Further, when, besides ceramics, a metal material such as stainless steel with high rigidity is used for improving the rigidity, another problem arises. Since the bobbin moves in a very strong magnetic field between parallel magnets of the voice coil motor, a conductive metal material produces an eddy current in its surface which in turn generates a reverse magnetic field, reducing the electromagnetic force produced in the coil.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of the present invention to increase the rigidity of a carriage so as to improve the magnetic head positioning accuracy, thereby providing a magnetic disk drive with an increased recording capacity. Another object of the invention is to provide a method of assembling a carriage having a coil and a bobbin that can increase the rigidity of the carriage.
The above objectives can be achieved by a magnetic disk drive which comprises at least one magnetic head reading and writing information on at least one magnetic disk, a carriage supporting the magnetic head over the magnetic disk for movement about a pivot shaft, and an annular coil supported by a bobbin provided on the carriage and subjected to an electromagnetic force for driving the carriage. The drive further comprises a first connection member joining the annular coil and the bobbin, an in-coil member arranged on an inner side of the annular coil, and a second connection member joining the in-coil member and the annular coil, wherein a modulus of longitudinal elasticity of the in-coil member is larger than that of the first or second connection member.
Further, the first connection member is formed to cover surfaces of the in-coil member that face in an axial direction of the pivot shaft. The in-coil member is sealed in the second connection member.
Moreover, a surface of the in-coil member is formed with recessed and raised portions or with through-holes.
Furthermore, the above objectives can be achieved by a method of manufacturing a carriage for at least one magnetic disk of a magnetic disk drive that includes at lease one magnetic head reading and writing information on the magnetic disk, a carriage supporting the magnetic head over the magnetic disk for movement about a predetermined shaft, and an annular coil supported by a bobbin provided on the carriage and subjected to an electromagnetic force for driving the carriage. The method comprises the step of insert-molding, inside the annulation of the coil, a member that is larger in rigidity than a connection member used to join the coil to the bobbin and another connection member filled inside the annulation of the coil, so that the insert-molded member is joined to the inside of the annulation of the coil.
With this construction, the coil and the reinforcement member can be joined to the bobbin in one step, thus improving the assembling productivity. In addition, a hardening jig as used in the case of bonding is not required, thereby enabling a reduction of the cost.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiment of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a cut-away view of a carriage in an embodiment of the present invention.
FIG. 2 is an overall view of the carriage in the embodiment of the invention.
FIG. 3 is an enlarged view of a bobbin in the embodiment of the invention.
FIG. 4 is an outside view of a reinforcement plate 15 .
FIG. 5 shows another example of a reinforcement plate 15 .
FIG. 6 shows still another example of a reinforcement plate 15 .
FIG. 7 is a view showing an assembling method of the carriage in the embodiment of the invention.
FIG. 8 is an outline view of a magnetic disk drive to which the embodiment of the invention is applied.
FIG. 9 is a diagram showing a transfer characteristic of the carriage.
FIG. 10 is a schematic view showing a shape of the carriage in a main resonance mode.
FIG. 11 is a diagram showing a relation between a main resonance frequency increase and an inertia increase.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the present invention will be now described with reference to the accompanying drawings.
FIG. 2 is a perspective view showing the overall configuration of a carriage according to the first embodiment of the invention. A carriage block 1 , serving as a body of the carriage, is made by extruding an aluminum material into its outline and then machining it to form the shapes of arms 2 , a coil bobbin 3 and so forth. The coil bobbin has two arm portions and is provided on the carriage block 1 at a central portion thereof with respect to a direction of height, which is an axial direction of a pivot 7 described later. Between these arm portions is disposed a coil 6 which is joined by a connection member to the arm portions or the pivot shaft of the carriage block 1 to be supported on the carriage. An electromagnetic force generated by an electric field acts on the coil and works about the pivot shaft along a plane defined by the arm portions (a plane almost parallel to the magnetic disk surface and flush with the annulation of the coil).
Installed on the carriage body 1 are suspensions 5 , on which magnetic heads 4 are mounted, the coil 6 for generating a driving force, the pivot 7 supporting the carriage for swing motion, and a flexible printed circuit board (EPC) 8 having an amplifier mounted thereon for relaying or amplifying signals from the magnetic head 4 .
In most of the drives currently available the coil 6 and the coil bobbin 3 supporting it are provided on an opposite side of the pivot 7 , serving as a rotating center, to the magnetic heads 4 . The FPC 8 is installed on a side surface of the carriage block 1 near its center. The FPC 8 is formed by bonding together a laminated portion having the amplifier mounted thereon and a thin FPC portion of a single layer. A part of the single-layer FPC portion is extended to form coil current lines 9 that are soldered to the ends of the coil 6 on terminals 14 .
FIG. 3 is an enlarged view of the coil 6 , the bobbin 3 and their associated components in FIG. 2 . In this figure individual turns or windings of the coil 6 are not shown. The coil 6 is joined to the bobbin 3 by an external molding 10 filled between them so that the coil 6 is supported by the bobbin. On the inner side of the coil 6 is filled an internal molding 11 . The both end windings of the coil 6 pass through an inside of a cover molding 12 to be connected to the terminals 14 on the top of a terminal molding 13 . These external molding 10 , internal molding 11 , cover molding 12 and terminal molding 13 are given different names for explanation of their shapes but actually are molded of the same material at once during injection molding.
The internal molding 11 and the external molding 10 , although formed of the same material in this embodiment, may be made of different materials.
FIG. 1 shows a cross section of the bobbin 3 and the coil 6 partly cut away. On the inner side of the generally annular coil 6 are provided with a member of a plate shape and the internal molding 11 that encloses and supports the member while joining to the coil. In this embodiment, the plate-shaped member sealed inside the internal molding 11 is a reinforcement plate 15 . The surfaces of the reinforcement plate 15 facing in the direction of the pivot shaft 7 are covered with the internal molding 11 . FIG. 4 shows the reinforcement plate 15 . In this embodiment the reinforcement plate 15 is made from alumina (Al 2 O 3 ), which has a volume specific resistance of 10 14 Ωcm or higher and therefore substantially no electrical conductivity. It has a very high modulus of longitudinal elasticity of 3.7×10 11 N/m 2 , about five times that of aluminum (6.8×10 10 N/m 2 ) and 18 times that of resin (1.6×10 11 N/m 2 ) used for insert molding of liquid crystal polymer or the like, and is very high in rigidity. In this invention it is also possible to use ceramic materials such as silicon nitride (Si 3 N 4 ), silicon carbide (SiC) and zirconia (ZrO 2 ) which also have large volume specific resistances and almost no conductivity. Even silicon nitride and silicon carbide have moduli of longitudinal elasticity of 2.9×10 11 N/m 2 or more, which are very large as compared to that of aluminum, and thus can greatly increase the rigidity of this reinforcement member.
Although an electromagnetic steel sheet (silicon steel sheet) with a low conductivity may be used, because its modulus of longitudinal elasticity is 1.9×10 11 N/m 2 and its density is 8.0×10 3 kg/m 3 , which is higher than that of ceramics (3.0–4.0×10 3 kg/m 3 ), it is slightly inferior in terms of specific or comparable rigidity. Since the carriage is provided for swing motion to move the head, the smaller the inertia, the more improved its acceleration ability will be. Thus, even the reinforcement plate 15 used to improve the flexural rigidity of the bobbin 3 and coil 6 preferably has a lighter weight. Hence, it is worth using ceramic materials with high specific rigidity for the reinforcement plate.
The reinforcement plate 15 is shaped like a flat plate and its outer side geometry is determined so as to conform to the inner side geometry of the coil 6 . Although in this embodiment the reinforcement plate 15 is formed with through-holes 16 , it may be provided with notches 17 in its outer periphery as shown in FIG. 5 or, instead of the through-holes, with recessed and raised portions 18 as shown in FIG. 6 . The similar effects may be produced by forming grooves in the surface of the reinforcement plate 15 .
There are two purposes for forming these through-holes 16 or the like. The first purpose is to reduce the weight. Although the ceramic has a high specific rigidity, it is preferred that the reinforcement plate 15 have as small a weight as possible. Therefore, holes, grooves or recesses are formed to reduce the weight of the reinforcement plate while maintaining an enough stiffness.
The second purpose is to have the resin fill the holes, grooves or recesses so as to increase an area for contact with the internal molding 11 and, in terms of geometry, firmly engage the reinforcement plate 15 with the molding resin, thus enhancing their intimate contact. This can avoid a reduction in contact rigidity at the boundary portion. Although the provision of these through-holes 16 and notches 17 renders the reinforcement plate 15 complex in shape, the productivity cannot be impaired as long as the material is ceramics, because the ceramic material is formed in that shape through sintering. Further, since during the injection molding the resin of the internal molding 11 flows around the reinforcement plate 15 and fills the holes or recesses, no special manufacturing process is required.
Further, the upper and lower surfaces and side surfaces of the reinforcement plate 15 are completely covered with the resin, and therefore, when the reinforcement plate 15 is made from ceramics, fine hard dust particles that may chip away from the surface can be shut in the resin, greatly reducing a possibility of these particles scattering inside the magnetic disk drive 21 . Hard dust particles, when they fall on the surface of the disk 22 , may be trapped between the head 4 and the disk 22 to cause damages to the disk 22 and head 4 . Thus, it is necessary to minimize the possibility that such particles may disperse in the disk drive.
FIG. 7 shows a part of the process of assembling the carriage using insert molding. The carriage block 1 , the coil 6 and the reinforcement plate 15 are manufactured separately, and these parts are placed in a mold. High-temperature and high-pressure resin is injected into the mold in a direction of arrows 19 to fill spaces between the parts and join them together. At this time, pin holes 20 shown in FIG. 2 may be formed in the molded resin by pins used to position or hold the coil 6 and reinforcement plate 15 in the mold. Particularly, the pin holes 20 formed for supporting the reinforcement plate 15 can partly expose the reinforcement plate 15 . Thus, it is desired to seal the pin holes 20 by, for example, dropping a diluted adhesive into the holes at the last of the assembly process.
The carriage block 1 having the coil 6 and the reinforcement plate 15 joined in the process shown in FIG. 7 is then installed with the suspensions 5 , the FPC 8 and the pivot 7 to complete the assembly of the carriage. The carriage thus assembled is mounted on a base 25 along with a disk spindle assembly 23 having disks 22 thereon and a magnet assembly 24 , thus completing the magnetic disk drive 21 . The outline view of the assembled magnetic disk drive is shown in FIG. 8 . The voice coil motor made up of the coil 6 and the magnet assembly 24 swings the carriage in the directions of arrows 26 to position the head 4 at a targeted track (not shown). A servo band of a positioning control system is determined by a transfer characteristic of the carriage which is represented by a frequency characteristic of a displacement of the head 4 relative to a thrust input to the coil 6 . FIG. 9 shows the transfer characteristic. Herein, an intrinsic or natural mode of the lowest order on the transfer characteristic is referred to as a main resonance mode. This is the resonance mode in which the entire carriage vibrates in the direction of a head movement as described above. In this mode the servo band of the control system is limited by the main resonance frequency 27 . Thus, to improve a disturbance suppression capability of the disk drive for precision positioning requires expanding the servo band. Therefore, increasing the main resonance frequency leads to an improved positioning accuracy of the magnetic disk drive, which in turn increases the recording capacity of the disk drive.
FIG. 10 shows an outline of a mode shape for the main resonance mode. This main resonance mode is a vibration mode that can be modeled by the carriage mass and a total spring rigidity, which is a combination of a rigidity of a bearing of the pivot 7 and a flexural rigidity of the carriage against its entire bending. Hence, it is required for increase of the main resonance frequency to improve the flexural rigidity of the carriage. Because the arm 2 and the bobbin 3 are bent to a particularly large extent, it is understood that a flexural rigidity of the bobbin 3 and coil 6 as well as an in-plane flexural rigidity of the arm needs to be improved. When focusing on the bending of the bobbin 3 and coil 6 , in the main resonance mode the generally annular coil 6 deforms in the plane thereof in a manner of collapsing the annulation. It is therefore possible to greatly improve the flexural rigidity of the coil by placing the reinforcement plate 15 of a high rigidity inside the coil 6 .
Further, the materials of the external molding 10 and the internal molding 11 may be changed, or the rigidity of the internal molding 11 may be set higher than that of the external molding 10 . The thus increased rigidity inside the coil ring can reduce the deformation of the coil 6 caused by a vibration force applied and thereby minimize the deformation of the carriage. Furthermore, the reinforcement plate 15 placed inside the internal molding 11 which has a still higher rigidity can further minimize the deformation of the carriage.
Taking the case of a carriage in a general 3.5-inch magnetic disk drive, when the internal molding 11 and the reinforcement plate 15 are not provided inside the coil 6 , the main resonance frequency of the carriage is 4.1 kHz. In contrast, when only the internal molding 11 is used to fill the interior of the coil 6 , without using the reinforcement plate 15 , the main resonance frequency becomes 4.25 kHz, bringing about an improvement of 150 Hz. Further, when a reinforcement plate 15 of alumina is insert-molded in the molding of the same thickness, the main resonance frequency is 4.6 kHz, achieving an improvement of 500 Hz. If the material of the reinforcement plate 15 is changed to aluminum, the main resonance frequency is 4.38 kHz, and the improvement is about a 280 Hz. When stainless steel is used, it is 4.3 kHz, and the improvement is about 200 Hz. This may be explained that since stainless steel has a higher density, the increased mass reduces the effect of an improved rigidity. It is therefore possible to improve the main resonance frequency by selecting for the material of the reinforcement plate 15 a ceramic that has a very large ratio of the modulus of longitudinal elasticity relative to the density.
In practice, however, since the carriage preferably has as small an inertia about the rotating shaft as possible in terms of an acceleration capability, the material selection is a tradeoff between the elastic modulus-to-density ratio and an increased inertia. FIG. 11 shows a relation between the rate of a main resonance frequency increase from a reference frequency of the molding resin and the rate of an inertia increase. In this diagram the characteristic becomes more desirable as a characteristic plot in the diagram approaches the lower right where the main resonance frequency increase is large for an inertia increase. Taking the case where the inside of the coil is filled with a resin as a reference, a characteristic plot needs to fall on the lower side of a line 28 of FIG. 11 to be a more preferred change from the resin filling.
From FIG. 11 the materials conforming to this requirement include aluminum, silicon nitride and alumina. Aluminum has a high electrical conductivity, and a reduction in thrust due to an eddy current must be taken into account. A ceramic, such as alumina, has a low conductivity and also can meet conflicting requirements, i.e., a main resonance improvement and an inertia reduction. The reason that these conflicting performances can be improved simultaneously is that these materials have high rigidities which are more than 18 times higher as compared with the molding resin in terms of the modulus of longitudinal elasticity and more than 10 times higher in terms of the ratio of modulus of longitudinal elasticity relative to the density.
Compared with a carriage to which the above construction is not applied, the carriage according to the embodiment of the invention can improve the servo band by the transfer characteristic of a mechanism system having a high main resonance frequency even when they have the similar acceleration capabilities in terms of thrust and inertia. Further, this construction can provide the carriage which does not suffer from a decrease of the reliability due to dust particles and which excels in assembling productivity. Further, with this carriage it is possible to provide a high-speed, high-density magnetic disk drive.
In the drawings made reference to for the above description, the ratio of length and breadth of the drive and the proportion of respective parts are not necessarily correct for the sake of explanation.
According to the above embodiment, it is possible to provide a carriage which can realize a high main resonance frequency without a reduction in the acceleration capability as an actuator, such as a thrust reduction and an inertia increase, and without a reduction in reliability due to dust particles, and which excels in assembling productivity. This in turn leads to a fast-speed, high-density magnetic disk drive.
As described above, according to the invention the rigidity of a carriage can be increased to improve the positioning accuracy of the magnetic head, thereby realizing a magnetic disk drive with a large recording capacity. Another feature of the invention can provide a method of assembling a carriage that has a coil and a bobbin capable of increasing the rigidity of the carriage.
It will be further understood by those skilled in the art that the foregoing description has been made on the embodiment of the invention and that various changes and modifications may be made in the invention without departing from the spirit of the invention and the scope of the appended claims.
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A magnetic disk drive comprises at least one magnetic head for reading and writing information on at least one magnetic disk, a carriage supporting the magnetic head over the magnetic disk for movement of the magnetic head about a predetermined shaft, an annular coil supported by a bobbin provided on the carriage and subjected to an electromagnetic force for driving the carriage. The drive further comprises a first connection member for joining the annular coil and the bobbin, an in-coil member arranged inside the annular coil, and a second connection member for joining the in-coil member and the annular coil. A modulus of longitudinal elasticity of the in-coil member is larger than that of the first or second connection member. The drive thus formed has the increased carriage rigidity, the improved positioning accuracy of a magnetic head and the increased recording capacity of the disk.
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[0001] The present invention refers to the use of microcrystalline cellulose and, optionally, a surfactant in an aqueous pharmaceutical composition in order to inhibit the extraction of ephedrine for the purpose of drug abuse.
BACKGROUND OF THE INVENTION
[0002] Ephedrine is a sympathomimetic drug used in the treatment of cough, rhinitis, hay fever and asthma bronchiale. Due to its stimulating and appetite suppressing effect ephedrine has a high potential of being abused. Moreover, ephedrine can serve as a precursor in the synthesis of other amphetamines, in particular N-methylamphetamine (“Crystal” or “Meth”).
[0003] For the purpose of abuse ephedrine is extracted from pharmaceutical products, e.g. Vicks® nasal inhaler, commercially available in the US at drug stores. Instructions on how to recover ephedrine can be found on the interne (see, for example, http://www.phrack.org). Accordingly, the inner package of the pharmaceutical product is destroyed and both the package material and pharmaceutical composition is treated with a strong hydrochloric solution (see FIG. 1 ). Such a solution is obtained by diluting a brick and driveway cleaner purchased at the hardware store in water. The resulting solution is filtered through a commonly available coffee filter. Addition of solid sodium hydroxide contained in drain cleaners produces an alkaline shift in pH leading to a precipitation of free ephedrine base [1, 2]. Then, this solution is mixed with diethyl ether at a volume ratio of one-third aqueous solution and two-third organic solvent. Since the solubility of free ephedrine base in diethyl ether is superior over its water solubility the drug will enter into the organic solvent [1, 2, 3]. Thus, after partition of the aqueous and organic phases, the aqueous layer is discarded while the organic layer is used for further processing.
[0004] Due to its great volatility [1, 2] free ephedrine base is converted into the less volatile hydrochloride salt by mixing the organic phase with an equal volume of water slightly acidified by hydrochloric acid. In contrast to the free base, ephedrine hydrochloride is virtually insoluble in diethyl ether but dissolves well in water [1, 2]. Thus, after partition of the aqueous and organic phases, the organic layer is discarded and ephedrine hydrochloride is obtained after evaporation of the aqueous solvent at room temperature.
[0005] There is a need to make the abusive recovery of ephedrine from commercially available pharmaceutical products much more difficult. Thus, the object of the present invention is to provide methods and means interfering with ephedrine extraction.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is solved by a method for inhibiting a phase separation in a mixture of an aqueous pharmaceutical composition comprising ephedrine or a salt or a derivative thereof and one or more water-insoluble organic solvents, preferably a diethyl ether, the method comprising the step of adding one or more microcrystalline celluloses to the aqueous pharmaceutical composition.
[0007] In one embodiment, the method further comprises the step of adding one or more surfactants to the aqueous pharmaceutical composition.
[0008] The object of the present invention is further solved by a method of using one or more microcrystalline celluloses for inhibiting an extraction of ephedrine or a salt or a derivative thereof from an aqueous pharmaceutical composition.
[0009] In one embodiment, the method further uses one or more surfactants.
[0010] The object of the present invention is further solved by an aqueous pharmaceutical composition comprising ephedrine or a salt or a derivative thereof and one or more microcrystalline celluloses.
[0011] In one embodiment, the aqueous pharmaceutical composition further comprises one or more surfactants.
[0012] In one embodiment of the methods or the aqueous pharmaceutical composition, the aqueous pharmaceutical composition is selected from the group comprising a nasal spray composition, an asthma spray composition and a cough syrup. A nasal spray composition is particularly preferred.
[0013] In one embodiment of the methods or the aqueous pharmaceutical composition, the microcrystalline cellulose is present in the aqueous pharmaceutical composition at an amount of about 1.0% to about 10.0% by weight, preferably of about 1.4% to about 8.7% by weight, and most preferably at about 1.4%, 3.0%, 4.7%, 5.0%, 6.3%, 8.6%, or 8.7% by weight.
[0014] In one embodiment of the methods or the aqueous pharmaceutical composition, the microcrystalline cellulose has a nominal particle size of about 10 μm to about 50 μm, preferably of about 15 μm to about 25 μm, and most preferably of about 15 μm, 20 μm or 25 μm.
[0015] In one embodiment of the methods or the aqueous pharmaceutical composition, the microcrystalline cellulose is selected from the group comprising Avicel® PH105, VivaPur® 105 and Emcocel® SP15.
[0016] In one embodiment of the methods or the aqueous pharmaceutical composition, the surfactant is present in the aqueous pharmaceutical composition at an amount of about 1.0% to about 5.0% by weight, preferably of about 1.4% to about 3.9% by weight, most preferably of about 1.4%, 2.9%, 3.0%, 3.3% or 3.9% by weight.
[0017] In one embodiment of the methods or the aqueous pharmaceutical composition, the surfactant is a polysorbate, preferably is Tween® 20 or Tween® 80.
[0018] The present invention provides a method for inhibiting, i.e. preventing or reducing, a phase separation in a mixture of an aqueous pharmaceutical composition comprising ephedrine and diethyl ether used for extracting the drug. The effect of such inhibition is that a recovery of ephedrine from the aqueous pharmaceutical composition becomes much more difficult and laborious, i.e. impractical.
[0019] According to the present invention, the mixture (emulsion) of the aqueous solution and the organic solvent is stabilized by adding to the aqueous pharmaceutical composition (1) microcrystalline cellulose (MCC) and, optionally, (2) a surfactant (or mixtures of surfactants). In order to be effective with regard to a prevention of drug abuse, microcrystalline cellulose and the optional surfactant must be included in the original aqueous pharmaceutical composition as it is commercially available.
[0020] Microcrystalline cellulose is widely used as an additive in food and pharmaceutical industry. As a white, free flowing powder it is available with different particle sizes. In pharmaceutical tablets, in particular in tablets produced by direct tabletting, microcrystalline cellulose is commonly used as a vehicle and disintegrating agent [4]. In food technology microcrystalline cellulose is used as a thickening agent since it has the capability of forming stable gels in aqueous media [5]. The viscosity of such gels increases with increasing solid contents of microcrystalline cellulose, and solids contents of 10% and above are employed.
[0021] The present invention is based on the finding that the addition of microcrystalline cellulose to an aqueous pharmaceutical composition significantly delays the phase separation after mixing the same with diethyl ether. Obviously, microcrystalline cellulose stabilizes the emulsion of diethyl ether and water. Only a very small volume of clear organic solvent separates from the emulsion after a while, and this small organic layer is difficult to remove and does not contain considerable amounts of drug.
[0022] In one aspect of the present invention, the solids content of microcrystalline cellulose is of importance since this affects the viscosity of the emulsion of diethyl ether and the aqueous pharmaceutical composition. The higher the viscosity of the emulsion the lesser is the chance that individual water droplets or individual diethyl ether droplets converge and combine. On the other hand, it may be desirable to limit the viscosity of the original aqueous pharmaceutical composition. While the viscosity may be less relevant in case of e.g. a cough syrup, it may matter in case of an aqueous pharmaceutical composition intended for use with a spraying, nebulizing or vaporizing device, e.g. a nasal spray or asthma spray.
[0023] In another aspect of the present invention the particle size of microcrystalline cellulose is of particular importance. On the one hand, the particle size affects the extent to which the emulsion is stabilized. It is assumed that, just as for the formation of gels, the microcrystalline cellulose particles form a kind of stable mesh structure trapping both water and diethyl ether droplets. Thus, individual water or diethyl ether droplets are immobilized and their converging and combining is inhibited. On the other hand, in order that the invention works it is essential that the microcrystalline cellulose particles are not retained by the coffee filter which is used prior to the addition of diethyl ether to the aqueous pharmaceutical composition.
[0024] Another finding of which the present invention takes advantage is that the addition of a surfactant to the aqueous pharmaceutical composition further supports the inhibition of the phase separation. A surfactant reduces the interface tension between the aqueous and organic phases and thus assists in the stabilization of the emulsion. The surfactant should be water-soluble and should not adversely affect the action of the original aqueous pharmaceutical composition.
DETAILED DESCRIPTION OF THE INVENTION
[0025] In the following, the present invention will be described in more detail by means of the accompanying figures and the examples.
[0026] FIG. 1 is a flow chart demonstrating the steps involved in the abusive extraction of ephedrine from a Vicks® nasal inhaler and where in this process the present invention interferes with.
[0027] FIG. 2 is a photography showing an aqueous pharmaceutical composition containing microcrystalline cellulose directly after mixing with diethyl ether. Percentages of Avicel® PH105 in the mixtures: 0.44%, 0.61%, 0.35%, and 0.21% by weight.
[0028] FIG. 3 is a photography showing the mixtures as in FIG. 2 after being allowed to rest over night.
[0029] FIG. 4 is a photography showing an aqueous pharmaceutical composition containing microcrystalline cellulose and a surfactant of (Tween® 20) directly after mixing with diethyl ether. Percentages of Avicel® PH105 in the mixtures: 0.44%, 0.60%, 0.33%, 0.21%, and 0.1% by weight.
[0030] FIG. 5 is a photography showing the mixtures as in FIG. 4 after being allowed to rest over night.
EXAMPLES
Example 1
Microcrystalline Cellulose
[0031] To the aqueous pharmaceutical composition of Vicks® nasal inhaler a microcrystalline cellulose, i.e. Avicel® PH105 (FMC Corporation, USA), nominal particle size 20 μm, was added at different percentages. Addition of sodium hydroxide resulted in pH>12. Then, diethyl ether was added and the mixtures were vigorously agitated (vortexed). The composition of the mixtures is shown in Table 1 below.
[0000]
TABLE 1
Avicel ®
Diethyl
No.
PH105 [g]
H 2 O + NaOH [g]
Ether [g]
1
0.0405
3.1492
6.0172
0.44% (=6.3%)
2
0.0553
3.0406
6.0095
0.61% (=8.7%)
3
0.0318
3.0209
6.0103
0.35% (=5.0%)
4
0.0199
3.4689
6.0153
0.21% (=3.0%)
In round brackets: % of aqueous pharmaceutical composition
[0032] FIG. 2 shows for all percentages of microcrystalline cellulose optically homogenous emulsions directly after mixing. A first phase separation could be observed after about 30 minutes, i.e. a separation between an aqueous and an emulsion layer (not shown). As shown in FIG. 3 , the emulsion layers are still maintained after the mixtures were allowed to rest over night with only a very small volume of diethyl ether being separated.
[0033] It also turned out that the high pH does not affect the stabilization of the emulsion.
[0034] Compared to Avicel® PH105, 0.2%, other microcrystalline celluloses, i.e. Emcocel SP15, nominal particle size 15 μm, 0.2%, or VivaPur® 105, nominal particle size 25 μm, 0.2%, (both from J. Rettenmaier & Söhne GmbH & Co. KG, Rosenberg, Germany) did not produce any difference with regard to the capability of stabilizing the emulsion.
Example 2
Microcrystalline Cellulose and Surfactant
[0035] The pharmaceutical composition of a Vicks® nasal inhaler was similarly treated as described in Example 1 above except that Tween® 20 was additionally added. The composition of the mixtures is shown in Table 2 below.
[0000]
TABLE 2
Avicel ®
Diethyl
No.
PH105 [g]
Tween ® 20 [g]
H 2 O + NaOH [g]
Ether [g]
5
0.0402
0.0194
3.0225
6.1145
0.44% (=6.3%)
0.21% (=3.0%)
6
0.0546
0.0187
3.0488
6.0491
0.60% (=8.6%)
0.20% (=2.9%)
7
0.0305
0.0187
3.0581
6.0281
0.33% (=4.7%)
0.23% (=3.3%)
8
0.0198
0.0274
3.0883
6.0981
0.21% (=3.0%)
0.3% (=3.9%)
9
0.0088
0.0096
3.0200
6.0448
0.01% (=1.4%)
0.10% (=1.4%)
In round brackets: % of aqueous pharmaceutical composition
[0036] FIG. 4 shows for all percentages of microcrystalline cellulose optically homogenous emulsions directly after mixing. After about 5 hours, a phase separation could be observed, i.e. a separation between an aqueous and an emulsion layer without a clear organic phase being formed (not shown). As shown in FIG. 5 , the emulsion layers are still maintained after the mixtures were allowed to rest over night with only a very small volume of diethyl ether being separated.
REFERENCES
[0000]
[1] EuAB 6.5, Monography Ephedrin, Ephedrin-HCl
[2] Comments on Monography Ephedrin in EuAB 6.5
[3] Lin, H. et al., J. Pharm. Sci. 82 (10), 1993, pp 1018-1026
[4] Reier, G. et al., J. Pharm. Sci 55 (5), 1966, pp 510-514
[5] Battista, O. A. et al., Ind. Eng. Chem. 54 (9), 1962, pp 20-29
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Use of microcrystalline cellulose and, optionally, a surfactant in an aqueous pharmaceutical composition in order to inhibit the extraction of ephedrine for the purpose of drug abuse.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the construction of a windshield wiper frame and connector and more particularly, to an improved wiper arm and blade unit connector assembly for windshield wipers, whereby the wiper frame accommodates a versatile connector in a manner that permits easy assembly and replacement of the wiper arm.
2. Description of the Prior Art
Various types of windshield wiper arm and blade unit connectors for a windshield wiper assembly are well known. Such windshield wiper frame connectors include a pair of apertured ears pivotally connected to a pin of the pin type arm as shown in the U.S. Pat. No. 3,425,089 to Quinlan et al and U.S. Pat. No. 3,780,395 to Quinlan et al. However, such prior art wiper frame connectors are costly to manufacture and difficult to assemble with the wiper arm and the blade unit due to their complicated structure. Furthermore, such prior art connectors are incapable of receiving the widely used hook type arm of the windshield wiper assembly that restricts their use in many applicable circumstances.
Conventionally, the windshield wiper frame connector 1 as shown in FIG. 1 is equipped with first, second, and third slots 2, 3, and 4 and an L-shaped recess 5 for receiving both the hook type arm and the pin type arm. However, the windshield wiper frame connector 1 suffers from a number of problems. For example, the difference in depth between the first slot 2 of a pin of the blade unit and the second slot of a rolled bushing of the pin type arm causes instability when the pin type arm is connected to the wiper frame connector 1. Moreover, receiving the hook type arm lacks any locking members that would securely lock the hook type arm to the wiper frame connector. The body 6 of such a wiper frame connector 1 uses much material and is heavy in weight. These characteristics and above stated problems are disadvantages in achieving an efficient and economical windshield wiper assembly.
U.S. Pat. No. 5,289,608 to Kim discloses a windshield wiper frame connector shown in FIGS. 2 and 3 which accommodates different size wiper arms and is incorporated herein by reference. The wiper assembly of this patent suffers from serious drawbacks inherent in the wiper frame structure that prevent proper assembly and disassembly of hook-type wiper arms from the wiper frame and the adapter.
The need therefore exists for an improved versatile windshield wiper frame and adapter assembly that is easy to assemble and disassemble, particularly for hook-type wiper arms.
SUMMARY OF THE INVENTION
The present invention provides an improved windshield wiper bridge and connector assembly for use in a windshield wiper assembly for motor vehicles, that improves the assembly process when compared to the prior art designs. The present invention further provides a windshield wiper bridge design wherein a cutout portion is provided in the lower edge of each bridge member in order to facilitate removal of the hook-type wiper arm when it is affixed to the wiper adapter.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
FIG. 1 shows the conventional wiper frame connector;
FIG. 2 is a plan view of a prior art windshield wiper frame connector for a hook type wiper arm;
FIG. 3 is a perspective view of a prior art windshield wiper frame connector for a pin type wiper arm;
FIG. 4 is a top elevational view of the wiper adapter according to a preferred embodiment of this invention;
FIG. 5 is a side view of the wiper adapter of FIG. 4;
FIG. 6 is a bottom view of the wiper adapter of FIG. 4;
FIG. 7 is a rear view of the adapter of FIG. 4;
FIG. 8 is an enlarged view of the wiper adapter of FIG. 4;
FIG. 9 is an enlarged partial bottom view of the rear portion of the adapter of FIG. 4 showing the cantilevered release tab;
FIG. 10 is an enlarged partial top view of the front portion of the wiper adapter of FIG. 4 showing the retention tabs;
FIG. 11 is a cross sectional view taken along line XI--XI of FIG. 4.
FIG. 12 is a perspective view of the hook-type wiper arm being engaged/disengaged from the wiper blade assembly and adapter 10.
FIG. 13 is a side view showing the main bridge curve or cutout in the middle portion of the wiper frame and the adapter 10 as disposed during the assembly/disassembly stage.
FIG. 14 is the adapter 10 having the retention tabs disposed on the wing portion of the sidewalls being spread apart as during the assembly/disassembly stage.
FIG. 15 is a perspective view of the adapter 10 with an adapter pin mounted therein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings illustrating preferred embodiments of the present invention, the windshield wiper frame adapter 10 is designed to be connected to any one of a hook type wiper arm 100 (FIG. 2), a pin type wiper arm 200 (FIG. 3), or a bayonet type wiper arm (not shown). The adapter 10 snugly fits between the sidewalls 12c of the wiper frame 12, and it snaps in connecting relation onto the transverse pin 12b. In this manner, the suitable blade unit 12 may be installed as a windshield wiper assembly for a variety of motor vehicles as exemplified by FIGS. 2 and 3.
As shown in FIGS. 4-11, the connector or adapter 10 comprises a body member 10a, a pair of sidewalls 1, and a first slot 13 and a second slot 15 disposed in the lower portion of the body member 10a.
A channel 3 is formed and defined between the sidewalls 1 to accommodate a hook type wiper arm 100. Hook arms 100 of different width may be accommodated within or on top of the channel 3.
The sidewalls 1 each have a wing portion 4 extending forwardly. A pair of retention tabs 5a, 5b, 5c, 5d are formed on the inner surface of each of the wing portions 4. Retention tabs 5a, 5b associated with one of sidewalls each extend more inwardly than a corresponding opposite retention tab 5c, 5d. Such an arrangement has been shown to provide a dramatic improvement in the ease of installation and removal of hook type wiper arms.
A transverse notch 6 (See FIG. 5) is formed in each of the sidewalls 1 to promote flexure of the wiper adapter. In the preferred embodiment, the transverse notch 6 extends downward from a top portion of each sidewall. Such an arrangement particularly provides proper flexure when the wiper adapter is attached to a pin type wiper arm.
Each of the sidewalls 1 has an external surface with raised bearing surfaces 7 (See FIGS. 5, and 14) which bearing directly against the inner surface of the sidewalls 12c of the wiper frame 12 (See FIG. 6). Such raised bearing surfaces 7 are preferably arranged to define recessed radial channels 8. The recessed radial channels 8 provide space for foreign material such as grease and dirt thereby promoting free rotation of the wiper adapter when pressed between the sidewalls 12c and onto the transverse portion or pin 12b of the main bridge of the wiper blade.
The wiper blade has a bayonet retention bore 9 to receive an extended portion of the bayonet type wiper arm. FIGS. 5, 6, 7, 9 and 14 show a cantilevered release tab 11 extending from the rear portion of the cross member 2. Referring to FIG. 14, a channel 12 is defined between the cantilevered release tab 11 and the bayonet retention member 9 to retain the bayonet type wiper arm. The release tab 11 extends substantially more rearwardly than the bayonet retention member to facilitate easy removal of the bayonet arm. The release tab 11 is simply depressed at the groove portion 13 such that the release tab deflects downwardly sufficient to allow the extended portion of the bayonet arm to be removed from the bore 9. Such an arrangement has been shown to ease installation and removal of the bayonet arm.
A first slot 13, preferably a keyhole slot, is provided in a lower portion of the wiper adapter for rotatably receiving and retaining the transverse pin 12b formed on the wiper blade unit. A second slot 15 is also provided in the lower portion of the wiper adapter adjacent the first slot 13. (See FIG. 15). The second slot 15 is adapted to receive and retain a pin of the pin type wiper arm. A raised arc surface is also provided. In the preferred embodiment, the second slot 15 and the raised arc surface have dimensions to enable respective retainment of 1/4 inch and 3/16 inch diameter pin arms.
As seen in FIGS. 12 and 13, in order to remove the hook type wiper arm from the wiper frame, the wiper frame must be rotated to an angle of about 90 degrees from the hook type wiper arm. The wing portions 4 sidewalls 1 are then spread apart and the hook type wiper arm is released from the retention tabs 5a, 5c. FIG. 10 shows the direction of spread (direction A) for the wing portions 4. To facilitate removal of the hook type wiper arm from the wiper frame, the main bridge of the wiper frame is provided with a cutout or curve 12a as shown in FIGS. 12 and 13. With the cutout or curve 12a, the sidewalls 1 may be easily spread apart without interference or hindrance from the side frame members of the wiper frame 12; thereby permitting the hook-type wiper arm to be released from the retention tabs 5a, 5b, 5c, 5d. The exterior surface of the sidewalls 1 of the adapter 10 maintain a snug-fit relation with the inner surface of the wiper frame sidewalls 12c (See FIG. 6). Therefore, without the cutout or main bride curve 12a, the sidewalls 1 are maintained in an evenly spaced relation and, as a result, the hook type wiper arm cannot effectively be removed from the wiper frame, i.e. they are effectively blocked by the retention tabs.
As a result of the cutout portion 12a, the wing portions 4 and associated retention tabs 5a, 5b, 5c, 5d are permitted to spread to the disengaged state while the adapter 10 is still affixed to the transverse pin 12b of the wiper frame 12. This improvement is accomplished by the structural and spacial interrelation of the adapter 10 and the cutout portion 12a formed in the wiper frame 12 (See FIGS. 12 and 13). The prior art designs did not permit efficient and effective removal of the hook-type wiper arm, and as a result, the defective prior art design caused adapter breakage and wiper failure.
It is noted that the cutout portion 12a is slightly offset from the longitudinal mid-point of the wiper frame in order to align the cutout portion 12a with the wing portions 4 when the adapter 10 is rotated to approximately 75-90 degrees with respect to the wiper frame (See FIG. 13).
Accordingly, the wiper frame connector 10 of the present invention can be easily used as an adapter for the blade unit 12 to connect to the hook type wiper arm 11, or the pin type wiper arm 110, or the bayonet type wiper arm 116 if necessary. Furthermore, the wiper arms 11, 110 and 116 are tightly and securely connected to the blade unit 12 so that the wiper connector 10 of the present invention achieves an effective connecting operation and improves the wiping performance of the windshield wiper assembly a well as its operational lifetime.
From the invention described above, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included in the scope of the following claims.
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A windshield wiper frame connector assembly for a windshield wiper assembly for motor vehicles which accommodates different size wiper arms, wherein the assembly accommodates connectors adapted to receive a hook type wiper arm, or a pin type wiper arm, or a bayonet type wiper arm. The wiper blade frame is designed to make assembly and disassembly of the hook-type wiper arms more efficient by providing a cutout portion formed in at least one wall of the wiper frame.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to support brackets, and more specifically, to a collapsible hanging scaffold bracket for engagement with the top horizontal stud of a wall structure.
[0003] 2. Description of the Related Art
[0004] As generally well known, in the building industry, it is often necessary during construction of a wall, either freestanding or as part of a building to support workers above the ground on a scaffold so they can conveniently reach and work on parts of the wall higher than they can reach from the ground. These walls range in type from hard masonry or concrete to walls supported by spaced wood studs and sheathed with relatively fragile and/or soft materials; such as, insulating board and/or aluminum siding.
[0005] These scaffold brackets, the scaffold boards they support and ladders as well as other equipment are normally carried from one job to another on trucks to which they are often attached by roof brackets or the like designed to carry slender, relatively light objects.
[0006] It is believed desirable to provide a scaffold bracket that can be engaged with the top horizontal stud of a wall structure and can be used to adequately and safely support workers for work on all of the various types of walls which may be encountered, without damage to the wall. It is desirable that the bracket allow the user to be spaced away from the wall for ease in applying external wall coverings as well as soffits, rafters, and ceiling joists. It is also desirable that it can be easily handled by one person and that it be collapsible into a unitary, relatively slender, flat unit readily transportable in the bed or on a roof bracket disposed on a truck or other similar carrier.
[0007] Thus, a collapsible hanging scaffold bracket solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
[0008] The collapsible hanging scaffold bracket of the present invention includes a first elongated bracket member, a second elongated bracket member, a third elongated bracket member, a fourth elongated bracket member, a fifth elongated bracket member, and a tee-bar member.
[0009] The first elongated bracket member has a hook portion for engaging the top horizontal stud of a wall structure and is disposed in a substantially vertical position when the collapsible hanging scaffold bracket is engaged with the top horizontal stud of a wall structure. The second elongated bracket member is designed to telescopically receive the first elongated bracket member through the first end and is disposed in a substantially vertical position when the collapsible hanging scaffold bracket is engaged with the top horizontal stud of a wall structure. A locking means is provided for locking the first and second elongated bracket members together at a selected length.
[0010] The third elongated bracket member is pivotally engaged with the second elongated bracket member and is disposed in a substantially horizontal position when the collapsible hanging scaffold bracket is engaged with the top horizontal stud of a wall structure. The fourth elongated bracket member is pivotally engaged with the third elongated bracket member. The fifth elongated bracket member is pivotally engaged with the second elongated bracket member at a point substantially near the second end of the second elongated bracket member. The fifth elongated bracket member telescopically receives the fourth elongated bracket member. A second locking means is provided for locking the fourth and fifth elongated bracket members together at a selected length.
[0011] The tee-bar member includes a leg that is telescopically disposed within the second end of the second elongated bracket member and is in a substantially horizontal position when the collapsible hanging scaffold bracket is engaged with the top horizontal stud of a wall structure, with the arm of the tee-bar member supporting the collapsible hanging scaffold bracket against the wall structure.
[0012] In an additional embodiment, a sixth and seventh elongated bracket member are included. These two additional members can be used to lengthen the overall size of the bracket and provided and easier way to support the bracket near the ground when the bracket is being used on a horizontal beam without a supporting wall.
[0013] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an environmental, perspective view of a pair of collapsible hanging scaffold brackets according to the present invention.
[0015] FIG. 2 is an exploded view of a collapsible hanging scaffold bracket according to the present invention.
[0016] FIG. 3 is an enlarged, partial perspective view of a collapsible hanging scaffold bracket according to the present invention.
[0017] FIG. 4 is a top view of a collapsible hanging scaffold bracket in a collapsed position according to the present invention.
[0018] FIG. 5 is an enlarged, partial perspective view of an alternate embodiment of a collapsible hanging scaffold bracket according to the present invention.
[0019] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention is a collapsible hanging scaffold bracket, designated generally as 10 in the drawings.
[0021] Referring to FIGS. 1-3 of the drawings, the collapsible hanging scaffold bracket 10 is made up of first elongated bracket member 20 , second elongated bracket member 30 , third elongated bracket member 40 , fourth elongated bracket member 50 , fifth elongated bracket member 60 , and tee-bar member 70 . One or more collapsible hanging scaffold brackets 10 can be aligned in order to support scaffold boards that can be used to perform work on the supporting wall and surrounding structures.
[0022] First elongated bracket member 20 has a hook portion 22 for engaging the top horizontal stud of a wall structure. If necessary, hook portion 22 can be used in conjunction with a standard two-by-four (2″×4″) that can be nailed along the top horizontal stud of a wall structure to provide added thickness in order for the hook portion to tightly grab the wall. First elongated bracket member 20 is provided with a plurality of spaced apertures 24 therethrough and is disposed in a substantially vertical position when the collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure.
[0023] Second elongated bracket member 30 is adapted for telescopically receiving the first elongated bracket member 20 . Second elongated bracket member 30 is provided with one or more apertures 34 therethrough, each of the one or more apertures 34 being located substantially near a first end and a second end of the second elongated bracket member 30 . The one or more apertures 34 located substantially near the first end of second elongated bracket member 30 are brought into alignment with one or more of the plurality of apertures 24 in the first elongated bracket member in order to selectively lock first elongated bracket member 20 and second elongated bracket member 30 at a selected length. A locking pin 14 is used for selectively locking first elongated bracket member 20 and second elongated bracket member 30 together at a selected length. Second elongated bracket member 30 is disposed in a substantially vertical position when the collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure.
[0024] Third elongated bracket member 40 is pivotally engaged at a pivot 12 with second elongated bracket member 30 at a first end of third elongated bracket member 40 . In the preferred embodiment, the pivot 12 is secured with a bolt and lock nut combination. Third elongated bracket member 40 has a end tab 42 extending from a second end. Third elongated bracket member 40 disposed in a substantially horizontal position when the collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure and is used to support the scaffold boards used by those working on the wall structure. End tab 42 prevents scaffold boards that are being supported by collapsible hanging scaffold bracket 10 from sliding off of elongated bracket member 40 while in use.
[0025] Fourth elongated bracket member 50 is pivotally engaged at a pivot 12 third elongated bracket member 40 . In the preferred embodiment, the pivot 12 is secured with a bolt and lock nut combination. Fourth elongated bracket member 50 is provided with a plurality of spaced apertures 54 therethrough. A first end of fifth elongated bracket member 60 is pivotally engaged at a pivot 12 with second elongated bracket member 30 substantially near the second end of second elongated bracket member 30 . In the preferred embodiment, the pivot 12 is secured with a bolt and lock nut combination.
[0026] Fifth elongated bracket member 60 is designed to telescopically receive fourth elongated bracket member 50 . Fifth elongated bracket member 60 is provided with one or more apertures therethrough along a second end for aligning with one or more of the plurality of apertures 54 in fourth elongated bracket member 50 in order to selectively lock the fourth elongated bracket member 50 and fifth elongated bracket member 60 together at a selected length. A locking pin 14 is used for selectively locking fourth elongated bracket member 50 and fifth elongated bracket member 60 together at a selected length. Fourth elongated bracket member 50 and fifth elongated bracket member 60 combine to provide extra support for elongated bracket member 40 as it supports scaffold boards and the weight of any one who may be working from on top of the scaffold boards.
[0027] Tee-bar member 70 has a leg that is provided with a plurality of apertures 74 therethrough and is designed to be telescopically disposed within the second end second elongated bracket member 30 such that one or more of the plurality of apertures 74 in the leg align with one or more of the apertures 34 located substantially near the second end of second elongated bracket member 30 in order to selectively lock tee-bar member 70 at a selected length. A locking pin 14 is used for selectively locking tee-bar member 70 at a selected length. Tee-bar member 70 is disposed in a substantially horizontal position when collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure, the arm of tee-bar member 70 supporting the collapsible hanging scaffold bracket 10 against the wall structure. Tee-bar member 70 is adjustable horizontally in order to provide the user with a means for spacing himself out from the wall when applying external wall coverings.
[0028] In the preferred embodiment, first elongated bracket member 20 , second elongated bracket member 30 , third elongated bracket member 40 , fourth elongated bracket member 50 , fifth elongated bracket member 60 , and tee-bar 70 are made from 14 GA steel square tubing ranging from one inch in width to one-and-a-half inches in width.
[0029] FIG. 4 shows a collapsible hanging scaffold bracket 10 in a collapsed state. In order to collapse collapsible hanging scaffold bracket 10 , tee-bar member 70 must be completely released from its telescoping engagement with second elongated bracket member 30 . Also, fourth elongate bracket member 50 and fifth elongated bracket member 60 must be disengaged from one another. At this point, third elongated bracket member 40 may be pivoted upward such that it substantially rests against second elongated bracket member 30 . Fifth elongated bracket member 60 may also be pivoted upward to a position resting against second elongated bracket member 30 . Finally, tee-bar 70 can be pinned to fourth elongated bracket member 50 , creating a single, collapsed piece that can be easily transported.
[0030] FIG. 5 shows an alternate embodiment of collapsible hanging scaffold bracket 10 that can be used when work is being done in an area where there is not a supporting wall under collapsible hanging scaffold bracket 10 as it hangs from a horizontal stud or other horizontal support member. The alternate embodiment provides added length to collapsible hanging scaffold bracket 10 such that it may rest against a concrete foundation or other support on the ground while still providing the needed height for the user.
[0031] In this embodiment, tee-bar member 70 is not directly engaged with second elongated bracket member 30 . Instead, sixth elongated bracket member 80 has a first end that is telescopically engaged within the second end of second elongated bracket member 30 . Sixth elongated bracket member 80 is provided with a plurality of apertures 84 therethrough. One or more of the plurality of apertures 84 sixth elongated bracket member 80 is aligned with one or more of the apertures located substantially near the second end of second elongated bracket member 30 in order to selectively lock sixth elongated bracket member 80 normal to second elongated bracket member 30 at a selected position. A locking pin 14 is used for selectively locking sixth elongated bracket member 80 to second elongated bracket member 30 . Sixth elongated bracket member 80 is disposed in a substantially horizontal position when collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure.
[0032] Seventh elongated bracket member 90 has a first end that is telescopically disposed within the first end of sixth elongated bracket member 80 . Seventh elongated bracket member 90 is provided with a plurality of apertures 94 therethrough such that one or more of the plurality of apertures 94 in seventh elongated bracket member 90 are aligned with one or more of the apertures 84 in sixth elongated bracket member 80 in order to selectively lock seventh elongated bracket member 90 normal to sixth elongated bracket member 80 at a selected position. A locking pin 14 is used for selectively locking sixth elongated bracket member 80 to seventh elongated bracket member 90 . Seventh elongated bracket member 90 is disposed in a substantially vertical position when collapsible hanging scaffold bracket 10 is engaged with the top horizontal stud of a wall structure.
[0033] Tee-bar member 70 is now telescopically disposed within the second end of seventh elongated bracket member 90 .
[0034] It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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The collapsible hanging scaffold bracket is a bracket for supporting scaffold boards and is designed to be engaged with the top horizontal stud of a wall structure and can be used to adequately and safely support workers for work on all of the various types of walls that may be encountered. The bracket includes a series of pivoting and telescoping elongated bracket members, a series of locking pins, and a wall engaging tee-bar member and allows the user to be spaced away from the wall for ease in applying external wall coverings, as well as soffits, rafters, and ceiling joists. The bracket can be easily handled by one person is collapsible into a unitary, relatively slender, flat unit readily that is readily transportable.
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RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 09/283,606, filed on Apr. 1, 1999, which is a divisional of U.S. patent application Ser. No. 08/906,213, filed on Aug. 4, 1997, now U.S. Pat. No. 6,043,119, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. The Field of the Invention
[0003] The present invention is directed to the fabrication of microelectronic storage devices. In particular the present invention is concerned with methods of making a concave shaped capacitor in a stacked capacitor memory device such as a dynamic random-access memory (DRAM) where a large ratio of surface area to capacitor volume is desired.
[0004] 2. The Relevant Technology
[0005] In fabrication of microelectronic devices there exists a relentless pressure to continue miniaturization for higher device density on a single chip and to increase device speed and reliability. It is advantageous to form integrated circuits with smaller individual elements so that as many elements as possible may be formed in a single chip. In this way, electronic equipment becomes smaller and more reliable, assembly and packaging costs are minimized, and integrated circuit performance is improved.
[0006] One device that is subject to the ever-increasing pressure to miniaturize is the DRAM. DRAMs comprise arrays of memory cells that contain two basic components—a field effect access transistor and a capacitor. Typically, one side of the transistor is connected to one side of the capacitor. The other side of the transistor and the transistor gate electrode are connected to external connection lines called a bit line and a word line, respectively. The other side of the capacitor is connected to a reference voltage. Therefore, the formation of the DRAM memory cell comprises the formation of a transistor, a capacitor and contacts to external circuits. The DRAM has one MOS transistor and one capacitor within a semiconductor substrate on which a plurality of spaced gates, that is, word lines, and a plurality of spaced metal wires, that is, bit lines are aligned perpendicular to each other in width-wise and lengthwise directions. Additionally, one capacitor having a contact hole in the center thereof is formed for every two gates and extends across the bit lines.
[0007] The recent trend of high integration of semiconductor devices, especially DRAM devices, has been based on the diminution of the capacitor storage cell, which leads to difficulty in providing a capacitor with sufficient capacitance to hold a charge long enough between refreshes for an optimally desired length of time.
[0008] The capacitor is usually the largest element of the integrated circuit chip. Consequently, the development of smaller DRAMs focuses to a large extent on the capacitor. Three basic types of capacitors are used in DRAMs—planar capacitors, trench capacitors, and stacked capacitors. Most large capacity DRAMs use stacked capacitors because of their greater capacitance, reliability, and ease of formation. For stacked capacitors, the side of the capacitor connected to the transistor is commonly referred to as the storage node, and the side of the capacitor connected to the reference voltage is called the cell plate. The cell plate is a layer that covers the entire top array of all the substrate-connected devices, and the storage node is compartmentalized for each respective bit storage site.
[0009] In a stacked capacitor, a conductor is usually made mainly of polysilicon, and a dielectric material is selected from a group consisting broadly of an oxide, a nitride and an oxide-nitride-oxide (ONO) laminator. In general, a capacitor occupies a large area on a semiconductor chip. Accordingly, it is one of the most important factors for high integration of DRAM devices to reduce the size of the capacitor yet to maintain the capacitance thereof.
[0010] The capacitance of a capacitor is represented by C=(κ∈ 0 A)/T where C is capacitance, ∈ 0 is permitivity of vacuum, κ is the dielectric constant of the dielectric layer, A is the surface area of the capacitor, and T is the thickness of dielectric layer. The equation illustrates that the capacitance can be increased by employing dielectric materials with high dielectric constants, making the dielectric layer thin, and increasing the surface area of the capacitor.
[0011] The areas in a DRAM to which electrical connections are made are generally referred to as active areas. Active areas, which serve as source and drain regions for transistors, are discrete specially doped regions in the surface of the silicon substrate.
[0012] The ever-increasing pressure to miniaturize has placed capacitors of DRAMs under the strain of becoming ever smaller without losing the ability to hold a sufficient charge between refreshes. The challenge of making a capacitor that can hold a charge between refreshes can be approached by a larger capacitor surface area in a smaller space, or by insulating the capacitor to resist significant charge bleed-off between refreshes.
[0013] A need exists in the art for a capacitor that is contained in a small total volume that optimizes the surface area for charge storage, which capacitor is fabricated without costly and difficult extra processing steps.
SUMMARY OF THE INVENTION
[0014] In the microelectronics industry, a substrate refers to one or more semiconductor layers or structures which includes active or operable portions of semiconductor devices. In the context of this document, the term “semiconductor substrate” is defined to mean any construction comprising semiconductive material, including but not limited to bulk semiconductive material such as a semiconductor wafer, either alone or in assemblies comprising other materials thereon, and semiconductive material layers, either alone or in assemblies comprising other materials. The term substrate refers to any supporting structure including but not limited to the semiconductor substrates described above.
[0015] The present invention is directed to fabrication of capacitors that have concave shapes and optional convoluted surfaces in order to optimize surface area in a confined volume. The capacitors are fabricated in microelectronic fashion in order to make dense DRAM arrays. Capacitors that hold significant charges for a given volume assist in increased miniaturization efforts in the microelectronic field where a significant charge is stored in a smaller volume.
[0016] Methods of fabrication include stack building with storage nodes that extend both above the semiconductor substrate surface in some embodiments of the inventive method, and above and below the semiconductor substrate in others. Isolation trenches are included in the manufacturing methods in order to resist charge bleed off between refreshes.
[0017] The first twelve embodiments of the present inventive method are methods of stacked capacitor formation in which a polysilicon plug between gate stacks forms part of the structure. The thirteenth through twentieth embodiments of the inventive method are methods of stacked capacitor formation with no polysilicon plug between the gate stacks.
[0018] A preferable aspect to each of the first through the twentieth embodiments of the inventive method is that each of the embodiments requires only a single masking step in the formation of the concave storage container cell into which a capacitor is formed.
[0019] These and other features 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
[0020] In order to illustrate the manner in which the above-recited and other advantages of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. The appended drawings depict structures accomplished by methods of the present invention but the structures are depicted qualitatively and dimensions are not quantitatively restrictive. 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:
[0021] [0021]FIG. 1 shows a cross-sectional view of semiconductor device before fabrication of a concave shaped capacitor.
[0022] [0022]FIG. 2 shows the device of FIG. 1 after a partially-penetrating etch as a precursor hole that will become a concave storage container cell after an isotropic etch.
[0023] [0023]FIG. 3 shows the device of FIG. 2 where there is depicted a space that has been etched out of the oxide layer after an isotropic etch to form the concave storage container cell.
[0024] [0024]FIG. 4 shows the device of FIG. 3 and further depicts the concave storage container cell with a precursor polysilicon layer coating the cell that will become the storage node.
[0025] [0025]FIG. 5 shows the structure of FIG. 4 with sacrificial layers removed.
[0026] [0026]FIG. 6 shows the device of FIG. 5 with a completed stacked capacitor having concave interior walls.
[0027] [0027]FIG. 7 shows an alternative completed capacitor in which the cell polysilicon has a larger surface area wrapped around the storage node than that which is shown in FIG. 6.
[0028] [0028]FIG. 8 shows a cross-sectional view of a semiconductor device before fabrication of a concave shaped capacitor in which spacers are formed in order to create a convoluted capacitor surface.
[0029] [0029]FIG. 9 shows a cross-sectional view of a semiconductor device before fabrication of a concave shaped capacitor, wherein a single etch has etched through a photomask layer, hard mask, an oxide layer, and onto a polysilicon plug between two gate stacks.
[0030] [0030]FIG. 10 shows the device of FIG. 9 further processed to incorporate a completed capacitor, wherein the storage node contacts the polysilicon plug across the upper surface thereof.
[0031] [0031]FIG. 11 shows a cross-sectional view of a semiconductor device before fabrication of a concave shaped capacitor, wherein a single etch has etched through a photomask layer, hard mask, an oxide layer, and partially into a polysilicon plug between two gate stacks.
[0032] [0032]FIG. 12 shows the device of FIG. 11 after a completed capacitor has been formed between and above the dual gate stack and on the polysilicon plug having a recess in a top surface thereof.
[0033] [0033]FIG. 13 shows a cross-sectional view of a semiconductor device before fabrication of a concave shaped capacitor, wherein a single etch has etched through a hard mask, an oxide layer, and partially into a polysilicon plug between two gate stacks, wherein the etch is a mid-process anisotropic etch following by a spacer formation at an opening to volume created by the single etch, the opening being for the placement for an eventual convoluted capacitor surface.
[0034] [0034]FIG. 14 shows the device of FIG. 13 having a completed capacitor structure in which both a storage node and a cell plate polysilicon have convoluted surfaces.
[0035] [0035]FIG. 15 shows a cross-sectional view of semiconductor device before fabrication of a concave shaped capacitor, wherein a single etch has etched through a photomask layer, a hard mask, and an oxide layer to expose an opening on a surface of a substrate of a semiconductor wafer between two gate stacks, wherein the single etch, unlike that process illustrated in FIG. 9, has no polysilicon plug between the two gate stacks.
[0036] [0036]FIG. 16 shows a cross-sectional view of a completed capacitor made from a process option depicted in FIG. 15.
[0037] [0037]FIG. 17 shows a cross-sectional view of semiconductor device before fabrication of a concave shaped capacitor, wherein a single etch has etched through a hard mask and has partially etched into an oxide layer to a depth extending between two gate stacks but above a surface of a substrate of a semiconductor wafer therebetween, wherein an incomplete isotropic etch with spacers extending vertically towards the substrate from the hard mask, the device requiring an additional step of removing the oxide layer between the gate stacks prior to formation of the intended capacitor structure.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The present invention is directed to methods of formation of a concave shaped capacitor. The methods of the present invention are used to obtain novel capacitor structures as well.
[0039] The concave shape for a capacitor is desirable in the present invention in order to increase surface area beyond that of prior art stacked capacitors that are straight cylinders or open boxes in shape. Although the concave shape of the present invention can be a simple, virtually enclosed container, the container can also include additional surfaces, such as convoluted surfaces.
[0040] Various means for achieving desired structural and functional results are used in the practice of the instant methods and in the achieved structures. The integrated circuit DRAM device of the present invention is comprised of dual gate structures that are situated above a substrate on a semiconductor substrate. The substrate integrally has active areas that enable the gate structures to function as respective transistors. Transistor structures of this type are well known in the art in which various capacitor structures for use on an integrated circuit DRAM have first and second word lines and first and second digit lines, the integrated circuit being fabricated on the semiconductor substrate.
[0041] The methods disclosed herein and the achieved structures preferably incorporate a doped or undoped polysilicon storage node, which can be employed within a stacked capacitor. A polysilicon plug is used to contact the polysilicon storage node. A hard mask, which is preferably a nitride or oxide layer, is described below, which is preferably easily formed and sacrificed. The cell dielectric is preferably composed of oxide or nitride dielectric materials that deposit and cover thinly and evenly upon storage node materials. The cell plate is preferably made of doped polysilicon and is formed by known methods. The spacers discussed below are made from polysilicon and oxides or nitrides that can be etched selectively over materials into which the spacers are formed.
[0042] The first twelve embodiments of the present inventive method are methods of stacked capacitor formation in which a polysilicon plug between gate stacks forms part of the structure.
[0043] The first embodiment of the present invention involves a starting structure illustrated in FIG. 1. In FIG. 1 a semiconductor device 10 is being fabricated from a semiconductor substrate 12 with active areas (not shown) and two gate stacks 14 to form portions of a transistor. A polysilicon plug 20 is formed between gate stacks 14 . An oxide layer 16 , preferably borophospho silicate glass (BPSG), is formed over gate stacks 14 and polysilicon plug 20 . A hard mask layer 18 , preferably made of undoped or doped polysilicon or of a nitride composition, is formed over oxide layer 16 . To this structure a photomask 22 is spun on, aligned, exposed and patterned, as illustrated in FIG. 2. Patterning and etching of hard mask 18 and a partially-penetrating etch into oxide layer 16 can be accomplished simultaneously or in a series of etching steps to result in the structure illustrated in FIG. 2.
[0044] Following the partially-penetrating dry etch into oxide layer 16 illustrated in FIG. 2, an isotropic etch, preferably wet, is conducted in which hard mask 18 is undercut, as illustrated in FIG. 3. The isotropic etch creates the concave storage container cell. Undercutting creates a greater surface area to be layered over by a plate of the capacitor structure that forms on the undercut-exposed surface of hard mask 18 .
[0045] If the isotropic etch does not remove oxide layer 16 down to the upper surface of polysilicon plug 20 , as illustrated in FIG. 3, an optional etch that is preferably anisotropic is needed to expose polysilicon plug 20 . This optional etch can be accomplished while leaving photomask 22 in place or it can be accomplished by using hard mask 18 as the masking medium. Because either photomask 22 or hard mask 18 are in place during both the isotropic concave shape forming etch and the optional anisotropic etch to expose polysilicon plug 20 , the anisotropic etch is self-aligning to photomask 22 or hard mask 18 such that the concave shape formed by the anisotropic etch will be centered in the bottom thereof.
[0046] Following the optional anisotropic etch to expose polysilicon plug 20 , storage node formation is done by chemical vapor deposition (CVD). The CVD process is a deposition of a polysilicon which is preferably doped with a doping that is similar to the doping of polysilicon plug 20 . The CVD process forms a storage node precursor or a doped polysilicon storage layer 24 . Doped polysilicon storage layer 24 is formed in such a way that the entire inside of the concave storage container cell is coated, and the upper surface of hard mask layer 18 is incidentally also coated, as illustrated in FIG. 4.
[0047] In a next step, all material above oxide layer 16 is to be removed. Removal of both hard mask 18 and that portion of polysilicon storage layer 24 covering hard mask layer 18 can be accomplished by one of at least three methods.
[0048] The first method of removing all material above oxide layer 16 is to optionally fill the concave storage container cell with photomasking material and to planarize such as by chemical-mechanical polishing (CMP) of the superficial portions of polysilicon storage layer 24 and all of hard mask layer 18 , stopping on oxide layer 16 . Filling the concave storage container cell with photomasking material prevents fine slurry particulates used in CMP from becoming lodged in the concave storage container cell. Removal of photomasking material can be done by any method known and preferred in the art. In this first method, the sacrificial portions of polysilicon storage layer 24 can be removed before the CMP by a dry etch of upper portions of polysilicon storage layer 24 .
[0049] The second method of removing all material above oxide layer 16 is a dry anisotropic etch of both the superficial portions of polysilicon storage layer 24 and of hard mask layer 18 . In this etch, some etching of horizontally-situated portions of polysilicon storage layer 24 within the concave storage container cell will occur, such as at the bottom of the concave storage container cell where polysilicon storage layer 24 contacts substrate 12 . The anisotropic dry etch will likely etch away any horizontally-situated portions of polysilicon storage layer 24 to form what has now become storage node 26 . The anisotropic dry etch can also etch into polysilicon plug 20 to create a recessed area at a top surface thereof. Such an etch will lessen the contact area between storage node 26 and polysilicon plug 20 . FIG. 5 illustrates the accomplished removal of superficial polysilicon storage layer 24 and of hard mask layer 18 by use of any of the first to the third methods as set forth above and below, respectively.
[0050] The third method of removing all material above oxide layer 16 is accomplished with a wet etch that is selective to oxide layer 16 and is not selective to polysilicon storage layer 24 . In this etch there will be some inevitable etching of the storage node portions of polysilicon storage layer 24 unless the concave storage container cell is likewise filled with a photomasking material such as in the CMP option described above. In such case, the wet etch will also be selective to the photomasking material within the concave storage container cell.
[0051] To complete the capacitor, FIG. 6 illustrates formation of a cell dielectric 28 that both coats the exposed surface of storage node 26 and the upper surface of oxide layer 16 where hard mask layer 18 formerly was situated. Cell dielectric 28 is deposited preferably by CVD. Finally, a cell plate polysilicon layer 30 is formed over cell dielectric 28 , and a superficial insulating layer 34 is formed over the entire structure and optionally CMP processed.
[0052] The second embodiment of the present inventive method, aspects of which are seen in FIG. 7, is accomplished with an additional process step in the first embodiment in which, following removal of superficial portions of polysilicon storage layer 24 and prior to formation of cell dielectric 28 , external lateral surfaces of storage node 26 are exposed through an additional etch of oxide layer 16 . By the additional etch to remove some of oxide layer 16 , there is a larger surface area possible for cell plate polysilicon layer 30 such that a larger charge can be induced on storage node 26 . The extent of exposing external lateral surfaces of storage node 26 is limited by the ability of storage node 26 to be laid bare and yet to resist physical damage during the remainder of capacitor fabrication.
[0053] After the additional etch that removes some of oxide layer 16 surrounding storage node 26 , cell dielectric 28 formation, cell plate polysilicon layer 30 formation, and a superficial insulating layer 34 formation are accomplished. By way of example, in this second embodiment seen in FIG. 7, the means for inducing a charge is in contact with the means for insulating, and the means for insulating contacts at least two surfaces of the means for charge storing in regions above the gate structure.
[0054] Third and fourth embodiments of the present inventive method incorporate an additional process step to that of the first and second embodiments of the inventive method. In the third and fourth embodiments of the inventive method, a partial etch into oxide layer 16 is followed by formation of spacers 32 , illustrated in FIG. 8.
[0055] Although it is desirable to maximize the depth of spacers 32 in order to increase the storage node surface area that will be formed on both sides of spacers 32 , spacer depth is dictated by the eventual “bread loafing” of the opening to the concave storage container cell during all required deposition operations in which deposition materials must pass through the opening. Some materials will inevitably deposit so as to narrow the opening, while others will pass through and deposit on the inner walls of the concave storage container cell. With increased depth of the longitudinally vertical extension of the spacers, an exacerbation of the bread loafing effect may take place between the spacers of node, dielectric, or plate materials in the opening to the concave storage container cell before the capacitor structure is completed.
[0056] Following spacer formation, an isotropic etch is carried out for the third embodiment of the inventive method to open up the concave storage container cell. For the fourth embodiment, as seen in FIG. 9, an alternative step of an anisotropic etch penetrates oxide layer 16 down to the upper surface of polysilicon plug 20 . This is followed by an isotropic etch in oxide layer 16 to etch out the concave storage container cell.
[0057] The fifth, sixth, seventh, and eighth embodiments of the present inventive method are illustrated in part within FIGS. 9 and 10. In the fifth embodiment, an anisotropic dry etch etches through oxide layer 16 to extend downwardly to the top surface of polysilicon plug 20 , as seen in FIG. 9. In this fifth embodiment, there is a finished storage node-polysilicon plug contact interface wherein polysilicon plug 20 contacts the storage node across an entire upper surface of polysilicon plug 20 , as illustrated in FIG. 10. In the sixth embodiment, an anisotropic etch etches through oxide layer 16 and partially into polysilicon plug 20 , as seen in FIG. 11. In both fifth and sixth embodiments of the inventive method, an isotropic etch follows to open the concave storage container cell. In the fifth and sixth embodiments of the inventive method, there is a finished storage node-polysilicon plug contact interface wherein polysilicon plug 20 contacts the storage node across an entire upper surface of polysilicon plug 20 . The interface may include a recessed area at a top surface of the polysilicon plug as illustrated in FIG. 12.
[0058] Formation of doped polysilicon storage layer 24 followed by any of the three above-disclosed methods of removing sacrificial portions of polysilicon layer 24 and hard mask layer 18 is next accomplished. The structure achieved by the sixth embodiment is illustrated in FIG. 12.
[0059] Seventh and eighth embodiments of the inventive method are variations of the fifth and sixth embodiments of the inventive method, respectively, that include the optional removal etch of some of oxide layer 16 that exposes external lateral surfaces of storage node 26 in order to increase the cell plate polysilicon surface area similar to that illustrated in FIG. 7.
[0060] The ninth and tenth embodiments of the present inventive method, illustrated in part in FIG. 8 for the ninth embodiment and FIGS. 8,13, and 14 for the tenth embodiment, include a partially-penetrating anisotropic etch of oxide layer 16 followed by spacer 32 formation. Once again, if the isotropic etch that follows formation of spacer 32 is insufficient to contact polysilicon plug 20 , an additional etch that is anisotropic is carried out to place a contact corridor in the bottom of the concave storage container cell, so as to open up and expose a surface on polysilicon plug 20 .
[0061] The tenth embodiment, seen in FIGS. 8, 13, and 14 , includes a partially-penetrating anisotropic etch of oxide layer 16 followed by formation of spacer 32 , the same as in the ninth embodiment, but then a subsequent anisotropic etch penetrates through the remaining portions of oxide layer 16 to expose a surface on polysilicon plug 20 , and then partially etches into polysilicon plug 20 . There follows an isotropic etch to create the concave storage container cell, the upper surfaces removal by any of the three disclosed methods set forth above, and the formation of cell dielectric 28 and cell plate polysilicon 30 to accomplish the structure illustrated in FIG. 14.
[0062] The eleventh and twelfth embodiments of the present inventive method are variations of the ninth and tenth embodiments of the inventive method that include the optional removal etch of some of oxide layer 16 that exposes external lateral surfaces of storage node 26 in order to increase the cell plate polysilicon surface area similar to that illustrated in FIG. 7.
[0063] The thirteenth through twentieth embodiments of the inventive method are methods of stacked capacitor formation where polysilicon plug 20 between gate stacks 14 has been omitted.
[0064] [0064]FIG. 15 illustrates a thirteenth embodiment of the present inventive method in which a semiconductor device 10 is being fabricated, from a structure similar to that illustrated in FIG. 1, but without a polysilicon plug 20 . Substrate 12 with active areas (not shown) and two gate stacks 14 form portions of a transistor. Oxide layer 16 is formed over gate stacks 14 and hard mask layer 18 composed of polysilicon, is formed over oxide layer 16 . Photomask 22 is spun on, aligned, exposed and patterned, as was illustrated analogously in FIG. 2. An anisotropic etch that is selective to photomask 22 is accomplished through hard mask layer 18 and oxide layer 16 so as to etch down to an opening that exposes a surface on substrate 12 . Gate stacks 14 act to align the anisotropic etch, if the anisotropic etch is selective to spacers forming the periphery of gate sacks 14 . An isotropic etch of oxide layer 16 that is selective to hard mask layer 18 and gate stacks 14 significantly undercuts hard mask layer 18 so as to create a concave storage container cell.
[0065] A formation of polysilicon storage layer 24 follows, which deposits within the concave storage container cell and upon hard mask layer 18 . The next step is removing of all superficial portions of polysilicon storage layer 24 above hard mask layer 18 . This removing step can be accomplished by any of three methods as disclosed above. To complete the capacitor of the thirteenth embodiment, as seen in FIG. 16, a cell dielectric 28 is formed over storage node 26 and a cell plate polysilicon layer 30 is formed over cell dielectric 28 . The device is finished with formation of superficial insulating layer 34 which may at least partially fill the concave storage container cell so as to be in contact with cell plate polysilicon layer 30 .
[0066] Regarding the thirteenth embodiment, because of the uniformity of an isotropic etch, and a large relative depth of the isotropic etch down to substrate 12 , it may occur that a small portion of oxide layer 16 will lie unremoved at the area between gate stacks 14 as illustrated in FIG. 17. Unremoved oxide layer 16 between gate stacks 14 is removed before forming polysilicon storage layer 24 in order to complete an electrical connection with substrate 12 .
[0067] Removal of that portion of oxide layer 16 lying between gate stacks 14 can be accomplished by an anisotropic etch prior to the isotropic etch of the concave storage container cell, where the anisotropic etch penetrates substantially all the way down to substrate 12 . In this way, a substantially uniform isotropic etch occurs in oxide layer 16 . Additionally, with an isotropic etch that is selective to both gate stacks 14 and substrate 12 , substantially vertical walls are formed above substrate 12 between gate stacks 14 within the concave storage container cell. Removal of that portion of oxide layer 16 between gate stacks 14 can also be done by an anisotropic etch after the isotropic etch. This option simply removes that portion of oxide layer 16 that remains between gate stacks 14 .
[0068] A process engineer may choose to remove a portion of oxide layer 16 , illustrated analogously in FIG. 7, in order to expose external lateral surfaces of storage node 26 that would further increase the surface area between storage node 26 and cell plate polysilicon 30 , similar to the exposed external lateral portions of storage polysilicon for creation of a fourteenth embodiment.
[0069] The fifteenth and sixteenth embodiments of the inventive method are accomplished as optional steps to the thirteenth and fourteenth embodiments of the present inventive method by the step of forming a spacer immediately below the level of hard mask layer 18 that will increase the surface area of the capacitor. A spacer is formed into a concave storage container cell precursor that is followed by an isotropic etch for the fifteenth embodiment, or that is followed by an anisotropic etch to the substrate and an isotropic etch for the sixteenth embodiment. For both embodiments, the isotropic etch opens the concave storage container cell. The fifteenth and sixteenth embodiments of the present inventive method are combinations of the ninth with the thirteenth, and the tenth with the fourteenth embodiments of the inventive method, respectively, in which spacers are formed to increase the surface area of the subsequently formed polysilicon storage layer 24 . The fifteenth and sixteenth embodiments of the inventive method are illustrated by way of analogy in FIG. 8 in which the process is started, and in FIG. 13 in which the penetrating etch down to substrate 12 is accomplished, with the exception that there is no polysilicon plug 20 in the structure realized by the fifteenth and sixteenth embodiments of the inventive method.
[0070] In seventeenth, eighteenth, nineteenth, and twentieth embodiments of the present inventive method, described below, a further increase in storage capacity is accomplished in a starting structure in which polysilicon plug 20 is likewise not present. Spacers 32 are formed as in the third embodiment.
[0071] In the seventeenth embodiment, an isotropic etch follows formation of spacer 32 as illustrated in FIG. 17. Following a partially-penetrating dry etch into oxide layer 16 , spacers 32 are formed and an isotropic wet etch is conducted in which hard mask 18 and spacers 32 are undercut, as illustrated in FIG. 17. The isotropic etch clears out a concave shape to form the concave storage container cell. Undercutting creates a greater surface area for formation of a polysilicon storage layer 24 that forms on the undercut-exposed surface of hard mask 18 .
[0072] If the isotropic etch does not remove oxide layer 16 between gate stacks 14 , down to the upper surface of substrate 12 , as illustrated in FIG. 17, an optional etch that is preferably anisotropic is needed to expose substrate 12 . This optional etch can be accomplished while leaving photomask 22 , as seen in FIG. 9, in place or it can be accomplished by using hard mask 18 as the masking medium. Because either photomask 22 or hard mask 18 are in place during both the isotropic concave shape forming etch and the optional anisotropic etch to expose a surface upon substrate 12 , the anisotropic etch is self-aligning to photomask 22 or hard mask 18 such that the hole formed by the anisotropic etch will be centered in the bottom of the concave storage container cell.
[0073] Following the optional anisotropic etch to expose substrate 12 , a doped polysilicon storage layer 24 is formed in such a way that the inside of the concave storage container cell is coated, and the upper surface of hard mask layer 18 is incidentally also coated. Removal of both hard mask 18 and that portion of polysilicon storage layer 24 covering hard mask layer 18 can be accomplished by one of the three methods disclosed above.
[0074] The eighteenth embodiment includes a single penetrating anisotropic etch of oxide layer 16 that contacts substrate 12 after formation of spacers 32 . There follows an isotropic etch that opens up the concave storage container cell. Formation of polysilicon storage layer 24 and removal of sacrificial portions thereof along with hard mask layer 18 , is followed by formations of cell dielectric 28 and cell plate polysilicon 30 .
[0075] The nineteenth and twentieth embodiments of the inventive method reflect the optional external surface area exposure of storage node 26 in the seventeenth and eighteenth embodiments of the inventive method by etching some of oxide layer 16 to lower its topographical profile as illustrated analogously in the exposed external lateral surfaces of storage node 26 in FIG. 7.
[0076] 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 illustrated and not restrictive. The scope of the invention is, therefore, indicated by the appended claims and their combination in whole or in part rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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The present invention is directed to fabrication of a capacitor formed with a substantially concave shape and having optional folded or convoluted surfaces. The concave shape optimizes surface area within a small volume and thereby enables the capacitor to hold a significant charge so as to assist in increased miniaturization efforts in the microelectronic field. The capacitor is fabricated in microelectronic fashion consistent with a dense DRAM array. Methods of fabrication include stack building with storage nodes that extend above a semiconductor substrate surface.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of application Ser. No. 11/246,145, filed Oct. 11, 2005 now abandoned, and is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2004-311927, filed on Oct. 27, 2004, the entire contents of both of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor manufacturing apparatus, a liquid container and a semiconductor device manufacturing method.
2. Related Art
A semiconductor device such as a NAND flash memory is required to bury a silicon oxide film in a trench having a high aspect ratio so as to form deep STI (shallow trench isolation) in a narrow region.
To meet this demand, a film formation technique for using both an HDP (high density plasma) film and an SOG (spin on glass) film has been developed (see Japanese Patent No. 3178412). According to this technique, a silicon oxide film is deposited by HDP-CVD (chemical vapor deposition), and a film coated with a perhydropolysilazane liquid (hereinafter, “PSZ (Polysilazane)”) is coated on the silicon oxide film by spin coating. The coated film is then silicified by a cure treatment. It is thereby possible to bury the silicon oxide film in a trench having a high aspect ratio.
FIG. 14 is a conceptual view showing a conventional SOG step. Normally, a bottled PSZ liquid filled with nitrogen is commercially available. When a bottle cap is opened at a time of a used PSZ bottle being replaced by a new one, the air never fails to enter the bottles. In addition, during the replacement, the air may possibly enter a PSZ liquid supply nozzle from a tip end of the PSZ liquid supply nozzle. If so, the PSZ liquid unavoidably contacts with the air.
The PSZ developed to be silicified at a temperature as low as about several hundred Celsius (° C.) can react with water and oxygen as represented by Chemical Formula 1, and can be solidified even at a room temperature when being exposed to the atmosphere.
—(SiH 2 NH) n —+2 n O→ n SiO 2 +n NH 3 (Formula 1)
When the PSZ is solidified in a piping from a PSZ container to a discharge nozzle, the solidified PSZ fixedly adheres onto a semiconductor substrate after being discharged together with the PSZ-coating liquid, thereby disadvantageously causing bulges, divots, and streaks. Even if the solidified PSZ is not formed, the air mixed into the piping and discharged onto the semiconductor substrate as air bubbles may possibly cause the bulges, divots, and streaks. Furthermore, the solidified PSZ may possibly damage the semiconductor substrate and a polishing cloth or cause a contamination during CMP (Chemical Mechanical Polish) process.
When the PSZ remains in the used container, the PSZ reacts with water and oxygen to generate ammonium (NH 3 ) and silane (SiH 4 ). The ammonium and silane bring about considerably serious environmental and safety problems. It is, therefore, difficult to manage and handle the PSZ and the PSZ container in manufacturing of semiconductor products.
In these circumstances, therefore, a semiconductor manufacturing apparatus, which airtightly transports a liquid to be coated on a substrate from a container to a discharge portion and suppresses the liquid from coming in contact with the air when the container is replaced by another one, has been desired.
Furthermore, a liquid container detachable from the semiconductor manufacturing apparatus, which airtightly transports the liquid to be coated on the substrate from the container to the discharge portion and suppresses the liquid from coming in contact with the air when the container is replaced by another one, has been desired.
SUMMARY OF THE INVENTION
A semiconductor manufacturing apparatus according to an embodiment of the present invention comprises a discharge portion discharging a coating liquid onto a substrate; a gas supply tube supplying an inert gas into a liquid container that contains the coating liquid, and pressurizing an interior of the liquid container; a coating liquid supply tube airtightly supplying the coating liquid from the liquid container to the discharge portion using pressurization from the gas supply tube; a first connecting portion capable of attaching and detaching the liquid container to and from the coating liquid supply tube; a second connecting portion capable of attaching and detaching the liquid container to and from the gas supply tube; and a solvent supply tube supplying a solvent, which can dissolve the coating liquid, to the first connecting portion.
A semiconductor manufacturing apparatus according to an embodiment of the present invention comprises a discharge portion discharging a coating liquid onto a substrate; a gas supply tube supplying an inert gas into a liquid container that contains the coating liquid, and pressurizing an interior of the liquid container; a coating liquid supply tube airtightly supplying the coating liquid from the liquid container to the discharge portion using pressurization from the gas supply tube; a first connecting portion capable of attaching and detaching the liquid container to and from the coating liquid supply tube; a second connecting portion capable of attaching and detaching the liquid container to and from the gas supply tube; and a liquid bath including the solvent capable of dissolving the coating liquid,
wherein the first connecting portion and the second connecting portion are present in the liquid bath.
A liquid container according to an embodiment of the present invention which contains a coating liquid and which is undesirable to expose to the atmosphere before utilizing for semiconductor manufacturing, the liquid container being attachable to or detachable from a semiconductor manufacturing apparatus, wherein
the liquid container seals a coating liquid and a protection liquid, which is lower specific gravity than that of the coating liquid and does not react with the coating liquid, in a pressurized atmosphere with an inert gas higher than the atmospheric pressure.
A semiconductor manufacturing method using a semiconductor manufacturing apparatus according to an embodiment of the present invention comprises a discharge portion discharging a coating liquid onto a substrate; a gas supply tube pressurizing an interior of the liquid container with an inert gas; a coating liquid supply tube airtightly supplying the coating liquid from the liquid container to the discharge portion using pressurization from the gas supply tube; a first connecting portion capable of attaching and detaching the liquid container to and from the coating liquid supply tube; a second connecting portion capable of attaching and detaching the liquid container to and from the gas supply tube; and an exhaust tube capable of reducing an internal pressure of the coating liquid supply tube including the first connecting portion:
the method comprising:
attaching the liquid container to the first connecting portion and the second connecting portion;
supplying the inert gas to the liquid container via the gas supply tube, thereby carrying the coating liquid to the discharge portion via the coating liquid supply tube;
discharging the coating liquid to the substrate from the discharge portion;
reducing an internal pressure of the liquid container via the exhaust tube and the second connecting portion after discharging the coating liquid; and
returning the coating liquid in the first connecting portion and the liquid supply tube to the liquid container by using the pressure in the liquid container.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container according to a first embodiment of the present invention;
FIG. 2 shows a PSZ container 20 ;
FIG. 3 shows an operation for detaching the PSZ container 20 ;
FIG. 4 is a flowchart that shows a flow of an operation for detaching the PSZ container 20 ;
FIG. 5 is a flowchart that shows a flow of an operation for attaching the PSZ container 20 ;
FIG. 6 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container according to a second embodiment of the present invention;
FIG. 7 is a cross-sectional view of a PSZ container according to the second embodiment;
FIG. 8 is a cross-sectional view of a PSZ container according to the second embodiment;
FIG. 9 is a cross-sectional view of a PSZ container according to a third embodiment of the present invention;
FIG. 10 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container according to a fourth embodiment of the present invention;
FIG. 11 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container according to a fifth embodiment of the present invention;
FIG. 12 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container according to a sixth embodiment of the present invention;
FIG. 13 is a table that shows effects of the respective embodiments of the present invention; and
FIG. 14 is a schematic diagram showing a conventional SOG step.
DETAILED DESCRIPTION OF THE INVENTION
Hereafter, exemplary embodiments of the present invention will be described more specifically with reference to the drawings. Note that the invention is not limited to the embodiments.
First Embodiment
FIG. 1 is a schematic diagram of a semiconductor manufacturing apparatus 10 and a PSZ container 20 according to a first embodiment of the present invention. The semiconductor manufacturing apparatus 10 is an apparatus for dropping a PSZ liquid from a discharge nozzle onto a semiconductor substrate, and spreading the PSZ liquid on the semiconductor substrate by spin coating at an SOG step.
The semiconductor manufacturing apparatus 10 includes a coating liquid discharge portion (not shown), a PSZ supply tube 12 serving as a coating liquid supply tube, a dibutyl ether supply tube (hereinafter, “DBE supply tube”) 15 serving as a solvent supply tube, a helium supply tube (hereinafter, “He supply tube”) 16 serving as a gas supply tube, an exhaust tube 17 , and branch tubes 13 and 14 . Since the discharge portion may be identical to the discharge nozzle shown in FIG. 14 , it is not shown in FIG. 1 .
The semiconductor manufacturing apparatus 10 also includes a connector C 1 a serving as a first connecting portion and a connector C 2 a serving as a second connecting portion. The PSZ supply tube 12 is connected to the connector C 1 a through a valve 102 . One end of the branch tube 13 is connected to the PSZ supply tube 12 between the valve 102 and the connector C 1 a through a valve 103 . The other end of the branch tube 13 is connected to one end of the branch tube 14 through a valve 104 , and also connected to the DBE supply tube 15 through a valve 105 .
The He supply tube 16 is connected to the connector C 2 a through a valve 106 . The other end of the branch tube 14 is connected to the He supply tube 16 between the valve 106 and the connector C 2 a , and the exhaust tube 17 is connected to the He supply tube 16 through a valve 107 . A vacuum pomp, e.g., a turbomolecular pump, not shown, is connected to the exhaust pipe 17 .
As shown in FIG. 2 , the PSZ container. 20 includes a pair of connectors C 1 b and C 2 b connectable to the connectors C 1 a and C 2 a of the semiconductor manufacturing apparatus 10 , respectively. The PSZ container 20 can be thereby attached to or detached from the PSZ supply tube 12 and the He supply tube 16 .
The PSZ container 20 also includes a PSZ outlet tube 21 provided from the connector C 1 b to neighborhoods of a bottom of the container 20 , and a He inlet tube 22 provided from the connector C 2 b to neighborhoods of an upper surface of the container 20 . Valves 101 and 100 are provided at the PSZ outlet tube 21 near the connector C 1 b and the He inlet tube 22 near the connector C 2 b , respectively, whereby an interior of the PSZ container 20 is shut off from the atmosphere.
The PSZ container 20 is withdrawn in a sealed state after usage and recyclable by filling a PSZ liquid again into the container 20 . An inert gas as well as the PSZ liquid is filled into the PSZ container 20 with the inert gas pressurized at a slightly higher pressure than an atmospheric pressure. By doing so, the air is not mixed into the PSZ container 20 . The PSZ liquid is contained in the PSZ container 20 up to a portion near the valve 100 but contained so as not to reach the valve 100 . It is thereby possible to prevent air bubbles from being generated in the PSZ liquid. The PSZ liquid is contained in the PSZ container 20 in a state, for example, in which the PSZ liquid is dissolved into a solvent such as dibutyl ether (hereinafter, “DBE”).
The inert gas filled into the PSZ container 20 is preferably the same as the inert gas, i.e., helium gas supplied to the semiconductor manufacturing apparatus 10 for the following reasons. The helium possesses a property that it is insoluble with an organic solvent such as the PSZ or DBE, and the helium is less expensive than the other inert gas such as xenon. The PSZ container 20 and the semiconductor manufacturing apparatus 10 are preferably made of stainless steel (SUS). However, the material for the PSZ container 20 and the semiconductor manufacturing apparatus 10 is not limited to SUS but may be an arbitrary material that has good airtightness, that does not react with the PSZ, and that does not cause a metal contamination.
(PSZ Supply Operation)
When the PSZ liquid is supplied to the discharge portion, the PSZ supply tube 12 and the He supply tube 16 are used but the DBE supply tube 15 and the exhaust tube 17 are not used. Due to this, the valves 100 , 101 , 102 , and 106 are open whereas the valves 103 , 104 , 105 , and 107 are closed. In this state, the He supply tube 16 supplies the He gas to the PSZ container 20 to pressurize an interior of the PSZ container 20 . An internal atmospheric pressure of the PSZ container 20 is made thereby higher than a surrounding atmospheric pressure, so that the PSZ liquid is supplied to the discharge portion through the PSZ supply tube 12 . At this time, the PSZ supply tube 12 airtightly supplies the PSZ liquid from the PSZ container 20 to the discharge portion. The discharge portion discharges the coating liquid onto the semiconductor substrate (see FIG. 14 ).
(PSZ Container Detachment Operation)
FIG. 3 shows a manner of detaching the PSZ container 20 from the semiconductor manufacturing apparatus 10 . FIG. 4 is a flowchart that shows a flow of an operation for detaching the PSZ container 20 . With reference to FIGS. 3 and 4 , the operation for detaching the PSZ container 20 will be described.
When the PSZ liquid is supplied to the discharge portion and a residual amount of the PSZ liquid in the PSZ container 20 is small, it is necessary to replace the PSZ container 20 by a new PSZ container 20 . At this time, if the valves 100 , 101 , 102 , and 106 are simply closed to disconnect the connector C 1 a from the connector C 1 b and the connector C 2 a from the connector C 2 b , the PSZ liquid remaining in the PSZ supply tube 12 from the connector C 1 a to the valve 102 may possibly come in contact with the air.
To prevent this contact, when the PSZ container 20 is detached, the valves 101 , 102 , and 106 are closed in this order and the valve 107 is opened (at a step S 10 ). At this step, since the valves 100 and 107 are open, the exhaust pipe 17 communicates with the PSZ container 20 while the valves other than the valves 100 and 107 are closed. The internal pressure of the PSZ container 20 is thereby reduced to about 600 Torr through the exhaust tube 17 (at a step S 10 ).
After the valve 107 is closed, the valves 105 , 103 , and 101 are opened in this order. At this time, the internal pressure of the PSZ container 20 is lower than the atmospheric pressure (about 760 Torr). Due to this, DBE is supplied into the PSZ container 20 through the DBE supply tube 15 , the branch tube 13 , the PSZ supply tube from the valve 102 to the connector C 1 a (hereinafter, the PSZ supply tube 12 in this section will be referred to as “piping 12 a ”), and the PSZ outlet tube 21 . The PSZ liquid remaining in the piping 12 a and the PSZ outlet tube 21 is thereby forced into the PSZ container 20 . At the same time, the piping 12 a and the PSZ outlet tube 21 are filled with the DBE (at a step S 30 ).
After the internal pressure of the PSZ container 20 is identical to the atmospheric pressure, the valves 100 and 105 are closed (at a step S 40 ). The valves 106 and 104 are then opened in this order. The He supply tube 16 thereby communicates with the PSZ container 20 through the branch tubes 14 and 13 . By supplying the pressurized He gas from the He supply tube 16 , the DBE remaining in the branch tube 13 , the piping 12 a , and the PSZ outlet tube 21 is forced into the PSZ container 20 (at a step S 60 ). When the internal pressure of the PSZ container 20 reaches at about 900 Torr, the valves 103 and 106 are closed (at a step S 70 ). Thereafter, the connector C 1 a is disconnected from the connector C 1 b , and the connector C 2 a is disconnected from the connector C 2 b , and the used PSZ container 20 is detached from the semiconductor manufacturing apparatus 10 (at a step S 80 ).
Since the He gas at the higher pressure than the atmospheric pressure is filled into the used PSZ container 20 , the air is not mixed into the PSZ container 20 . It is, therefore, possible to prevent oxygen and water from reacting with the PSZ liquid in the PSZ container 20 .
When the used PSZ container 20 is detached from the semiconductor manufacturing apparatus 10 , the PSZ supply tube 12 from the valve 102 to the discharge portion is filled with the PSZ liquid. The piping 12 a and a piping (hereinafter, “piping 21 a ”) from the connector C 1 b of the PSZ container 20 to the valve 101 are exposed to the atmosphere. In this embodiment, however, the piping 12 a is washed by the DBE used as the solvent for the PSZ liquid in the PSZ container 20 , no PSZ liquid remains in the piping 12 a . Therefore, no PSZ solid matter is generated in the pipings 12 a and 21 a.
(PSZ Container Attachment Operation)
FIG. 5 is a flowchart that shows a flow of an operation for attaching the PSZ container 20 to the semiconductor manufacturing apparatus 10 . With reference to FIGS. 1 and 5 , an operation for attaching the new PSZ container 20 to the apparatus 10 will be described.
Although no PSZ liquid is contained in the piping 21 a of the new PSZ container 20 , the piping 21 a is exposed to the atmosphere. Due to this, it is necessary to take care not to contact the air present in the pipings 12 a and 21 a with the PSZ liquid.
The new PSZ container 20 is connected to the semiconductor manufacturing apparatus 10 (at a step S 90 ). At this time, all the valves 100 to 107 are closed. The valves 107 , 104 , and 103 are then opened in this order. Internal pressures of the piping 12 a and the branch tubes 103 and 104 are reduced to 10 −4 to 10 −5 Torr (at a step S 100 ).
After closing the valves 107 and 104 in this order, the valve 101 is opened. At this time, a piping including the piping 12 a from the valve 101 to the valve 103 and the branch tube 13 are in a low pressure state close to a vacuum. Therefore, the PSZ liquid in the PSZ container 20 promptly reaches close to the valve 104 (at a step S 110 ).
After closing the valve 103 , the valve 105 is opened. The PSZ liquid in the branch tube 13 is thereby mixed with the DBE (at a step S 120 ).
Next, the valve 106 is opened, the He gas is supplied into a crisscross piping partitioned by the valves 100 , 107 , 106 , and 104 , and an internal pressure of the crisscross piping is thereby returned to about 600 Torr (at a step S 130 ). After closing the valve 106 , the valve 100 is opened. At this time, the internal pressure of the crisscross piping partitioned by the valves 100 , 107 , 106 , and 104 is slightly lower than the atmospheric pressure. Due to this, a mixture liquid of the PSZ, and the DBE in the branch tube 13 is returned to at least the piping 12 a (at a step S 140 ). Since the DBE liquid is used as the solvent for the PSZ liquid in the PSZ container 20 , no problem occurs even if a small amount of the mixture liquid enters the PSZ container 20 . It is noted that He air bubbles are sometimes mixed into this mixture liquid of the PSZ and the DBE.
After closing the valve 103 , the valve 106 is opened (at a step S 150 ). The PSZ liquid in the PSZ container 20 can be thereby supplied to the discharge portion through the PSZ supply tube 12 . Since the initially supplied liquid is either the mixture liquid of the PSZ and the DBE or the mixture liquid containing the He air bubbles, the liquid is disposed of.
When the amount of the PSZ liquid in the PSZ container 20 is reduced, the detachment operation and the attachment operation for detaching and attaching the PSZ container 20 are repeatedly carried out according to the steps S 10 to S 150 . As described above, according to the first embodiment, the PSZ liquid can be supplied to the discharge portion without exposure to the air.
In recent years, following an increase in the aspect ratio of STI, it has been difficult to bury the silicon oxide film in the trench. The STI in the NAND flash memory is, in particular, high in aspect ration as compared with a logic circuit, and required to bury the silicon oxide film in a non-tapered trench.
When the present embodiment is applied, such defects as bumps, divots, and streaks can be prevented even at manufacturing steps of a NAND flash memory with a trench having an opening width of, for example, 90 to 70 nm. This can contribute to an improvement in the yield of semiconductor devices.
Furthermore, in the used PSZ container 20 , the residual liquid does not contact with the atmosphere and no hazardous and ignitable gas such as ammonium or silane is generated.
The valves 102 to 105 are preferably gate valves, e.g., block valves, without any excessive space at branch portions.
Second Embodiment
FIG. 6 is a schematic diagram of a semiconductor manufacturing apparatus 40 and a PSZ container 50 according to a second embodiment of the present invention. The semiconductor manufacturing apparatus 40 differs from the semiconductor manufacturing apparatus shown in FIG. 14 in that a tip end of a PSZ supply tube 42 is formed into a “J” shape. The other constituent elements of the semiconductor manufacturing apparatus 40 may be identical to those of the semiconductor manufacturing apparatus shown in FIG. 14 . The PSZ container 50 contains not only a PSZ liquid but also a protection liquid 52 that shuts off the PSZ liquid from the atmosphere. The other constituent elements of the PSZ container 50 may be identical to those of the PSZ container shown in FIG. 14 .
In the semiconductor manufacturing apparatus shown in FIG. 14 , an end of the PSZ supply tube is directed downward. Due to this, when the PSZ container is attached to the semiconductor manufacturing apparatus, air bubbles tend to be mixed into the PSZ supply tube. When the air bubbles are oxygen or water bubbles, they may disadvantageously cause the PSZ liquid to be solidified. When the air bubbles are inert gas bubbles such as helium bubbles, the PSZ liquid is disadvantageously difficult to discharge from the discharge portion.
In the semiconductor manufacturing apparatus 40 according to the second embodiment, by contrast, an end of the PSZ supply tube 42 is directed upward. This can make it more difficult to mix air bubbles into the PSZ supply tube 42 when the PSZ container 50 is attached to the semiconductor manufacturing apparatus 40 . It is noted that the PSZ container 50 is attached to the semiconductor manufacturing apparatus 40 after a valve 501 is closed. By doing so, even while the PSZ container 50 is being attached to the apparatus 40 , the PSZ liquid remains at the tip end of the PSZ supply tube 42 .
FIGS. 7 and 8 are cross-sectional views of the PSZ container 50 according to the second embodiment. FIG. 7 shows the PSZ container 50 when being attached to the semiconductor manufacturing apparatus 40 , and FIG. 8 shows the PSZ container 50 when being detached from the semiconductor manufacturing apparatus 40 .
Desirable conditions for the protection liquid 52 that covers the PSZ in the PSZ container 50 are: no reaction with the PSZ liquid (condition 1), lower specific gravity than that of the PSZ liquid and no mixture with the PSZ liquid (condition 2), higher wettability with an inner wall of the PSZ container 50 than that of the PSZ liquid (condition 3), and non-inclusion of carbon (C) in impurities (condition 4). The conditions 1 and 2 are necessary conditions. Examples of a material that satisfies the conditions 1 and 2 include straight-chain-hydrocarbon and cyclic cyclohexane.
When the protection liquid 52 satisfies the conditions 1 and 2, the protection liquid 52 can cover a liquid level of the PSZ liquid in the PSZ container 50 . When the protection liquid 52 satisfies the conditions 3, the protection liquid 52 can cover the inner wall of the PSZ container 50 and the residual PSZ liquid tends to reside on a bottom of the PSZ container 50 as shown in FIG. 8 . It is thereby possible to ensure that the PSZ liquid is shut off from the atmosphere. The condition 4 is intended to eliminate carbon that may have a conductive type of either p or n as much as possible.
In the second embodiment, when the new PSZ container 50 is attached to the semiconductor manufacturing apparatus 40 , the air enters the PSZ container 50 . However, since the protection liquid 52 covers the surface of the PSZ, it is possible to prevent contact of the PSZ with the air. Further, when the used PSZ container 50 is detached from the semiconductor manufacturing apparatus 40 , it is possible to prevent the contact of the PSZ liquid with the air since the protection film 52 covers the surface of the PSZ. In addition, while the PSZ liquid is being supplied, the liquid level of the PSZ is lowered. However, since the protection liquid 52 has a favorable wettability, the protection liquid 52 even covers the surface of the PSZ adhering to the inner wall of the PSZ container 50 .
As shown in FIG. 8 , even if the PSZ container 50 is temporarily held at a different location, the air in the PSZ container 50 does not contact with the PSZ liquid and no ammonium or silane is, therefore, generated in the PSZ container 50 .
When the PSZ container 50 is attached to the semiconductor manufacturing apparatus 40 , the protection liquid 52 enters the PSZ supply tube 42 . However, since the specific gravity of the protection liquid 52 is lower than that of the PSZ liquid and the tip end of the PSZ supply tube 42 is J-shaped and directed upward, the protection liquid 52 surfaces on the tip end of the PSZ supply tube 42 . Therefore, the protection liquid 52 is not supplied to a discharge portion 44 .
In the second embodiment, the protection liquid 52 may be also used in a waste liquid container provided below a spin coater. If so, a waste liquid is thereby out of contact with the air. The second embodiment is, therefore, more preferable in environmental and safety aspects.
The semiconductor manufacturing apparatus 40 and the PSZ container 50 according to the second embodiment are relatively inexpensive and can be realized by simple changes in designs of the conventional semiconductor manufacturing apparatus and the conventional PSZ container, respectively.
Third Embodiment
FIG. 9 is a cross-sectional view of a semiconductor manufacturing apparatus 40 and a PSZ container 60 according to a third embodiment of the present invention. The PSZ container 60 according to the third embodiment includes a narrow opening portion 61 and a concave portion 63 that can accept a J-shaped tip end E of a PSZ supply tube 42 . The semiconductor manufacturing apparatus 40 is identical to the semiconductor manufacturing apparatus 40 according to the second embodiment.
According to the third embodiment, since the opening portion 61 is narrow, an area by which a PSZ liquid contacts with the air can be made small. In addition, by inserting the tip end E of the PSZ supply tube 42 into the concave portion 63 , the PSZ liquid can be made most use of to the end.
The semiconductor manufacturing apparatus 40 and the PSZ container 60 according to the third embodiment are also relatively inexpensive and can be realized by simple changes in designs of the conventional semiconductor manufacturing apparatus and the conventional PSZ container, respectively.
Fourth Embodiment
FIG. 10 is a schematic diagram of a semiconductor manufacturing apparatus 70 and a PSZ container 80 according to a fourth embodiment of the present invention. The semiconductor manufacturing apparatus 70 differs from the semiconductor manufacturing apparatus shown in FIG. 14 in that the apparatus 70 includes a liquid bath 73 that contains a DBE liquid. A PSZ supply tube 72 and a He supply tube 71 are inserted into the liquid bath 73 , and a tip end of the PSZ supply tube 72 and that of the He supply tube 71 are arranged below a liquid level of the DBE liquid.
Female connectors 75 are provided at tip ends of the He supply tube 71 and the PSZ supply tube 72 , respectively, and corresponding male connectors 85 having a valve are provided at the PSZ container 80 . By one-touch connection between the female connectors 75 and the corresponding male connectors 85 , the PSZ container 80 is connected to the He supply tube 71 and the PSZ supply tube 72 .
Attachment and detachment of the PSZ container 80 to and from the semiconductor manufacturing apparatus 70 are executed in the DBE liquid. Therefore, the air does not contact with the PSZ liquid. Since the DBE liquid is contained in the PSZ container 80 as a solvent for the PSZ liquid, no problem occurs even if a small amount of the DBE liquid is mixed into the PSZ container 80 .
Furthermore, the semiconductor manufacturing apparatus and the PSZ container 80 according to the fourth embodiment are also relatively inexpensive, and can be realized by simple changes in designs of the conventional semiconductor manufacturing apparatus and the conventional PSZ container, respectively.
A material for the PSZ container 80 may be a flexible material such as polyethylene in place of glass. When the PSZ container 80 consists of the flexible material and the air is mixed into the male connectors 85 , the air can be easily removed by an operator's compressing the PSZ container 80 by an operator's hand after the PSZ container 80 is dipped into the liquid bath 73 . It is noted that the DBE liquid does not flow backward into the PSZ container 80 since the respective male connectors 85 include valves.
Fifth Embodiment
FIG. 11 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container 80 according to a fifth embodiment of the present invention. The fifth embodiment differs from the fourth embodiment in a shape of a liquid bath. 91 . Other constituent elements in the fifth embodiment may be identical to those in the fourth embodiment. A region R 1 of the liquid bath 91 , into which a tip end of a He supply tube 71 and that of a PSZ supply tube 72 are inserted, is filled with a DBE liquid. Therefore, a PSZ liquid does not contact with not only the air but also a gas such as He.
A region R 2 of the liquid bath 91 has an upper opening portion. The PSZ container 80 can be attached to the He supply tube 71 and the PSZ supply tube 72 by operator's inserting the PSZ container 80 into the liquid bath 91 from this opening portion. The liquid bath 91 includes a porthole 93 . The operator can, therefore, connect the PSZ container 80 to the He supply tube 71 and the PSZ supply tube 72 while viewing the liquid bath 91 from the porthole 93 .
Sixth Embodiment
FIG. 12 is a schematic diagram of a semiconductor manufacturing apparatus and a PSZ container 81 according to a sixth embodiment of the present invention. In the fourth and the fifth embodiments, the attachment and detachment of the PSZ container are executed in the DBE liquid. In the sixth embodiment, the attachment and detachment of the PSZ container are executed in a He gas atmosphere.
An upper portion of a region R 1 of the PSZ container 81 is filled with the He gas. A liquid bath 92 includes a supply port 350 for supplying the He gas and an exhaust port 351 for exhausting the air or the like mixed into the liquid bath 92 together with the He gas. By so constituting, even if the gas other than the He gas is mixed into the PSZ container 81 while the PSZ container 81 is being replaced with another container 81 , the gas can be exhausted.
In the semiconductor manufacturing apparatus, a connector C 3 a is connected to a PSZ supply tube 312 through a valve 310 , and also connected to a balloon 360 through a valve 309 . A connector C 4 a is connected to a He supply tube 316 . The balloon 360 consists of, for example, a rubber having a high elasticity and a low reaction with the PSZ liquid. The balloon 360 is filled with the PSZ liquid in advance. A valve 307 is provided at the He supply tube 316 , and an exhaust tube 317 is connected between the valve 307 and the connector C 4 a through a valve 308 .
A PSZ outlet tube 321 and a He inlet tube 322 of the PSZ container 81 include two valves 304 and 306 and two valves 303 and 305 , respectively. Connectors C 3 b and C 4 b of the PSZ outlet tube 321 and the He inlet tube 322 are formed to be directed downward. The PSZ outlet tube 321 from the PSZ container 81 to the valve 304 is filled with the PSZ liquid in advance, and a piping between the valves 303 and 305 and a piping between the valves 304 and 306 are each filled with a pressurized He gas in advance.
An operation for attaching the PSZ container 81 to the semiconductor manufacturing apparatus will be described. The PSZ container 81 is moved into the liquid bath 92 so that the connectors C 3 b and C 4 b are provided in the He gas atmosphere in the region R 1 (at a step S 300 ). At this time, the air may possibly remain in a piping from the valve 306 to the connector C 3 b and a piping from the valve 305 to the connector C 4 b . Considering this, by opening the valves 305 and 306 , the pressurized He gas is ejected (at a step S 310 ). By doing so, the air is discharged to the outside of the connectors C 3 b and C 4 b . Since the air is higher in specific gravity than the He gas, the air is moved to a liquid level of the DBE liquid and exhausted from the exhaust port 351 .
Thereafter, the connector C 3 a is connected to the connector C 3 b and the connector C 4 a is connected to the connector C 4 b (at a step S 320 ). At this time, the valves 307 , 308 , 309 , and 310 are closed. The valves 309 and 308 are then opened in this order (at a step S 330 ). The balloon 360 filled with the PSZ liquid is thereby contracted and the He gas residing in a piping from the valve 304 to the valve 309 is returned into the PSZ container 81 .
After closing the valves 308 and 309 in this order, the valves 307 and 310 are opened in this order (at a step S 340 ). The He supply tube 316 thereby supplies the He gas into the PSZ container 81 and the PSZ liquid is supplied to a discharge portion through the PSZ supply tube 312 .
When the PSZ container 81 is to be detached from the semiconductor manufacturing apparatus, then the valve 310 is closed, and the valve 309 is closed after the balloon 360 is filled with the PSZ liquid to some degree. After closing all the valves 303 to 308 , the PSZ container 81 is detached.
According to the fifth embodiment, the PSZ container 81 can be replaced by a new PSZ container 81 in an environment shut off from the air while preventing mixture of the He gas.
As described above, in the embodiments, it is preferable that the PSZ liquid is discharged onto a dummy wafer before being coated on a desired wafer. This is because the DBE liquid may possibly enter the PSZ container 81 during the replacement.
The embodiments may be executed in combination. For example, the PSZ container 50 shown in FIGS. 7 and 8 can be applied to any one of the first and the third to the fifth embodiments.
FIG. 13 is a table that shows effects of the respective embodiments. In the table of FIG. 13 , the numbers of particles generated when the PSZ liquid is coated on the semiconductor substrate at the SOG step are shown. In the conventional technique shown in FIG. 14 , many particles having respective particle diameters are generated. In the first to the sixth embodiments, particles having particle diameters of 0.2 to 1.0 μm are hardly generated. According to the embodiments of the present invention, therefore, it is expected to improve the yield of semiconductor devices.
In the respective embodiments of the present invention, the coating liquid is not limited to the PSZ liquid but may be any coating liquid for forming a silica-containing film or the like.
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A semiconductor manufacturing apparatus comprises a discharge portion discharging a coating liquid onto a substrate; a gas supply tube supplying an inert gas into a liquid container that contains the coating liquid, and pressurizing an interior of the liquid container; a coating liquid supply tube airtightly supplying the coating liquid from the liquid container to the discharge portion using pressurization from the gas supply tube; a first connecting portion capable of attaching and detaching the liquid container to and from the coating liquid supply tube; a second connecting portion capable of attaching and detaching the liquid container to and from the gas supply tube; and a solvent supply tube supplying a solvent, which can dissolve the coating liquid, to the first connecting portion.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/627,628, filed Nov. 30, 2009, the content of which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present disclosure relates generally to knowledge management and, in particular, to methods, systems, and computer program products for implementing an integrated knowledge management system.
[0003] In recent years, many traditional telecommunication companies have transformed themselves from network transport providers to rich information and entertainment service providers. To facilitate this transition, these companies are building new network infrastructures. However, to fully support rich information and entertainment services, system infrastructures that support these diversified services (e.g., wireless and wireline), as well as applications (e.g., IP telephone, data, and IP video applications) need to be established and/or enhanced.
[0004] One of such supporting infrastructures is in the knowledge management domain of the service provider's customer care organization. For example, in the telecommunications industry, a customer care organization provides assistance to its customers and/or prospective customers, such as provisioning telecommunications services, providing information concerning service offerings, product offerings, account information, and technical support, to name a few.
[0005] Knowledge management has been defined as a process for gathering and organizing information for subsequent use. An efficient way to supply relevant information to a knowledge consumer may enable the service provider to reduce overall support costs. Some service providers utilize industry standard models in developing business and operations support systems (BSS/OSS), e.g., enhanced Telecommunications Operations Map (eTOM) and Telecommunications Management Network (TMN). However, what continues to be lacking from these models is a cohesive knowledge management reference framework that addresses the collective needs of knowledge consumers across varying platforms by supporting knowledge consumption for varying access channels utilized by end consumers, as well as support agents and field technicians of the service provider.
[0006] Using telecommunications services as an example, knowledge consumption needs are typically segmented according to business organizations (e.g., wireline services versus wireless services). Requirements for implementing an end-to-end knowledge management system are oftentimes developed by a respective business owner that does not leverage existing knowledge bases and is known to employ specific login restrictions to limit other business organizations in consuming the domain knowledge. For example, in the wireline group, multiple knowledge management systems may be developed to support self service channels and assisted care channels, while in the wireless group a different set of knowledge management systems may be implemented to support these corresponding channels.
[0007] Furthermore, some service providers implement different knowledge management systems based on product lines. For example, in some instances when a new product organization is established, system designers may not have a clear roadmap to follow and thus may end up developing duplicate sets of information into a new knowledge management system. Many service providers today are known to use a traditional content creation environment that utilizes dedicated Methods and Procedures (M&P) writers to create content in a formal process. Informal content, such as customer relationship management (CRM) notes, Web 2.0 blogs, wikis, and communities are typically ignored. Additionally, there is no easy way to integrate diagnostic, testing and CRM systems with the knowledge management systems. Thus, it becomes difficult to present relevant content to the users in the right context.
[0008] What is needed, therefore, is a way to provide a common, shared knowledge management infrastructure accessible via varying communications channels to a knowledge consumption base.
BRIEF SUMMARY OF THE INVENTION
[0009] Exemplary embodiments of the invention include methods, systems, and computer program products for implementing a knowledge management system. A method includes receiving, at a computer processor that implements the knowledge management service, a request for information from a requesting entity. The method also includes generating, by the computer processor, a search query to search for the information across multiple compartmentalized data sources that are non-local to the automated knowledge management service, searching the multiple compartmentalized data sources for the information, and retrieving the information from one of the multiple compartmentalized data sources. The method further includes determining an access channel for transmitting the information, formatting the information to correspond to a format recognized by the access channel, and transmitting formatted information to the requesting entity.
[0010] Other systems, methods, and computer program products according to embodiments will be or become apparent to one with skill in the art upon review of the following drawings and detailed description. It is intended that all such additional systems, methods, and computer program products be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0012] FIG. 1 is a block diagram depicting a system upon which an integrated knowledge management system may be implemented in exemplary embodiments;
[0013] FIG. 2 is a diagram depicting an integrated knowledge management system architecture in exemplary embodiments;
[0014] FIG. 3 is a diagram of a detailed portion of the integrated knowledge management system of FIG. 2 in exemplary embodiments;
[0015] FIG. 4 is a diagram of another detailed portion of the integrated knowledge management system of FIG. 2 in exemplary embodiments; and
[0016] FIG. 5 is a flow diagram describing a process for implementing the integrated knowledge management system in exemplary embodiments.
[0017] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0018] An integrated knowledge management system in support of a customer care domain of a product/service provider is described in accordance with exemplary embodiments. The integrated knowledge management system provides a knowledge management reference framework to support information consumption in response to requests for information originating from a variety of access channels (e.g., home portals, registration portals, interactive voice response (IVR) portals, assisted care portals, and technicians operating in remote locations, to name a few). In an exemplary embodiment, the knowledge management system integrates self-help and agent help together by sharing a common knowledge management infrastructure and key information/content.
[0019] In an exemplary embodiment, the integrated knowledge management system is implemented by a telecommunications service provider and supports complex services, such as voice, data, and video services, as well as related applications. In addition, the integrated knowledge management system provides cohesive support to address the knowledge needs of both end users (e.g., consumers of the services) and agents of the service provider.
[0020] Turning now to FIG. 1 , an exemplary system 100 for implementing the integrated knowledge management system will now be described. The system 100 of FIG. 1 includes a host system 102 in communication with user systems 104 and one or more external knowledge sources 112 over one or more network(s) 106 . In an exemplary embodiment, the host system 102 represents a telecommunications service provider that provides network transport and communications services to its customer base.
[0021] Host system 102 may be implemented using one or more servers operating in response to a computer program stored in a storage medium accessible by the server(s). The host system 102 may operate as a network server (e.g., a web server) to communicate with the user systems 104 and external knowledge sources 112 . The host system 102 handles sending and receiving information to and from the user systems 104 and external knowledge sources 112 and can perform associated tasks. The host system 102 executes one or more applications in support of the telecommunications services provided to its customers. Such applications may include, e.g., a customer care application (e.g., one of care applications 210 and/or IPTV care applications 218 shown in FIG. 2 ) that provides product/service information, technical support, customer account, and provisioning information and services (not shown). In an exemplary embodiment, the host system 102 also executes one or more applications for facilitating the integrated knowledge management system. These one or more applications are collectively referred to herein as an integrated knowledge management system application 110 . Various supporting functions may also be implemented by the host system 102 as will be described further in FIG. 2 .
[0022] In exemplary embodiments, host system 102 is in communication with a storage device 108 . Storage device 108 may be implemented using memory contained in the host system 102 or it may be a separate physical or virtual or logical device. As shown in FIG. 1 , the storage device 108 is in direct communication with the host system 102 (via, e.g., cabling). However, other network implementations may be utilized. For example, storage device 108 may be logically addressable as a consolidated data source across a distributed environment that includes one or more networks 108 . Information stored in the storage device 108 may be retrieved and manipulated via the host system 102 . Storage device 108 is referred to herein as an internal knowledge source and stores a care knowledge base, as described further herein. Internal knowledge source is also referred to herein as “local information source.” While the knowledge from the information source need not be physically local to the host system 102 , it will be understood that “local information source” refers to information sources that are either proprietary systems or are otherwise non-public sources of information.
[0023] As indicated above, the host system 102 is also in communication with external knowledge sources 112 . The external knowledge sources 112 are also referred to herein as “non-local information sources” to clearly differentiate from “internal,” or “local” information sources. These external knowledge sources 112 may include independent sources of information stored in separately located data repositories that are accessed by the integrated knowledge management system to enhance the knowledge management base serviced by the integrated knowledge management system. Examples of external sources of knowledge are described further herein. External knowledge sources 112 may be may be implemented using memory contained in physical or virtual or logical devices that are distinct from the storage device 108 . For example, external knowledge sources 112 may each be logically addressable as a consolidated data source across a distributed environment that includes one or more networks 106 . Information stored in the external knowledge sources 112 may be retrieved and manipulated via the host system 102 .
[0024] User systems 104 are operated by users at one or more geographic locations who may be agents of the service provider of host system 102 (administrative entities, customer service representatives, information technology specialists, and field technicians, to name a few). User systems 104 may also be operated by users who are customers or prospective customers of the service provider of host system 102 . Operators of user systems 104 request and receive information provided via the integrated knowledge management system. In exemplary embodiments, the user systems 104 access the integrated knowledge management system via various types of access channels that include, e.g., portals configured for particular entities, services, products, or communications means. These access channels are described further herein.
[0025] As shown in FIG. 1 , non-limiting examples of the types of user systems 104 that may receive services via the integrated knowledge management system include a wireless/wireline laptop computer, a mobile telephone, a general-purpose desktop computer, a POTs-enabled telephone, and an IP-enabled television and set top box.
[0026] One or more of the user systems 104 may include a computer processor and an interactive network component for communicating with the host system 102 . In addition, one or more of the user systems 104 may include memory for storing at least a portion of knowledge bases offered by the integrated knowledge management system. While only five user systems 104 are shown in the system 100 of FIG. 1 , it will be understood that many user systems may be implemented in order to realize the advantages of the integrated knowledge management system.
[0027] Network(s) 106 may include any type of known networks including, but not limited to, a wide area network (WAN), a local area network (LAN), a global network (e.g. Internet), a virtual private network (VPN), and an intranet. The network(s) 106 may be implemented using wireless networks (WiFi, satellite, cellular, etc.) or any kind of physical network implementation known in the art. A user system 104 may be coupled to the host system 102 through multiple networks (e.g., intranet and Internet) so that not all user systems 104 are coupled to the host system 102 through the same network.
[0028] FIG. 2 depicts a block diagram of the integrated knowledge management system infrastructure with supporting functions and components. FIG. 3 depicts a detailed portion of the integrated knowledge management system infrastructure of FIG. 2 . FIG. 4 depicts another detailed portion of the integrated knowledge management system infrastructure of FIG. 2 . Turning now to FIGS. 2-4 , the integrated knowledge management system infrastructure will now be described in accordance with exemplary embodiments. In an exemplary embodiment, the integrated knowledge management system includes three horizontal layers, and the three layers are configured to communicate amongst one another via one or more Web Services application programming interfaces (APIs). In an exemplary embodiment, the integrated knowledge management system is configured to provide APIs/portlets for enabling services to external domains (e.g., portals for knowledge access channels 202 , data warehouses 214 , care applications 210 , IPTV care applications 218 , etc. These APIs/portlets are also referred to herein as “access interfaces.” In cooperation with the three horizontal layers, the integrated knowledge management system framework includes knowledge authoring, workflow and configuration supporting functions, as well as internal knowledge databases.
[0029] In an exemplary embodiment, a first of the three layers is referred to herein as a knowledge service domain 204 . The knowledge service domain 204 supports an intelligent search engine and a content re-presentation engine, collectively referred to herein as knowledge engine or query processor 304 . The intelligent search engine provides the access interfaces to support multiple access channels (e.g., knowledge access channels 202 ) and provides federated search capabilities to retrieve information from multiple content sources (in lieu of requiring a distinct login procedure to each individual knowledge management system). The intelligent search engine may include a processor to support application-to-application searches for knowledge management searches on behalf of care applications 210 . For example, when a user types keywords in a search box provided by the API, the intelligent search engine provides suggested categories for the user to select. In addition, the intelligent search engine may provide auto-search capability (e.g., automatically searching for answers before the user finishes typing the search request). Further, the intelligent search engine may support ‘concept’ or ‘intent’ based search capability to provide the requestor the most relevant answers.
[0030] The content re-presentation engine of the knowledge service domain 204 provides flexible content re-presentation to the information requestor (e.g., a request for a different view, different language, adaptive formats based on the user device type—i.e., cellular telephone, personal computer, POTS-enabled telephone, personal digital assistant, etc.—and/or the requestor's role classification).
[0031] The second of the three layers is referred to herein as a pre-processing and retrieval domain 206 . The second layer includes various modules including a discovering module 402 , a crawling module 404 , a retrieving module 406 , an indexing module 408 , a tagging module 410 , and a converting module 412 . The discovering module 402 discovers new knowledge from other knowledge sources (i.e., checking indices of other data sources or asking other data sources to notify the discovery module of new knowledge). The discovering domain communicates with a centralized data store which stores, e.g., customer repair records, such as trouble cases, test results, trouble histories, etc. The central data store may be housed in the care knowledge base shown in FIG. 3 .
[0032] The crawling module 404 crawls external knowledge management databases to learn of new knowledge. The retrieving module 406 retrieves content from various external sources (e.g., knowledge sources 208 ). The indexing module 408 indexes the contents of the internal knowledge bases (e.g., care knowledge base) and the external knowledge bases (e.g., knowledge sources 208 ). The tagging module 410 tags the contents (e.g., information derived from either internal or external sources). The converting module 412 associates the external knowledge with the integrated knowledge management system, e.g., by converting the format of the external knowledge to one that is consistent with the internal knowledge store (i.e., care knowledge base). When the intelligent search engine (i.e., knowledge engine 304 ) performs a federated search, the converting module 412 may convert the search results to the format understood by the integrated knowledge management system platform. In addition, the converting module 412 may later convert the results to a presentation format upon a request by the knowledge engine 304 .
[0033] In an exemplary embodiment, the third layer of the integrated knowledge management system includes external content sources and one IPTV content source 208 . As shown in FIG. 4 , by way of non-limiting example, the four external content sources include enterprise care content sources 415 , internal Web 2.0 collaboration sources 425 , other public sources 435 , rules repository 445 , and other enterprise knowledge management domains 460 . The enterprise care content sources 415 may include existing knowledge management content management system (CMS) content, which in turn may include customer relationship management (CRM) notes 426 , self-service information 420 , assisted care help content and M&Ps 422 , customer contact history logs 424 , as well as other similar types of information.
[0034] The internal Web 2.0 collaboration sources 425 may include blogs 430 , forums, network communities 434 , wikis 432 , or other collaborative content sources. Other public sources 435 include knowledge sources outside of the service provider's business domain (e.g., vendor web sites 446 , customer premise equipment (CPE) manufacturers' web sites 440 , standards body web sites 444 , industry forums 442 , public collaborative content sources, etc.). The rules repository 445 may include rules determined as critical knowledge sources (e.g., care application rule-set 456 —e.g., diagnostic/testing rules, IVR rule-set, self-service rule-set 452 , and assisted care rule-set 454 ). All rules may have an English language equivalent content mapping, which provides tier 1 and tier 2 agent educational sources, as well as helps trouble shoot faulty rules that are known to cause mishandling of customer reported issues.
[0035] Other enterprise knowledge domains 460 may be integrated with the integrated knowledge management system for enabling access to content from sales, marketing, ordering, and billing domains, to name a few.
[0036] When a user of user devices 104 (e.g., IPTV) browses through care content (e.g., care infomercials), this content may be considered part of the knowledge management domain. Many of these IPTV care video clip contents may be viewed by web channel as well. Thus, the integrated knowledge management system provides integration between IPTV care content and the integrated knowledge management system platform.
[0037] As indicated above, the knowledge service domain 204 supports an intelligent search engine and a content re-presentation engine (collectively, knowledge engine 304 ). Various supporting functions may be enabled via the knowledge service domain 204 . As shown in FIG. 3 , e.g., configuration & authoring, auto-reply (referred to herein as “communications”) 306 , analytical reports 310 , customer experience tracking 308 , and a knowledge management graphical user interface (GUI) 220 .
[0038] Configuration and authoring capabilities are configured for internal knowledge management repositories (e.g., care knowledge base). The configuration and authoring also enables knowledge management administrators (e.g., through one of user systems 104 ) to create views/profiles/rules 324 for a business organization via the knowledge management GUI 220 . Further, the configuration and authorizing also enables an administrator to create user role classifications 322 . These classifications are enabled through logic provided via authoring 326 , KM configuration 328 , and role configuration 330 functions of the configuration and authoring component. User role classifications 322 may differentiate among the types of users who access the integrated knowledge management system. For example, a user who is technologically educated in the products/services offered by the service provider (e.g., a field representative) may be classified in a first role, whereas another user who is a customer/end user of the products/services offered by the service provider may be classified in a second role. By differentiating system users by classification, the integrated knowledge management system, via the configuration and authoring function, may provide customized information to requests for information based upon a user's knowledge/skills. A view refers to the format in which information responsive to user requests are provided (e.g., a view for an IPTV end user may be configured to include familiar control options common to a remote control-operated system).
[0039] The auto-reply function 306 provides the ability to intercept messages (e.g., emails) from user systems 104 and present choices (e.g., the type of information the user prefers to allow the knowledge management to retrieve before the user sends the message). The auto-reply function 306 further acts as a virtual agent to conduct conversations after receiving a message (e.g., email or SMS queries). This function involves automatically researching the query text and sending the answer back to the requestor.
[0040] The analytical reporting function 310 keeps track of comments, ratings of content, and generates reports to be used by content authors or administrators to improve the content itself or the presentation format of the content. The analytical reporting function also reads user comments/ratings, and applies tags to this information (e.g., via the tagging module 410 ) for analysis (e.g., determining whether the comments/ratings are useful). The filtered comments/ratings may be stored in an informal data store (e.g., informal content knowledge base 318 ).
[0041] The customer experience tracking function 308 may be used to track all customer experience indicators relating to knowledge management content and its supporting functions. Some of the data may be fed to the analytical reporting module 310 to generate internal knowledge management reports. Some of the data may be fed to an external key performance indicator (KPI) system 212 to generate business intelligence summary reports 216 .
[0042] The knowledge management GUI 220 provides an internal portal to support content authorizing and system administration and configuration functions.
[0043] In addition to the above-referenced supporting functions of the knowledge service domain 204 , the care knowledge base is also configured to support the knowledge service domain. The care knowledge base includes two components: knowledge repositories 316 and supporting repositories 320 . Knowledge repositories 316 support local, regional, customized, and temporary databases. The knowledge repositories 316 further provide support to create a temporary, regionalized, special-purposed knowledge base (e.g., a temporary center to support a disaster region, an Olympic event in a local city, etc.). The knowledge repositories 316 also support the use of mini knowledge bases to prototype new businesses and user requirements. The knowledge repositories 316 may also support informal content knowledge base 318 , which houses informal content (e.g., emails, notes, quality information, blog/forum information, etc.).
[0044] Supporting repositories include content cache repositories 320 , knowledge management meta data 312 , index data store 314 , tagging, user role classification definition data 322 , and rule/profile/view definition data 324 .
[0045] Content cache repositories 320 store the most frequently used content, in addition to static content that is determined to improve system performance. Meta data 312 may be created by knowledge management systems or may be defined by authors (e.g., including titles, abstracts, location of data, applications, versions, media types, information sensitivity, etc). Metadata 312 may be searched via the search function of the knowledge engine 304 before it searches for content.
[0046] The index data store 314 may house the location of content, categories of content, and/or similar characteristics. Tagging store (not shown) may index entire content and/or index segments of the content. The user role classification definitions data 322 may be stored by product, level of competency, or other criteria defined via the knowledge management GUI. As indicated above, the Rule/Profile/View definitions data 324 may be used by an administrator to create distinct views based on the needs of different organizations or portal requests. An administrator may create profiles for a group, an organization, a category of document, etc. (e.g., one of such rules may be to exclude all DSL modem type information for a particular product from being indexed due to retirement of the modem).
[0047] In an exemplary embodiment, the integrated knowledge management system provides external interface domains for enabling a single knowledge management consumption point for all channels and applications in order to provide internally-owned or externally-owned content to requesting entities.
[0048] As shown in FIG. 2 , external domains include access portals 202 , care applications 210 / 218 , and KPI applications 212 . The access portals 202 allow external channels to consume information stored either internally or externally to the knowledge management repository. Non-limiting examples of access portals include a home knowledge management portal, a self-care portal, an IVR portal, a registration portal, messaging response system portal, and a single agent portal (not shown).
[0049] The home knowledge management portal provides a home knowledge management repository locally resident with the customer premise equipment (CPE). The home knowledge management portal may receive a periodic feed including a subset of knowledge management data that allows the customer to access the information even when the CPE is offline. The self-care portal is configured to enable access to knowledge through a help feature. The help feature may provide knowledge to a user through a guided flow in order to solve problems or reconfigure corrupted profiles (or reset a password), etc. Additionally, when a customer is using an IPTV channel (e.g., an emulated Web channel) to access care knowledge management information, this information may be adjusted to the format of the IPTV channel (e.g., remote control click functions) and then supplied to the customer.
[0050] The IVR portal may provide guided flow access to knowledge (e.g., to resolve issues or reset a password). The knowledge may be indirectly accessed to obtain knowledge information (e.g., knowledge may be requested via the IVR channel but routed through a different access channel, such as email).
[0051] The registration portal may be utilized when a user initiates a registration process and encounters an error condition. The error handling processes configured for the error condition interface with the integrated knowledge management system to determine resolutions for the condition.
[0052] Messaging response systems may include a knowledge management auto-reply module to intercept a query message from an email server, SMS server, etc., and provide a relevant answer (or send links or documents) back to the requestor via the query processor module.
[0053] The single agent portal provides access for assisted care agents using a ‘search’ function that directly or indirectly invokes the integrated knowledge management system knowledge base via a care application's user interface (e.g., CRM, diagnostic, testing systems, etc.). The assisted care agents are not required to logon to any backend knowledge management system or even to know the existence of any external knowledge management systems.
[0054] The external interface domain for the customer care applications 210 supports a pre-defined format to craft a trouble care flow. The knowledge management output may become an input to a care system to be converted into a step-by-step flow for providing guided help. When a care application 210 has partially completed execution of particular trouble shooting functions, and needs assistance to continue operations, it may access knowledge management resources via the external interface domain for this assistance in real time.
[0055] The external interface domain for the KPI applications 212 provide key performance raw data or pre-generated reports to the external KPI applications 212 , which integrate knowledge management KPIs with other KPI data stored in a data warehouse (e.g., 214 ) to generate enterprise-wide analytical reports. Optionally, the integrated knowledge management system may retrieve business intelligence reports 216 on behalf of a requestor in the care domain.
[0056] Turning now to FIG. 5 , a process for implementing the integrated knowledge management system will now be described. At step 502 , an access interface is configured for communications between each of corresponding one or more external domains and a knowledge management system via the integrated knowledge management application 110 . At step 504 , an access interface is configured for communications between corresponding one or more access channels and the knowledge management system via the integrated knowledge management application 110 . In response to a request for information via the knowledge engine 304 from at least one of the access interfaces at step 506 , the knowledge engine 304 searches one or more knowledge bases (e.g., care knowledge base, knowledge sources 208 ) at step 508 , and provides a response to the request for information as a result of the search at step 510 . As indicated above, the integrated knowledge management system utilizes components of the domains 204 , 206 , and 208 to process information from the request, search the appropriate content sources, retrieve relevant responsive information, and re-format the responsive information according to criteria including the capabilities/characteristics of the requesting source, as well as authoring/configuration/classifications provided by the system. A search query relating to the request may first be created and implemented for internal knowledge sources, and if the search results are not satisfactory or otherwise not fully responsive to the request, a second search query may be created and implemented for external knowledge sources, thereby expanding the knowledge base.
[0057] As described above, by providing the integrated knowledge management system infrastructure, user devices that span varying types of access channels, as well as relevant business organizations, may benefit from a cohesive information source, thereby providing improved customer experiences upon encountering any issues with products/services, operational efficiencies, reducing operational costs, and increasing customer retention rates.
[0058] As described above, embodiments can be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. In exemplary embodiments, the invention is embodied in computer program code executed by one or more network elements. Embodiments include computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. Embodiments include computer program code, for example, whether stored in a storage medium, loaded into or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
[0059] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
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Embodiments provide an automated knowledge management service. A method includes receiving, at a computer processor that implements the knowledge management service, a request for information from a requesting entity. The method also includes generating, by the computer processor, a search query to search for the information across multiple compartmentalized data sources that are non-local to the automated knowledge management service, searching the multiple compartmentalized data sources for the information, and retrieving the information from one of the multiple compartmentalized data sources. The method further includes determining an access channel for transmitting the information, formatting the information to correspond to a format recognized by the access channel, and transmitting formatted information to the requesting entity.
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BACKGROUND OF THE INVENTION
The invention concerns a fuel composition comprising at least 75% by volume C4 to C14 isoalkanes.
GB 465,459 discloses a fuel composition that is comprised exclusively of alkanes. Fuels that are comprised primarily of alkanes are used, for example, in forestry. Regular gasoline contains, in addition to alkanes, considerable proportions of aromatic compounds, oxygenates, olefins, and naphthenes. Further components can be contained also. Fuels that are comprised primarily or completely of alkanes cause in operation in an internal combustion engine a deterioration in the acceleration behavior in comparison to regular gasoline. Disadvantages are observed also for decelerating from is full load, the so-called “rich come down”.
It is an object of the invention to provide a fuel composition of the aforementioned kind with which an excellent acceleration behavior and an excellent rich come down behavior of an internal combustion engine is achieved.
SUMMARY OF THE INVENTION
This object is solved by a fuel composition that is characterized in that, when determining the distillation characteristics according to DIN EN ISO 3405, at least 25% by volume of the fuel composition evaporate at temperatures (T) above 110° C.
Known fuel compositions with a high alkane contents have a boiling point curve that deviates from that of regular gasoline. Starting at approximately 100° C., the boiling point curve of known fuel compositions with high alkane proportion extends very flat because these fuels usually have an isooctane proportion of more than 70%. On the other hand, the boiling point curve of regular gasoline continues to ascend above 100° C. Below 100° C. the boiling point curve of fuels with high alkane proportion is however steeper than the boiling point curve of regular gasoline.
It has been found that with a suitable adjustment of the boiling point curve of fuel compositions with high alkane proportions to the boiling point curve of regular gasoline the operating behavior of an internal combustion engine operated with this fuel composition can be significantly improved.
In order to achieve in particular for deceleration of the internal combustion engine from full load, i.e., for rich come down, an improved operating behavior, it is provided that at least 25% by volume of the fuel composition evaporate at temperatures above 110° C. In this connection, the distillation characteristics according to DIN EN ISO 3405 is determined. The distillation characteristics should reach the indicated value within the limits of the measuring precision that is achievable with the method set forth. This temperature that is higher in comparison to known fuel compositions with high alkane proportions is closer to the temperature for regular gasoline. In this way, an improved operating behavior can be achieved.
In particular, at least 30% by volume of the fuel composition evaporate at temperatures above 110° C. All parameters in regard to evaporation of the fuel composition relate in this connection to the determination of the distillation characteristics according to DIN EN ISO 3405.
Advantageously, at least 20% by volume of the fuel composition evaporate at temperatures above 130° C., in particular at least at 140° C. Expediently, at least 10% by volume of the fuel composition evaporate at temperatures above 165° C. In known fuel compositions with high alkane proportion, no, or hardly any, components are contained that boil above 165° C. By designing the boiling point curve in such a way that at least 10% by volume of the fuel composition evaporate at temperatures above 165° C., the operating behavior of the internal combustion engine can be significantly improved.
In order to improve the acceleration behavior of an internal combustion engine operated with the fuel composition it is provided that at least 20% by volume of the fuel composition evaporate at temperatures below 70° C., in particular at temperatures below 65° C. Expediently, at least 30% by volume of the fuel composition evaporate at temperatures below 85° C.
In order to enable, for example, the use of the fuel composition also in forestry, it is provided that the alkane proportion of the fuel composition is more than 85% by volume. Advantageously, the fuel composition comprises up to approximately 97% by volume of C4 to C14 isoalkanes.
For adjusting the boiling point curve, it is provided that the fuel composition contains approximately 7% by volume up to approximately 57% by volume, in particular approximately 12% by volume up to approximately 45% by volume, expediently approximately 18% by volume up to approximately 30% by volume, advantageously approximately 25% by volume, of C10 to C14 alkanes. For a proportion of approximately 7% by volume up to approximately 57% by volume of C10 to C14 alkanes, in particular isoalkanes, the rich come down behavior is improved in comparison to known fuels with high isoalkane proportion. In addition, an improved acceleration and starting behavior can be achieved in particular for a C10 to C14 alkane proportion of approximately 18% by volume up to approximately 30% by volume. C10 to C14 alkanes are alkanes with 10 to 14 carbon atoms. For adjustment of the boiling point curve in the lower range it is provided that the fuel composition contains approximately 10% by volume up to approximately 40% by volume, expediently approximately 13% by volume up to approximately 30% by volume, advantageously approximately 15% by volume up to approximately 25% by volume, especially preferred approximately 20% by volume, of C4 to C5 isoalkanes. C4 and C5 alkanes are alkanes with four or five carbon atoms, i.e., butane and pentane. In comparison to known fuel compositions with high alkane proportion the proportion of C4 and C5 alkanes is increased. In this way, a greater proportion of the fuel composition already evaporates at lower temperatures. In this way, an improved starting behavior and acceleration behavior can be achieved. For a C4 and C5 alkane proportion of approximately 15% by volume up to approximately 25% by volume, the acceleration behavior and starting behavior can be further improved.
It is provided to reduce the proportion of C6 to C9 alkanes in favor of higher boiling C10 to C14 alkanes and in favor of lower boiling C4 and C5 alkanes. Advantageously, the fuel composition contains no more than 60% by volume C6 to C9 alkanes. C6 to C9 alkanes are alkanes with 6 to 9 carbon atoms, i.e., hexanes, heptanes, octanes, and nonanes. Advantageously, the fuel composition contains approximately 30% by volume up to approximately 60% by volume, in particular approximately 40% by volume to approximately 55% by volume of C6 to C9 alkanes. For a C6 to C9 alkane proportion an excellent rich come down behavior results, and for a C6 to C9 alkanes proportion of approximately 40% by volume up to 55% by volume the acceleration and starting behaviors are also further improved. The C6 to C9 alkanes are advantageously isoalkanes.
It can be advantageous that the fuel composition contains up to approximately 20% by volume of oxygen-containing organic compounds. In this way, the proportion of biogenic substances, i.e., the substances of biologic or organic origin in the fuel composition, can be up to approximately 20% by volume. Expediently, the proportion of oxygen-containing organic compounds is up to approximately 10% by volume, in particular up to approximately 6% by volume. For a proportion of oxygen-containing organic compounds of up to approximately 6% by volume, a comparatively minimal leaning results for the fuel/air mixture generated in operation of an internal combustion engine from the fuel composition and the combustion air. At the same time, the octane rating of the fuel composition increases by means of the proportion of oxygen-containing organic components. For a proportion of oxygen-containing organic components of approximately 6% by volume up to approximately 10% by volume the octane rating increases further. At the same time, the fuel/air mixture is becoming more lean. This leads to an increased operating temperature of the internal combustion engine so that for an increase of the proportion of oxygen-containing organic components suitable measures must be taken in order to avoid an operating temperature of the internal combustion engine that is too high.
In this connection, the oxygen-containing organic compounds can be methanol, ethanol, ethyl tertiary-butyl ether (ETBE), methyl tertiary-butyl ether (MTBE), and/or butanol. It is provided that the proportion of C6 to C9 alkanes is reduced in favor of oxygen-containing organic compounds. The proportion of C6 to C9 alkanes and of the oxygen-containing organic compounds in the fuel composition together is advantageously approximately 30% by volume up to 60% by volume, in particular approximately 40% by volume up to approximately 55% by volume.
In order to avoid autoignition of the fuel in operation, it is provided that the fuel composition has an engine octane rating of more than 87, in particular of more than 90. It is provided that the fuel composition is suitable for a two-stroke engine or for a mixture-lubricated four-stroke engine. Advantageously, the fuel composition contains a two-stroke engine oil for lubricating the two-stroke engine or mixture-lubricated four-stroke engine. The proportion of the two-stroke engine oil is advantageously less than approximately 5% by volume, expediently approximately 1% by volume up to approximately 3% by volume, in particular approximately 2% by volume, of the fuel composition.
Advantageously, the fuel composition comprises aromatic compounds wherein the proportion of aromatic compounds is advantageously less than approximately 5% by volume, in particular less than approximately 1% by volume. It is provided that the fuel composition contains benzene wherein the proportion of benzene in the fuel composition is advantageously less than approximately 0.2% by volume, in particular less than approximately 0.1% by volume. Expediently, the fuel composition contains olefins wherein less than approximately 5% by volume, in particular less than approximately 1% by volume, of olefins are contained in the fuel composition. It is provided that the fuel composition contains naphthenes wherein advantageously less than approximately 5% by volume, in particular less than approximately 1% by volume, of naphthenes are contained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a diagram that illustrates the boiling point curve of different fuel compositions.
FIG. 2 shows the acceleration behavior of an internal combustion engine with a conventional fuel composition and with a fuel composition according to the invention.
FIG. 3 shows the rich come down behavior of an internal combustion engine with a conventional fuel composition and with a fuel composition according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 , the boiling point curve of different fuel compositions is shown. The temperature T in ° C. is plotted against the fuel proportion in % by volume evaporated at this temperature. The boiling point curve is measured and plotted in accordance with DIN EN ISO 3405. Curve 1 shows the boiling point curve of regular gasoline. The boiling point curve ascends comparatively constantly. Components are contained that evaporate above 180° C. The curve 2 shows the boiling point curve for conventional specialty fuel that has a high proportion of alkanes. The boiling point curve of this fuel extends below 100° C. more steeply than the boiling point curve of regular gasoline and has then a very flat course. Curve 3 shows an exemplary boiling point curve for the new fuel composition. The course of the boiling point curve is approximated to the course of the boiling point curve of regular gasoline. Up to approximately 100° C., the course of the boiling point curve is more flat than the course of the curve 2 of conventional specialty fuel, i.e., fuel that has a high isoalkane proportion and that is used e.g. in forestry. The adjoining course of the boiling point curve is significantly steeper than for conventional specialty fuel. The new fuel composition comprises also higher-boiling components.
The boiling point curve of the new fuel composition is adjusted such that at least 25% by volume, in particular at least 30% by volume, of the fuel composition evaporate at temperatures T above 110° C. The point of the boiling point curve where approximately 70% by volume of a sample has evaporated is at approximately 116° C. to approximately 125° C. At least 20% by volume of the fuel composition evaporate at temperatures T above 130° C. in particular at least at 140° C. The point of the boiling point curve at which 80% by volume of a sample have evaporated is at approximately 140° C. to approximately 152° C. 10% by volume of the fuel composition evaporate at temperatures T above 165° C. The point of the boiling point curve at which 90% by volume of a sample have evaporated, is approximately at 168° C. to approximately 178° C. The end of boiling is at approximately 200° C. in the low boiling range it is provided that at least 20% by volume of the fuel composition T evaporate at temperatures T below approximately 70° C., in particular temperatures T below 65° C. The point of the boiling point curve at which 20% by volume of the sample have evaporated is at approximately 59° C. to approximately 68° C. The point of the boiling point curve at which 30% by volume of the sample have evaporated is at approximately 65° C. to approximately 85° C.
In order to reach this course of the boiling point curve, the proportion of C10 to C14 alkanes is increased at the expense of the proportion of C6 to C9. Moreover, the proportion of C4 and C5 alkanes is increased at the expense of C6 to C9. An advantageous fuel composition that has a boiling point curve in accordance with curve 3 contains approximately 5% by volume of C4 alkanes, approximately 20% by volume of C5 alkanes, approximately 48% by volume of C8 alkanes, approximately 6% by volume of C11 alkanes, and approximately 17% by volume C12 alkanes. In more detail, the fuel can comprise approximately 4.8% by volume of n-butane, approximately 19.7% by volume of 2-methyl butane, approximately 32.5% by volume 2,2,4-trimethyl pentane, approximately 1% by volume 2,2-dimethyl hexane, approximately 1.5% by volume of 2,2,3-trimethyl pentane, approximately 1.4% by volume of 2,4-dimethyl hexane, approximately 6.2% by volume of 2,3,4-trimethyl pentane, approximately 3.3% by volume of 2,3,3-trimethyl pentane, approximately 15% by volume of 2,3-dimethyl hexane, approximately 17.2% by volume of C12 isoparafins as well as a total of approximately 6% by volume of different isomers of C11 isoparafins, and approximately 2% by volume two-stroke engine oil. Further components whose proportion in the fuel composition is less than 1% by volume are not listed in detail. The proportion of aromatic compounds, olefins, and naphthenes is less than 1% by volume, respectively. The proportion of benzene is less than 0.1% by volume. In this connection, a proportion of 0.5% by volume of aromatic compounds and 0.05% by volume of benzene can be provided. The proportion of olefins can be approximately 0.2% by volume and the proportion of naphthenes can be approximately 0.1% by volume. In this first fuel composition no oxygen-containing organic compounds are contained.
A second fuel composition that contains oxygen-containing organic compounds can have the following composition: 4% by volume of n-butane 1.1% by volume of 2-methyl butane, 38.8% by volume of 2,2,4-trimethyl pentane, 7.1% by volume of 2,3,4-trimethyl pentane, 5.2% by volume of 2,3,3-rmethyl pentane, 18.2% by volume of C12 isoparafins, and 5.5% by volume of ethanol.
A third fuel composition contains also additional oxygen-containing organic compounds, The proportion of C6 to C9 alkanes is accordingly reduced. The third fuel composition contains 23.1% by volume of 2-methyl butane, 51.3% by volume of 2,2,4-trimethyl pentane, 18.1% by volume of C12 isoparafins, 5.5% by volume of ethanol, and 2% by volume of methyl tertiary-butyl ether (MTBE).
A fourth fuel composition that contains no oxygen-containing organic compounds can comprise 29.9% by volume of 2-methyl butane, 57.3% by volume of 2,2,4-trimethyl pentane, 3.0% by volume of isoundecane, 6.2% by volume of isododecane, as well as 3.6% by volume of p-xylene.
A fifth fuel composition contains 11.2% by volume of 2-methyl butane, 30.2% by volume of 2,2,4-trimethyl pentane, 45% by volume of isodecane, 2.0% by volume of two-stroke engine oil, for example, HP Super of the Stihl company, 2.5% by volume of ethanol, 2.0% by volume MTBE, 4.8% by volume of p-xylene, and 2.3% by volume of cyclopentane.
The illustration of FIG. 2 shows the acceleration behavior of a proposed new fuel composition with adjusted boiling point curve in comparison to a conventional specially fuel with high alkane proportion. In this connection, the engine speed n is plotted against the time t. Curve 4 shows the acceleration behavior of conventional specially fuel. As can be taken from the illustration, the engine speed n does not increase uniformly but increases first to a plateau, from where the engine speed n first increases slowly to a maximum engine speed. For the new fuel composition illustrated by curve 5 a uniform acceleration up to the maximum engine speed is achieved. The maximum engine speed is reached earlier than for conventional specialty fuel.
For the deceleration process when the throttle in the intake passage of the internal combustion engine is suddenly closed, i.e., the so-called rich come down, a strong enrichment of the fuel/air mixture in the internal combustion engine occurs. This causes a very strong drop in engine speed. For the new fuel composition the engine speed drop is less pronounced as for conventional specialty fuel. This is illustrated in FIG. 3 . Here, the engine speed n is plotted against time t. The engine speed course for the conventional specialty fuel is illustrated by curve 6 . Upon sudden closure of the throttle, the engine speed n drops sharply to a minimal engine speed n o that is far below the idle speed n L . Subsequently, the engine speed n increases to the idle speed n L . The engine speed course for the new fuel composition is illustrated by curve 7 . Both curves 6 and 7 show only the general course of the engine speed n. With the new fuel composition the engine speed drop is less pronounced. The engine speed n drops to a minimal engine speed n 1 that is also below the idle speed n L but the engine speed n 1 is significantly above the engine speed n o . Overshooting of the engine speed course is significantly attenuated by the new fuel composition. After reaching the minimal engine speed n 1 , the engine speed n increases with the new fuel composition also to the idle speed n L .
The increased proportion of low-boiling components such as C4 and C5 alkanes improves also the starting behavior of the engine so that an improved operating behavior results.
All disclosed fuel composition have advantageously an engine octane rating that is greater than 87, in particular greater than 90.
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A fuel composition contains at least 74% by volume of C4 to C14 isoalkanes and, pursuant to the determination of the distillation characteristics according to DIN EN ISO 3405, at least 25% by volume of the fuel composition evaporate at temperatures above 110° C. The fuel composition can also contain oxygen-containing organic compounds, aromatic compounds, olefins, and naphthenes.
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FIELD OF THE INVENTION
[0001] The present invention relates to a light emitting device for light-transmissive picture, especially to a compact light emitting device for transparent picture and having versatile usage.
BACKGROUND OF THE INVENTION
[0002] Image can convey more abundant meaning and concept than word can do. Conventionally, image playing device such as slide projector is used for presentation or demonstration.
[0003] As the progress of semiconductor manufacture skill, various innovations are developed to enrich the display and image-fetching field. For example, the digital camera is popular due to the maturity of charge coupled device (CCD) and the breaking through of while LED also provide new product idea.
[0004] For nowadays promotion advertisement or souvenir, photo or picture are usually adopted. However, the photo or picture are dull due to lack of sound and lightening effect.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a compact light emitting device for transparent picture and having versatile usage.
[0006] To achieve the above objects, the present invention provides a light emitting device for a light-transmissive picture includes a casing with the light-transmissive picture placed therein, a background light source unit in the housing; and a power supply supplying electrical power to the background light source for emitting a light, whereby the light-transmissive picture can be illuminated for better visibility. The light emitting device further comprises a decorative light source and a controller for controlling the decorative light source.
[0007] According to one aspect of the present invention, the light emitting device further comprises voice IC or audio IC for better sound effect.
[0008] According to another aspect of the present invention, the light emitting device according to the present invention can be embodied in the form of tie clip or earring.
[0009] According to still another aspect of the present invention, the light emitting device according to the present invention can be integrated into watch or mobile phone, which are portable to user. The light emitting device according to the present invention also can be integrated to CD box or souvenir to increase the value thereof. The light emitting device 1 according to the present invention can also be assembled in plural form for decoration or use with mobile phone for incoming call notice.
[0010] The various objects and advantages of the present invention will be more readily understood from the following detailed description when read in conjunction with the appended drawing, in which:
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 shows a front view of the light emitting device for light-transmissive picture according to the first preferred embodiment of the present invention;
[0012] FIG. 2 shows a sectional view of the light emitting device for light-transmissive picture according to the first preferred embodiment of the present invention;
[0013] FIG. 3 shows a block diagram of the light emitting device for light-transmissive picture according to the second preferred embodiment of the present invention;
[0014] FIG. 4 shows a front view of the light emitting device for light-transmissive picture according to the third preferred embodiment of the present invention; and
[0015] FIG. 5 shows a front view of the light emitting device for light-transmissive picture according to the fourth preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 shows a front view of the light emitting device for light-transmissive picture according to the first preferred embodiment of the present invention, and FIG. 2 shows a sectional view of the light emitting device for light-transmissive picture according to the first preferred embodiment of the present invention. The light emitting device 1 for light-transmissive picture according to the present invention mainly comprises a casing 10 , a plurality of light sources 32 , 34 and a controller 40 .
[0017] As shown in FIG. 2 , the casing 10 comprises a hollow front shell 12 and a rear shell 14 . A plurality of retainers 16 is formed at rear side of the front shell 12 to define a recess 13 between the front shell 12 and the rear shell 14 . The recess 13 is used to accommodate a light-transmissive picture 20 . The light-transmissive picture 20 can be glass plate, acrylic plate, plastic plate or positive film plate. In the first preferred embodiment of the present invention, the light-transmissive picture 20 is a positive film plate.
[0018] With reference again to FIG. 1 , the light sources include a background light source 32 mounted on the rear shell 14 and electrically connected to the controller 40 , and a decorative light source 34 mounted on a front peripheral surface of the hollow front shell 12 and also electrically connected to the controller 40 . The electrically connected to the controller 40 is electrically connected to a battery 42 besides connecting to the background light source 32 and the decorative light source 34 . The battery 42 provides electric power to the controller 40 , the background light source 32 and the decorative light source 34 .
[0019] As shown in FIG. 1 , after turning on a switch (not shown), electrical power is supplied from the battery 42 to the background light source 32 such that the light-transmissive picture 20 can be more clearly displayed. The background light source 32 can be, for example, white light LED. Moreover, a light-sensitive switch (not shown) can be provided on the light emitting device for light-transmissive picture. Therefore, the background light source 32 can be automatically turned on instead of manually turning on in a dark place. The controller 40 can be programmed to control a flashing mode of the decorative light source 34 . The decorative light source 34 can be LED or primitive color (red, blue or green color), or LED of other colors to enhance decorative effect of the light emitting device for light-transmissive picture.
[0020] FIG. 3 shows a block diagram of the light emitting device 1 for light-transmissive picture according to the second preferred embodiment of the present invention. The light emitting device 1 has similar components as that shown in the first preferred embodiment except that the controller 40 is composed of a background light controller 40 A and a decorative light controller 40 B for controlling the background light source 32 and the decorative light source 34 , respectively. The light emitting device 1 further comprises a voice IC 44 connected to a loudspeaker 46 . The voice IC 44 can be controlled by the e controller 40 to speak a predetermined speech. The voice IC 44 can also be replaced by an audio IC to play music.
[0021] FIG. 4 shows a front view of the light emitting device 1 for light-transmissive picture according to the third preferred embodiment of the present invention. The light emitting device 1 shown in FIG. 4 comprises a casing 10 and a plurality of light sources 33 , 34 inducing background light source 33 and decorative light source 34 . The background light sources 33 are arranged on both sides of a rear shell 14 of the casing 10 and electrically connected to a battery 42 of a controller for obtaining electrical power therefrom. The background light source 33 emits light toward both sides of a light-transmissive picture 20 for manifest the display of the light-transmissive picture 20 .
[0022] With reference to FIGS. 2 and 5 , FIG. 5 shows a front view of the light emitting device 1 for light-transmissive picture according to the fourth preferred embodiment of the present invention. The light emitting device 1 according to this embodiment has similar components as previously embodiments. The light emitting device 1 shown in FIG. 5 comprises a casing 10 and a plurality of light sources 33 , 34 and 35 inducing background light source 33 , 35 and decorative light source 34 . The background light sources 33 , 35 are arranged on a rear shell 14 of the casing 10 and on peripheral locations with respect to the light-transmissive picture 20 . The background light source 33 , 35 emits light toward peripheral sides of a light-transmissive picture 20 for manifest the display of the light-transmissive picture 20 .
[0023] In application, the light emitting device 1 according to the present invention can be embodied in the form of tie clip or earring. For example, user can place idol's photo in the form of the light-transmissive picture 20 on the light emitting device 1 when they attend a party. The light emitting device 1 with idol's photo can create fantastic effect.
[0024] Moreover, the light emitting device 1 according to the present invention has the advantage of miniature size. Therefore, the light emitting device 1 according to the present invention can be integrated into watch or mobile phone, which are portable to user. The light emitting device 1 according to the present invention also can be integrated to CD box or souvenir to increase the value thereof. The light emitting device 1 according to the present invention can also be assembled in plural form for decoration or use with mobile phone for incoming call notice.
[0025] Although the present invention has been described with reference to the preferred embodiment thereof, it will be understood that the invention is not limited to the details thereof. Various substitutions and modifications have suggested in the foregoing description, and other will occur to those of ordinary skill in the art. For example, the background light source and decorative light source can also adopt EL light source. The light-transmissive picture can be attached to a front face of the light emitting device. Therefore, all such substitutions and modifications are intended to be embraced within the scope of the invention as defined in the appended claims.
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A light emitting device for a light-transmissive picture includes a casing with the light-transmissive picture placed therein, a background light source unit in the housing; and a power supply supplying electrical power to the background light source for emitting a light, whereby the light-transmissive picture can be illuminated for better visibility. The light emitting device further comprises a decorative light source and a controller for controlling the decorative light source.
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FIELD OF THE INVENTION
The present invention relates to a cheese conveying system with a junction or interface interposed between the outlets of at least two delivery belts and the inlet of a collecting belt, by means of which textile cheeses or bobbins can be transferred.
BACKGROUND OF THE INVENTION
Various types of textile machines, such as spinning frames or winding frames, deposit finished cheeses or bobbins on a conveyor belt. Many of these machines have a plurality of spinning or winding stations aligned along each opposite side of the machine and utilize one conveyor belt along each longitudinal side for servicing the spinning or winding stations therealong, which over time is filled with the produced cheeses. The instant invention is primarily concerned with the transport of cheeses which have yarn wound about the surface of a bobbin tube and are transferred to a conveying belt such that their tubes or winding axes are placed approximately in the conveying direction of the belt and such that the bobbin can roll, if necessary, transversely with respect to the conveying direction of the belt. The bobbins are passed on in this position with the aid of the conveyor belt which is also serves as a delivery belt for the following operation.
As soon as the respective delivery belt is filled with bobbins, it is cleared. In the process, the bobbins reach an intermediate storage position or station for further processing. Clearing of the cheeses or bobbins can be performed manually, but, in general, an automatic operation is performed wherein the bobbins are transported to a collecting belt via an interface. Because the bobbins are lying on their yarn surface, it is necessary to take the vulnerability of their yarn into consideration during their further transport. With each start of the delivery belt, the sensitive surface of the wound yarn can be negatively affected. Therefore the respective delivery belt is only actuated when the entire belt is to be cleared. In addition, the deflection of the individual bobbins from the belt should be performed in such a way that if possible no friction is exerted on the yarn surface.
In such textile machines having a delivery belt on each longitudinal side, it is accordingly necessary to assign a clearing interface or junction to each of these delivery belts as a connection with the collecting belt. However, in accordance with German Patent Publication DE 39 12 683 A1 it is also possible to utilize only one main collecting belt between the outlet of the one delivery belt and the inlet of the collecting belt, provided a transfer line to the main collection belt is associated with the outlet of the other delivery belt of the same machine. On such a transfer line the individual bobbin is first cleared from the respective delivery belt and is then transferred to the main collecting belt by rolling it to the side. However, the appropriate mechanical devices for doing so are very expensive and the bobbins can be injured in the course of the lateral transfer.
In order to meet these problems, it is possible in accordance with European Patent Publication EP 0 500 389 A1 to place the bobbins on transport pallets, so that the bobbins themselves do not touch the belt but instead are placed in an upstanding disposition on a peg fastened approximately perpendicularly to the transport pallet. In this case, the bobbins from two or more delivery belts can be transferred onto a collecting belt via a triangular lapping shunt, along which the transport pallets slide after leaving each respective delivery belt. However, this method not only requires additional transport pallets, but also a mechanical device for placing the tubes of the respective bobbins onto the pegs of the transport pallets so that the tubes stand perpendicularly with respect to the belt.
OBJECT AND SUMMARY OF THE INVENTION
It is accordingly an object of the present invention to provide an improved cheese conveying system with an interface or junction disposed between the outlets of at least two delivery belts and the inlet of a collecting belt, by means of which textile bobbins in the form of cheeses may be transported in a position lying on their yarn surface and transferred from such position while preventing damage to the wound yarn surface to the greatest possible extent without the need to employ special transport pallets or like devices and without the use of complicated lapping lines for lateral insertion of a transport line into a main line (DE 39 12 683 A1).
This object is attained in accordance with the invention by means of a textile cheese conveying system comprising at least two delivery belts each having a bobbin delivery outlet end, a collecting belt having a bobbin receiving end, and an interface interposed between the outlet ends of the delivery belts and the inlet end of the collecting belt for transferring bobbins from the delivery belts to the collecting belt. According to the present invention, the interface includes an interface belt having a transverse extent spanning between the outlet ends of the delivery belts for receiving bobbins from both thereof. The interface belt is of a trough shape in transverse cross-section to define a central bobbin collecting depression extending longitudinally along the interface belt and for inducing bobbins transferred onto the interface belt to roll transversely into the depression. Appropriate means is provided for alternately actuating the delivery belts, and means is also provided for actuating the interface belt and the delivery belts substantially at the same speed.
Thus, a conveyor belt is created by means of the present invention which serves as a junction or interface effective to unite textile bobbins from two or more delivery belts of a textile machine preparing cheeses and to supply the bobbins to a single collecting belt. In accordance with the invention, a Y-shaped belt as described hereinafter is used as the interface.
Depending on the type of machine it can also be necessary to insert an additional pivotable conveyor belt into the connection between the bobbin delivery system of the textile machine and the bobbin collecting system of the textile mill, which is pivoted away during normal operation of the machine, for example to make space for a circulating bobbin changer or a piecing carriage. The junction/interface belt in accordance with the present invention is preferably inserted between this pivotable conveyor belt, which may be designated as an "I-belt" for shorthand purposes, and the outlets of the delivery belts. The junction/interface belt is designed and operated in such a way that a gentle transfer of the bobbin lying on its surface from the delivery belts to the lapping belt and from the latter to the I-belt is possible. For this reason the belt speeds are strictly synchronized in accordance with the invention, i.e., the surfaces of successive belts have the same circulating speed.
In a preferred embodiment, the junction/interface belt is a conveyor belt defining in its lateral or transverse cross-section a slightly depressed trough, preferably in a Y-shape, and is sufficiently wide in its lateral dimension to extend between the outlets of at least two delivery belts of a cheese-producing textile machine. As a result of the orientation of their tubes in the longitudinal direction of the belt, the cheeses transferred to the Y-belt follow its trough shape and thereby roll on it to the lengthwise center of the belt. The trough is particularly designed to be sufficiently deep that each delivered bobbin comes to rest gently in the center of this belt by no later than the time required to reach the outlet of the Y-belt.
In accordance with the invention, the Y-belt is driven at the same speed as the delivery belts bringing the bobbins. For this reason it is practical to connect the same drive unit to the successive belts. The drive of the Y-belt can preferably be achieved with the aid of a toothed belt on a toothed belt pulley connected via a free-wheeling device or a coupling device with the drive shaft of the delivery belts whereby the successive belts necessarily have the same speed. In the course of operating the cheese-producing textile machine, the delivery belts as a rule are cleared sequentially rather than simultaneously. The next delivery belt is engaged only when the delivery belt of one machine is empty. With the use of an appropriate free-wheeling or coupling device, it can be accomplished that initially one delivery belt is driven at the same speed as the interface belt, while the other delivery belt stands still. Subsequently the first delivery belt is stopped and the second delivery belt is actuated at the same speed as the Y-belt.
An embodiment is also possible in which the first-cleared delivery belt continues to run while the second delivery belt is subsequently cleared. In such case a free-wheeling or coupling device is only needed on one of the delivery belts.
Instead of a connection of the Y-belt with the delivery belts by means of free-wheeling or coupling devices, a variant is contemplated wherein the delivery belts and the Y-belt have separate respective drive units, which drive the belts at the same circulating speed and are controlled by means of a control device.
In each embodiment, the bobbins reach a collection belt, which is a part of the textile mill, from the junction/interface belt, for example, via the aforementioned pivotably arranged I-belt and possibly via further intermediate belts, such as a curvilinear conveyor belt. The collecting belt transports the cheeses to a bobbin storage location, a shipping station or to a downstream processing device. Since all conveyor belts are driven at the same speed, no damage of the bobbin surface occurs either in the transfer of the cheeses from the delivery belts to the Y-belt, or the transfer from the Y-belt to the I-belt. In the course of subsequent transfers to further belts, damage to the surface of the bobbins, such as can be caused by acceleration, braking, pile-ups, etc., is assuredly prevented.
Details of the invention will be explained by means of the schematic representation of an exemplary embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation in top plan view of the Y-shaped junction/interface belt according to the preferred embodiment of the present invention, disposed for operation for receiving bobbins at the bobbin clearing area of a spinning machine with two parallel arranged delivery belts;
FIG. 2 is a lateral side elevational view of the spinning machine clearing area of FIG. 1;
FIG. 3 is a vertical cross-sectional view of the Y-belt along the section III--III in FIG. 4;
FIG. 4 is another top plan view of the spinning machine clearing area of FIG. 1, showing a first embodiment of a drive system for the Y-belt; and
FIG. 5 is a side elevational view of the spinning machine clearing area of FIG. 1, showing an alternate embodiment of Y-belt drive system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An open-end spinning machine or open-end rotor spinning machine 1 is indicated only representatively in FIGS. 1 and 2 as a source of supply or means of producing wound yarn bobbins or cheeses, it being understood that the particular cheese supply or bobbin-producing apparatus from which cheeses or bobbins are delivered to the conveying system of the present invention is not a part of or any limitation on the potential applications of the present invention. At one end along the longitudinal axis or centerline of the machine, the open-end spinning machine 1 has two delivery belts, specifically a left delivery belt 2 and a right delivery belt 3, on which are collected finished cheeses 4 created at spinning stations (not shown). The delivery belts 2, 3 are cleared from time to time of the collected cheeses and, for this purpose, the delivery belts 2, 3 are alternatingly actuated in a delivery direction indicated by the arrows 5.
In accordance with the invention, the cheeses 4 from the delivery belt 2 or 3 reach an intermediate belt 6, hereinafter identified as a Y-belt, which spans laterally between the delivery belts 2, 3 to serve as an interface or junction therebetween. The Y-belt 6 transports the cheeses 4 further in the direction 5 to another intermediate belt 7, herein designated as an I-belt, which is pivotable into a position for transporting the cheeses to a curvilinear conveyor 8 which to a position alongside a collecting belt 9. At its terminal end area, the curvilinear conveyor 8 has a contour which induces the cheeses 4 to roll off laterally onto the collecting belt 9.
In general, the I-belt 7 is embodied to be pivotable around a shaft 10 extending horizontally and transversely in respect to the conveying direction 5, so that during normal operation of the open-end spinning machine 1 the I-belt may be pivoted into an inoperative position to avoid interference with the circulation of a piecing carriage 11, which is guided on a rail 40. This pivoted inoperative position of the I-belt is identified at 7' in FIG. 2.
As represented in FIG. 2, the transport of the cheeses 4 alternatingly from the right and left delivery belts 2, 3 via the Y-belt 6, the I-belt 7 and the curvilinear conveyor 8 to the collection belt 9 can take place at an obliquely upward angle to horizontal. In this manner, it is possible to transfer the cheeses 4 to the collection belt 9, which is preferably and normally positioned above head height over the mill floor 12.
As represented in FIGS. 1 and 4, the Y-belt 6 is embodied in accordance with the invention to be sufficiently wide so that its inlet, i.e. bobbin receiving, end 13 spans laterally across substantially the full width of the respective outlet ends 14 of the delivery belts 2 and 3. Each delivery belt 2, 3 receives the individual cheeses 4 lying in a substantially horizontal position with the bobbin tubes 15 oriented parallel and in alignment with the delivery direction 5 and therefore in parallel alignment with the longitudinal centerline 16 of the delivery belts 2 or 3.
In accordance with the present invention, the lengthwise extent of the interface/junction belt 6 is of a trough-like shape in its transverse cross-section (see FIG. 3) to define a longitudinal belt centerline 17 extending intermediately of and parallel with the belt centerlines 16 of the delivery belts 2, 3. In this embodiment, the trough is configured such that a bobbin 4 placed on the Y-belt 6 with its tube 15 oriented parallel with the delivery belt centerline 16, rolls into the center of the Y-belt 6. Thus, following the transfer of a cheese 4 from one of the delivery belts 2, 3 to the Y-belt 6 and its further movement as indicated in FIGS. 1 or 3, the cheese 4 rolls out of alignment with the previous belt centerline 16, approximately along an oblique line 18, into alignment with the belt centerline 17, so that, before reaching the end of the Y-belt 6, the cheese 4 lies centered on the Y-belt 6. Subsequently, the cheese 4 is transferred in the customary manner from the Y-belt 6 to the I-belt 7 and therefrom to the collection belt 9 via the curvilinear conveyor 8.
Synchronous operation of the several successive conveyor belts is important for the optimal operation of the present invention and, thus, the respective conveying delivery belts 2, 3, the interface or Y-belt 6, the I-belt 7, etc., should travel at the same surface speed during the time in which cheeses 4 are transferred so that each transferring belt surface and the accepting belt surface will have the same speed.
In accordance with the instant exemplary embodiment, the Y-belt 6 is disposed to be pivotable to a limited extent around a shaft 19 in the area of the outlets 14 of the delivery belts 2, 3. As a result, it is possible to embody the Y-belt 6 similar to the I-belt 7 as a passive uniting element or interface. The pivotable Y-belt 6 in particular can be positioned for automatic operation at the slight incline represented in FIG. 2 of the drawings. For manual operation, the Y-belt can be arranged with a slightly descending slope for making the bobbins accessible to operational personnel at a lower manipulation height, this position of the Y-belt 6 being indicated by 6' in FIG. 2.
As indicated, FIG. 3 represents a lateral cross section of the Y-belt 6. As shown, the conveying surface of the Y-belt rests on a trough-shaped support structure 20, so that the cheeses 4 or 4 ' delivered by means of the delivery belts 2 or 3 roll laterally of their lengthwise axes automatically to the belt centerline 17 for protection of their wound yarn surface.
A first embodiment of a synchronous drive arrangement for the several conveyor belts is represented in FIG. 4. As indicated in this exemplary embodiment, the delivery belts 2 and 3 have separate respective motor drives 22 and 23 which drive respective rollers 24 and 25 of the delivery belts 2, 3 by means of appropriate gears. In addition, the drives 22, 23 are connected to coupling devices 26 and 27, which are controlled by means of a control device 28. In turn, the coupling devices 26, 27 are connected with the drive roller 21 of the Y-belt 6 by means of suitable connecting means, for example toothed belts 29, 30.
Further similar embodiments of a synchronous drive arrangement are of course also possible. For example, the coupling devices 26, 27 can also be positioned in the immediate area of the drive roller 21 of the Y-belt 6. In place of the coupling devices, it is also possible to employ free-wheeling devices which prevent the respective conveyor belt 2 or 3, which is not being driven at a given time in the operation of the present invention, from being dragged along by the driven conveyor belt.
FIG. 5 shows another alternative variant for a synchronous drive of the delivery belts 2, 3, the Y-belt 6 and the I-belt 7. As indicated, the individual belts have separate respective drives 22, 23, 31, 33, which are connected by means of control lines 32, 34, 35 with a common central control device 28. A defined, i.e., controlled, operation of the sequentially arranged delivery belts at the same circulating speed is also possible with such an arrangement so that, hereagain, damage of the yarn surface of the bobbins during the transfer of the bobbins from one to the other belt is assuredly prevented.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of a broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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A cheese conveying system has an interface belt centrally trough-shaped along its length and disposed to span between the outlets of two delivery belts and to extend therefrom to the inlet of a collection belt, by means of which cheeses transported from the delivery belts in a lying position roll transversely to the center of the interface belt to accomplish a gentle uncomplicated transfer of the bobbins from the delivery belts to the collection belt. The delivery belts are alternately actuable and the respectively delivery, interface and collecting belts are driven at the same speed.
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This application is the national phase under 35 U.S.C. §371 of PCT International Application No. PCT/EP98/06120 which has an International filing date of Sep.25, 1998, which designated the United States of America.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention involves a process for applying powder on a moving printed sheet, where powder is added into an airflow directed at the printed sheet, so that this powder is transported by the airflow to the printed sheet. The invention also involves a device for applying powder to the moving printed sheet using a first nozzle for discharging an airflow loaded with powder, which is directed at the printed sheet.
2. Related Art
A device of this type is disclosed, for example, in German patent document DE-AS 12 52 703. In that patent, several nozzle base structures are attached to a girder beam. These nozzle base structures discharge, in a fan-like manner a carrier airflow, into which an airflow loaded with powder is supplied. This is necessary since printing ink is still moist on the individual printed sheets when the printed sheets are stacked, and therefore, the printed sheets must be kept at a distance from each other using the powder. Because a spacing of individual nozzle base structures is relatively large because of a move-by gripper that grasps the printed sheet, normally between 50 to 150 mm, the carrier airflow must be adjusted in such a manner that the powder is transported with certainty to the printed sheet. Because the gripper speed is approximately 4 m/s at a printing output of 18,000 sheets per hour, relatively high cross-currents are predominant, which negatively impair the carrier airflow and thus the powder application. For example, the carrier airflow may not, under certain circumstances, spread out vertically downward as desired and thus may fail to deposit the powder as intended on the printed sheet. Thus, the carrier airflow is adjusted in such a manner that it has a relatively high air impulse current, which lies in the area of 0.04 N. In addition, the individual nozzles are arranged in such a way on each nozzle base structure that several carrier airflows of a nozzle base structure form a fan-like jet, where the individual carrier airflows relatively rapidly become unified after exiting from the nozzles into this fan-like jet. The nozzle base structures are arranged in such a way that the fan-like jets overlap each other. Therefore, the printed sheet should be relatively uniformly dusted with powder. However, it is considered disadvantageous to have fan-like jets of this type, which are relatively susceptible to cross-currents, and to have a printed sheet, which is impinged with a relatively large air impulse current. This leads to a disadvantageous effect on paper flow of the printed sheet.
SUMMARY OF THE INVENTION
It is thus an object of this invention to provide a process and/or a device, with which the printed sheet can be optimally dusted, the loss of powder is reduced and the printed sheet is impinged with a lower air impulse current.
This purpose is achieved according to the invention in a process of the type set forth at the beginning hereof, in that the airflow that carries the powder is surrounded by a powderless supporting airflow that at least partially envelops it.
A process according the invention thus provides that in addition to the airflow, which is loaded with powder, an additional airflow, namely a supporting airflow, is generated, which at least partially surrounds the powder airflow and supports and protects it in the direction to the printed sheet. The supporting airflow forms a sheath or a protective envelope around the powder airflow, so that it stays bundled on the one hand over a longer section, and on the other hand, possibly prevalent cross-currents do not act directly on the powder airflow, but instead first contact the supporting airflow. By enveloping the powder airflow with powderless air, interactions of the powder airflow with surrounding air are prevented or at least considerably reduced. Possible interfering air only entrains powderless air out of the supporting airflow, thereby ensuring no powder loss occurs.
An additional advantage is seen in that by enveloping the powder airflow, the powder airflow retains its form for a considerably longer period, so that a smaller air impulse current is necessary in order to transport the powder to the printed sheet. It has shown that in the process according to the invention, an air impulse current is required in the range from 0.01 to 0.02 N. This, however also leads to the fact that the paper flow is improved, since the printed sheet is much less loaded.
An additional embodiment provides that the supporting airflow is formed from several air jets. Instead of one ring-shaped supporting airflow, the airflow can also be formed from several, e.g. from four individual airflows, which unite immediately after exiting from additional nozzles into an enveloping jet or into several partial enveloping jets.
Advantageously, the powder airflow is supported on sides of the supporting airflow that are orthogonal to the transport direction of the printed sheet. This is advantageous because the powder airflow is protected by the supporting airflow, so that cross currents caused by the gripper only have a relatively small effect on the powder airflow.
Advantageously, the powder airflow is a discrete omnidirectional jet, as such is better suited for the transport of the powder to the printed sheet. In addition, omnidirectional jets are less susceptible to cross currents than fan jets.
The purpose of the present invention discussed heretofore is achieved using a device according to the invention in that along with a first nozzle for discharging the powder airflow, at least one additional nozzle is provided for discharging a powderless supporting airflow that at least partially envelops the powder airflow.
Thus with the device according to the present invention, two airflows are discharged which are different from each other. Via the one airflow, the powder airflow, the powder is transported to the printed sheet. The other airflow is powderless and has the functionality of supporting and protecting the powder airflow. The supporting of the powder airflow allows the airflow to retain its form over a wide range. The protective function is seen in that possible interferences through cross currents do not directly act on the powder airflow and entrain the powder, but instead possibly act on the supporting airflow, which is powderless.
In one embodiment, it is provided that to every first nozzle, four other nozzles are allocated. These four other nozzles form four partial airflows, which relatively quickly unify after they are let out of the other nozzles into the supporting airflow. Advantageously, the supporting airflow has the same flow speed as the powder airflow, so that the two currents can be fed onto each other without interference and essentially will not mix.
In order to be able to optimally oppose cross currents, the additional nozzles are arranged on the nozzle base structure essentially perpendicular to the transport direction of the printed sheet. In this manner, the powder airflow is more or less protected through an especially two-sided protected curtain.
According to the invention, the first nozzle powder airflow is constructed such that the powder airflow is a circular section jet. Circular section jets have, as already mentioned, the considerable advantage that they are relatively less susceptible to interference because of their smaller surface area and that they transport the powder optimally in the desired direction.
According to the invention, the first nozzle is constructed so that it is relatively long, so that the circular section jet can be shaped in the nozzle and keeps its shape for a relatively long time, even without the protective airflow.
Advantageously, the cross section of the first nozzle is substantially larger than the second nozzle. Since the protective airflow is not needed for the transport of the powder, but instead only in order to support and protect against interference effects, it can be constructed as a relatively thin envelope. This also has the advantage that the air impulse current, as already mentioned above, is reduced, and by this the paper flow of the printed sheet is improved. In addition, the powder airflow can, because of the protecting envelope, be supplied to the printed sheet with a smaller impulse current, where the air impulse current of the protecting current is as a rule even smaller than the powder airflow.
In one embodiment it is provided that the nozzle base structure has two first nozzles and four other nozzles allocated to each of the first nozzles. Nozzle structures with three first nozzles are also conceivable. Regardless, it is not necessary to provide nozzle structures with a plurality of nozzles in order to ensure a fan-like discharge of the powder. It is sufficient to provide two or three first nozzles, by which the powder is discharged into the powder airflow.
A special embodiment form of the nozzle structure provides that the nozzles are arranged in at least two, in particular, three planes perpendicular to the transport direction. Therefore, the other nozzles for the supporting airflow are provided in one or two planes and the nozzles for the powder airflow are provided in one plane. In this way, the prerequisite is created that the individual partial airflows form the supporting airflow relatively quickly and the two or three powder airflows, which transport the powder in the direction to the printed sheet for a relatively long time as a circular section jet, become unified with the adjacent powder airflows into a fan-like jet only shortly before the printed sheet surface.
A simple construction of the nozzle base structure is obtained according to the invention in that the nozzle is constructed in a plate-like manner in the area of the nozzle, such that one plate is provided with the first nozzle and other plates are provided with the other nozzles. This platelike construction has the advantage that the nozzle base structure can be put together in a module-like manner, and in this way can be adapted for injection molding technique.
Additional characteristics, advantages and details of the invention can be gathered from the claims as well as from the following description, in which, in reference to the drawings a particularly preferred embodiment is described in detail.
BRIEF DESCRIPTION OF THE DRAWINGS
In the process, the characteristics depicted in the drawings and mentioned in the description and in the claims can each be inventive individually or in any desired combination. Shown in the drawings are:
FIG. 1 is a sectional view through a nozzle base structure that is affixed to a beam;
FIG. 2 is a view in the direction of arrow II according to FIG. 1;
FIG. 3 is a view in the direction of arrow III according to FIG. 2;
FIG. 4 is a section IV—IV according to FIG. 1; and
FIG. 5 is a section V—V according to FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a gripper 1 is shown in a suggested form, which transports a printed sheet 2 in the direction of the arrow 3 (transport direction). Above the printed sheet 2 and at a distance from the printed sheet 2 , which ensures an unobstructed passing by of the gripper 1 , several nozzle base structures 4 are located, of which one is shown. These nozzle base structures 4 are affixed on a beam 5 extending perpendicular to the transport direction 3 , and are shiftable in a direction of the beam 5 , i.e. perpendicularly to the transport direction 3 and perpendicularly to the plane of the drawing. The nozzle base structure 4 has a housing 6 , in which a flow channel 7 is provided for a powder airflow 8 loaded with powder. This flow channel 7 discharges at a first nozzle 9 out of the nozzle base structure 4 . The nozzle head 11 of the nozzle base structure 4 is constructed in a sandwich-like manner from several plates, which can be seen clearly in FIG. 1 . The flow channel 7 is surrounded by an air channel 10 , into which powderless air is supplied. In the nozzle head 11 , there are additional nozzles out of which a supporting airflow 13 discharges. These other nozzles 12 are connected to the air channel 10 .
From FIG. 2, which shows a front view II, it can be recognized that the air channel 10 is connected via bore holes 14 to ring channels 15 , via which the powderless air flows into the other nozzles 12 . In addition, in FIGS. 1 and 2 it is shown clearly that on a facing surface 16 , the first nozzle discharges and on sloped side surfaces 17 , the other nozzles 12 discharge. This has the advantage that the supporting airflow 13 discharges in front of a powder airflow 8 and in this way an envelope can be readily formed, into which the powder airflow 8 is blown.
From FIGS. 2 and 3, the facing surface 16 and the side surfaces 17 can be clearly recognized and in the embodiment shown, the nozzle head 11 has two first nozzles 9 and four other nozzles 12 allocated to each of the first nozzles 9 . In addition, it can be recognized that the cross-section of the first nozzles 9 is considerably larger than the cross-section of the other nozzles 12 , so that the powder airflow 8 leaving the first nozzles 9 has a considerably larger volume than the supporting airflow 13 leaving the other nozzles 12 .
From FIG. 1 it can also be recognized that the powder airflow 8 is essentially blown out from the first nozzle 9 as a bundled jet in the direction of the printed sheet 2 . This is also shown clearly in section IV—IV (FIG. 4 ), where the powder airflow 8 still forms a circular section jet with the indicated powder. The partial airflows blown out of the other nozzles 12 , which have a considerably smaller volume have already become partially unified and form the supporting airflow 13 that flanks the powder airflow 8 . This supporting airflow 13 must not necessarily completely surround the powder airflow 8 . It is sufficient when the supporting airflow 13 protects the powder airflow 8 from interference effects, which are caused by the passing gripper 1 . In addition, the two powder airflows 8 can expand to the side, i.e. in the direction towards each other, so that they mix together in the area of the printed sheet surface and hit the printed sheet as continuous, powderloaded strips of air. Not only do the powder airflows 8 expand in the perpendicular direction, but the supporting airflows 13 do as well, so that they gradually form a closed curtain with the powder airflows 8 located in between.
From the section V—V shown in FIG. 5, it can be recognized clearly that the powder airflow 8 is flanked on both sides by the supporting airflow 13 . This supporting airflow 13 thus supports the powder airflow 8 from the nozzle 9 to the point of striking the printed sheet 2 and holds the powder airflow bundled in the transport direction 3 . In addition, in case of an interference, only air portions out of the supporting airflow 13 , but not out of the powder airflow 8 , are torn away. Since the individual powder airflows 8 first fuse shortly before the striking on the printed sheet 2 and until then, are discrete circular section jets, they can be protected in an easier manner from the surroundings, such that on the one hand, less additional air is needed, and on the other hand, this air has a smaller air impulse current.
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The invention concerns a method and a device for applying powder on sections of printing sheets ( 2 ). The invention includes a powder airflow ( 8 ) enclosed in a protective airflow ( 13 ) such that the powder airflow is steady and protected against the action of possible disturbances until it reaches the sections of printing sheets ( 2 ).
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This application is a continuation application of Ser. No. 09/927,327 filed Aug. 13, 2001 now abandoned, which is a continuation application of Ser. No. 09/630,562 filed Aug. 2, 2000, now U.S. Pat. No. 6,284,264, which is a divisional application of Ser. No. 09/287,181 filed Apr. 6, 1999, now U.S. Pat. No. 6,177,096, which is a continuation of Ser. No. 08/904,607 filed Aug. 1, 1997, now U.S. Pat. No. 5,948,430.
A composition containing therapeutic agents and/or breath freshening agents for use in the oral cavity is disclosed. The carrier comprises water-soluble polymers in combination with certain ingredients and provides a therapeutic and/or cosmetic effect. The film is coated and dried utilizing existing coating technology and exhibits instant wettability followed by rapid dissolution/disintegration upon administration in the oral cavity.
BACKGROUND OF THE INVENTION
Mucoadhesive dosage forms for application to the oral cavity which are designed to deliver therapeutic and/or cosmetic agents to the oral mucosa are known in the art. U.S. Pat. No. 5,047,244 describes a mucoadhesive carrier allowing the controlled release of a therapeutic agent via the mucosal tissue comprising an anhydrous but hydratable polymer matrix and amorphous fumed silica. An optional water-insoluble film can be added to provide a non-adhereing surface. In WO 91/06270, the same authors disclose a trilaminate film suitable for prolonged delivery of an active ingredient in the oral cavity.
In a similar way, U.S. Pat. No. 4,876,092 discloses a sheet-shaped adhesive preparation comprising an adhesive layer containing certain water-soluble and water-insoluble polymers and a water-insoluble carrier which can adhere to the oral mucosa thereby releasing an active agent to the oral cavity. All the devices so far cited are not completely water soluble and will stay in the oral cavity even after the therapeutic goal has been achieved leaving the patient with a certain discomfort in the mouth resulting mainly from the support layer which leaves an insoluble residue in the mouth.
A number of attempts have been made to reduce the adverse feeling in the oral cavity caused by the rigidity and inflexibility of the support layer by introducing soft film supports. EP 0 200 508 B1 and EP 0 381 194 B1 disclose the use of the polyethylene films, polyvinyl acetate, ethylene-vinyl acetate copolymers, metal foils, laminates of cloth or paper and a plastic film, and similar materials as soft film supports, whereby synthetic resins like polyethylene, vinyl acetate homopolymers, and ethylene-vinyl acetate are the preferred materials. In a similar way, CA 1 263 312 discloses the use of polyolefines such as polyethylene, polypropylene, polyesters, PVC, and non-woven fabrics as soft support materials.
However, these devices still leave the patient with a considerable amount of residue from the water-insoluble support film thereby still causing a feeling of discomfort. The obvious solution to overcome this problem was to develop mucoadhesive films which completely disintegrate, or even completely dissolve in the saliva. Fuchs and Hilmann (DE 24 49 865.5) prepared homogeneous, water-soluble films intended for buccal administration of hormones. They proposed the use of water-soluble cellulose-derivatives, like hydroxyethyl cellulose, hydroxypropyl cellulose, or methyl hydroxypropyl cellulose, as film forming agents.
Both DE 36 30 603 and EP 0 219 762 disclose the use of swellable polymers such as gelatine or corn starch as film forming agents, which upon application to the oral cavity slowly disintegrate, thereby releasing an active ingredient incorporated in the film. The same polymers can also be used to prepare films which are intended for dental cleansing, as described in EP 0 452 446 B1.
These preparations still create an adverse feeling in the mouth which is mainly caused by their initial rigidity and delayed softening. Thus, there has still been a demand for a composition for use in the oral cavity which meets the requirement of providing a pleasant feeling in the mouth. The present invention discloses methods and compositions that are capable of avoiding an adverse feeling by providing the film which is intended for application to the oral mucosa with instant wettability, while achieving adequate tensile strength in the free film to allow for easy coating, converting, and packaging of a consumer-friendly product.
DESCRIPTION OF THE INVENTION
The present invention contemplates a rapidly dissolving film which can be adhered to the oral cavity thereby releasing a pharmaceutically or cosmetically active agent, said film comprising water-soluble polymers, one or more polyalcohols, and one or more pharmaceutically or cosmetically active ingredients. Optionally, the formulation may contain a combination of certain plasticizers or surfactants, colorants, sweetening agents, flavors, flavor enhancers, or other excipients commonly used to modify the taste of formulations intended for application to the oral cavity. The resulting film is characterized by an instant wettability which causes the film to soften immediately after application to the mucosal tissue thus preventing the patient from experiencing any prolonged adverse feeling in the mouth, and a tensile strength suitable for normal coating, cutting, slitting, and packaging operations.
The mucoadhesive film of the present invention contains as essential components a water-soluble polymer or a combination of water-soluble polymers, one or more plasticizers or surfactants, one or more polyalcohols, and a pharmaceutically or cosmetically active ingredient.
The polymers used for the mucoadhesive film include polymers which are hydrophilic and/or water-dispersible. Preferred polymers are water-soluble cellulose-derivatives. Hydroxypropylmethyl cellulose, hydroxyethyl cellulose, or hydroxypropyl cellulose, either alone, or mixtures thereof, are particularly preferred. Other optional polymers, without limiting the invention, include polyvinyl pyrrolidone, carboxymethyl cellulose, polyvinyl alcohol, sodium alginate, polyethylene glycol, natural gums like xanthane gum, tragacantha, guar gum, acacia gum, arabic gum, water-dispersible polyacrylates like polyacrylic acid, methylmethacrylate copolymer, carboxyvinyl copolymers. The concentration of the water-soluble polymer in the final film can vary between 20 and 75% (w/w), preferably between 50 and 75% (w/w).
The surfactants used for the mucoadhesive film may be one or more nonionic surfactants. When a combination of surfactants is used, the first component may be a polyoxyethylene sorbitan fatty acid ester or a α-hydro-ω-hydroxypoly (oxyethylene)poly(oxypropylene)poly(oxyethylene) block copolymer, while the second component may be a polyoxyethylene alkyl ether or a polyoxyethylene castor oil derivative. Preferably, the HLB value of the polyoxyethylene sorbitan fatty acid ester should be between 10 and 20, whereby a range of 13 to 17 is particularly preferred. The α-hydro-ω-hydroxypoly (oxyethylene)poly(oxypropylene) poly(oxyethylene) block copolymer should contain at least 35 oxypropylene-units, preferably not less than 50 oxypropylene-units.
The polyoxyethylene alkyl ether should have an HLB value between 10 and 20, whereby an HLB value of not less than 15 is preferred. The polyoxyethylene castor oil derivative has to have an HLB value of 14-16.
In order to achieve the desired instant wettability, the ratio between the first and second component of the binary surfactant mixture should be kept within 1:10 and 1:1, more preferably between 1:5 and 1:3.
The total concentration of surfactants in the final film depends on the properties of the other ingredients, but usually has to stay between 0.1 and 5% (w/w).
The polyalcohol is used to achieve the desired level of softness of the film. Examples of polyalcohols include glycerol, polyethylene glycol, propylene glycol, glycerol monoesters with fatty acids of other pharmaceutically used polyalcohols. The concentration of the polyalcohol in the dry film usually ranges between 0.1 and 5% (w/w).
The film is well suited for the delivery of a wide range of pharmaceutically active ingredients via the mucous membranes of a patient, particularly the buccal mucosa. Therapeutic agents which exhibit absorption problems due to solubility limitations, degradation in the gastro-intestinal tract, or extensive metabolism, are particularly well suited. Without limiting the invention, examples of the therapeutic agents include hypnotics, sedatives, antiepileptics, awakening agents, psychoneurotropic agents, neuromuscular blocking agents, antispasmodic agents, antihistaminics, antiallergics, cardiotonics, antiarryhythmics, diuretics, hypotensives, vasopressors, antitussive expectorants, thyroid hormones, sexual hormones, antidiabetics, antitumor agents, antibiotics and chemotherapeutics, and narcotics.
The amount of drug to be incorporated into the film depends on the kind of drug and is usually between 0.01 and 20% (w/w), but it can be higher if necessary to achieve the desired effect.
Cosmetically active agents may include breath freshening compounds like menthol, other flavors or fragrances commonly used for oral hygiene, and/or actives and used for dental and/or oral cleansing like quartenary ammonium bases. The effect of flavors may be enhanced using flavor enhancers like tartaric acid, citric acid, vanillin, or the like. Colorants which may optionally be mixed in the film must be safe in terms of toxicity and should be accepted by the Food And Drug Administration for use in cosmetics.
The mucoadhesive film according to the present invention can be prepared as follows: The polyalcohol, surfactants, plasticizers, and possible other ingredients except the water-soluble or water-dispersible polymer(s) are dissolved in a sufficient amount of a solvent which is compatible with them. Examples of compatible solvents include water, alcohols or mixtures thereof. After a clear solution has been formed, the water-dispersible polymer or mixture of water-dispersible polymers is slowly added with stirring, and heat if necessary, until a clear and homogeneous solution has been formed, followed by the addition of active ingredients and flavors. The solution is coated onto a suitable carrier material and dried to form a film. The carrier material must have a surface tension which allows the polymer solution to spread evenly across the intended coating width without soaking in to form a destructive bond between the two. Examples of suitable materials include non-siliconized polyethylene terephthalate film, non-siliconized kraft paper, polyethylene-impregnated kraft paper, or non-siliconized polyethylene film.
The coating of the solution onto the carrier material can be performed using any conventionl coating equipment. A more preferred coating technique would involve a knife-over-roll coating head.
The thickness of the resulting film depends on the concentration of solids in the coating solution and on the gap of the coating head and can vary between 5 and 200 μm. Drying of the film is carried out in a high-temperature air-bath using a drying oven, drying tunnel, vacuum drier, or any other suitable drying equipment, which does not adversely affect the active ingredient(s) or flavor of the film. In order to reliably avoid an adverse feeling in the mouth, a dry film thickness of 70 μm should not be exceeded. For better ease of use, the dry film can be cut into pieces of suitable size and shape and packed into a suitable container.
The invention will now be explained more specifically with reference to the following examples, which are given for illustration of this invention and are not intended to be limiting thereof.
EXAMPLE 1
15 g of sorbitol, 6 g of glycerol, 0.5 g of polysorbate 80 (Tween 80), 2 g of Brij 35, 25 g of lemon mint flavor, 3 g of aspartame, 15 g of 1-menthol, and 3 g of citric acid are stirred at 60° C. in a mixture of 250 g water and 250 g ethanol unitl a clear solution has been formed. To the solution, 30 g of hydroxypropylmethyl cellulose are added slowly under stirring unitl a clear and homogeneous solution has been formed. The resulting solution is allowed to cool to room temperature and coated onto a suitable carrier material, for example non-siliconized, polyethylene-coated kraft paper using conventional coating/drying equipment. Coating gap and web speed have to be adjustable to achieve a dry film thickness between 20 and 50 μm. The drying temperature depends on the length of the drying oven and the web speed and has to be adjusted to remove the solvents completely, or almost completely, from the film. The resulting film is peeled off the carrier web and cut into pieces of a shape and size suitable for the intended use.
EXAMPLE 2
3 g sorbitol, 1.5 g Kollidon 30 (supplier: BAST), 5 g glycerol, 5 g propylene glycol, 5 g polyethylene glycol, 4 g polysorbate 80 (Tween 80), 8 g Brij 35, 12 g peppermint flavor, and 0.8 g aspartame are dissolved in a mixture containing 400 g water and 400 g ethanol at 60° C. under stirring. To the clear solution, 28 g hydroxypropylmethyl cellulose are added slowly under stirring. After the polymer is completely dissolved, the solution is cooled to room temperature and coated onto a suitable carrier web using the coating and drying conditions as described in the previous example. The dry film is again out into pieces of suitable size and shape.
EXAMPLE 3
15 g sorbitol, 22.5 g glycerol, 2.5 g propylene glycol, 2.5 g Brij 35, 2.5 g poloxamer 407, 3.5 g Cremophor RH 40, 9 g herb mint flavor, and 0.5 g aspartame are dissolved under stirring at 60° C. in a mixture containing 250 g water and 250 g ethanol. To the clear solution, 75 g hydroxypropyl cellulose are added slowly under continuous stirring. The clear solution is again coated and dried under the conditions as described in EXAMPLE 1 and the dry film is cut into pieces of a shape and size suitable for the intended use.
EXAMPLE 4
3.6 g Twen 80, 3.6 g glycerol, 39 g menthol, and 171 g Kollidon 30 are dissolved in a solution of 600 ml water and 2800 ml ethanol at ambient temperature with stirring. 247.5 g hydroxypropylmethyl cellulose is then added slowly and portionwise at 50-55° C. and stirred unitl completely dissolved. The mixture is then allowed to cool and added in succession are 90 g lemon mint flavor followed by a solution/suspension of 27.13 g aspartame, 18 g citric acid, and 0.17 g FD&C yellow #5 in 120 ml water with stirring. The clear solution is coated and dried under the conditions as described in EXAMPLE and the dry film is cut into pieces of a shape and size suitable for the intended use.
EXAMPLE 5
165.4 g Kollidon 30 are dissolved in a solution of 720 ml water and 2660 ml ethanol at ambient temperature with stirring. 220.5 g hydroxypropylmethyl cellulose is then added at 55-60° C. and stirred vigorously until clear and homogeneous. The mixture is then allowed to cool and added in succession are 78.75 g flavor followed by a mixture of 28.88 g nicotine salicylate and 31.5 g caramel liquid in 120 ml water with stirring. The clear, tan-colored solution is coated and dried under the conditions as described in EXAMPLE 1 and the dry film is cut into pieces of a shape and size suitable for the intended use so as to deliver a nicotine dose between 1-2 mg per piece.
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A composition containing therapeutic agents and/or breath freshening agents for use in the oral cavity is disclosed. The carrier comprises water-soluble polymers in combination with certain ingredients and provides a therapeutic and/or cosmetic effect. The film is coated and dried utilizing existing coating technology and exhibits instant wettability followed by rapid dissolution/disintegration upon administration in the oral cavity.
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[0001] The present invention relates to a production method for a tool socket, especially for a handheld rotating and chiseling power tool.
BACKGROUND
[0002] U.S. Pat. No. 7,338,051 describes a tool socket for a combination hammer drill. The tool socket has a tubular main body in whose interior the drill bit is accommodated so that it can be moved along its axis. Locking elements engage in the interior and secure the drill bit against falling out. Moreover, the tool socket has ribs that engage with corresponding grooves of the drill bit in order to transfer a torque from the tool socket to the drill bit. The ribs are made of a sintered hard metal and are inserted into the main body as inserts. The sintered hard metal is very abrasion-resistant. The ribs are secured in overlapping holes drilled in the main body. Adhesives, a press fit, soldering or welding as well as laser welding can all be employed to achieve a durable fixation.
SUMMARY OF THE INVENTION
[0003] The rib is subject to very high mechanical loads. Peak loads of the torque occur, among other things, when the drill bit gets caught on a piece of rebar during the drilling procedure. Moreover, the insert and the main body are subject to vibrations caused by the striking mechanism. High requirements are made of the durability of the connection between the rib and the main body. The process of soldering and welding sintered hard metals is laborious, while adhesives and a press fit do not appear to be suitable measures.
[0004] The rib should have a high abrasion resistance and nevertheless be easy to process during the production of the tool socket.
[0005] The second material is preferably a cold work tool steel or a high-speed tool steel; hot work tool steels prove to be relatively soft after the soldering and heating treatment.
[0006] The production method according to the invention for a tool socket comprises the following steps: a hollow spindle (main body) is formed. At least one elongated recess is provided in the wall. The spindle is made of a first material comprising unalloyed or low-alloyed steel grades. An insert is formed from a second material comprising a high-alloyed tool steel. The insert has a pedestal that is complementary to the recess and it also has a rib. The insert is placed into the hollow spindle in such a way that the pedestal rests in the recess and the rib projects into the interior of the spindle. The pedestal is soldered into the recess at a temperature that is above the Ac3 temperatures of the steel grades employed. The combined structure consisting of the hollow spindle and the insert is cooled off. The combined structure undergoes a heat treatment in an atmosphere containing sufficient carbon to carburize the hollow spindle but not sufficient to carburize the insert. The heat treatment of the combined structure is carried out at a temperature between 800° C. and 950° C. The combined structure is cooled down in a salt bath or liquid bath subsequent to the heat treatment.
[0007] Surprisingly, this production method yields an abrasion-resistant rib. A tool steel acquires its hardness from a very specific multi-stage hardening process whose temperature profile is indicated by the steel suppliers. The hardening process entails at least heating the steel up to a temperature at which carbides dissolve as well as a tempering procedure repeated three times at a temperature between 500° C. and 600° C. The third tempering procedure is described in the literature as being essential in order to eliminate residual austenite from the second material as well as to remove the vitreous martensite formed during cooling off, thus resulting in the desired strength of the tool steel. The tool steel loses its hardness when it is heated to considerably above 600° C., while soft annealing can be expected at approximately 800° C. According to conventional teaching, the temperature during soldering as well as during the subsequent heat treatment step speaks against the use of tool steel for the rib.
[0008] The heat treatment of the combined structure can be followed by tempering at 180° C. to 210° C., which eliminates stresses, especially in the hollow spindle.
[0009] The insert is advantageously formed by means of a forging process or an investment cast process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The description below explains the invention on the basis of embodiments and figures provided by way of an example. The figures show the following:
[0011] FIG. 1 : a combination hammer drill;
[0012] FIG. 2 : a tool socket;
[0013] FIG. 3 : the tool socket in a cross-sectional view along plane III;
[0014] FIG. 4 : an insert in a top view.
[0015] Unless otherwise indicated, identical or functionally equivalent elements are designated in the figures by the same reference numerals.
DETAILED DESCRIPTION
[0016] FIG. 1 schematically shows a combination hammer drill 1 as an example of a handheld chiseling power tool. The combination hammer drill 1 has a tool socket 2 into which one shank end 3 of a tool, for example, a hammer drill bit 4 , can be inserted. The primary drive of the combination hammer drill 1 is in the form of a motor 5 which drives a striking mechanism 6 as well as a driven shaft 7 . The user can guide the combination hammer drill 1 by means of a handle 8 and can start up the combination hammer drill 1 by means of a system switch 9 . During operation, the combination hammer drill 1 continuously rotates the hammer drill bit 4 around the working axis 10 and, in this process, it can strike the hammer drill bit 4 into a substrate in the striking direction 11 along the working axis 10 . The striking mechanism 6 is preferably a motor-driven pneumatic striking mechanism 6 . A striker 12 is coupled via an air spring 13 to a piston 14 that is moved back and forth along a working axis 10 by the motor 5 . The striker 12 strikes the shank end 3 either directly or else indirectly via a striking pin 15 .
[0017] The tool socket 2 is shown in detail in a longitudinal sectional view in FIG. 2 , and in a cross-sectional view in FIG. 3 . The tool socket 2 has a hollow spindle 16 (main body) that is driven by the driven shaft 7 and it has a receptacle 17 for the tool 4 . The hammer drill bit 4 can be inserted in the insertion direction (counter to the striking direction 11 ) into the receptacle 17 through an opening 18 located on the driven side. The receptacle 17 is preferably configured so as to be complementary to the shank end 3 , for example, cylindrically.
[0018] The hammer drill bit 4 , which is provided with locking grooves, can be reversibly locked in the receptacle 17 by means of locking elements, here, for instance, pawls 19 . The pawls 19 are inserted into elongated holes 20 situated in a wall of the hollow spindle 16 . Radial blocking of the pawls 19 is effectuated by a locking ring 21 on which the pawls 19 partially protrude into the receptacle 17 radially from the inside. The part of the pawls 19 that protrudes into the receptacle 17 can engage with the locking groove of the tool 4 . A spring-loaded slide 22 holds the pawls 19 inside the locking ring 21 , that is to say, so as to overlap axially with the locking ring 21 . When the hammer drill bit 4 is inserted, the pawls 19 are moved counter to the spring-loaded slide 22 and they are disengaged from the locking ring 21 . The pawls 19 can deflect radially and give access to the receptacle 17 . The pawls 19 can be moved counter to the spring-loaded slide 22 by an actuating sleeve 23 , as a result of which the radial blocking of the pawls 19 is eliminated and the hammer drill bit 4 can be removed.
[0019] The rotational movement of the hollow spindle 16 is transferred to the hammer drill bit 4 via ribs 24 that protrude into the receptacle 17 . The tool socket 2 configuration given by way of an example has a rib 24 . Alternative tool sockets 4 , especially for hammer drill bits having a large diameter, can have two or more ribs 24 . Along the working axis 10 , the rib 24 is at the height of the elongated holes 20 for the pawls 19 .
[0020] The rib 24 is the part of an insert 25 that extends beyond the receptacle 17 . The insert 25 has the rib 24 and a pedestal 26 . For each rib 24 , the hollow spindle 16 has a recess 27 into which the pedestal 26 is inserted in the radial direction 28 . The recess 27 is complementary to the pedestal 26 . The pedestal 26 is permanently affixed in the recess 27 by soldering. The entire insert 25 is preferably monolithic, that is to say, made contiguously of one material, without joining zones. The insert 25 can be made of a tool steel. The hollow spindle 16 is made of a different material, for instance, of an unalloyed or low-alloyed steel.
[0021] The rib 24 has a main section 29 . The main section 29 transmits essentially the entire torque to the combination hammer drill 1 . The exposed outer surfaces—especially a top surface 30 and two side surfaces 31 —of the main section 29 are parallel to the working axis 10 . The outer surfaces delimit a trapezoidal cross section that is constant along the working axis 10 over the entire length of the main section 29 . The top surface 30 is situated perpendicular to a radial direction 28 (vertical direction). The side surfaces 31 preferably adjoin the opposite lengthwise edges of the top surface 30 . The side surfaces 31 are preferably slanted relative to each other by between 20° and 40°. Therefore, the rib 24 is preferably wider at its bottom surface, that is to say, at the pedestal 26 , than at the top surface 30 . The center width 32 of the rib 24 is approximately the same as the height 33 of the rib 24 , differing, for example, by less than 20%. The length 34 of the main section 29 is at least three times the value of the height 33 . The rib 24 has to be sufficiently long to transfer the torque to the drill bit 4 .
[0022] The rib 24 has a rear section 35 that is arranged behind the main section 29 in the striking direction 11 . The rear section 35 has a front face 36 that faces in the striking direction 11 . The front face 36 is preferably trapezoidal. The normal of the front face 36 lies in a plane formed by the working axis 10 and the vertical direction 28 . The front face 36 given by way of an example is not perpendicular to the working axis 10 but rather, it is slanted by between 70° and 80°. The front face 36 is preferably flat. The front face 36 is somewhat narrower than the main section 29 , that is to say, smaller than the trapezoidal cross section. The width 37 of the front face 36 at the pedestal 26 is between 80% and 90% of the width 32 of the cross section at the pedestal 26 .
[0023] Two opposite inlet surfaces 38 laterally adjoin the front face 36 . The inlet surfaces 38 connect the front face 36 to the side surfaces 31 . The flat inlet surfaces 38 are somewhat slanted relative to the side surfaces 31 , preferably by between 2° and 10°. The inlet surfaces 38 preferably extend from the pedestal 26 all the way to the top surface 30 . The length 39 of the inlet surfaces 38 corresponds approximately to the distance of the two inlet surfaces 38 , that is to say, the width 37 of the rib 24 .
[0024] The pedestal 26 is longer and wider than the rib 2 . The pedestal 26 is closed off at its lengthwise ends by semi-cylindrical end pieces. The pedestal 26 is essentially cuboidal between the two end pieces. The recess 27 correspondingly has likewise semi-cylindrical ends with a cuboidal intermediate area.
[0025] The hollow spindle 16 is made, for instance, out of a tubular blank. The tubular blank can be cold-expanded to give it the desired inner profile. Subsequently, the inner and outer surfaces are machined. Moreover, the elongated holes 29 for the pawls 19 and also the recess 27 for the insert 25 are machined, for instance, with a grinding head. Bearing sections can be trimmed and polished to the target diameter.
[0026] The steel of the tubular blank is preferably a low-alloyed steel, for instance, 16MnCr5. The carbon content is less than 0.4% by weight, preferably more than 0.1% by weight. The steel is low-alloyed; the total admixture of alloy elements is less than 5% by weight. Here, chromium can make up the largest amount, for instance, between 1.0% and 2.2% by weight. The steel can also be unalloyed. The carbon content in this case is likewise less than 0.4% by weight.
[0027] The insert 25 is preferably made without involving machining work. The insert 25 is forged, for example, from a steel blank. The shaping is done using, for example, a die into which the blank is placed. The die can consist of multiple parts and it has a shape that is complementary to the insert 25 , that is to say, the rib 24 with the pedestal 26 . The blank is forged at a temperature between 950° C. and 1150° C. In this process, the Ac3 temperature of the steel is exceeded, as a result of which austenite is formed. After the shaping procedure, the insert 25 cools down, preferably in the air, to room temperature. As an alternative, the insert 25 can be produced by means of an investment cast process.
[0028] The blank for the insert 25 is a tool steel, for instance, X155CrVMo12-1. The carbon content is more than 0.8% by weight, preferably less than 2.2% by weight. The blank is high-alloyed, the percentage of the totality of alloy elements is more than 7% by weight.
[0029] The insert 25 is placed into the recess 27 of the hollow spindle 16 . A soldering agent, preferably a solder containing copper, is inserted between the insert 25 and the hollow spindle 16 . The insert 25 is soldered to the hollow spindle 16 , for example, in a soldering oven, at a temperature within the range from 1030° C. and 1070° C. The soldering operation takes between 20 and 60 minutes. During the soldering, the steels of the hollow spindle 16 and of the insert 25 are heated up to above their re-crystallization temperature. The tool steel loses hardness in this process. After the soldering, the combined structure consisting of the hollow spindle 16 and the insert 25 cools down in air or in some other gas atmosphere.
[0030] The combined structure undergoes heat treatment in the immediately following step. The combined structure is heated up to a temperature between 800° C. and 950° C. The temperature can be raised in two or more steps in order to minimize thermomechanical stresses in the combined structure. The combined structure is kept at this temperature for 30 minutes to 2 hours. This temperature is considerably lower than the temperature that is suitable for hardening the tool steel. In the case of the tool steel X155CrVMo12-1 given by way of an example, this temperature is indicated as being 1160° C. to 1190° C. This temperature is likewise atypical for the heat treatments that are repeated three times for tool steel and that are carried out at a temperature between 400° C. and 600° C. in order to yield the typical hardness and strength of a tool steel.
[0031] The heat treatment is carried out in an atmosphere containing carbon, for example, in a gas carburizing furnace. The carbon level is raised by admixing, for instance, methanol and propane. Regulation of the carbon level serves to keep the carbon level preferably constant during the heat treatment. The carbon level is selected in such a way that the hollow spindle 16 is carburized. The carbon level for the selected steel can be obtained from tables or simulations, or else it can be ascertained with just a few experiments. The carbon level is measured in a known manner, indirectly on the basis of the partial pressure of oxygen. The carbon level is also set in such a manner that the tool steel of the insert 25 is not carburized. For instance, the carbon level is between 0.7 and 0.75. The carbon in the insert 25 can be reduced or kept at the same level.
[0032] The heat treatment is ended by means of rapid quenching, for example, in oil. The combined structure is hardened. Advantageously, the heat treatment is followed by a one-time tempering procedure at a low temperature between 180° C. and 210° C. in order to relieve internal stresses.
[0033] In one embodiment, the quenching of the combined structure to room temperature can be followed by cooling to a temperature between −60° C. and −120° C. Low-temperature cooling is conducive to the hardening of the combined structure. The low-temperature cooling is followed by the one-time tempering procedure.
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A production method for a tool socket includes forming a hollow spindle An elongated recess is provided in the wall. The spindle includes unalloyed or low-alloyed steel grades. An insert includes a high-alloyed tool steel. The insert has a pedestal that is complementary to the recess and it also has a rib. The insert is placed into the hollow spindle in such a way that the pedestal rests in the recess and the rib projects into the interior of the spindle. The pedestal is soldered into the recess at a temperature that is above the Ac3 temperatures of the steel grades employed. The combined structure is cooled and then undergoes a heat treatment in an atmosphere containing sufficient carbon to carburize the hollow spindle but not sufficient to carburize the insert. The heat treatment of the combined structure is carried out at a temperature between 800° C. and 950° C. The combined structure is cooled down in a salt bath or liquid bath subsequent to the heat treatment.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of international application number PCT/KR99/00116, filed on Mar. 15, 1999, which is pending.
FIELD OF THE INVENTION
The present invention relates to novel fluorovinyloxyacetamides, a process for preparing same and a highly selective and effective herbicidal composition comprising same.
DESCRIPTION OF THE PRIOR ART
Due to the perpetual emergence of weeds resistant to the herbicide in use, there always exists a need to develop a new class of effective herbicides that can protect crops without harming the environment. For example, the sulfonylurea-based herbicides that have been widely used in controlling rice-field weeds for the last two decades have now become less effective, particularly in controlling annual weeds. Accordingly, many attempts have been made to develop new rice-field herbicides of different chemical classes, including those based on amides and carbamates.
There has recently been reported a new class of herbicides based on heteroaryloxyacetamide derivatives (DE Patent No. 2903966; DE Patent No. 3038636; DE Patent No. 3323334; DE Patent No. 3344236; DE Patent No. 3418167; DE Patent No. 3422861; DE Patent No. 440596; WO 95/34560; WO 96/08488; WO 96/11575; WO 96/28434; and WO 97/08160). However, these heteroaryloxyacetamides have limited herbicidal activity against a narrow spectrum of weeds.
SUMMARY OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a novel compound having superior herbicidal activity against a wide spectrum of weeds.
It is another object of the present invention to provide a process for the preparation of said compound.
It is a further object of the present invention-to provide a herbicidal composition comprising said compound.
In accordance with one aspect of the present invention, there is provided a novel fluorovinyloxyacetamide compound of formula (I):
wherein:
R 1 is a phenyl group optionally having one or more substituents selected from the group consisting of C 1-6 alkyl, halogen-substituted C 1-6 alkyl, C 1-6 alkoxy and halogen;
R 2 is a C 1-6 alkyl group; or
R 1 and R 2 together with the nitrogen atom to which they are bound form a 5-, 6- or 7-membered nitrogen heterocycle optionally having one or more ring oxygen atoms, double bonds and C 1-6 alkyl substituents;
R 3 is a phenyl or thiophen-2-yl group optionally having one or more substituents selected from the group consisting of C 1-6 alkyl, halogen-substituted C 1-6 alkyl, C 1-6 alkoxy, methylenedioxy and halogen; and
R 4 is a perfluoro C 1-6 alkyl group.
DETAILED DESCRIPTION OF THE INVENTION
The compound of formula (I) of the present invention may be in the form of the E isomer of formula (I-a), the Z isomer of formula (I-b), or a mixture thereof:
wherein R 1 , R 2 , R 3 and R 4 have the same meanings as defined in formula (I) above. The two stereoisomers, E and X isomers, are defined according to the terminology of the Cahn-Ingold-Prelog system(J. March, Advanced organic Chemistry , 3rd Ed., Wiley-Interscience) which is incorporated herein by way of reference.
Among the compounds of the present invention, preferred are: those wherein R 1 is a phenyl group optionally having a halogen, methyl or methoxy substituent, R 2 is a methyl or ipropyl group, R 3 is a phenyl group optionally substituted with a halogen or methoxy group and R 4 is CF 3 or CF 2 CF 3 ; and those wherein R 1 and R 2 together with the nitrogen atom to which they are bound form a piperidino, hexamethyleneimino, morphorino or 1,2,3,6-tetrahydropyridino ring optionally having one or two C 1-2 alkyl substituents, R 3 is a phenyl group optionally substituted with a halogen or methoxy group and R 4 is CF 3 .
The compound of the present invention may be prepared by reacting an alcoholic compound of formula (II) with a fluorovinyl compound of formula (III) in the presence of a base, as shown in Reaction Scheme A:
wherein R 1 , R 2 , R 3 and R 4 have the same meanings as defined in formula (I) above.
An alcoholic compound of formula (II) may be prepared by substitution, acetylation and hydrolysis of an amine of formula (VI) according to a conventional method(Hamm, P. C., J. Amer. Chem. Soc ., 78, 2556 (1956); Hartman, W. W. et al., Org. Syn., Coll ., 3, 650 (1955); and Brasen, W. R. et al., Org. Syn. Coll ., 4, 582 (1963)), as shown in Reaction Scheme B:
wherein R 1 and R 2 have the same meanings as defined in formula (I) above.
A difluorovinyl compound of formula (III) may be prepared form a halogen compound of formula (VIII) by Grignard and Wittig reactions(Herkes, F. E. et al., J. Org. Chem ., 32, 1311 (1967); and Wheaton, G. A. et al., J. Org. Chem ., 48, 917 (1983)), as shown in Reaction Scheme C:
wherein X is Br or Cl; and R 3 and R 4 have the same meanings as defined in formula (I) above.
As shown in Reaction Scheme A, the fluorovinyloxyacetamide compound of the present invention may be prepared by reacting an alcoholic compound of formula (II) with a fluorovinyl compound of formula (III) in the presence of a base. Each of compounds of formula (II) and (III) may be used in equimolar amounts and the base may be used in one to two equivalent amounts. The base may be an inorganic base, e.g., sodium hydride, potassium hydride, potassium t-butoxide, sodium hydroxide, potassium hydroxide, sodium carbonate or potassium carbonate; or an organic base, e.g., triethylamine or pyridine. The solvent which may be used in the reaction is benzene, toluene, tetrahydrofuran, acetone, acetonitrile, dichloromethane, dimethylformamideor dimethylsulfoxide, individually or combined with water. The reaction may be conducted at a temperature ranging from room temperature to 100° C. The progress of the reaction is conveniently followed by measuring the disappearance of the compound of formula (II) with thin layer chromatography(TLC).
The compound of the present invention is obtained as a mixture of two isomers, i.e., the E and Z isomers.
For example, in the case of the compound of the present invention wherein R 1 is phenyl, R 2 is methyl, R 3 is phenyl and R 4 is CF 3 (Compound 1), a 2:1 mixture of the Z and F isomers is obtained, the isomer ratio being determined on the basis of both 1 H-NMR and 19 F-NMR analysis of the product. Namely, the peak area ratio of the 1 H-NMR peak for the methylene group of the Z isomer(a singlet at 4.30 ppm relative to CHCl 3 ) to that of E isomer(a singlet at 4.49 ppm) is about 2:1; and 19 F-NMR analysis(reference compound: CFCl 3 ) shows a peak area ratio of about 2:1 when the peaks for the fluorine and CF 3 substituents of the Z isomer(a quartet having a coupling constant of 24.08 Hz at −84.99 ppm and a doublet having a coupling constant of 25.07 Hz at −57.36 ppm, respectively) are compared with those of the E isomer(a quartet having a coupling constant of 12.43 Hz at −83.40 ppm and a doublet having a coupling constant of 12.66 Hz at −57.95 ppm, respectively).
Likewise, the preparation of the compound of the present invention wherein R 1 and R 2 together with the nitrogen atom to which they are attached form a piperidino group, R 3 is phenyl and R 4 is CF 3 (Compound 221) leads to a 2:1 mixture of the Z and E isomers. Namely, the peak area ratio of the 1H-NMR peak for the methylene group of the Z isomer(a singlet at 4.67 ppm) to that of the E isomer(a singlet 4.79 ppm) is about 2:1; and the 19 F-NMR analysis(reference compound: CFCl 3 ) shows a peak area ratio of 2:1 when the peaks for the fluorine and CF 3 substituent of the Z isomer(a quartet having a coupling constant of 25.15 Hz at −84.28 ppm and a doublet having a coupling constant of 24.85 Hz at −57.38 ppm, respectively) are compared with those of the E isomer(a quartet having a coupling constant of 12.46 Hz at −82.24 ppm and a doublet having a coupling constant of 12.32 Hz at −57.83 ppm, respectively).
The compound of the present invention has herbicidal activity against a broad spectrum of weeds, in particular, against those belonging to the Gramineae family, e.g., rice( Oryza sativa L.), barnyardgrass( Echinochlora crus - galli 8P. BEAUV. var. oryzicola OHWI), bulrush( Scirpus juncoides ROXB), umbrellaplant( Cyperus difformis L.), flatsedge( Cyperus serotinus ROTTB), dayflower( Aneilema keisak HASSK), monochoria( Monochoria vaginalis PRESL), toothcup( Rotala indica KOEHE) and arrow head( Sagittaria pygmaea MIQ).
Accordingly, the present invention also includes within its scope a herbicidal composition comprising one or more of the compounds of formula (I) as an active ingredient, in association with herbicidally acceptable carriers.
The herbicidal composition of the invention may be formulated in various forms such as an emulsion, aqueous dispersion, powder and granules which may contain herbicidally acceptable carriers and additives. The compound of the formula (I) may be used in an amount of 10 to 90% on the basis of the weight of an emulsion or aqueous dispersion, 0.1 to 10% on the basis of the weight of powder, 1 to 30 % on the basis of the weight of granules.
Herbicidally acceptable carrier that may be used in the composition of the present invention is a liquid carrier, e.g., water, an alcohol(ethanol, ethylene glycol, glycerine), ketone(acetone, methylethylketone), ether(dioxane, tetrahydrofuran, cellosolve), aliphatic hydrocarbon(gasoline, Kerosene), halogenated hydrocarbon(chloroform, carbon tetrachloride), amide(dimethylformamide), ester(ethyl acetate, butyl acetate, fatty glycerine ester) and acetonitrile; and a solid carrier, e.g., mineral particle(Kaoline, clay, bentonite, dolomite, talc, silica, sand) and vegetable powder(shrubs).
The additive that may be used in the herbicidal composition of the present invention includes an emulsifier, adhesive, dispersion agent or permeating agent, e.g., nonionic, anionic or cationic interface active agent(fatty acid sodium salt, polyoxy alkyl ester, alkyl sulfonate ester). Further, an agrochemically active ingredient, e.g., an insecticide, fungicide, plant growth regulator, germicide, and fertilizer, may be added in the composition of the present invention.
The following Preparations and Examples are given for the purpose of illustration only and are not intended to limit the scope of the invention.
PREPARATION 1
Preparation of L-Methyl-2-hydroxyacetanilide(II)
Step 1: Preparation of N-Methyl-2-chloroacetanilide(V)
10.7 g(0.1 mol) of N-methylaniline(VI) was dissolved in 150 ml of dichloromethane containing 10.12 g(0.1 mol) of triethylamine, and 13.55 g(0.12 mol) of chloroacetylchloride was added dropwise thereto while cooling. The resulting solution was stirred at room temperature for 1 hour, and washed three times with water. The organic layer was dried and recrystallized in n-hexane to obtain 17.6 g(yield 96%) of the title compound as a yellowish brown solid.
1 H-NMR (CDCl 3 , TMS) δ: 7.68-7.12(m, 5H), 3.92(s, 2H), 3.45(s, 3H); MS (m/e): 183(M + , 37), 134(51), 106(100), 90(52), 51(59). m.p.: 61-62° C.
Step 2 : Preparation of N-Methyl-2-acetoxyacetanilide(IV)
18.3 g(0.1 mol) of the compound obtained in Step 1 was added to 50 ml of dry dimethylformamide(DMF), and 9.8 g(0.12 mol) of sodium acetate was added thereto. The resulting solution was heated for 1 hour, cooled and 50 ml of water was added thereto. The resulting solution was extracted three times with ethyl acetate and the organic layer was dried. After removing the solvent, the residue was subjected to column chromatography using a mixture of n-hexane and ethyl acetate(9:1) as an eluent to obtain 19 g(yield 92%) of the title compound as a liquid.
1 H-NMR (CDCl 3 , TMS) δ: 7.78-7.21(m, 5H), 4.48(s, 2H), 3.36(s, 3H), 2.21(s, 3H); MS (m/e): 207(M + , 8), 107(61), 77(30), 43(100).
Step 3: Preparation of N-Methyl-2-hydroxyacetanilide(II)
20.7 g(0.1 mol) of the compound obtained in Step 2 was added to 100 ml of methanol, and 4.8 g(0.12 mol) of sodium hydroxide was added slowly thereto. The resulting solution was refluxed with heating for 1 hour. The solvent was removed under a reduced pressure and 50 ml of water was added thereto. The resulting solution was extracted three times with ethyl acetate. The organic layer was dried, the solvent was removed and the residue was recrystallized in n-hexane to obtain 14 g(yield 85%) of the title compound as a white solid.
1 H-NMR (CDCl 3 , TMS) δ: 7.54-7.15(m, 5H), 3.82(d, 2H), 3.38(t, 1H), 3.32(s, 3H); MS (m/e): 165(M + , 34), 134(41), 106(100), 77(81); m.p.: 41-42° C.
PREPARATIONS 2 to 31
The procedure of Preparation 1 was repeated to obtain compounds of formula (II) having various R 1 and R 2 groups, as in Table 1. The 1 H-NMR and MS analysis data and melting points of these compounds are also shown in Table 1. L in Table 1 represents liquid.
TABLE 1
(II)
Prep.
No.
R 1
R 2
state(° C.)
NMR (CDCl 3 , TMS) δ (ppm)
MS (m/e)
1
C 6 H 5
CH 3
41˜42
7.54˜7.15(m, 5H), 3.82(d, 2H), 3.38(t, 1H), 3.32(s, 3H)
165(34), 134(41), 106(100), 77(81)
2
4-CH 3 O—C 6 H 4
CH 3
78˜79
7.38˜6.88(m, 4H), 3.85(s, 3H), 3.81(d, 2H), 3.40(t, 1H),
195(42), 136(100), 122(58)
3.35(s, 3H)
3
4-F—C 6 H 4
CH 3
105˜106
7.36˜7.04(m, 4H), 3.80(d, 2H), 3.40(t, 1H), 3.31(s, 3H)
183(31), 152(45), 125(100), 95(28)
4
4-Cl-C 6 H 4
CH 3
80˜81
7.54˜7.05(m, 4H), 3.84(d, 2H), 3.37(t, 1H), 3.34(s, 3H)
199(41), 168(39), 140(100), 45(54)
5
2, 4-F 2 —C 6 H 3
CH 3
117˜118
7.12˜6.78(m, 3H), 4.35(b, 1H), 3.82(s, 2H), 3.29(s, 3H)
201(46), 170(42), 142(100), 59(82)
6
2, 4-Cl 2 —C 6 H 3
CH 3
58˜59
7.67˜7.08(m, 3H), 3.81(d, 2H), 3.39(t, 1H), 3.38(s, 3H)
233(23), 198(100), 174(79)
7
C 6 H 5
C 2 H 5
38˜39
7.56˜7.02(m, 5H), 3.88(q, 2H), 3.83(d, 2H), 3.42(t, 1H),
179(21), 120(100), 106(73), 77(87)
1.20(t, 3H)
8
4-CH 3 -C 6 H 4
C 2 H 5
63˜64
7.28˜6.96(m, 4H), 3.78(q, 2H), 3.72(d, 2H), 3.42(t, 1H),
193(47), 162(37), 134(100),
2.36(s, 3H), 1.12(t, 3H)
120(68), 91(50)
9
4-CH 3 O-C 6 H 4
C 2 H 5
53˜54
7.38˜6.78(m, 4H), 3.86(s, 3H), 3.84(q, 2H), 3.83(d, 2H),
209(77), 150(100), 136(78)
3.50(t, 1H), 1.18(t, 3H)
10
3-CF 3 -C 6 H 4
C 2 H 5
L
7.95˜7.20(m, 4H), 3.95(q, 2H), 3.80(d, 2H), 3.51(t, 1H),
247(31), 188(100), 174(92),
1.18(t, 3H)
145(47)
11
2-Cl-C 6 H 4
C 2 H 5
47˜48
7.75˜7.05(m, 4H), 4.13(m, 1H), 3.82(m, 1H), 3.76(d, 2H),
213(26), 178(100), 154(42),
3.48(t, 1H), 1.20(t, 3H)
140(42)
12
3-Cl-C 6 H 4
C 2 H 5
L
7.51˜6.95(m, 4H), 3.86(q, 2H), 3.83(d, 2H), 3.53(t, 1H),
213(38), 182(57), 154(100),
1.20(t, 3H)
140(79)
13
4-Cl—C 6 H 4
C 2 H 5
111˜112
7.62˜7.00(m, 4H), 3.86(q, 2H), 3.84(d, 2H), 3.55(t, 1H),
213(36), 154(100), 140(84)
1.23(t, 3H)
14
C 6 H 5
n-C 3 H 7
58˜59
7.62˜6.98(m, 5H), 3.86(t, 2H), 3.80(d, 2H), 3.45(t, 1H),
193(23), 151(44), 106(100), 77(53)
1.85˜1.20(m, 2H), 1.20(t, 3H)
15
4-CH 3 O—C 6 H 4
n-C 3 H 7
40˜41
7.16˜6.85(m, 4H), 3.84(s, 3H), 3.71(d, 2H), 3.65(t, 2H),
223(63), 150(40), 136(100), 43(47)
3.46(t, 1H), 1.63-1.46(m, 2H), 0.90(t, 3H)
16
C 6 H 5
i-C 3 H 7
42˜43
7.48-6.88(m, 5H), 5.05˜4.65(m, 1H), 3.64(d, 2H),
193(24), 120(100), 77(52),
3.52(t, 1H), 1.02(d, 6H)
43(100)
17
2-CH 3 —C 6 H 4
i-C 3 H 7
L
7.48˜6.98(m, 4H), 5.12˜4.64(m, 1H), 3.62(d, 2H),
207(47), 134(100), 45(89)
3.34(t, 1H), 2.37(s, 3H), 1.28(d, 3H), 1.00(d, 3H)
18
3-CH 3 —C 6 H 4
i-C 3 H 7
51˜52
7.49˜6.85(m, 4H), 5.15˜4.72(m, 1H), 3.72(d, 2H),
207(48), 134(94), 91(72), 45(100)
3.55(t, 1H), 2.48(s, 3H), 1.08(d, 6H)
19
3-CH 3 O—C 6 H 4
i-C 3 H 7
L
7.41˜6.61(m, 4H), 5.08˜4.84(m, 1H), 3.84(s, 3H),
223(18), 15O(100), 84(26), 45(38)
3.69(d, 2H), 3.57(t, 1H), 1.08(d, 6H)
20
4-CH 3 O—C 6 H 4
i-C 3 H 7
96˜97
7.32˜6.78(m, 4H), 5.25˜4.76(m, 1H), 3.86(s, 3H),
223(27), 181(47), 150(100),
3.68(d, 2H), 3.51(t, 1H), 1.10(d, 6H)
123(79), 107(65), 45(54)
21
3-CF 3 —C 6 H 4
i-C 3 H 7
48˜49
7.87˜7.21(m, 4H), 5.18˜4.86(m, 1H), 3.76(d, 2H),
261(26), 188(63), 43(100)
3.51(t, 1H), 1.08(d, 6H)
22
4-F—C 6 H 4
i-C 3 H 7
52˜53
7.21˜7.03(m, 4H), 5.08˜4.86(m, 1H), 3.61(d, 2H),
211(20), 138(100), 95(33), 43(86)
3.45(t, 1H), 1.07(d, 6H)
23
2-Cl—C 6 H 4
i-C 3 H 7
67˜68
7.78˜7.23(m, 4H), 5.16˜4.85(m, 1H), 3.78(d, 2H),
227(8), 192(69), 154(83), 45(100)
3.50(t, 1H), 1.35(d, 3H), 1.20(d, 3H)
24
3-Cl—C 6 H 4
i-C 3 H 7
62˜63
7.58˜6.95(m, 4H), 5.15˜4.85(m, 1H), 3.80(d, 2H),
227(27), 154(100), 43(76)
3.54(t, 1H), 1.08(d, 6H)
25
2-Cl-4-F—C 6 H 3
i-C 3 H 7
51˜52
7.51˜7.15(m, 3H), 5.14˜4.87(m, 1H), 3.78(d, 2H),
245(19), 210(24), 172(28), 43(100)
3.48(t, 1H), 1.32(d, 3H), 1.15(d, 3H)
26
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
67˜68
7.72˜6.97(m, 3H), 5.12˜4.84(m, 1H), 3.75(d, 2H),
261(36), 188(28), 45(100)
3.46(t, 1H), 1.16(d, 6H)
27
3-CH 3 —C 6 H 4
CH 3
L
7.42˜6.84(m, 4H), 3.82(d, 2H), 3.41(t, 1H), 3.32(s, 3H),
179(61), 120(100), 59(67)
2.37(s, 3H)
28
4-CH 3 —C 6 H 4
CH 3
58
7.38˜6.87(m, 4H), 3.81(d, 2H), 3.38(t, 1H), 3.31(s, 3H),
179(47), 120(100), 59(86)
2.35(s, 3H)
29
3,4-
CH 3
80
7.37˜6.84(m, 3H), 3.82(d, 2H), 3.36(t, 1H), 3.33(s, 3H),
193(57), 134(100)
(CH 3‘) 2‘—C 6 H 3
2.25(s, 6H)
30
3-Cl—C 6 H 4
CH 3
66
7.67˜7.01(m, 4H), 3.84(d, 2H), 3.53(t, 1H), 3.36(s, 3H)
199(58), 140(100), 75(82)
31
3,4-
i-C 3 H 7
L
7.43˜6.85(m, 3H), 5.32˜4.84(m, 1H), 3.70(d, 2H), 3.31(t, 1H),
221(61), 162(100), 59(48)
(CH 3 ) 2 —C 6 H 3
2.34(s, 6H), 1.18(d, 6H)
PREPARATION 32
Preparation of N-2-Hydroxyacetylpiperidine(II)
Step 1: Preparation of N-2-Chloroacetylpiperidine(V)
The procedure of Step 1 of Preparation 1 was repeated except that 8.5 g of piperidine was used in place of N-methylaniline and that column chromatography using a mixture of n-hexane and ethyl acetate(4:1) as an eluent was conducted in place of recrystallization to obtain 14.8 g(yield 92%) of the title compound as a yellowish brown liquid.
1 H-NMR (CDCl 3 , TMS) δ: 4.08(s, 2H), 3.76-3.18(m, 4H), 1.98-1.21(m, 6H); MS (m/e): 161(M + , 26), 126(100), 69(37), 41(68).
Step 2: Preparation of N-2-Acetoxyacetylpiperidine(IV)
The procedure of Step 2 of Preparation 1 was repeated except that 16.1 g(0.1 mol) of the compound obtained in Step 1 was used and that column chromatography was conducted using a 4:1 mixture of n-hexane and ethyl acetate as an eluent to obtain 16.5 g(yield 89%) of the title compound as a liquid.
1 H-NMR (CDCl 3 , TMS) δ: 4.67(s, 2H), 3.68-3.10(m, 4H), 2.12(s, 3H), 1.68-1.38(m, 6H); MS (m/e): 185(M + , 21), 112(51), 69(73), 43(100).
Step 3: Preparation of N-2-Hydroxyacetylpiperidine(II)
The procedure of Step 3 of Preparation 1 was repeated except that 18.5 g of the compound obtained in Step 2 was used and that column chromatography using a 2:1 mixture of n-hexane and ethyl acetate as an eluent was conducted in place of recrystallization to obtain 11.7 g(yield 82%) of the title compound.
1 H-NMR (CDCl 3 , TMS) δ: 4.08(d, 2H), 3.97(t, 1H), 3.67-3.02(m, 4H), 1.75-1.15(m, 6H), MS (m/e): 143(M + , 35), 112(86), 69(77), 43(100).
PREPARATIONS 33 to 48
The procedure of Preparation 32 was repeated to obtain compounds of formula (II) having various R 1 and R 2 groups, as in Table 2. The 1 H-NMR and MS analysis data and melting points of these compounds are also shown in Table 2. L in Table 2 represents liquid.
TABLE 2
(II)
Prep.
state
No.
R 1
R 2
(° C.)
NMR (CDCl 3 , TMS) δ (ppm)
MS (m/e)
32
—(CH 2 ) 5 —
L
4.08(d, 2H), 3.97(t, 1H), 3.67˜3.02(m, 4H), 1.75˜1.15(m, 6H)
143(35), 112(86), 69(77), 43(100)
33
—CH(CH 3 )(CH 2 ) 4 —
L
4.12(d, 2H), 3.85(t, 1H), 3.46˜2.67(m, 3H), 1.94˜1.46(m, 6H),
157(37), 126(72), 84(100), 55(66)
1.23(d, 3H)
34
—CH(CH 3 CH 2 )(CH 2 ) 4 —
L
4.13(d, 2H), 4.08(t, 1H), 3.45˜2.64(m, 3H), 1.85˜1.38(m, 8H),
171(16), 142(38), 84(100), 55(48)
0.86(t, 3H)
35
—CH(CH 3 )(CH 2 ) 3
L
4.71(b, 1H), 4.15(d, 2H), 3.98˜3.54(m, 2H), 1.97˜1.46(m, 6H),
171(28), 98(97), 55(99), 41(100)
CH(CH 3 )—
1.25(d, 6H)
36
—(CH 2 ) 2 CH═CHCH 2 —
77˜78
5.86˜5.69(m, 2H), 4.16(d, 2H), 4.15(t, 1H), 3.75˜3.64(m, 2H),
141(39), 82(57), 67(86), 54(83), 41
3.30(t, 2H), 2.27˜2.05(m, 2H)
(100)
37
—(CH 2 ) 2 O(CH 2 ) 2 —
52˜53
4.13(d, 2H), 3.80˜3.48(m, 8H), 3.41(1, 1H)
145(75), 100(67), 86(55), 42(100)
38
—(CH 2 ) 3 C(C 4 H 4 )C—
78˜79
7.28˜7.03(m, 4H), 4.18(d, 2H), 3.80(t, 1H), 3.78˜3.54(m, 2H),
191(36), 132(100), 117(30), 77(49)
2.75(t, 2H), 1.98(t, 2H)
39
—(CH 2 ) 6 —
L
4.15(d, 2H), 3.84(t, 1H), 3.78˜3.12(m, 4H), 1.98˜1.28(m, 5H)
157(11), 126(72), 84(100), 47(79)
40
C 2 H 5
C 2 H 5
L
4.05(d, 2H), 3.78(t, 1H), 3.48(q, 2H), 3.23(q, 2H), 1.15(t, 6H)
131(25), 100(71), 72(100), 44(86)
41
n-C 3 H 7
n-C 3 H 7
L
4.06(d, 2H), 3.80(t, 1H), 3.42(q, 2H), 3.15(q, 2H), 1.85˜1.15
159(23), 86(29), 72(100), 43(94)
(m, 4H), 0.97(t, 6H)
42
i-C 3 H 7
i-C 3 H 7
63˜64
4.08(d, 2H), 3.95(t, 1H), 3.84˜3.35(m, 2H), 1.42(d, 6H), 1.28
159(45), 128(36), 86(94), 43(100)
(d, 6H)
43
CH 2 ═CHCH 2
CH 2‘═
L
6.12˜5.02(m, 6H), 4.12(d, 2H), 4.01˜3.94(m, 4H), 3.65(t, 1H)
155(36), 124(27), 56(37), 41(100)
CHCH 2
44
n-C 4 H 9
n-C 4 H 9
L
4.14(d, 2H), 3.72(t, 1H), 3.36(t, 4H), 1.64˜1.19(m, 8H),
187(21), 86(57), 57(100), 44(58)
0.96(t, 6H)
45
i-C 4 H 9
i-C 4 H 9
L
4.12(d, 2H), 3.74(t, 1H), 3.24(d, 4H), 2.13˜1.78(m, 2H),
187(44), 144(31), 86(100), 57(69)
0.87(d, 12H)
46
C 2 H 5
i-C 3 H 7
L
4.14(d, 2H), 3.81(t, 1H), 3.75˜3.56(m, 1H), 3.27(q, 2H),
145(11), 86(38), 72(97), 43(100)
1.18(d, 6H), 1.15(t, 3H)
47
CH 3
n-C 4 H 9
L
4.08(d, 2H), 3.79(t, 1H), 3.45(t, 2H), 2.85(s, 3H), 1.78˜1.08
145(12), 114(21), 57(41), 44(100)
(m, 4H), 0.98(t, 3H)
48
CH 3
C 6 H 5 CH 2
L
7.25˜7.09(m, 5H), 5.45(t, 1H), 4.58(s, 2H), 4.38(d, 2H),
179(48), 120(87), 59(100)
2.98(s, 3H)
PREPARATION 49
Preparation of 2,2-Difluoro-1-trifluoromethyl-4′-methoxy styrene(III)
Step 1: Preparation of 2,2,2-Trifluoromethyl-4′-methoxyphenylketone(VII)
5.1 g(0.21 g atom) of magnesium was placed in 300 ml of dry diethyl ether and 37.4 g(0.2 mol) of p-bromoanisole was added dropwise thereto under a nitrogen atmosphere to prepare a Grignard reagent. The Grignard reagent solution was cooled to −78° C. and 28.4 g(0.2 mol) of ethyl trif luoroacetate was added dropwise thereto. The resulting solution was stirred for 30 to 60 minutes, mixed with crushed ice, acidified with concentrated hydrochloric acid and then extracted three times with diethyl ether. The organic layer was dried over magnesium sulfate and the solvent was removed under a reduced pressure to obtain a residue. The residue was distilled at 72 to 73° C./20 mmHg to obtain 35.09 g (yield 86%) of the title compound as a colorless oil.
1 H-NMR (CDCl 3 , TMS) δ: 7.62-6.81(m, 4H), 3.86(s, 3H); MS (m/e): 204(M + , 56), 135(100), 107(86), 92(66), 77(92).
Step 2: Preparation of 2,2-Difluoro-1-trifluoromethyl-4′-methoxy Styrene(III)
26.2 g(0.1 mol) of triphenylphosphine was dissolved in 250 ml of dry THF and 25.2 g(0.12 mol) of dibromodifluoromethane was added dropwise thereto under a nitrogen atmosphere at a temperature below 10° C. The resulting solution was stirred for thirty minutes and 10.2 g(0.05 mol) of the compound obtained in Step 1 was added thereto. The resultant solution was refluxed for 12 hours, cooled and distilled under a reduced pressure. The product was redistilled at 72 to 74° C. at 10 mmHg to obtain 9.36 g(yield 78.7%) of the title compound as a colorless liquid.
1 H-NMR (CDCl 3 , TMS) δ: 7.48-6.79(m, 4H), 3.79(s, 3H); MS (m/e): 238(M + , 69), 195(14), 145(35), 74(33), 59(100).
PREPARATIONS 50 to 65
The procedure of Preparation 49 was repeated to obtain compounds of formulas (VII) and (III) having various R 3 and R 4 groups, as in Tables 3a and 3b, respectively. The 1 H-NMR and MS analysis data and melting points of these compounds are also shown in respective tables.
PREPARATION 66
Preparation of 2,2-Difluoro-1-pentafluoroethyl styrene(III)
The procedure of Preparation 49 was repeated except that bromobenzene and ethyl pentaf luoropropionate were used in place of bromoanisole and ethyl trifluoroacetate, respectively, to obtain the title compound. The 1 H-NMR and MS analysis data and melting points of the compounds of formulas (VII) and (III) are also shown in Tables 3a and 3b, respectively.
TABLE 3a
(VII)
Prep. Nos. 49-65: R 4 = CF 3
Prep. No. 66: R 4 = CF 2 CF 3
Prep.
No.
R 3
1 H-NMR(CDCl 3 , TMS) δ (ppm)
MS (m/e)
yield (%)
b.p. (mmHg)
49
4-CH 3 O—C 6 H 4 —
7.62˜6.81(m, 4H), 3.86(s, 3H)
204(56), 135(100), 107(86), 92(66), 77(92)
86
72˜73 (20)
50
3-CH 3 —C 6 H 4 —
7.52˜6.92(m, 4H), 2.25(s, 3H)
188(16), 135(45), 119(96), 91(100), 65(45)
61
70˜71 (20)
51
4-CH 3 —C 6 H 4 —
7.42˜6.92(m, 4H), 2.25(s, 3H)
188(12), 119(100), 91(96), 65(45)
68
65˜66 (8)
52
4-C 2 H 3 —C 6 H 4 —
7.46˜7.19(m, 4H), 2.68(q, 2H), 1.23(t, 3H)
202(40), 133(91), 105(100), 76(64)
62
column
53
3,4-(CH 3 ) 2 —C 6 H 3 —
7.52˜6.69(m, 3H), 2.23(s, 3H), 2.20(s, 3H)
202(43), 133(98), 69(100)
71
column
54
3,5-(CH 3 ) 2 —C 6 H 3 —
7.31˜7.01(m, 3H), 2.25(s, 6H)
202(24), 133(100), 69(24)
69
column
55
3-CH 3 O—C 6 H 4 —
7.41˜6.79(m, 4H), 3.79(s, 3H)
204(36), 135(100), 107(56), 77(94)
78
64˜65 (33)
56
C 6 H 3 —
7.52˜7.12(m, 5H)
174(21), 105(100), 77(82), 69(54)
71
64˜65 (33)
57
4-C 2 H 3 O—C 6 H 4 —
7.54˜6.76(m, 4H), 4.09(q, 2H), 1.32(t, 3H)
218(16), 149(88), 121(62), 76(100)
69
column
58
3,4-OCH 2 O—C 6 H 4 —
7.92˜7.43(m, 3H), 6.25˜6.01(s, 2H)
218(42), 149(100), 65(49)
73
column
59
3-CF 3 —C 6 H 4 —
8.60˜7.61(m, 4H)
242(10), 173(68), 145(100), 76(62)
67
column
60
3-F—C 6 H 4 —
7.56˜6.89(m, 4H)
192(25), 123(100), 95(78), 75(31)
54
59˜60 (30)
61
4-F—C 6 H 4 —
7.76˜6.92(m, 4H)
192(16), 169(54), 123(100), 95(91), 75(76)
59
66˜67 (34)
62
3-Cl—C 6 H 4 —
8.38˜7.45(m, 4H)
208(10), 139(93), 111(100), 75(64)
70
58˜59 (10)
63
4-Cl—C 6 H 4 —
7.51˜7.41(m, 4H)
208(100), 173(92), 97(54), 69(24)
61
83˜84 (24)
64
3,5-Cl 2 —C 6 H 3 —
8.12˜7.86(m, 3H)
242(55), 173(100), 145(64), 109(32)
45
75˜76 (4)
65
C 4 H 3 S-2-yl-
8.28˜7.28(m, 3H)
180(23), 111(45), 84(100)
76
column
66
C 6 H 5
7.48˜7.02(m, 5H)
224(48), 205(100), 119(75)
68
62˜63(22)
TABLE 3b
(III)
Prep. Nos. 49-65: R 4 = CF 3
Prep. No. 66: R 4 = CF 2 CF 3
Prep.
No.
R 3
1 H-NMR(CDCl 3 , TMS) δ (ppm)
MS (m/e)
yield (%)
b.p. (mmHg)
49
4-CH 3 O—C 6 H 4 —
7.48˜6.79(m, 4H), 3.79(s, 3H)
238(69), 195(14), 145(35), 74(33), 59(100)
79
72˜74 (10)
50
3-CH 3 —C 6 H 4 —
7.46˜6.98(m, 4H), 2.43(s, 3H)
222(20), 203(70), 134(100)
45
column
51
4-CH 3 —C 6 H 4 —
7.32˜7.18(m, 4H), 2.45(s, 3H)
222(64), 203(23), 134(100)
62
column
52
4-C 2 H 3 —C 6 H 4 —
7.38˜7.25(m, 4H), 2.68(q, 2H), 1.19(t, 3H)
236(20), 145(100), 90(54)
62
column
53
3,4-(CH 3 ) 2 —C 6 H 4 —
7.28˜7.02(m, 3H), 2.38(s, 3H), 2.32(s, 3H)
236(18), 84(33), 45(100)
78
column
54
3,5-(CH 3 ) 2 —C 6 H 4 —
7.32˜7.12(m, 3H), 2.41(s, 6H)
236(29), 217(65), 148(100), 45(92)
98
column
55
3-CH 3 O—C 6 H 4 —
7.48˜6.87(m, 4H), 3.81(s, 3H)
238(42), 207(45), 188(37), 139(100), 69(94)
54
75 (10)
56
C 6 H 3 —
7.59˜7.31(m, 5H)
208(48), 84(83), 43(100)
67
column
57
4-C 2 H 5 O—C 6 H 4 —
7.51˜6.85(m, 4H), 4.12(q, 2H), 1.29(t, 3H)
252(47), 233(100), 84(64)
73
column
58
3,4-OCH 2 O—C 6 H 4 —
7.01˜6.79(m, 3H), 6.01(s, 2H)
252(46), 233(63), 164(82), 69(100)
72
column
59
3-CF 3 —C 6 H 4 —
7.82˜7.18(m, 4H)
276(52), 257(92), 188(100)
52
column
60
3-F—C 6 H 4 —
7.53˜6.96(m, 4H)
226(52), 207(25), 54(100)
54
column
61
4-F—C 6 H 4 —
7.52˜6.83(m, 4H)
226(20), 84(100)
63
column
62
3-Cl—C 6 H 4 —
7.54˜7.23(m, 4H)
242(26), 223(72), 188(49), 169(100)
63
column
63
4-Cl—C 6 H 4 —
7.56˜7.21(m, 4H)
242(35), 207(25), 174(70), 139(100), 60(79)
45
58 (10)
64
3,5-Cl 2 —C 6 H 5 —
7.57˜7.19(m, 3H)
276(100), 241(45)
84
85 (10)
65
C 4 H 3 S-2-yl-
7.67˜6.92(m, 3H)
214(42), 195(92), 126(100), 47(86)
63
column
66
C 6 H 5
7.57˜6.89(m, 5H)
246(67), 227(57), 127(100), 119(35)
48
138˜139(737)
EXAMPLE 1
Preparation of N-Methyl-(2′-fluoro-1′-trifluoromethylstyryl-2′-oxy)acetanilide (Compound 1)
330 mg(2 mmol) of N-methyl-2-hydroxyacetanilide obtained in Preparation 1 was added to 10 ml of acetone and 0.22 ml of lOM sodium hydroxide solution(2.2 mmol) was added thereto. The resulting solution was stirred for 30 minutes and 416 mg(2 mmol) of 2,2-difluoro-1-trifluoromethyl styrene obtained in Preparation 56 was added slowly thereto. The resultant solution was stirred for 1 to 2 hours. Acetone was removed under a reduced pressure and the resulting solution was mixed with water and extracted with ethyl acetate. The organic layer was dried over magnesium sulfate and the solvent was removed under a reduced pressure. The residue was subjected to silica gel column chromatography using a mixture of n-hexane and ethyl acetate (9:1) as an eluent to obtain 655 mg(yield 92.8%) of the title compound having two isomers as a colorless liquid. 1H-NMR (CDCl 3 TMS) δ: 7.52-6.91(m, 10H), 4.49(E isomer) 4.30(Z isomer)(s, 2H), 3.30(s, 3H)
MS (m/e): 353(M + , 12), 177(42), 120(100), 91(72), 77(96) 19 F-NMR (CDCl 3 , CFCl 3 ) δ: −57.36(Z isomer) −57.95(E isomer)(d, 3F), −83.40(E, isomer) −84.99(Z isomer)(q, 1F)
EXAMPLE 2
Preparation of (E)-N-Methyl-(2′-fluoro-1′-trifluoromethylstyryl-2′-oxy)acetanilide (Compound 2)
The compound obtained in Example 1 was subjected to column chromatography using a mixture of n-hexane and ethyl acetate(9:1) as an eluent to isolate a pure form of the E isomer as a colorless solid.
E isomer; 1 H-NMR (CDCl 3 , TMS) δ: 7.54-6.90(m, 10H), 4.49(s, 2H), 3.31(s, 3H); MS (m/e): 353(M + , 43), 177(48), 120(100), 91(68), 7(82); 19 F-NMR (CDCl 3 , CFCl 3 ) δ: −57.95(d, 3F), −83.40(q, 1F) m.p.: 91-92° C.
EXAMPLE 3
Preparation of (Z)-N-Methyl-(2′-fluoro-1′-trifluoromethylstyryl-2′-oxy)acetanilide (Compound 3)
The compound obtained in Example 1 was subjected to column chromatography using a mixture of n-hexane and ethyl acetate(9:1) as an eluent to isolate a pure form of the Z isomer as a colorless oil.
Z isomer; 1 H-NMR (CDCl 3 , TMS) δ: 7.51-7.11(m, 10H), 4.30(s, 2H), 3.30(s, 3H); MS (m/e): 353(M + , 57), 177(40), 120(100), 91(70), 77(97); 19 F-NMR (CDCl 3 , CFCl 3 ) δ: −57.36(d, 3F), −84.99(q, 1F).
EXAMPLES 4 to 220
Using each of the alcoholic compounds obtained in Preparations 1 to 31 and each of the fluorovinyl compounds obtained in Preparations 49 to 66, the procedure of Example 1 was repeated to obtain 217 compounds(Compounds 4 to 220) of formula (I) of the present invention having various R 1 , R 2 , R 3 and R 4 groups listed in Table 4. The 1 H-NMR and MS data and melting points of these compounds are also shown in Table 4. L in Table 4 represents liquid.
TABLE 4
R 4 = CF 3
(I)
Comp. No.
R 1
R 2
R 3
state (° C.)
NMR (CDCl 3 , TMS) δ (ppm)
MS (m/e)
1
C 6 H 5
CH 3
C 6 H 5
L
7.52˜6.91(m, 10H), 4.49(E) 4.30(Z) (s, 2H), 3.30(s, 3H)
353(12), 177(42), 120(100),
91(72), 77(96)
2
C 6 H 5
CH 3
C 6 H 5
91-92
7.54˜6.90(m, 10H), 4.49(s, 2H), 3.31(s, 3H)
353(43), 177(48), 120(100),
91(68), 77(82)
3
C 6 H 5
CH 3
C 6 H 5
L
7.51˜7.11(m, 10H), 4.30(s, 2H), 3.30(s, 3H)
353(57), 177(40), 120(100),
91(70), 77(97)
4
C 6 H 5
CH 3
3-CH 3 —C 6 H 4
L
7.51˜6.98(m, 9H), 4.48(E) 4.31(Z) (s, 2H), 3.31(s, 3H),
367(45), 148(100), 120(54),
2.35(s, 3H)
91(37)
5
C 6 H 5
CH 3
4-CH 3 —C 6 H 4
L
7.54˜6.89(m, 9H), 4.49(E) 4.31(Z) (s, 2H), 3.32(s, 3H),
367(28), 148(100), 120(68),
2.34(s, 3H))
92(52)
6
C 6 H 5
CH 3
4-C 2 H 3 —C 6 H 4
L
7.57˜7.01(m, 9H), 4.48(E) 4.30(Z) (s, 2H), 3.30(s, 3H),
381(68), 148(100), 120(75),
2.64(q, 2H), 1.21(t, 3H)
91(74), 77(76)
7
C 6 H 5
CH 3
3,4-(CH 3 ) 2 —C 6 H 3
L
7.51˜7.02(m, 8H), 4.49(E) 4.31(Z) (s, 2H), 3.31(s, 3H),
381(25), 148(92), 120(100),
2.30(s, 6H)
91(46), 77(59)
8
C 6 H 5
CH 3
3,5-(CH 3 ) 2 —C 6 H 3
L
7.58˜6.85(m, 8H), 4.48(E) 4.29(Z) (s, 2H), 3.32(s, 3H),
381(25), 148(100), 120(59),
2.31(s, 6H)
92(28)
9
C 6 H 5
CH 3
3-CH 3 O—C 6 H 4
L
7.65˜6.79(m, 9H), 4.49(E) 4.30(Z) (s, 2H), 3.85(s, 3H),
383(46), 364(28), 148(100),
3.33(s, 3H)
120(99)
10
C 6 H 5
CH 3
4-CH 3 O—C 6 H 4
L
7.66˜6.81(m, 9H), 4.49(E) 4.31(Z) (s, 2H), 3.86(s, 3H),
383(51), 207(55), 148(100),
3.32(s, 3H)
120(59)
11
C 6 H 5
CH 3
4-C 2 H 3 O—C 6 H 4
L
7.42˜6.80(m, 9H), 4.48(E) 4,30(Z) (s, 2H), 3.98(q, 2H),
397(49), 249(30), 148(100),
3.32(s, 3H), 1.39(t, 3H)
120(81)
12
C 6 H 5
CH 3
3,4-OCH 2 O—C 6 H 3
L
7.68˜6.82(m, 8H), 5.92(s, 2H), 4.49(E) 4.30(Z) (s, 2H),
397(35), 148(100), 120(70),
3.33(s, 3H)
77(43)
13
C 6 H 5
CH 3
3-CF 3 —C 6 H 4
L
7.68˜6.91(m, 9H), 4.48(E) 4.31(Z) (s, 2H), 3.31(s, 3H)
421(35), 402(19), 148(100),
120(99), 91(54)
14
C 6 H 5
CH 3
3-F—C 6 H 4
L
7.62˜6.99(m, 9H), 4.49(E) 4.31(Z) (s, 2H), 3.32(s, 3H)
371(40), 148(100), 120(91),
96(41), 77(37)
15
C 6 H 5
CH 3
4-F—C 6 H 4
L
7.68˜6.98(m, 9H), 4.48(E) 4.30(Z) (s, 2H), 3.33(s, 3H)
371(30), 148(100), 120(78),
77(42)
16
C 6 H 5
CH 3
3-Cl—C 6 H 4
L
7.72˜7.01(m, 9H), 4.49(E) 4.30(Z) (s, 2H), 3.34(s, 3H)
387(62), 148(100), 120(45),
77(47)
17
C 6 H 5
CH 3
4-Cl—C 6 H 4
L
7.65˜6.98(m, 9H), 4.48(E) 4.31(Z) (s, 2H), 3.35(s, 3H)
387(59), 148(100), 120(95),
91(46)
18
C 6 H 5
CH 3
3,5-Cl 2 —C 6 H 3
L
7.52˜7.09(m, 8H), 4.49(E) 4.32(Z) (s, 2H), 3.31(s, 3H)
421(25), 148(100), 120(84),
77(48)
19
C 6 H 5
CH 3
C 4 H 3 S-2-yl
L
7.62˜6.95(m, 8H), 4.49(E) 4.32(Z) (s, 2H), 3.32(s, 3H)
359(10), 148(100), 120(58),
77(15)
20
4-CH 3 O—C 6 H 4
CH 3
C 6 H 5
L
7.52˜6.87(m, 9H), 4.49(E) 4.31(Z) (s, 2H), 3.85(s, 3H),
383(12), 178(100), 144(81),
3.32(s, 3H)
121(48)
21
4-CH 3 O—C 6 H 4
CH 3
3-CH 3 —C 6 H 4
L
7.43˜6.76(m, 8H), 4.48(E) 4.29(Z) (s, 2H), 3.85(s, 3H),
397(47), 178(100), 147(40)
3.31(s, 3H), 2.35(s, 3H)
22
4-CH 3 O—C 6 H 4
CH 3
4-CH 3 —C 6 H 4
L
7.49˜6.79(m, 8H), 4.48(E) 4.28(Z) (s, 2H), 3.84(s, 3H),
397(100), 372(33), 178(98),
3.31(s, 3H), 2.35(s, 3H)
150(53)
23
4-CH 3 O—C 6 H 4
CH 3
3,4-(CH 3 ) 2 —C 6 H 3
81˜82
7.55˜6.79(m, 7H), 4.49(E) 4.29(Z) (s, 2H), 3.85(s, 3H),
411(40), 178(100), 147(69)
3.33(s, 3H), 2.31(s, 6H)
24
4-CH 3 O—C 6 H 4
CH 3
3,5-(CH 3 ) 2 —C 6 H 3
L
7.62˜6.78(m, 7H), 4.49(E) 4.30(Z) (s, 2H), 3.86(s, 3H),
411(51), 178(100), 147(47),
3.32(s, 3H), 2.30(s, 6H)
121(36)
25
4-CH 3 O—C 6 H 4
CH 3
3-CH 3 —C 6 H 4
L
7.56˜6.72(m, 8H), 4.49(E) 4.32(Z) (s, 2H), 3.87(s, 3H),
413(24), 178(100), 147(37)
3.85(s, 3H), 2.30(s, 3H)
26
4-CH 3 O—C 6 H 4
CH 3
3,4-OCH 2 O—C 6 H 3
L
7.59˜6.52(m, 7H), 5.94(s, 2H), 4.49(E) 4.31(Z) (s, 2H),
427(41), 178(100), 147(25),
3.86(s, 3H), 3.31(s, 3H)
121(24)
27
4-CH 3 O—C 6 H 4
CH 3
3,5-Cl—C 6 H 4
L
7.56˜6.85(m, 8H), 4.49(E) 4.30(Z) (s, 2H), 3.86(s, 3H),
417(18), 178(100), 147(46),
3.34(s, 3H)
121(41)
28
4-CH 3 O—C 6 H 4
CH 3
4-Cl—C 6 H 4
82˜83
7.49˜6.87(m, 8H), 4.48(E) 4.30(Z) (s, 2H), 3.85(s, 3H),
417(20), 178(100), 147(88),
3.42(s, 3H)
121(58)
29
4-CH 3 O—C 6 H 4
CH 3
3,5-Cl—C 6 H 4
L
7.71˜6.98(m, 7H), 4.49(E) 4.31(Z) (s, 2H), 3.85(s, 3H),
451(35), 178(100), 147(82),
3.32(s, 3H)
121(70)
30
4-F—C 6 H 4
CH 3
C 6 H 5
L
7.54˜7.03(m, 9H), 4.49(E) 4.31(Z) (s, 2H), 3.53(s, 3H),
371(41), 166(100), 138(84),
109(78)
31
4-F—C 6 H 4
CH 3
3-CH 3 —C 6 H 4
L
7.32˜7.02(m, 8H), 4.49(E) 4.30(Z) (s, 2H), 3.30(s, 3H),
385(43), 166(100), 138(82),
2.35(s, 3H)
109(79), 95(30)
32
4-F—C 6 H 4
CH 3
4-CH 3 —C 6 H 4
L
7.36˜7.00(m, 8H), 4.49(E) 4.31(Z) (s, 2H), 3.32(s, 3H),
385(21), 166(100), 138(94),
2.33(s, 3H)
109(80)
33
4-F—C 6 H 4
CH 3
3,5-(CH 3 ) 2 —C 6 H 3
L
7.30˜6.93(m, 7H), 4.49(E) 4.30(Z) (s, 2H), 3.31(s, 3H),
399(50), 166(100), 138(76),
2.32(s, 6H)
109(69)
34
4-F—C 6 H 4
CH 3
3-CH 3 O—C 6 H 4
L
7.31˜6.83(m, 8H), 4.48(E) 4.30(Z) (s, 2H), 3.86(s, 3H),
401(57), 166(100), 138(67),
3.32(s, 3H)
109(45)
35
4-F—C 6 H 4
CH 3
4-CH 3 O—C 6 H 4
L
7.35˜6.78(m, 8H), 4.49(E) 4.30(Z) (s, 2H), 3.84(s, 3H),
401(42), 166(100), 138(52),
3.33(s, 3H)
109(44)
36
4-F—C 6 H 4
CH 3
3-F—C 6 H 4
L
7.39˜6.94(m, 8H), 4.48(E) 4.31(Z) (s, 2H), 3.31(s, 3H)
389(41), 166(89), 138(100),
109(80), 95(30)
37
4-F—C 6 H 4
CH 3
4-F—C 6 H 4
L
7.46˜6.94(m, 8H), 4.49(E) 4.31(Z) (s, 2H), 3.32(s, 3H)
389(56), 166(100), 138(91),
109(76), 95(29)
38
4-F—C 6 H 4
CH 3
3-Cl—C 6 H 4
L
7.48˜7.06(m, 8H), 4.49(E) 4.32(Z) (s, 2H), 3.33(s, 3H)
405(26), 166(60), 138(42),
109(39), 43(100)
39
4-F—C 6 H 4
CH 3
4-Cl—C 6 H 4
L
7.45˜7.05(m, 8H), 4.48(E) 4.30(Z) (s, 2H), 3.32(s, 3H)
405(41), 166(100), 138(84),
109(73), 95(35)
40
4-F—C 6 H 4
CH 3
3.5-Cl 2 —C 6 H 3
L
7.34˜7.08(m, 7H), 4.49(E) 4.31(Z) (s, 2H), 3.30(s, 3H)
439(46), 166(100), 138(89),
109(90), 95(38)
41
4-Cl—C 6 H 4
CH 3
3,5-Cl 2 —C 6 H 3
136˜137
7.50˜7.05(m, 7H), 4.48(E) 4.30(Z) (s, 2H), 3.31(s, 3H)
455(31), 182(56), 147(100),
118(35), 77(24)
42
2,4-F 2 —C 6 H 3
CH 3
3-Cl—C 6 H 4
L
7.45˜6.85(m, 7H), 4.49(E) 4.31(Z) (s, 2H), 3.32(s, 3H)
423(21), 184(34), 156(24),
127(100)
43
2,4-Cl 2 —C 6 H 3
CH 3
4-F—C 6 H 4
L
7.79˜6.87(m, 7H), 4.48(E) 4.31(Z) (s, 2H), 3.33(s, 3H)
439(34), 216(57), 181(100),
145(50)
44
C 6 H 5
C 2 H 5
C 6 H 5
L
7.65˜7.09(m, 10H), 4.41(E) 4.28(Z) (s, 2H), 3.75(q, 2H),
367(12), 162(100), 134(79),
1.13(t, 3H)
106(57), 91(55)
45
C 6 H 5
C 2 H 5
3-CH 3 —C 6 H 4
L
7.49˜7.01(m, 9H), 4.42(E) 4.29(Z) (s, 2H), 3.76(q, 2H),
381(100), 363(10), 162(56),
2.39(s, 3H), 1.14(t, 3H)
134(64)
46
C 6 H 5
C 2 H 5
3-CH 3 O—C 6 H 4
L
7.62˜6.81(m, 9H), 4.43(E) 4.28(Z) (s, 2H), 3.85(s, 3H),
397(29), 378(16), 162(99),
3.74(q, 2H), 1.14(t, 3H)
134(100), 106(78)
47
C 6 H 5
C 2 H 5
4-C 2 H 3 O—C 6 H 4
L
7.42˜6.75(m, 9H), 4.42(E) 4.28(Z) (s, 2H), 3.94(q, 2H),
411(25), 221(54), 162(100),
3.72(q, 2H), 1.34(t, 3H), 1.13(t, 3H)
134(72)
48
C 6 H 5
C 2 H 5
3-CF 3 —C 6 H 4
L
7.82˜7.02(m, 9H), 4.42(E) 4.29(Z) (s, 2H), 3.74(q, 2H),
435(16), 162(100), 134(89),
1.14(t, 3H)
106(46)
49
C 6 H 5
C 2 H 5
3-F—C 6 H 4
L
7.49˜6.90(m, 9H), 4.42(E) 4.28(Z) (s, 2H), 3.75(q, 2H),
385(30), 162(100), 134(71),
1.13(t, 3H)
106(43)
50
C 6 H 5
C 2 H 5
4-F—C 6 H 4
L
7.62˜6.92(m, 9H), 4.41(E) 4.29(Z) (s, 2H), 3.76(q, 2H),
385(39), 162(100), 133(80),
1.14(t, 3H)
91(53)
51
C 6 H 3
C 2 H 5
4-Cl—C 6 H 4
L
7.57˜6.98(m, 9H), 4.42(E) 4.29(Z) (s, 2H), 3.76(q, 2H),
401(40), 162(100), 134(56)
1.14(t, 3H)
52
C 6 H 3
C 2 H 5
C 4 H 3 S-2-yl
L
7.68˜6.93(m, 8H), 4.42(E) 4.28(Z) (s, 2H), 3.75(q, 2H),
373(31), 162(100), 134(32)
1.16(t, 3H)
53
4-CH 3 —C 6 H 4
C 2 H 5
C 6 H 3
L
7.49˜6.94(m, 9H), 4.43(E) 4.29(Z) (s, 2H), 3.74(q, 2H),
381(55), 176(100, 105(44)
2.39(s, 3H), 1.13(t, 3H)
54
4-CH 3 —C 6 H 4
C 2 H 5
4-F—C 6 H 4
L
7.63˜6.89(m, 8H), 4.42(E) 4.29(Z) (s, 2H), 3.74(q, 2H),
399(55), 176(100), 148(55)
2.38(s, 3H), 1.12(t, 3H)
55
4-CH 3 O—C 6 H 4
C 2 H 5
C 6 H 3
L
7.49˜6.85(m, 9H), 4.41(E) 4.27(Z) (s, 2H), 3.81(s, 3H),
397(23), 378(12), 193(100),
3.72(q, 2H), 1.13(t, 3H)
165(36)
56
4-CH 3 O—C 6 H 4
C 2 H 5
4-F—C 6 H 4
L
7.48˜6.84(m, 8H), 4.42(E) 4.28(Z) (s, 2H), 3.82(s, 3H),
415(14), 192(100), 164(43),
3.75(q, 2H), 1.12(t, 3H)
121(75)
57
3-CF 3 —C 6 H 4
C 2 H 5
C 6 H 3
52˜53
7.81˜7.23(m, 9H), 4.43(E) 4.29(Z) (s, 2H), 3.75(q, 2H),
435(26), 221(100), 174(61),
1.13(t, 3H)
159(69)
58
3-CF 3 —C 6 H 4
C 2 H 5
4-CH 3 —C 6 H 4
48˜49
7.86˜7.02(m, 8H), 4.41(E) 4.28(Z) (s, 2H), 3.72(q, 2H),
449(10), 230(100), 202(36),
2.38(s, 3H), 1.12(t, 3H)
174(27)
59
3-CF 3 —C 6 H 4
C 2 H 5
4-F—C 6 H 4
L
7.89˜6.85(m, 8H), 4.41(E) 4.29(Z) (s, 2H), 3.73(q, 2H),
453(26), 231(100), 201(63)
1.14(t, 3H)
60
2-Cl—C 6 H 4
C 2 H 3
C 6 H 3
L
7.60˜7.12(m, 9H), 4.40(E) 4.28(Z) (s, 2H), 4.02(m, 1H),
401(72), 382(15), 196(100),
3.48(m, 1H), 1.12(t, 3H)
168(44), 146(35)
61
2-Cl—C 6 H 4
C 2 H 5
4-CH 3 —C 6 H 4
L
7.62˜7.02(m, 8H), 4.40(E) 4.28(Z) (s, 2H), 4.06(m, 1H),
415(26), 196(100), 118(35)
3.49(m, 1H), 2.39(s, 3H), 1.14(t, 3H)
62
3-Cl—C 6 H 4
C 2 H 5
C 6 H 3
L
7.49˜6.94(m, 9H), 4.41(E) 4.28(Z) (s, 2H), 3.73(q, 2H),
401(14), 196(100), 168(24),
1.13(t, 3H)
146(27)
63
4-Cl—C 6 H 4
C 2 H 5
C 6 H 5
L
7.50˜6.90(m, 9H), 4.40(E) 4.28(Z) (s, 2H), 3.74(q, 2H),
401(10), 196(100), 146(37),
1.14(t, 3H)
118(18)
64
4-Cl—C 6 H 4
C 2 H 5
4-CH 3 —C 6 H 4
70˜71
7.62˜6.95(m, 8H), 4.40(E) 4.29(Z) (s, 2H), 3.76(q, 2H),
415(12), 196(81), 161(100),
2.39(s, 3H), 1.14(t, 3H)
118(27)
65
C 6 H 5
n-C 3 H 7
C 6 H 3
L
7.50˜7.02(m, 10H), 4.40(E) 4.25(Z) (s, 2H), 3.65(t, 2H),
381(11), 176(100), 134(84),
1.68˜1.41(m, 2H), 0.91(t, 3H)
106(93), 77(62)
66
C 6 H 5
n-C 3 H 7
4-CH 3 —C 6 H 4
L
7.62˜6.97(m, 9H), 4.40(E) 4.26(Z) (s, 2H), 3.64(t, 2H),
395(20), 377(13), 176(100),
2.32(s, 3H), 1.67˜1.42(m, 2H), 0.91(t, 3H)
67
4-CH 3 O—C 6 H 4
n-C 3 H 7
C 6 H 3
L
7.53˜6.86(m, 9H), 4.40(E) 4.25(Z) (s, 2H), 3.81(s, 3H),
411(24), 206(100), 178(35),
3.65(t, 2H), 1.65˜1.41(m, 2H), 0.91(t, 3H)
164(48), 136(42)
68
4-CH 3 O—C 6 H 4
n-C 3 H 7
4-CH 3 —C 6 H 4
L
7.62˜6.79(m, 8H), 4.39(E) 4.25(Z) (s, 2H), 3.83(s, 3H),
425(29), 406(14), 203(100)
3.65(t, 2H), 2.32(s, 3H), 1.68˜1.42(m, 2H), 0.92(t, 3H)
69
C 6 H 3
i-C 3 H 7
C 6 H 3
54˜55
7.50˜7.01(m, 10H), 5.09˜4.87(m, 1H), 4.30(E) 4.14(Z)
381(12), 176(59), 134(100),
(s, 2H), 1.08(d, 6H)
106(97), 77(89)
70
C 6 H 3
i-C 3 H 7
3-CH 3 —C 6 H 4
L
7.62˜6.82(m, 9H), 5.10˜4.89(m, 1H), 4.29(E) 4.16(Z)
395(39), 176(34), 134(100),
(s, 2H), 2.39(s, 3H), 1.09(d, 6H)
106(69)
71
C 6 H 3
i-C 3 H 7
4-CH 3 —C 6 H 4
67˜68
7.62˜6.97(m, 9H), 5.28˜4.86(m, 1H), 4.29(E) 4.15(Z)
395(65), 376(49), 176(100),
(s, 2H), 2.46(s, 3H), 1.09(d, 6H)
106(76)
72
C 6 H 3
i-C 3 H 7
3,5-(CH 3 ) 2 —C 6 H 3
L
7.64˜6.85(m, 8H), 5.28˜4.88(m, 1H), 4.30(E) 4.16(Z)
409(56), 134(100), 106(87),
(s, 2H), 2.38(s, 6H), 1.09(d, 6H)
77(52)
73
C 6 H 3
i-C 3 H 7
3-CH 3 O—C 6 H 4
L
7.51˜6.79(m, 9H), 5.19˜4.84(m, 1H), 4.28(E) 4.14(Z)
411(30), 176(39), 134(100),
(s, 2H), 3.80(s, 3H), 1.08(d, 6H)
106(50)
74
C 6 H 3
i-C 3 H 7
4-CH 3 O—C 6 H 3
48˜49
7.71˜6.95(m, 9H), 5.21˜4.85(m, 1H), 4.29(E) 4.15(Z)
411(33), 176(57), 134(100),
(s, 2H), 3.81(s, 3H), 1.09(d, 6H)
106(74)
75
C 6 H 3
i-C 3 H 7
4-C 2 H 3 O—C 6 H 4
L
7.48˜6.79(m, 9H), 5.10˜4.84(m, 1H), 4.28(E) 4.16(Z)
425(70), 176(63), 134(100),
(s, 2H), 4.40(q, 2H), 1.38(t, 3H), 1.09(d, 6H)
106(69), 84(55)
76
C 6 H 3
i-C 3 H 7
3,4-OCH 2 O—C 6 H 3
L
7.59˜6.75(m, 8H), 5.96(s, 2H), 5.11˜4.86(m, 1H),
425(15), 219(30), 134(100),
4.29(E) 4.16(Z) (s, 2H), 1.08(d, 6H)
106(60)
77
C 6 H 3
i-C 3 H 7
3-F—C 6 H 4
L
7.50˜6.91(m, 9H), 5.10˜4.82(m, 1H), 4.29(E) 4.14(Z)
399(40), 134(100), 106(70)
(s, 2H), 1.09(d, 6H)
78
C 6 H 3
i-C 3 H 7
4-F—C 6 H 4
L
7.54˜6.89(m, 9H), 5.09˜4.84(m, 1H), 4.28(E) 4.15(Z)
399(35), 176(45), 134(100),
(s, 2H), 1.08(d, 6H)
106(83)
79
C 6 H 3
i-C 3 H 7
3-Cl—C 6 H 4
L
7.69˜6.94(m, 9H), 5.11˜4.88(m, 1H), 4.29(E) 4.15(Z)
415(45), 176(31), 134(100),
(s, 2H), 1.08(d, 6H)
106(65)
80
C 6 H 3
i-C 3 H 7
4-Cl—C 6 H 4
72˜73
7.87˜6.87(m, 9H), 5.21˜4.87(m, 1H), 4.28(E) 4.14(Z)
415(25), 176(28), 134(100),
(s, 2H), 1.09(d, 6H)
106(73), 78(34)
81
C 6 H 3
i-C 3 H 7
C 4 H 3 S-2-yl
63˜64
7.50˜6.94(m, 8H), 5.18˜4.81(m, 1H), 4.29(E) 4.16(Z)
387(22), 176(31), 134(100),
(s, 2H), 1.08(d, 6H)
106(85), 77(41), 43(46)
82
2-CH 3 —C 6 H 4
i-C 3 H 7
C 6 H 3
L
7.61˜6.97(m, 9H), 5.00˜4.78(m, 1H), 4.28(E) 4.17(Z)
395(46), 148(100), 120(47),
(dd, 2H), 2.32(s, 3H), 1.27(d, 3H), 1.02(d, 3H)
45(23)
83
2-CH 3 —C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
L
7.48˜6.95(m, 8H), 4.95˜4.75(m, 1H), 4.29(E) 4.15(Z)
409(9), 190(34), 148(100),
(dd, 2H), 2.33(s, 3H), 2.31(s, 3H), 1.30(d, 3H),
120(80), 118(30), 91(30),
1.00(d, 3H)
45(42)
84
2-CH 3 —C 6 H 4
i-C 3 H 7
3,4-(CH 3 ) 2 —C 6 H 3
L
7.42˜7.00(m, 7H), 4.96˜4.76(m, 1H), 4.28(E) 4.15(Z)
423(15), 148(100), 120(49),
(dd, 2H), 2.33(s, 3H), 2.30(s, 6H), 1.30(d, 3H),
45(22)
1.02(d, 3H)
85
2-CH 3 —C 6 H 4
i-C 3 H 7
3,5-(CH 3 ) 2 —C 6 H 3
L
7.40˜6.85(m, 7H), 4.95˜4.76(m, 1H), 4.28(E) 4.16(Z)
423(20), 148(100), 120(45),
(dd, 2H), 2.33(s, 3H), 2.31(s, 6H), 1.31(d, 3H),
45(24)
1.01(d, 3H)
86
2-CH 3 —C 6 H 4
i-C 3 H 7
3-CH 3 O—C 6 H 4
L
7.46˜6.75(m. 8H), 4.90˜4.72(m, 1H), 4.28(E) 4.16(Z)
425(R), 148(100), 120(82),
(dd, 2H), 3.82(s, 3H), 2.32(s, 3H), 1.28(d, 3H),
45(39)
0.98(d, 3H)
87
2-CH 3 —C 6 H 4
i-C 3 H 7
4-CH 3 O—C 6 H 4
L
7.40˜6.80(m, 8H), 4.91˜4.75(m, 1H), 4.28(E) 4.15(Z)
425(8), 148(100), 120(63),
(dd, 2H), 3.81(s, 3H), 2.31(s, 3H), 1.29(d, 3H),
45(25)
0.99(d, 3H)
88
2-CH 3 —C 6 H 4
i-C 3 H 7
3-F—C 6 H 4
L
7.38˜6.87(m, 8H), 4.91˜4.72(m, 1H), 4.28(E) 4.16(Z)
413(54), 148(100), 120(68),
(dd, 2H), 2.31(s, 3H), 1.29(d, 3H), 0.98(d, 3H)
45(39)
89
2-CH 3 —-C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.51˜6.95(m, 8H), 4.97˜4.78(m, 1H), 4.28(E) 4.15(Z)
413(22), 190(89), 148(100),
(dd, 2H), 2.30(s, 3H), 1.25(d, 3H), 1.01(d, 3H)
120(94), 91(73)
90
2-CH 3 —C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.54˜7.00(m, 8H), 4.96˜4.74(m, 1H), 4.27(E) 4.16(Z)
429(16), 148(100), 120(51),
(dd, 2H), 2.28(s, 3H), 1.30(d, 3H), 1.01(d, 3H)
45(23)
91
2-CH 3 —C 6 H 4
i-C 3 H 7
4-Cl—C 6 H 4
L
7.50˜7.00(m, 8H), 4.95˜4.76(m, 1H), 4.28(E) 4.15(Z)
429(30), 148(100), 120(52),
(dd, 2H), 2.29(s, 3H), 1.28(d, 3H), 1.00(d, 3H)
84(32), 45(36)
92
2-CH 3 —C 6 H 4
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
L
7.52˜7.00(m, 7H), 4.95˜4.75(m, 1H), 4.27(E) 4.15(Z)
463(16), 148(100), 120(73),
(dd, 2H), 228(s, 3H), 1.30(d, 3H), 1.01(d, 3H)
45(45)
93
3-CH 3 —C 6 H 4
i-C 3 H 7
C 6 H 5
64˜65
7.45˜6.80(m, 9H), 5.02˜4.79(m, 1H), 4.30(E) 4.12(Z)
395(14), 190(56), 148(100),
(s, 2H), 2.35(s, 3H), 1.08(d, 6H)
120(95), 91(35)
94
3-CH 3 —C 6 H 4
i-C 3 H 7
3-CH 3 —C 6 H 4
L
7.32˜6.79(m, 8H), 5.03˜4.80(m, 1H), 4.30(E) 4.15(Z)
409(11), 190(28), 148(100),
(s, 2H), 2.34(s, 3H), 2.30(s, 3H), 1.09(d, 6H)
120(51), 84(39)
95
3-CH 3 —C 6 H 4
i-C 3 H 7
4-C 2 H 5 —C 6 H 4
76˜77
7.32˜6.80(m, 8H), 5.04˜4.83(m, 1H), 4.28(E) 4.14(Z)
409(36), 190(60), 148(100),
(s, 2H), 2.38(s, 3H), 2.31(s, 3H), 1.05(d, 6H)
120(54)
96
3-CH 3 —C 6 H 4
i-C 3 H 7
4-C 2 H 5 —C 6 H 4
66˜67
7.40˜6.81(m, 8H), 5.04˜4.84(m, 1H), 4.30(E) 4.16(Z)
423(41), 190(47), 148(100),
(s, 2H), 2.65(q, 2H), 2.38(s, 3H), 1.26(1, 3H),
120(60), 91(21)
1.09(d, 6H)
97
3-CH 3 —C 6 H 4
i-C 3 H 7
3,4-(CH 3 ) 2 —C 6 H 3
L
7.48˜6.81(m, 7H), 5.03˜4.85(m, 1H), 4.31(E) 4.17(Z)
423(56), 190(39), 148(100),
(s, 2H), 2.39(s, 3H), 2.25(s, 6H), 1.08(d, 6H)
120(52), 91(20)
98
3-CH 3 —C 6 H 4
i-C 3 H 7
3,5-(CH 3 ) 2 —C 6 H 3
60˜61
7.38˜6.80(m, 7H), 5.05˜4.85(m, 1H), 4.29(E) 4.15(Z)
423(57), 190(69), 148(100),
(s, 2H), 2.35(s, 3H), 2.29(s, 6H), 1.07(d, 6H)
120(63), 91(24)
99
3-CH 3 —C 6 H 4
i-C 3 H 7
3-CH 3 —C 6 H 4
46˜47
7.41˜6.82(m, 8H), 5.06˜4.86(m, 1H), 4.30(E) 4.16(Z)
425(58), 190(37), 148(100),
(s, 2H), 3.80(s, 3H), 2.35(s, 3H), 1.10(d, 6H)
120(53)
100
3-CH 3 —C 6 H 4
i-C 3 H 7
4-CH 3 O—C 6 H 4
68˜69
7.37˜6.79(m, 8H), 5.01˜4.80(m, 1H), 4.30(E) 4.15(Z)
425(31), 190(11), 148(100),
(s, 2H), 3.82(s, 3H), 2.34(s, 3H), 1.07(d, 6H)
1.20(79), 91(30)
101
3-CH 3 —C 6 H 4
i-C 3 H 7
3-F—C 6 H 4
42˜43
7.35˜6.81(m, 8H), 5.01˜4.78(m, 1H), 4.30(E) 4.14(Z)
413(57), 190(37), 148(100),
(s, 2H) 2.35(s, 3H), 1.09(d, 6H)
120(54)
102
3-CH 3 —C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.50˜6.85(m, 8H), 5.04˜4.85(m, 1H), 4.30(E) 4.16(Z)
413(51), 148(100), 120(90)
(s, 2H), 2.39(s, 3H), 1.09(d, 6H)
103
3-CH 3 —C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.48˜6.78(m, 8H), 5.04˜4.85(m, 1H), 4.31(E) 4.14(Z)
429(25), 148(100), 120(83)
(s, 2H), 2.38(s, 3H), 1.08(d, 6H)
104
3-CH 3 —C 6 H 4
i-C 3 H 7
4-Cl—C 6 H 4
56˜57
7.40˜6.62(m, 8H), 5.02˜4.85(m, 1H), 4.30(E) 4.15(Z)
429(55), 190(23), 148(100),
(s, 2H), 2.38(s, 3H), 1.08(d, 6H)
120(53)
105
3-CH 3 —C 6 H 4
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
58˜59
7.35˜6.80(m, 7H), 5.00˜4.80(m, 1H), 4.31(E) 4.17(Z)
463(51), 148(100), 120(37)
(s, 2H), 2.35(s, 3H), 1.07(d, 6H)
106
3-CH 3 O—C 6 H 4
i-C 3 H 7
C 6 H 5
80˜81
7.50˜6.58(m, 9H), 5.08˜4.85(m, 1H), 4.29(E) 4.14(Z)
411(28), 208(100), 165(82),
(s, 2H), 3.82(s, 3H), 1.09(d, 6H)
137(36)
107
3-CH 3 O—C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
93˜94
7.52˜6.53(m, 8H), 5.23˜4.78(m, 1H), 4.30(E) 4.15(Z)
425(33), 375(100), 118(78)
(s, 2H), 3.82(s, 3H), 2.41(s, 3H), 1.12(d, 6H)
108
3-CH 3 O—C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
50˜51
7.45˜6.55(m, 8H), 5.02˜4.85(m, 1H), 4.31(E) 4.16(Z)
429(52), 206(82), 164(100),
(s, 2H), 3.80(s, 3H), 1.09(d, 6H)
136(86), 45(24)
109
3,4-CH 3 O—C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.51˜6.76(m, 8H), 5.02˜4.82(m, 1H), 4.30(E) 4.14(Z)
445(50), 206(50), 164(100),
(s, 2H), 3.82(s, 3H), 1.02(d, 6H)
136(68), 45(54)
110
3-CH 3 O—C 6 H 4
i-C 3 H 7
4-Cl—C 6 H 4
60˜61
7.45˜6.58(m, 8H), 5.02˜4.85(m, 1H), 4.29(E) 4.14(Z)
445(24), 206(66), 164(100),
(s, 2H), 3.81(s, 3H), 1.10(d, 6H)
136(92), 45(37)
111
3-CH 3 O—C 6 H 4
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
L
7.41˜6.61(m, 7H), 5.00˜4.84(m, 1H), 4.30(E) 4.15(Z)
479(51), 206(54), 164(100),
(s, 2H), 3.81(s, 3H), 1.09(d, 6H)
137(74), 45(26)
112
4-CH 3 O—C 6 H 4
i-C 3 H 7
C 6 H 3
L
7.49˜6.81(m, 9H), 5.04˜4.82(m, 1H), 4.29(E) 4.13(Z)
411(56), 206(68), 164(100),
(s, 2H), 3.81(s, 3H), 1.04(d, 6H)
136(52), 121(74)
113
4-CH 3 O—C 6 H 4
i-C 3 H 7
3-CH 3 —C 6 H 4
L
7.55˜6.88(m, 8H), 5.12˜4.79(m, 1H), 4.31(E) 4.16(Z)
425(26), 210(81), 168(100),
(s, 2H), 3.81(s, 3H), 2.38(s, 3H), 1.08(d, 6H)
140(53), 133(49), 45(51)
114
4-CH 3 O—C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
87˜88
7.62˜6.98(m, 8H), 5.21˜4.82(m, 1H), 4.29(E) 4.14(Z)
425(14), 406(10), 203(100),
(s, 2H), 3.82(s, 3H), 2.35(s, 3H), 1.08(d, 6H)
69(27)
115
4-CH 3 O—C 6 H 4
i-C 3 H 7
4-CH 3 O—C 6 H 4
L
7.40˜6.81(m, 8H), 5.02˜4.83(m, 1H), 4.29(E) 4.15(Z)
441(30), 206(76), 164(100),
(s, 2H), 3.81(s, 3H), 3.79(s, 3H), 1.08(d, 6H)
136(42), 121(47)
116
4-CH 3 O—C 6 H 4
i-C 3 H 4
4-F—C 6 H 4
L
7.49˜6.86(m, 8H), 5.03˜4.84(m, 1H), 4.30(E) 4.15(Z)
429(57), 206(36), 164(100),
(s, 2H), 3.82(s, 3H), 1.10(d, 6H)
136(52)
117
4-CH 3 O—C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.49˜6.88(m, 8H), 5.03˜4.85(m, 1H), 4.29(E) 4.17(Z)
445(62), 164(100), 121(42)
(s, 2H), 3.82(s, 3H), 1.10(d, 6H)
118
3-CF 3 —C 6 H 4
i-C 3 H 7
C 6 H 3
L
7.80˜7.23(m, 9H), 5.12˜4.89(m, 1H), 4.30(E) 4.15(Z)
449(36), 430(19), 244(100),
(s, 2H), 1.02(d, 6H)
174(40)
119
3-CF 2 —C 6 H 4
i-C 3 H 7
3,4-OCH 2 O—C 6 H 3
L
7.95˜6.72(m, 7H), 5.95(s, 2H), 5.28˜4.84(m, 1H),
493(35), 244(21), 202(100)
4.29(E) 4.14(Z) (s, 2H), 1.09(d, 6H)
120
3-CF 3 —C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.81˜6.98(m, 8H), 5.05˜4.92(m, 1H), 4.29(E) 4.16(Z)
467(30), 244(35), 203(100),
(s, 2H), 1.12(d, 6H)
174(78), 145(65)
121
3-CF 4 —C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.79˜7.18(m, 8H), 5.09˜4.89(m, 1H), 4.30(E) 4.14(Z)
483(24), 202(100), 174(31)
(s, 2H), 1.10(d, 6H)
122
4-F—C 6 H 4
i-C 3 H 7
C 6 H 5
75˜76
7.51˜6.91(m, 9H), 5.15˜4.67(m, 1H), 4.29(E) 4.14(Z)
399(70), 380(26), 194(100),
(s, 2H), 1.02(d, 6H)
152(94), 123(91), 109(36)
123
4-F—C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
68˜69
7.46˜6.98(m, 8H), 5.21˜4.78(m, 1H), 4.30(E) 4.15(Z)
413(45), 394(100), 109(36)
(s, 2H), 2.46(s, 3H), 1.07(d, 6H)
124
4-F—C 6 H 4
i-C 3 H 7
3-CH 3 O—C 6 H 4
L
7.51˜6.91(m, 8H), 5.51˜4.67(m, 1H), 4.29(E) 4.17(Z)
429(22), 410(15), 194(47),
(s, 2H), 3.85(s, 3H), 1.02(d, 6H)
152(100), 124(41)
125
4-F—C 6 H 4
i-C 3 H 7
3-CF 3 —C 6 H 4
L
7.79˜7.05(m, 1H), 5.23˜4.82(m, 1H), 4.30(E) 4.14(Z)
467(15), 194(51), 152(100),
(s, 2H), 1.08(d, 6H)
124(36)
126
4-F—C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.49˜6.98(m, 8H), 5.06˜4.87(m, 1H), 4.29(E) 4.16(Z)
417(36), 194(92), 152(100),
(m, 2H), 1.11(d, 6H)
122(86)
127
4-F—C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.41˜7.01(m, 8H), 5.02˜4.85(m, 1H), 4.30(E) 4.14(Z)
433(45), 152(100), 124(41)
(m, 2H), 1.02(d, 6H)
128
4-F—C 6 H 4
i-C 3 H 7
C 4 H 3 S-2-yl
L
7.46˜6.97(m, 7H), 5.21˜4.75(m, 1H), 4.29(E) 4.15(Z)
405(31), 194(36), 152(100)
(s, 2H), 1.09(d, 6H)
122(21), 109(24)
129
2-Cl—C 6 H 4
i-C 3 H 7
C 6 H 3
L
7.58˜7.02(m, 9H), 4.98˜4.79(m, 1H), 4.29(E) 4.15(Z)
415(25), 168(100), 140(64),
(dd, 2H, 1.24(d, 3H), 1.02(d, 3H)
45(57)
130
2-Cl—C 6 H 4
i-C 3 H 7
3-CH 3 —C 6 H 4
L
7.61˜7.02(m, 8H), 5.03˜4.79(m, 1H), 4.31(E) 4.14(Z)
429(60), 168(100), 140(53),
(dd, 2H), 2.35(s, 3H), 1.24(d, 3H), 1.02(d, 3H)
131
2-Cl—C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
L
7.61˜7.08(m, 8H), 4.98˜4.79(m, 1H), 4.30(E) 4.15(Z)
429(15), 168(100), 140(44)
(dd, 2H), 2.35(s, 3H), 1.25(d, 3H), 1.02(d, 3H)
132
2-Cl—C 6 H 4
i-C 3 H 7
4-C 2 H 5 —C 6 H 4
L
7.60˜7.08(m, 8H), 4.98˜4.78(m, 1H), 4.33(E) 4.14(Z)
443(17), 210(59), 168(100),
(dd, 2H), 2.65(q, 2H), 1.32(t, 3H), 1.25(d, 3H),
1.33(86), 45(78)
1.03(d, 3H)
133
2-Cl—C 6 H 4
i-C 3 H 7
3,4-(CH 3 ) 2 —C 6 H 3
L
7.59˜7.02(m, 7H), 4.98˜4.79(m, 1H), 4.29(E) 4.16(Z)
443(20), 170(59), 168(100),
(dd, 2H, 2.26(s, 6H), 1.23(d, 3H), 1.02(d, 3H)
140(59)
134
2-Cl—C 6 H 4
i-C 3 H 7
3,5-(CH 3 ) 2 —C 6 H 3
64˜65
7.58˜6.89(m, 7H), 5.02˜4.78(m, 1H), 4.30(E) 4.15(Z)
443(30), 168(100), 140(44)
(dd, 2H), 2.28(s, 6H), 1.23(d, 3H), 1.00(d, 3H)
135
2-Cl—C 6 H 4
i-C 3 H 7
3-CH 3 O—C 6 H 4
L
7.60˜6.80(m, 8H), 5.00˜4.80(m, 1H), 4.29(E) 4.17(Z)
445(30), 210(25), 168(100),
(dd, 2H) 3.79(s, 3H), 1.27(d, 3H), 1.01(d, 3H)
140(68), 133(56), 45(36)
136
2-Cl—C 6 H 4
i-C 3 H 7
4-CH 3 O—C 6 H 4
L
7.59˜6.87(m, 8H), 4.99˜4.78(m, 1H), 4.32(E) 4.13(Z)
445(25), 168(100), 140(49),
(dd, 2H), 3.79(s, 3H), 1.25(d, 3H), 1.03(d, 3H)
45(78)
137
2-Cl—C 6 H 4
i-C 3 H 7
3-F—C 6 H 4
L
7.61˜6.91(m, 8H), 5.01˜4.78(m, 1H), 4.30(E) 4.18(Z)
4.33(25), 210(57), 168(100),
(dd, 2H), 1.28(d, 3H), 1.02(d, 3H)
140(81), 133(56)
138
2-Cl—C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.60˜6.98(m, 8H), 5.02˜4.79(m, 1H), 4.32(E) 4.19(Z)
433(30), 168(100), 140(67),
(dd, 2H), 1.29(d, 3H), 1.03(d, 3H)
133(47)
139
2-Cl—C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.59˜7.04(m, 8H), 4.99˜4.78(m, 1H), 4.33(E) 4.16(Z)
449(20), 168(100), 140(64),
(dd, 2H), 1.25(d, 3H), 1.02(d, 3H)
45(75)
140
2-Cl—C 6 H 4
i-C 3 H 7
4-Cl—C 6 H 4
L
7.62˜7.15(m, 8H), 5.00˜4.75(m, 1H), 4.30(E) 4.17(Z)
449(15), 168(100), 140(49),
(dd, 2H), 1.29(d, 3H), 1.02(d, 3H)
133(37), 45(34)
141
2-Cl—C 6 H 4
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
L
7.57˜7.01(m, 7H), 4.97˜4.79(m, 1H), 4.30(E) 4.22(Z)
483(25), 168(100), 140(77),
(dd, 2H), 1.23(d, 3H), 1.02(d, 3H)
133(63)
142
3-Cl—C 6 H 4
i-C 3 H 7
C 6 H 3
L
7.65˜6.98(m, 9H), 5.09˜4.84(m, 1H), 4.30(E) 4.15(Z)
415(10), 211(45), 169(100),
(s, 2H), 1.09(d, 6H)
87(35)
143
3-Cl—C 6 H 4
i-C 3 H 7
4-CH 3 —C 6 H 4
79˜80
7.52˜6.53(m, 8H), 5.24˜4.72(m, 1H), 4.29(E) 4.17(Z)
429(15), 210(42), 168(100),
(s, 2H), 2.34(s, 3H), 1.21(d, 6H)
140(53), 133(41)
144
3-Cl—C 6 H 4
i-C 3 H 7
4-F—C 6 H 4
L
7.51˜6.90(m, 8H), 5.03˜4.83(m, 1H), 4.30(E) 4.16(Z)
433(45), 210(42), 168(100),
(s, 2H), 1.08(d, 6H)
140(80), 133(52)
145
3-Cl—C 6 H 4
i-C 3 H 7
3-Cl—C 6 H 4
L
7.69˜6.95(m, 8H), 5.09˜4.85(m, 1H), 4.31(E) 4.18(Z)
449(35), 168(100), 140(60),
(s, 2H), 1.10(d, 6H)
45(8H)
146
2-Cl-4-F—C 6 H 3
i-C 3 H 4
C 6 H 5
L
7.45˜6.92(m, 1), 5.00˜4.77(m, 1H), 4.32(E) 4.19(Z)
433(56), 193(54), 168(65),
(dd, 2H), 1.29(d, 3H), 1.03(d, 3H)
151(100), 45(46)
147
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3-CH 3 —C 6 H 4
L
7.34˜6.98(m, 7H), 5.00˜4.77(m, 1H), 4.32(E) 4.17(Z)
447(35), 186(33), 84(100),
(dd, 2H), 2.32(s, 3H), 1.27(d, 3H), 1.01(d, 3H)
45(49)
148
2-Cl-4-F—C 6 H 3
i-C 3 H 7
4-CH 3 —C 6 H 4
L
7.41˜6.99(m, 7H), 5.01˜4.76(m, 1H), 4.30(E) 4.16(Z)
447(55), 193(67), 186(78),
(dd, 2H), 2.33(s, 3H), 1.26(d, 3H), 1.04(d, 3H)
151(100), 45(35)
149
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3,4-(CH 3 ) 2 —C 6 H 3
L
7.35˜6.97(m, 6H), 5.01˜4.78(m,1H), 4.30(E) 4.19(Z)
461(56), 193(66), 186(88),
(dd, 2H), 2.33(s, 6H), 1.26(d, 3H), 1.02(d, 3H)
151(100), 45(49)
150
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3,5-(CH 3 ) 2 —C 6 H 3
70˜71
7.38˜6.82(m, 6H), 5.00˜4.76(m, 1H), 4.31(E) 4.16(Z)
461(31), 193(64), 186(85),
(dd, 2H), 2.30(s, 6H), 1.27(d, 3H), 1.00(d, 3H)
151(100), 45(54)
151
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3-F—C 6 H 4
L
7.40˜6.95(m, 7H), 5.00˜4.79(m, 1H), 4.31(E) 4.17(Z)
451(40), 193(61), 186(66),
(dd, 2H), 1.27(d, 3H), 1.03(d, 3H)
151(100), 45(48)
152
2-Cl-4-F—C 6 H 3
i-C 3 H 7
4-F—C 6 H 4
L
7.47˜6.94(m, 7H), 5.00˜4.78(m, 1H), 4.32(E) 4.16(Z)
451(22), 193(52), 186(73),
(dd, 2H), 1.26(d, 3H), 1.02(d, 3H)
151(100), 45(53)
153
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3-Cl—C 6 H 4
L
7.45˜6.98(m, 7H), 5.00˜4.79(m, 1H), 4.32(E) 4.16(Z)
467(39), 193(69), 186(74),
(dd, 2H), 1.28(d, 3H), 1.04(d, 3H)
151(100), 45(53)
154
2-Cl-4-F—C 6 H 3
i-C 3 H 7
4-Cl—C 6 H 4
L
7.44˜6.98(m, 7H), 4.98˜4.75(m, 1H), 4.30(E) 4.17(Z)
467(35), 193(71), 186(72),
(dd, 2H), 1.27(d, 3H), 1.03(d, 3H)
151(100), 45(60)
155
2-Cl-4-F—C 6 H 3
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
L
7.45˜7.01(m, 6H), 5.00˜4.78(m, 1H), 4.32(E) 4.15(Z)
501(41), 193(87), 186(76),
(dd, 2H), 1.27(d, 3H), 1.03(d, 3H)
151(100), 45(68)
156
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
C 6 H 3
96˜97
7.60˜6.87(m, 8H), 5.04˜4.84(m, 1H), 4.30(E) 4.15(Z)
449(30), 244,(31), 202(100),
(s, 2H), 1.07(d, 6H)
167(83), 45(65)
157
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
3-F—C 6 H 4
74˜75
7.61˜6.95(m, 7H), 5.05˜4.85(m, 1H), 4.29(E) 4.14(Z)
467(36), 244(28), 202(100),
(s, 2H), 1.12(d, 6H)
174(51), 167(82), 45(68)
158
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
4-F—C 6 H 4
L
7.59˜6.87(m, 7H), 5.03˜4.84(m, 1H), 4.30(E) 4.16(Z)
467(20), 202(98), 167(100)
(s, 2H), 1.09(d, 6H)
159
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
3-Cl—C 6 H 4
L
7.60˜6.92(m, 7H), 5.02˜4.82(m, 1H), 4.31(E) 4.15(Z)
483(42), 244(65), 204(100),
(s, 2H), 1.08(d, 6H)
167(72)
160
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
4-Cl—C 6 H 4
44˜45
7.70˜6.90(m, 7H), 5.02˜4.85(m, 1H), 4.30(E) 4.15(Z)
483(12), 244(39), 202(100),
(s, 2H), 1.07(d, 6H)
167(54), 45(48)
161
3,4-Cl 2 —C 6 H 3
i-C 3 H 7
3,5-Cl 2 —C 6 H 3
80˜81
7.61˜6.95(m, 6H), 5.05˜4.86(m, 1H), 4.28(E) 4.14(Z)
517(8), 202(99), 167(89),
(s, 2H), 1.09(d, 6H)
45(100)
162
3-CH 3 —C 6 H 4
CH 3
C 5 H 5
L
7.45˜6.90(m, 9H), 4.41(s, 2H), 3.27(s, 3H), 2.36(s, 3H)
367(15), 162(100), 147(34),
91(32)
163
3-CH 3 —C 6 H 4
CH 3
4-CH 3 —C 6 H 4
54
7.32˜6.90(m, 8H), 4.39(s, 2H), 3.26(s, 3H), 2.36(s, 3H),
381(13), 162(100), 147(37),
2.34(s, 3H)
91(34)
164
3-CH 3 —C 6 H 4
CH 3
4-CH 3 O—C 6 H 4
69
7.48˜6.79(m, 8H), 4.43(s, 2H), 3.82(s, 3H), 3.48(s, 3H),
397(15), 162(100), 134(42),
2.64(s, 3H)
91(42), 43(39)
165
3-CH 3 —C 6 H 4
CH 3
4-F—C 6 H 4
L
7.44˜6.93(m, 8H), 4.41(s, 2H), 3.27(s, 3H), 2.38(s, 3H)
385(16), 162(100), 147(60),
134(74), 91(65)
166
3-CH 3 —C 6 H 4
CH 3
3-CF 3 —C 6 H 4
L
7.82˜6.98(m, 8H), 4.49(s, 2H), 3.28(s, 3H), 3.39(s, 3H)
435(25), 162(100), 147(69),
134(64), 91(69)
167
3-CH 3 —C 6 H 4
CH 3
4-Cl—C 6 H 4
L
7.40˜6.97(m, 8H), 4.42(s, 2H), 3.28(s, 3H), 2.39(s, 3H)
401(12), 162(100), 147(50),
134(56), 91(48)
168
4-CH 3 —C 6 H 4
CH 3
C 6 H 4
90
7.44˜6.99(m, 9H), 4.40(s, 2H), 326(s, 3H), 2.38(s, 3H)
367(15), 162(100), 147(48),
134(46), 91(47)
169
4-CH 3 —C 6 H 4
CH 3
3-CH 3 —C 6 H 4
L
7.30˜6.99(m, 8H), 4.41(s, 2H), 3.27(s, 3H), 2.39(s, 3H),
381(14), 162(100), 147(46),
2.36(s, 3H)
134(36), 91(32)
170
4-CH 3 —C 6 H 4
CH 3
4-CH 3 —C 6 H 4
108
7.33˜6.99(m, 8H), 4.39(s, 2H), 3.28(s, 3H), 2.38(s, 3H),
381(13), 162(100), 147(41),
2.35(s, 3H)
134(36), 91(27)
171
4-CH 3 —C 6 H 4
CH 3
4-CH 3 O—C 6 H 4
83
7.36˜6.90(m, 8H), 4.38(s, 2H), 3.80(s, 3H), 3.28(s, 3H),
397(25), 162(100), 147(42),
2.37(s, 3H)
134(44), 91(43)
172
4-CH 3 —C 6 H 4
CH 3
4-F—C 6 H 4
71
7.44˜6.69(m, 8H), 3.27(s, 3H), 2.38(s, 3H)
385(23), 162(100), 134(46),
91(26)
173
4-CH 3 —C 6 H 4
CH 3
3-Cl—C 6 H 4
L
7.43˜7.02(m, 8H), 4.42(s, 2H), 3.27(s, 3H), 2.38(s, 3H)
401(11), 162(100), 147(48),
134(38), 91(36)
174
4-CH 3 —C 6 H 4
CH 3
3,5-Cl 2 —C 6 H 3
L
7.35˜7.04(m, 7H), 4.45(s, 2H), 3.28(s, 3H), 2.39(s, 3H)
435(15), 162(100), 147(54),
134(50)
175
4-CH 3 —C 6 H 4
CH 3
4-C 6 H 5 O—C 6 H 4
80
7.40˜6.94(m, 13H), 4.35(s, 2H), 3.27(s, 3H), 2.39(s, 3H)
459(15), 162(100), 147(33),
134(28)
176
4-CH 3 —C 6 H 4
CH 3
3,4-OCH 2 O—C 6 H 4
68
7.26˜6.77(m, 7H), 5.95(s, 2H), 4.40(s, 2H), 3.27(s, 3H),
411(15), 162(100), 147(39),
2.38(s, 3H)
134(32)
177
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
C 6 H 5
L
7.45˜6.89(m, 8H), 4.42(s, 2H), 3.27(s, 3H), 2.28(s, 3H),
381(13), 161(33), 86(72),
2.27(s, 3H)
84(100)
178
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
4-C 2 H 5 —C 6 H 4
L
7.34˜6.90(m, 7H), 4.41(s, 2H), 3.25(s, 3H), 2.30(s, 3H),
395(12), 176(100), 161(96),
2.28(s, 3H), 2.26(s, 3H)
43(49)
179
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
3,5-(CH 3 ) 2 —C 6 H 3
L
7.24˜6.86(m, 6H), 4.37(s, 2H), 3.22(s, 3H), 2.28(s, 6H),
409(19), 176(100), 161(65)
2.25(s, 3H), 2.31(s, 3H)
180
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
4-C 2 H 5 —C 6 H 4
L
7.37˜6.88(m, 7H), 4.41(s, 2H), 3.26(s, 3H), 2.65(q, 2H),
409(24), 176(100), 161(58)
2.30(s, 3H), 2.28(s, 3H), 1.26(t, 3H)
181
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
4-F—C 6 H 4
L
7.43˜6.83(m, 7H), 4.41(s, 2H), 3.25(s, 3H), 2.26(s, 6H)
399(18), 176(100), 161(99),
132(22)
182
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
4-CF 3 —C 6 H 4
L
7.69˜6.86(m, 7H), 4.39(s, 2H), 3.27(s, 3H), 2.89(s, 3H),
449(61), 176(100), 161(84)
2.27(s, 3H)
183
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
3-Cl—C 6 H 4
L
7.32˜6.81(m, 7H), 4.42(s, 2H), 3.26(s, 3H), 2.29(s, 3H),
415(12), 176(97), 161(100),
2.28(s, 3H)
84(42)
184
3,4-(CH 3 ) 2 —C 6 H 3
CH 3
4-C 6 H 5 O—C 6 H 4
L
7.40˜6.85(m, 12H), 4.42(s, 2H), 3.26(s, 3H), 2.28(s, 3H),
473(25), 176(100), 161(76)
2.27(s, 3H)
185
3,4-(CH 3 ) 2 —C 6 H 3
i-C 3 H 7
C 6 H 5
65
7.46˜6.78(m, 8H), 4.96(m, 1H), 4.30(s, 2H), 2.31(s, 3H),
409(36), 204(41), 162(100),
2.29(s, 3H), 1.06(d, 6H)
134(40)
186
3,4-(CH 3 ) 2 —C 6 H 3
i-C 3 H 7
4-CH 3 —C 6 H 4
L
7.27˜6.77(m, 7H), 4.95(m, 1H), 4.24(s, 2H), 2.35(s, 3H),
423(48), 204(51), 162(100),
2.29(s, 3H), 2.27(s, 3H), 1.05(d, 6H)
134(33)
187
3,4-(CH 3 ) 2 —C 6 H 3
i-C 3 H 7
4-F—C 6 H 4
52
7.45˜6.78(m, 7H), 4.93(m, 1H), 4.25(s, 2H), 2.28(s, 3H),
427(14), 204(37), 162(100),
2.26(s, 3H), 1.06(d, 6H)
134(34)
188
3,4-(CH 3 ) 2 —C 6 H 3
i-C 3 H 7
3-Cl—C 6 H 4
58
7.43˜6.79(m, 7H), 4.94(m, 1H), 4.26(s, 2H), 2.29(s, 3H),
443(18), 204(33), 162(100),
2.27(s, 3H), 1.06(d, 6H)
134(35)
189
4-CH 3 O—C 6 H 4
CH 3
4-F—C 6 H 4
L
7.44˜6.90(m, 8H), 4.39(s, 2H), 3.82(s, 3H), 3.25(s, 3H)
401(18), 178(100), 147(66),
121(53)
190
3-Cl—C 6 H 4
CH 3
C 6 H 5
L
7.42˜7.03(m, 9H), 4.41(s, 2H), 3.29(s, 3H)
387(14), 182(51), 147(100),
118(20)
191
3-Cl—C 6 H 4
CH 3
3-CH 3 —C 6 H 4
L
7.43˜7.16(m, 8H), 4.34(s, 2H), 3.27(s, 3H), 2.35(s, 3H)
401(14), 182(47), 147(100),
118(20)
192
3-Cl—C 6 H 4
CH 3
3,4-(CH 3 ) 2 —C 6 H 3
L
7.41˜7.01(m, 7H), 4.39(s, 2H), 3.27(s, 3H), 2.25(s, 6H)
415(17), 182(64), 147(100)
193
3-Cl—C 6 H 4
CH 3
4-C 2 H 5 —C 6 H 4
L
7.42˜7.02(m, 8H), 4.40(s, 2H), 3.26(s, 3H), 2.64(q, 2H),
415(21), 182(99), 147(100)
1.26(t, 3H)
194
3-Cl—C 6 H 4
CH 3
4-t-C 4 H 9 —C 6 H 4
L
7.42˜7.02(m, 8H), 4.41(s, 2H), 3.28(s, 3H), 1.31(s, 9H)
443(18), 182(72), 147(100)
195
3-Cl—C 6 H 4
CH 3
4-CH 3 O—C 6 H 4
L
7.43˜6.87(m, 8H), 4.40(s, 2H), 3.81(s, 3H), 3.29(s, 3H)
417(15), 182(52), 147(100),
78(19)
196
3-Cl—C 6 H 4
CH 3
3-F—C 6 H 4
L
7.43˜7.02(m, 8H), 4.44(s, 2H), 3.30(s, 3H)
405(17), 182(38), 147(100)
197
3-Cl—C 6 H 4
CH 3
4-F—C 6 H 4
L
7.43˜7.00(m, 8H), 4.36(s, 2H), 3.29(s, 3H)
405(30), 147(46), 85(60),
84(100), 43(51)
198
3-Cl—C 6 H 4
CH 3
4-Cl—C 6 H 4
L
7.42˜7.06(m, 8H), 4.43(s, 2H), 3.28(s, 3H)
421(13), 182(40), 147(100),
43(26)
199
4-Cl—C 6 H 4
CH 3
C 6 H 5
95
7.46˜7.09(m, 9H), 4.39(s, 2H), 3.29(s, 3H)
387(10), 181(28), 147(100)
200
4-Cl—C 6 H 4
CH 3
3-CH 3 —C 6 H 4
74
7.47˜7.05(m, 8H), 4.39(s, 2H), 3.25(s, 3H), 2.35(s, 3H)
401(19), 182(48), 147(100)
201
4-Cl—C 6 H 4
CH 3
4-CH 3 —C 6 H 4
99
7.48˜7.06(m, 8H), 4.38(s, 2H), 3.26(s, 3H), 2.34(s, 3H)
401(18), 147(71), 84(100),
47(83)
202
4-Cl—C 6 H 4
CH 3
3,4-(CH 3 ) 2 —C 6 H 3
76
7.43˜7.02(m, 7H), 4.35(s, 2H), 3.24(s, 3H), 2.22(s, 6H)
415(15), 182(59), 147(100)
203
4-Cl—C 6 H 4
CH 3
4-C 2 H 5 —C 6 H 4
85
7.46˜7.04(m, 8H), 4.38(s, 2H), 3.25(s, 3H), 2.64(q, 2H),
415(14), 182(47), 147(100),
1.22(t, 3H)
118(24)
204
4-Cl—C 6 H 4
CH 3
3-CH 3 O—C 6 H 4
L
7.43˜6.85(m, 8H), 4.40(s, 2H), 3.81(s, 3H), 3.26(s, 3H)
417(19), 182(23), 147(100)
205
4-Cl—C 6 H 4
CH 3
4-CH 3 O—C 6 H 4
90
7.43˜6.86(m, 8H), 4.31(s, 2H), 3.80(s, 3H), 3.26(s, 3H)
417(16), 182(47), 147(100)
206
4-Cl—C 6 H 4
CH 3
3-F—C 6 H 4
L
7.47˜7.01(m, 8H), 4.42(s, 2H), 3.28(s, 3H)
405(17), 182(42), 147(100)
207
4-Cl—C 6 H 4
CH 3
4-F—C 6 H 4
72
7.48˜7.00(m, 8H), 4.40(s, 2H), 3.26(s, 3H)
405(18), 182(77), 147(100)
208
4-Cl—C 6 H 4
CH 3
3-Cl—C 6 H 4
L
7.47˜7.09(m, 8H), 4.41(s, 2H), 3.27(s, 3H)
421(15), 182(45), 147(100)
209
4-Cl—C 6 H 4
CH 3
4-Cl—C 6 H 4
66
7.47˜7.09(m, 8H), 4.41(s, 2H), 3.28(s, 3H)
421(18), 182(29), 147(100),
118(29)
210
4-Cl—C 6 H 4
CH 3
thiophene-2-yl
L
7.47˜6.99(m, 7H), 4.45(s, 2H), 3.28(s, 3H)
393(24), 182(62), 147(100)
211
C 6 H 5
CH 3
C 6 H 5
L
7.51˜7.04(m, 10H), 4.32(s, 2H), 3.28(s, 3H)
403(23), 147(100), 120(94),
91(40)
212
C 6 H 5
C 2 H 5
C 6 H 5
L
7.49˜7.01(m, 10H), 4.28(s, 2H), 3.75(q, 2H), 1.10(t, 3H)
417(24), 162(100), 134(94),
106(71), 91(62), 77(57)
213
C 6 H 5
n-C 3 H 7
C 6 H 5
L
7.50˜7.02(m, 10H), 4.21(s, 2H), 3.67(t, 2H), 167˜1.45
431(63), 180(65), 133(60),
(m, 2H), 0.91(t, 3H)
106(100)
214
C 6 H 5
i-C 3 H 7
C 6 H 5
L
7.51˜7.00(m, 10H), 4.98(m, 1H), 4.10(s, 2H), 1.09(d, 6H)
431(24), 176(62), 133(100),
120(49)
215
4-CH 3 O—C 6 H 4
C 2 H 5
C 6 H 5
L
7.46˜6.84(m, 9H), 4.19(s, 2H), 3.81(s, 3H), 3.71(q, 2H),
447(55), 324(53), 239(52),
1.11(t, 3H)
149(100), 135(55), 120(41)
216
4-CH 3 O—C 6 H 4
n-C 3 H 7
C 6 H 5
L
7.47˜6.87(m, 9H), 4.26(s, 2H), 3.82(s, 3H), 3.65(t, 2H),
461(43), 206(100), 136(37),
1.67˜1.45(m, 2H), 0.90(t, 3H)
121(54)
217
3-CF 3 —C 6 H 4
i-C 3 H 7
C 6 H 5
L
7.76˜7.16(m, 9H), 4.94(m, 1H), 4.08(s, 2H), 1.08(d, 6H)
499(50), 244(46), 202(100),
174(66), 145(26), 43(74)
218
4-F—C 6 H 4
i-C 3 H 7
C 6 H 5
L
7.46˜6.97(m, 9H), 4.97(m, 1H), 4.15(s, 2H), 1.02(d, 6H)
449(21), 194(33), 152(100),
124(45)
219
4-Cl—C 6 H 4
C 2 H 5
C 6 H 5
L
7.49˜7.01(m, 9H), 4.20(s, 2H), 3.74(q, 2H), 1.10(t, 3H)
451(57), 324(47), 219(52),
182(78), 154(100), 139(42)
220
2,4-Cl 2 —C 6 H 4
CH 3
C 6 H 5
L
7.54˜7.01(m, 8H), 4.20(s, 2H), 3.21(s, 3H)
471(41), 436(73), 181(100)
EXAMPLE 221
Preparation of N-2-(2′-Fluoro-1′-trifluoromethylstyryl-2′-oxy)acetylpiperidine (Compound 221)
The procedure of Example 1 was repeated except that 286 mg(2 mmol) of N-2-hydroxyacetylpiperidine obtained in Preparation 32 and 2,2-difluoro-1-trifluoromethyl styrene obtained in Preparation 56 were used and that silica gel column chromatography was conducted using a mixture of n-hexane and ethyl acetate(2:1) as an eluent to obtain 600 mg(yield 90.6%) of the title compound as a white solid.
1 H-NMR (CDCl 3 , TMS) δ: 7.58-7.17(m, 5H), 4.79(E isomer) 4.67(Z isomer)(s, 2H), 3.17-3.05(m, 4H), 1.78-1.35(m, 6H); MS (m/e): 331(M + , 40), 126(85), 98(76), 84(100); 19 F-NMR (CDCl 3 , CFCl 3 ) δ: −57.38(Z isomer) −57.83(E isomer)(d,3F), −82.24(E isomer) −84.28(Z isomer)(q, 1F); m.p.: 78-79° C.
EXAMPLES 222 to 294
Using each of the alcoholic compounds obtained in Preparations 32 to 48 and each of the fluorovinyl compounds obtained in Preparations 49 to 56 and 58 to 65, the procedure of Example 221 was repeated to obtain 73 compounds(Compounds 222 to 294) of formula (I) of the present invention having various R 1 , R 2 and R 3 groups listed in Table 5. The 1 H-NMR and MS data and melting points of these compounds are also shown in Table 5. L in Table 5 represents liquid.
TABLE 5
(I)
R 4 = CF 3
Comp. No.
R 1
R 2
R 3
state (° C.)
NMR (CDCl 3 , TMS) δ (ppm)
MS (m/e)
221
—(CH 2 ) 5 —
C 6 H 5
78˜79
7.58˜7.17(m, 5H), 4.79(E) 4.67(Z) (s, 2H), 3.71˜3.05
331(40), 126(85), 98(76),
(m, 4H), 1.78˜1.35(m, 6H)
84(100)
222
—(CH 2 ) 5 —
3-CH 3 —C 6 H 4
L
7.31˜7.04(m, 4H), 4.78(E) 4.66(Z) (s, 2H), 3.64˜3.03
345(26), 126(71), 98(70),
(m, 4H), 2.37(s, 3H), 1.74˜1.38(m, 6H)
84(100)
223
—(CH 2 ) 5 —
4-CH 3 —C 6 H 4
L
7.43˜7.02(m, 4H), 4.79(E) 4.67(Z) (s, 2H), 3.64˜3.01
345(23), 326(18), 126(34),
(m, 4H), 2.43(s, 3H), 1.98˜1.17(m, 6H)
98(100), 84(94)
224
—(CH 2 ) 5 —
4-C 2 H 5 —C 6 H 4
L
7.41˜7.13(m, 4H), 4.77(E) 4.68(Z) (s, 2H), 3.61˜3.06
359(11), 126(100), 98(51),
(m, 4H), 2.64(q, 2H), 1.72˜1.38(m, 6H), 1.25(t, 3H)
84(61)
225
—(CH 2 ) 5 —
3,4-(CH 3 ) 2 —C 6 H 3
L
7.21˜7.00(m, 3H), 4.79(E) 4.67(Z) (s, 2H), 3.60˜3.04
359(36), 126(85), 98(41),
(m, 4H), 2.23(s, 6H), 1.70˜1.37(m, 6H)
84(100), 42(30)
226
—(CH 2 ) 5 —
3,5-(CH 3 ) 2 —C 6 H 3
L
7.03˜6.87(m, 3H), 4.78(E) 4.66(Z) (s, 2H), 3.59˜3.01
359(40), 126(55), 98(63),
(m, 4H), 2.26(s, 6H), 1.69˜1.34(m, 6H)
84(100), 42(57)
227
—(CH 2 ) 5 —
3-CH 3 O—C 6 H 4
L
7.48˜6.72(m, 4H), 4.78(E) 4.66(Z) (s, 2H), 3.82(s, 3H),
361(23), 126(33), 98(83),
3.78˜2.98(m, 4H), 1.82˜1.43(m, 6H)
84(100)
228
—(CH 2 ) 5 —
4-CH 3 O—C 6 H 4
L
7.52˜6.75(m, 4H), 4.79(E) 4.66(Z) (s, 2H), 3.84(s, 3H),
361(50), 157(44), 126(100)
3.78˜3.01(m, 4H), 1.84˜1.36(m, 6H)
98(92), 84(78), 55(69)
229
—(CH 2 ) 5 —
3,4-OCH 2 O—C 6 H 3
L
6.94˜6.75(m, 3H), 5.94(s, 2H), 4.78(E) 4.65(Z) (s, 2H),
375(50), 126(53), 98(60),
3.63˜3.00(m, 4H), 1.70˜1.44(m, 6H)
84(100), 43(90)
230
—(CH 2 ) 5 —
3-CF 3 —C 6 H 4
L
7.72˜7.32(m, 4H), 4.79(E) 4.65(Z) (s, 2H), 3.74˜3.02
399(87), 212(47), 127(100)
(m, 4H), 1.97˜1.18(m, 6H)
231
—(CH 2 ) 5 —
3-F—C 6 H 4
L
7.62˜6.89(m, 4H), 4.80(E) 4.68(Z) (s, 2H), 3.75˜3.04
349(47), 126(64), 98(100),
(m, 4H), 1.78˜0.94(m, 6H)
84(78)
232
—(CH 2 ) 5 —
4-F—C 6 H 4
L
7.51˜6.95(m, 4H), 4.79(E) 4.67(Z) (s, 2H), 3.62˜3.12
349(60), 126(66), 98(56),
(m, 4H), 1.73˜1.45(m, 6H)
84(100), 42(55)
233
—(CH 2 ) 5 —
3-Cl—C 6 H 4
L
7.49˜7.17(m, 4H), 4.80(E) 4.67(Z) (s, 2H), 3.61˜3.07
365(35), 126(32), 98(20),
(m, 4H), 1.72˜1.42(m, 6H)
84(100), 42(38)
234
—(CH 2 ) 5 —
4-Cl—C 6 H 4
L
7.78˜7.34(m, 4H), 4.79(E) 4.66(Z) (s, 2H), 3.85˜3.02
365(20), 126(57), 98(41),
(m, 4H), 1.83˜1.42(m, 6H)
84(100), 45(69)
235
—(CH 2 ) 5 —
3,5-Cl 2 —C 6 H 3
54˜55
7.39˜7.15(m, 3H), 4.81(E) 4.70(Z) (s, 2H), 3.60˜3.08
399(41), 126(60), 98(42),
(m, 4H), 1.78˜1.36(m, 6H)
84(100)
236
—(CH 2 ) 5 —
C 4 H 3 S-2-yl
L
7.47˜6.94(m, 3H), 4.80(E) 4.70(Z) (s, 2H), 3.82˜3.07
337(10), 126(100), 98(74),
(m, 4H), 1.81˜1.42(m, 6H)
84(80)
237
—CH(CH 3 ) (CH 2 ) 4 —
C 6 H 5
L
7.63˜7.18(m, 5H), 4.83(E) 4.74(Z) (s, 2H), 3.25˜2.76
345(46), 140(52), 98(100),
(m, 3H), 1.95˜1.48(m, 6H), 126(d, 3H)
84(46), 55(63)
238
—CH(CH 3 ) (CH 2 ) 4 —
3-CH 3 —C 6 H 4
L
7.44˜6.92(m, 4H), 4.82(E) 4.75(Z) (s, 2H), 3.18˜2.72
359(65), 242(40), 98(78),
(m, 3H), 2.35(s, 3H), 1.95˜1.46(m, 6H), 1.29(d, 3H)
84(92), 56(100)
239
—CH(CH 3 ) (CH 2 ) 4 —
4-CH 3 —C 6 H 4
L
7.44˜7.03(m, 4H), 4.80(E) 4.74(Z) (s, 2H), 3.82˜2.45
359(15), 140(66), 98(100)
(m, 3H), 2.42(s, 3H), 1.86˜1.42(m, 6H), 1.12(d, 3H)
240
—CH(CH 3 ) (CH 2 ) 4 —
3,4-(CH 3 ) 2 —C 6 H 3
L
7.31˜7.03(m, 3H), 4.81(E) 4.74(Z) (s, 2H), 3.24˜2.75
373(30), 140(86), 98(100),
(m, 3H), 2.28(s, 6H), 1.96˜1.45(m, 6H), 1.28(d, 3H)
55(75)
241
—CH(CH 3 )(CH 2 ) 4 —
3,5-(CH 3 ) 2 —C 6 H 3
L
7.28˜6.83(m, 3H), 4.80(E) 4.75(Z) (s, 2H), 3.25˜2.74
373(24), 140(89), 98(100),
(m, 3H), 2.29(s, 6H), 1.96˜1.44(m, 6H), 1.26(d, 3H)
55(76)
242
—CH(CH 3 )(CH 2 ) 4 —
4-C 2 H 5 —C 6 H 4
L
7.52˜7.05(m, 4H), 4.81(E) 4.76(Z) (s, 2H), 3.24˜2.85
373(45), 140(43), 98(100),
(m, 3H), 2.71(q, 2H), 1.95˜1.45(m, 6H), 1.28(t, 3H),
55(43)
1.15(d, 3H)
243
—CH(CH 3 )(CH 2 ) 4 —
3-CH 3 O—C 6 H 4
L
7.47˜6.74(m, 4H), 4.79(E) 4.74(Z) (s, 2H), 3.78(s, 3H),
375(20), 140(97), 98(100),
3.24˜2.73(m, 3H), 1.95˜1.43(m, 6H), 1.24(d, 3H)
55(84)
244
—CH(CH 3 )(CH 2 ) 4 —
4-CH 3 O—C 6 H 4
L
7.54˜6.79(m, 4H), 4.80(E) 4.76(Z) (s, 2H), 3.87(s, 3H),
375(20), 140(56), 98(100),
3.22˜2.91(m, 3H), 1.97˜1.48(m, 6H), 1.33(d, 3H)
56(32)
245
—CH(CH 3 )(CH 2 ) 4 —
3,4-OCH 2 O—C 6 H 3
L
7.20˜6.62(m, 3H), 6.01(s, 2H), 4.79(E) 4.75(Z) (s, 2H),
389(19), 219(40), 140(87),
3.23˜2.74(m, 3H), 1.97˜1.49(m, 6H), 1.29(d, 3H)
112(74), 98(100), 55(77)
246
—CH(CH 3 )(CH 2 ) 4 —
3-CF 3 —C 6 H 4
L
7.76˜7.37(m, 4H), 4.78(E) 4.73(Z) (s, 2H), 3.25˜2.72
413(51), 140(29), 98(62),
(m, 3H), 1.96˜1.42(m, 6H), 1.23(d, 3H)
84(69), 43(100)
247
—CH(CH 3 )(CH 2 ) 4 —
3-F—C 6 H 4
L
7.53˜6.78(m, 4H), 4.79(E) 4.74(Z) (s, 2H), 3.24˜2.75
363(38), 140(38), 98(100),
(m, 3H), 1.96˜1.46(m, 6H), 1.25(d, 3H)
55(45)
248
—CH(CH 3 )(CH 2 ) 4 —
4-F—C 6 H 4
L
7.65˜6.82(m, 4H), 4.81(E) 4.75(Z) (s, 2H), 3.28˜2.65
363(50), 140(78), 112(46),
(m, 3H), 1.95˜1.34(m, 6H), 1.16(d, 3H)
98(100), 55(57)
249
—CH(CH 3 )(CH 2 ) 4 —
3-Cl—C 6 H 4
L
7.58˜7.28(m, 4H), 4.80(E) 4.75(Z) (s, 2H), 3.21˜2.94
379(72), 140(44), 98(100),
(m, 3H), 1.98˜1.49(m, 6H), 1.32(d, 3H)
56(57)
250
—CH(CH 3 )(CH 2 ) 4 —
4-Cl—C 6 H 4
L
7.57˜7.18(m, 4H), 4.81(E) 4.74(Z) (s, 2H), 3.18˜2.74
379(35), 140(70), 98(100),
(m, 3H), 1.75˜1.35(m, 6H), 1.15(d, 3H)
55(47)
251
—CH(CH 3 )(CH 2 ) 4 —
3,5-Cl 2 —C 5 H 3
L
7.64˜7.18(m, 3H), 4.80(E) 4.75(Z) (s, 2H), 3.24˜2.75
413(35), 140(49), 98(100),
(m, 3H), 1.95˜1.44(m, 6H), 1.23(d, 3H)
55(57)
252
—CH(CH 3 )(CH 2 ) 4 —
C 4 H 3 S-2-yl
L
7.45˜6.91(m, 3H), 4.79(E) 4.74(Z) (s, 2H), 3.26˜2.73
351(20), 140(65), 98(100),
(m, 3H), 1.97˜1.41(m, 6H), 1.24(d, 3H)
55(66), 41(47)
253
—CH(C 2 H 5 )(CH 2 ) 4 —
C 6 H 5
L
7.48˜7.22(m, 5H), 4.80(E) 4.75(Z) (s, 2H), 3.58˜2.62
359(18), 154(100), 126(58),
(m, 3H), 1.81˜1.21(m, 8H), 0.83(t, 3H)
112(98)
254
—CH(C 2 H 5 )(CH 2 ) 4 —
4-CH 3 —C 6 H 4
L
7.43˜7.02(m, 4H), 4.81(E) 4.76(Z) (s, 2H), 4.01˜2.52
373(30), 354(15), 154(43),
(m, 3H), 2.41(s, 3H), 1.98˜1.12(m, 8H), 0.92(t, 3H)
112(100)
255
—CH(C 2 H 5 )(CH 2 ) 4 —
3-Cl—C 6 H 4
L
7.59˜7.15(m, 4H), 4.80(E) 4.75(Z) (s, 2H), 4.54˜3.91
393(71), 154(41), 112(100)
(m, 2H), 3.43˜3.12(m, 3H), 1.95˜1.23(m, 6H),
97(38), 55(61)
1.04(t, 3H)
256
—CH(CH 3 )(CH 2 ) 3 CH(CH 3 )—
4-CH 3 —C 6 H 4
L
7.49˜7.01(m, 4H), 4.80(E) 4.74(Z) (s, 2H), 4.54˜3.96
373(49), 354(21), 217(100)
(m, 2H), 2.42(s, 3H), 1.98˜1.51(m, 6H), 1.42(d, 6H)
153(48), 69(21)
257
—CH(CH 3 )(CH 2 ) 3 CH(CH 3 )—
3-Cl—C 6 H 4
58˜59
7.62˜7.18(m, 4H), 4.81(E) 4.75(2) (s, 2H), 3.75˜2.76
393(60), 154(30), 112(100)
(m, 2H), 1.98˜1.48(m, 6H), 1.42(d, 6H)
69(45), 55(62)
258
—CH(CH 3 )(CH 2 ) 3 CH(CH 3 )—
3,5-Cl 2 —C 6 H 3
98˜99
7.45˜7.21(m, 3H), 4.80(E) 4.76(Z) (s, 2H), 3.78˜3.54
427(20), 154(60), 112(100)
(m, 2H), 1.98˜1.47(m, 6H), 1.28(d, 6H)
69(64), 55(80)
259
—(CH 2 ) 2 CH═CHCH 2 —
4-CH 3 —C 6 H 4
L
7.51˜7.10(m, 4H), 5.92˜5.62(m, 2H), 4.81(E) 4.74(Z)
343(10), 324(48), 124(74),
(s, 2H), 4.18˜3.32(m, 4H), 2.43(s 3H),
96(42), 82(100)
2.42˜1.91(m, 2H)
260
—(CH 2 ) 2 O(CH 2 ) 2 —
C 6 H 5
L
7.42˜7.23(m, 5H), 4.80(E) 4.75(Z) (s, 2H), 3.72˜3.10
333(10), 129(69), 102(100)
(m, 8H)
87(30)
261
—(CH 2 ) 2 O(CH 2 ) 2 —
4-CH 3 —C 6 H 4
75˜76
7.43˜7.02(m, 4H), 4.81(E) 4.76(Z) (s, 2H), 4.02˜3.10
347(15), 128(48), 100(100)
(m, 8H), 2.41(s, 3H)
262
—(CH 2 ) 3 C(C 6 H 4 )C—
C 6 H 5
72˜73
7.45˜7.10(m, 9H), 4.80(E) 4.74(Z) (s, 2H), 3.79(t, 2H),
379(14), 360(15), 174(70),
2.70(t, 2H), 2.06˜1.87(m, 2H)
146(70), 118(100)
263
—(CH 2 ) 3 C(C 4 H 4 )C—
4-CH 3 —C 6 H 4
L
7.49˜7.02(m, 8H), 4.81(E) 4.76(Z) (s, 2H), 3.78(t, 2H),
393(38), 374(28), 174(89),
2.71(t, 2H), 2.42(s, 3H), 2.05˜1.86(m, 2H)
146(96), 118(100)
264
—(CH 2 ) 6 —
C 6 H 5
L
7.50˜7.25(m, 5H), 4.80(E) 4.75(Z) (s, 2H), 3.60˜3.10
345(16), 147(100), 112(46)
(m, 4H), 1.81˜1.45(m, 8H)
99(26)
265
—(CH 2 ) 6 —
3-CH 3 —C 6 H 4
L
7.38˜7.08(m, 4H), 4.81(E) 4.76(Z) (s, 2H), 3.60˜3.13
359(15), 140(44), 98(100),
(m, 4H), 2.31(s, 3H), 1.78˜1.38(m, 8H)
43(63)
266
—(CH 2 ) 6 —
4-CH 3 —C 6 H 4
L
7.40˜7.10(m, 4H), 4.80(E), 4.75(Z) (s, 2H), 3.61˜3.17
359(13), 140(56), 97(53),
(m, 4H), 2.38(s, 3H), 1.81˜1.48(m, 8H)
55(53), 43(100)
267
—(CH 2 ) 6 —
4-C 2 H 3 —C 6 H 4
L
7.40˜7.12(m, 4H), 4.81(E) 4.75(Z) (s, 2H), 3.60˜3.15
373(23), 140(100), 98(54)
(m, 4H), 2.65(q, 2H), 1.85˜1.48(m, 8H), 1.26(t, 3H)
268
—(CH 2 ) 6 —
3,4-(CH 3 ) 2 —C 6 H 3
L
7.24˜7.02(m, 3H), 4.79(E) 4.74(Z) (s, 2H), 3.58˜3.11
373(71), 140(51), 98(100)
(m, 4H), 2.32(s, 6H), 1.77˜1.41(m, 8H)
269
—(CH 2 ) 6 —
3,5-(CH 3 ) 2 —C 6 H 3
L
7.06˜6.91(m, 3H), 4.80(E) 4.75(Z) (s, 2H), 3.60˜3.12
373(31), 140(39), 98(100),
(m, 4H), 2.30(s, 6H), 1.80˜1.44(m, 8H)
42(39)
270
—(CH 2 ) 6 —
3-CH 3 O—C 6 H 3
L
7.29˜6.76(m, 4H), 4.80(E) 4.75(Z) (s, 2H), 3.74(s, 3H),
375(53), 140(55), 98(100),
3.54˜3.10(m, 4H), 1.78˜1.42(m, 8H)
43(56)
271
—(CH 2 ) 6 —
4-CH 3 O—C 6 H 4
L
7.38˜6.80(m, 4H), 4.79(E) 4.74(Z) (s, 2H), 3.76(s, 3H),
375(21), 140(29), 98(44),
3.58˜3.12(m, 4H), 1.81˜1.46(m, 8H)
59(38), 43(100)
272
—(CH 2 ) 6 —
3,4-OCH 2 O—C 6 H 3
L
7.15˜6.78(m, 3H), 5.97(s, 2H), 4.80(E) 4.75(Z) (s, 2H),
389(13), 140(70), 98(100)
3.75˜3.14(m, 4H), 1.98˜1.32(m, 8H)
273
—(CH 2 ) 6 —
3-F—C 6 H 4
L
7.40˜6.98(m, 4H), 4.79(E) 4.74(Z) (s, 2H), 3.61˜3.16
363(51), 140(42), 98(100),
(m, 4H), 1.81˜1.48(m, 8H)
55(54), 42(65)
274
—(CH 2 ) 6 —
4-F—C 6 H 4
L
7.50˜6.98(m, 4H), 4.80(E) 4.75(Z) (s, 2H), 3.60˜3.15
363(51), 140(45), 98(96),
(m, 4H), 1.81˜1.46(m, 8H)
55(58), 42(100)
275
—(CH 2 ) 6 —
3-Cl—C 6 H 4
L
7.49˜7.18(m, 4H), 4.81(E) 4.74(Z) (s, 2H), 3.62˜3.20
379(55), 140(52), 98(93),
(m, 4H), 1.82˜1.50(m, 8H)
55(73), 42(100)
276
—(CH 2 ) 6 —
4-Cl—C 6 H 4
L
7.50˜7.15(m, 4H), 4.80(E) 4.75(Z) (s, 2H), 3.61˜3.17
379(56), 140(51), 98(82),
(m, 4H), 1.83˜1.43(m, 8H)
55(70), 42(100)
277
—(CH 2 ) 6 —
3,5-Cl 2 —C 6 H 3
L
7.43˜7.16(m, 3H), 4.80(E) 4.75(Z) (s, 2H), 3.63˜3.18
413(45), 140(48), 98(100),
(m, 4H), 1.86˜1.47(m, 8H)
42(53)
278
—(CH 2 ) 6 —
C 4 H 3 S-2-yl
L
7.40˜6.94(m, 3H), 4.79(E) 4.75(Z) (s, 2H), 3.61˜3.13
351(11), 140(50), 98(100),
(m, 4H), 1.82˜1.43(m, 8H)
55(31), 42(41)
279
C 2 H 5
C 2 H 5
C 6 H 5
L
7.50˜7.21(m, 5H), 4.77(E) 4.64(Z) (s, 2H), 3.45(q, 411),
319(28), 114(88), 86(62),
1.15(t, 6H)
72(100)
280
C 2 H 5
C 2 H 5
4-CH 3 —C 6 H 4
L
7.45˜6.98(m, 4H), 4.78(E) 4.65(Z) (s, 2H), 3.45(q, 4H),
333(39), 314(75), 219(100),
2.38(s, 3H), 1.10(t, 6H)
72(82)
281
n-C 3 H 7
n-C 3 H 7
4-CH 3 —C 6 H 4
L
7.46˜6.97(m, 4H), 4.77(E) 4.65(Z) (s, 2H), 3.21(t, 4H),
361(43), 342(52), 261(100),
2.37(s, 3H), 1.98˜1.23(m, 4H), 0.91(t, 6H)
100(23), 69(58)
282
i-C 3 H 7
i-C 3 H 7
4-CH 3 —C 6 H 4
73˜74
7.45˜6.98(m, 4H), 4.78(E) 4.66(Z) (s, 2H), 3.82˜3.32
361(52), 342(40), 261(100),
(m, 2H), 2.38(s, 3H), 1.38(d, 12H)
158(49)
283
CH 2 ═CHCH 2
CH 2 ═CHCH 2
C 6 H 5
L
7.49˜7.19(m, 5H), 5.86˜5.59(m, 2H), 5.30˜5.02(m, 4H),
343(19), 138(92), 110(63),
4.79(E) 4.66(Z) (s, 2H), 4.10˜3.62(m, 4H)
55(100)
284
CH 2 ═CHCH 2
CH 2 ═CHCH 2
4-CH 3 —C 6 H 4
L
7.51˜6.97(m, 4H), 5.89˜5.42(m, 2H), 5.39˜4.98(m, 4H),
357(40), 138(54), 55(100)
4.77(E) 4.65(Z) (s, 2H), 4.18˜3.48(m, 4H), 2.38(s, 3H)
285
CH 2 ═CHCH 2
CH 2 ═CHCH 2
3-CH 3 O—C 6 H 4
L
7.51˜6.81(m, 4H), 6.10˜5.51(m, 2H), 5.49˜4.98(m, 4H),
373(66), 354(23), 138(41),
4.79(E) 4.66(Z) (s, 2H), 4.10˜3.62(m, 4H), 3.82(s, 3H)
56(100)
286
CH 2 ═CHCH 2
CH 2 ═CHCH 2
3-CF 3 —C 6 H 4
L
7.89˜7.21(m, 4H), 5.94˜5.42(m, 2H), 5.39˜4.96(m, 4H),
411(69), 195(100), 138(80),
4.79(E) 4.65(Z) (s, 2H), 4.18˜3.48(m, 4H)
110(51)
287
CH 2 ═CHCH 2
CH 2 ═CHCH 2
C 4 H 3 S-2-yl
L
7.50˜6.91(m, 3H), 6.11˜5.50(m, 2H), 5.50˜4.97(m, 4H),
349(13), 183(30), 138(100),
4.78(E) 4.66(Z) (s, 2H), 4.12˜3.61(m, 4H)
133(48)
288
n-C 4 H 9
n-C 4 H 9
4-CH 3 —C 6 H 4
L
7.48˜6.97(m, 4H), 4.79(E) 4.66(Z) (s, 2H), 3.21(t, 4H),
389(42), 370(21), 203(100),
2.38(s, 3H), 1.82˜1.10(m, 8H), 0.94(t, 6H)
186(72), 69(48)
289
i-C 4 H 9
i-C 4 H 9
4-CH 3 —C 6 H 4
L
7.45˜6.98(m, 4H), 4.79(E) 4.65(Z) (s, 2H), 2.83(d, 4H),
389(14), 170(17), 128(100),
2.37(s, 3H), 2.04˜1.37(m, 2H), 0.89(d, 12H)
72(34)
290
C 2 H 5
(CH 3 ) 2 CH
C 6 H 5
L
7.71˜7.28(m, 5H), 4.78(E) 4.64(Z) (s, 2H), 3.98˜3.63
333(12), 205(40), 128(62),
(m, 1H), 3.12(q, 2H), 1.12(t, 3H), 1.10(d, 6H)
86(100), 57(71)
291
CH 3
n-C 4 H 9
4-CH 3 —C 6 H 4
L
7.44˜6.97(m, 4H), 4.79(E) 4.64(Z) (s, 2H), 3.35(t, 2H),
347(28), 328(16), 203(100),
2.82(s, 3H), 2.28(s, 3H), 1.45˜1.30(m, 4H), 0.98(t, 3H)
144(67), 69(21)
292
C 2 H 5
n-C 4 H 9
4-CH 3 —C 6 H 4
L
7.45˜6.96(m, 4H), 4.79(E) 4.65(Z) (s, 2H), 3.40(t, 2H),
361(27), 342(12), 203(100),
3.21(q, 2H), 2.28(s, 3H), 1.46˜1.31(m, 4H), 1.10(t, 3H),
158(39), 69(13)
0.97(t, 3H)
293
CH 3
(C 6 H 5 )CH 2
C 6 H 5
L
7.49˜7.01(m, 10H), 4.80(E) 4.66(Z) (s, 2H), 4.41(s, 2H),
367(32), 164(100), 93(54),
2.82(s, 3H)
47(98)
294
CH 3
(C 6 H 5 )CH 2
4-CH 3 —C 6 H 4
L
7.48˜6.98(m, 9H), 4.81(E) 4.67(Z) (s, 2H), 4.43(s, 2H),
381(25), 162(68), 91(100),
2.84(s, 3H), 2.42(s, 3H)
44(28)
Herbicidal Activity Test
Herbicidal activity tests were conducted using test plants planted in screening pots as follows.
Each of screening pots, having the shape of a cube and a top surface area of 140 cm 2 , was filled with a wet mixture of paddy soil and a suitable amount of fertilizer, and sowed thereto were 100 barnyardgrass seeds, 20 bulrush seeds, 50 monochoria seeds, 2 flat-sedge tubers and 2 arrow head tubers(see Table 6). Two rice plant seedlings at the 3-leaf stage were then transplanted thereto, followed by filling water to a depth of 3 cm and kept in a greenhouse for 2 days.
Added to each of the screening pots thus prepared was 4 ml of a 50% acetone solution containing 0.1% Tween-20 and a predetermined amount of each of the compounds listed in Tables 4 and 5 so that the amount of the compound applied would correspond to 4, 1, 0.25, 0.0625 or 0.015 kg/ha. Then, the pot was kept in a greenhouse for 2 to 3 weeks.
The herbicidal activity was determined according to the procedure of Table 7 which was described by Frans et al., In research methods in weed science , ed. by Camper, 29-70 (1986) and Cho, K. Y., Search Report by Korea Research Institute of Chemical Technology , 916 (1989))”. The results are shown in Table 8.
TABLE 6
Abbreviation
Genus-species name
General name
ORYSA
Oryza sativa L.
Rice
ECHOR
Echinochlora crus-galli
Barnyardgrass
8P. BEAUV. var.
oryzicola OHWI
SCPJU
Scirpus juncoides ROXB
Bulrush
MOOVA
Monochoria vaginalis
Monochoria
PRESL
CYPSE
Cyperus serotinus ROTTB
Flat-sedge
SAGPY
Sagittaria pygmaea MIQ
Arrow head
TABLE 7
General
Score
Description
Rice
Weed
0
no effect
no damage
no preventive effect
10
week
week
a slight damage
a slight damage
20
medium
that can be
but no preventive
30
strong
recovered; no
effect
significant in-
fluence on the
harvest
40
medium
week
a visible damage
a significant pre-
50
medium
that can be re-
ventive effect
60
strong
covered but
would reduce
the harvest
70
strong
week
a severe damage
a practically high
80
medium
that can not
preventive effect,
90
strong
be recovered,
and eradication at
and extinction
a score of 80
at a score of
or higher
80 or higher
100
complete
total
complete
destruction
eradication
TABLE 8
Comp.
amount
No.
(kg/ha)
ORYSA
ECHOR
SCPJU
MOOVA
CYPSE
SAGPY
1
4.0000
90
100
100
100
100
100
1.0000
60
100
100
100
100
50
0.2500
10
100
10
90
40
50
0.0625
0
100
0
80
40
20
0.0156
0
60
0
40
10
0
2
1.0000
90
100
100
100
—
70
0.2500
40
100
70
90
—
60
0.0625
0
100
40
90
—
0
0.0156
0
100
20
90
—
0
0.0040
0
75
0
60
—
0
3
1.0000
80
100
100
100
—
70
0.2500
10
100
90
100
—
50
0.0625
0
100
70
80
—
20
0.0156
0
100
20
60
—
0
0.0040
0
60
0
20
—
0
4
1.0000
70
100
70
100
100
20
0.2500
10
100
70
100
100
0
0.0625
0
100
70
100
80
0
0.0156
0
100
50
100
0
0
0.0040
0
20
0
0
0
0
5
1.0000
20
100
100
100
100
60
0.2500
10
100
30
100
100
0
0.0625
0
100
0
100
0
0
0.0156
0
95
0
90
0
0
0.0040
0
50
0
10
0
0
6
1.0000
20
100
100
100
100
60
0.2500
0
100
0
90
100
0.0625
0
95
0
50
0
0
0.0156
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
7
1.0000
10
100
100
100
—
30
0.2500
0
100
100
100
—
30
0.0625
0
80
30
70
—
10
0.0156
0
60
0
40
—
0
0.0040
0
0
0
0
—
0
8
1.0000
0
100
20
90
30
70
0.2500
0
100
0
90
30
0
0.0625
0
95
0
0
10
0
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
9
4.0000
80
100
100
100
0
100
1.0000
50
100
60
100
0
60
0.2500
30
100
0
100
0
40
0.0625
0
100
0
100
0
0
0.0156
0
100
0
100
0
0
10
1.0000
20
100
100
100
100
0
0.2500
10
100
40
70
100
0
0.0625
0
100
0
30
10
0
0.0156
0
50
0
0
0
0
0.0040
0
0
0
0
0
0
11
4.0000
60
100
100
100
100
80
1.0000
10
100
100
100
100
50
0.2500
0
100
30
90
100
10
0.0625
0
90
10
60
100
0
0.0156
0
60
0
0
0
0
12
1.0000
0
100
100
100
100
50
0.2500
0
100
10
90
100
0
0.0625
0
100
0
60
10
0
0.0156
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
13
4.0000
40
100
70
100
0
100
1.0000
30
100
40
100
0
100
0.2500
0
100
0
100
0
100
0.0625
0
95
0
80
0
100
0.0156
0
70
0
40
0
0
14
1.0000
50
100
100
100
100
70
0.2500
10
100
40
90
100
20
0.0625
0
100
20
70
50
0
0.0156
0
80
0
20
0
0
0.0040
0
50
0
0
0
0
15
1.0000
60
100
100
100
100
100
0.2500
0
100
30
100
100
30
0.0625
0
100
0
90
100
20
0.0156
0
90
0
30
20
0
0.0040
0
70
0
0
0
16
1.0000
30
100
100
100
100
50
0.2500
10
100
50
100
50
0.0625
0
100
50
100
0
0
0.0156
0
40
0
0
0
0
0.0040
0
0
0
0
0
0
17
1.0000
30
100
20
100
100
20
0.2500
10
100
0
100
100
20
0.0625
0
100
0
100
100
20
0.0156
0
90
0
100
40
0
0.0040
0
20
0
0
0
0
18
4.0000
0
100
30
90
50
20
1.0000
0
100
70
90
0
—
0.2500
0
70
40
80
0
0
0.0625
0
10
0
0
0
0
0.0156
0
0
0
0
0
0
19
4.0000
50
100
100
100
—
100
1.0000
40
100
100
100
—
100
0.2500
40
100
70
100
—
0
0.0625
20
95
—
100
—
0
0.0156
0
70
0
40
—
0
20
4.0000
60
100
100
100
100
70
1.0000
30
100
100
100
100
50
0.2500
10
100
10
90
30
0
0.0625
0
100
0
80
20
0
0.0156
0
60
0
30
0
0
21
1.0000
45
100
80
100
100
10
0.2500
10
100
40
100
100
0
0.0625
0
95
10
60
0
0
0.0156
0
60
0
0
0
0
0.0040
0
30
0
0
0
0
22
4.0000
20
100
50
100
100
0
1.0000
0
100
30
100
100
0
0.2500
0
100
30
90
20
0
0.0625
0
100
30
60
0
0
0.0156
0
60
0
40
0
0
23
1.0000
30
100
0
90
60
70
0.2500
0
100
0
70
0
0
0.0625
0
95
0
50
0
0
0.0156
0
40
0
0
0
0
0.0040
0
0
0
0
0
0
24
1.0000
30
100
40
100
0
0
0.2500
10
100
20
70
0
0
0.0625
0
90
0
50
0
0
0.0156
0
30
0
0
0
0
0.0040
0
10
0
0
0
0
25
1.0000
10
100
40
100
100
50
0.2500
0
90
0
50
100
0
0.0625
0
80
0
0
100
0
0.0156
0
70
0
0
0
0
0.0040
0
0
0
0
0
0
26
1.0000
40
100
50
90
0
0
0.2500
10
100
40
90
0
0
0.0625
0
95
30
70
0
0
0.0156
0
70
20
50
0
0
0.0040
0
0
0
20
0
0
27
1.0000
20
100
20
100
100
10
0.2500
10
100
0
90
50
0
0.0625
0
80
0
30
30
0
0.0156
0
10
0
0
0
0
0.0040
0
0
0
0
0
0
28
1.0000
20
100
10
100
100
30
0.2500
0
100
0
100
0
0
0.0625
0
100
0
100
0
0
0.0156
0
50
0
0
0
0
0.0040
0
0
0
0
0
0
30
1.0000
60
100
100
100
—
100
0.2500
50
100
100
100
—
60
0.0625
40
100
30
90
—
50
0.0156
0
80
10
70
—
0
0.4000
0
50
0
20
—
0
31
1.0000
40
100
80
100
—
30
0.2500
20
100
50
90
—
0
0.0625
0
95
0
80
—
0
0.0156
0
70
0
50
—
0
0.0040
0
10
0
0
—
0
32
1.0000
40
100
100
100
—
40
0.2500
30
100
100
100
—
20
0.0625
0
90
20
80
—
0
0.0156
0
60
0
20
—
0
0.0040
0
20
0
0
—
0
33
1.0000
20
100
50
100
—
30
0.2500
0
100
30
80
—
0
0.0625
0
80
0
70
—
0
0.0156
0
40
0
20
—
0
0.0040
0
0
0
0
—
0
34
1.0000
20
100
100
100
—
20
0.2500
10
100
80
100
—
10
0.0625
0
90
10
70
—
10
0.0156
0
70
0
50
—
0
0.0040
0
0
0
0
—
0
35
1.0000
20
100
100
100
—
50
0.2500
0
100
50
90
—
0
0.0625
0
80
30
70
—
0
0.0156
0
50
0
50
—
0
0.0040
0
10
0
20
—
0
36
1.0000
40
100
100
100
—
60
0.2500
0
100
20
90
—
60
0.0625
0
90
10
80
—
20
0.0156
0
60
0
50
—
0
0.0040
0
20
0
20
—
0
37
1.0000
70
100
100
100
—
70
0.2500
20
100
100
100
—
50
0.0625
0
100
50
90
—
30
0.0156
0
80
40
80
—
30
0.0040
0
50
20
40
—
0
38
1.0000
20
100
70
100
—
30
0.2500
10
100
60
100
—
30
0.0625
0
80
30
80
—
0
0.0156
0
20
0
40
—
0
0.0040
0
0
0
0
—
0
39
1.0000
10
100
70
100
—
10
0.2506
0
100
10
100
—
0.0625
0
80
0
70
—
0
0.0156
0
50
0
50
—
0
0.0040
0
50
0
20
—
0
40
1.0000
0
80
30
100
—
10
0.2500
0
70
30
100
—
0
0.0625
0
30
0
30
—
0
0.0156
0
0
0
30
—
0
0.0040
0
0
0
0
—
0
42
1.0000
0
100
30
100
30
20
0.2500
0
100
30
100
30
20
0.0625
0
80
0
80
0
0
0.0156
0
80
0
50
0
0
0.0040
0
10
0
0
0
0
43
1.0000
0
100
0
90
100
0
0.2500
0
100
0
80
30
0
0.0625
0
95
0
40
10
0
0.0156
0
70
0
20
0
0
0.0040
0
0
0
0
0
0
44
4.0000
70
100
90
100
100
100
1.0000
60
100
50
100
100
100
0.2500
40
100
30
100
100
100
0.0625
20
100
0
70
80
50
0.0156
0
100
0
60
30
0
45
4.0000
50
100
70
100
100
100
1.0000
40
100
40
100
100
100
0.2500
30
100
0
90
100
100
0.0625
20
100
0
60
50
30
0.0156
0
100
0
60
0
0
46
4.0000
60
100
60
100
90
0
1.0000
20
100
50
100
0
0
0.2500
0
100
50
90
0
0
0.0625
0
95
30
70
0
0
0.0156
0
90
0
70
0
0
47
1.0000
10
100
30
90
90
50
0.2500
0
95
10
70
90
30
0.0625
0
80
0
30
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
48
4.0000
40
100
50
100
100
80
1.0000
30
100
40
90
60
0
0.2500
0
100
0
90
0
0
0.0625
0
100
0
50
0
0
0.0156
0
30
0
20
0
0
49
4.0000
90
100
100
100
0
50
1.0000
40
100
80
100
0
30
0.2500
0
100
70
100
0
0
0.0625
0
100
40
100
0
0
0.0156
0
95
20
50
0
0
50
1.0000
30
100
70
100
100
20
0.2500
20
100
10
90
100
0
0.0625
0
100
0
60
0
0
0.0156
0
95
0
20
0
0
0.0040
0
20
0
0
0
0
51
1.0000
20
100
30
100
100
0
0.2500
0
100
10
50
100
0
0.0625
0
100
0
20
0
0
0.0156
0
20
0
0
0
0
0.0040
0
0
0
0
0
0
52
4.0000
30
100
100
100
—
50
1.0000
20
100
50
100
—
0
0.2500
0
100
0
90
40
0
0.0625
0
70
0
50
30
0
0.0156
0
70
0
0
30
0
53
4.0000
20
100
30
100
100
30
1.0000
10
100
0
90
70
0
0.2500
0
100
0
80
50
0
0.0625
0
100
0
80
0
0
0.0156
0
40
0
30
0
0
54
4.0000
60
100
100
100
—
20
1.0000
0
100
50
100
—
0
0.2500
0
100
20
70
—
0
0.0625
0
100
0
70
—
0
0.0156
0
75
0
0
—
0
55
4.0000
40
100
100
100
100
90
1.0000
10
100
0
100
100
40
0.2500
0
100
0
80
20
20
0.0625
0
90
0
50
10
0
0.0156
0
60
0
0
0
0
56
4.0000
50
100
100
100
100
70
1.0000
10
100
10
100
100
0
0.2500
0
100
10
90
50
0
0.0625
0
100
10
70
0
0
0.0156
0
70
0
20
0
0
57
4.0000
0
100
0
100
100
0
1.0000
0
100
0
90
40
0
0.2500
0
80
0
50
0
0
0.0625
0
50
0
0
0
0
0.0156
0
0
0
0
0
0
58
4.0000
0
100
0
80
100
100
1.0000
0
100
0
70
100
100
0.2500
0
95
0
20
0
0
0.0625
0
60
0
0
0
0
0.0156
0
0
0
0
0
0
59
1.0000
0
100
20
40
100
10
0.2500
0
100
0
10
50
0
0.0625
0
10
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
60
4.0000
40
100
0
100
50
60
1.0000
10
100
0
100
50
20
0.2500
0
100
0
70
30
0
0.0625
0
90
0
30
0
0
0.0156
0
80
0
0
0
0
61
4.0000
20
100
40
100
0
0
1.0000
0
100
0
100
0
0
0.2500
0
100
0
80
0
0
0.0625
0
100
0
40
0
0
0.0156
0
0
0
0
0
0
62
4.0000
30
100
100
100
100
80
1.0000
10
100
0
90
60
0
0.2500
0
100
0
70
30
0
0.0625
0
80
0
10
0
0
0.0156
0
60
0
0
0
0
63
4.0000
20
100
0
100
100
0
1.0000
0
100
0
100
80
0
0.2500
0
100
0
80
40
0
0.0625
0
100
0
50
0
0
0.0156
0
20
0
0
0
0
64
4.0000
50
100
0
100
100
30
1.0000
20
100
0
100
100
0
0.2500
0
100
0
70
100
0
0.0625
0
70
0
50
0
0
0.0156
0
30
0
30
0
0
65
4.0000
10
100
30
100
0
30
1.0000
0
100
10
80
0
0
0.2500
0
100
0
50
0
0
0.0625
0
60
0
10
0
0
0.0156
0
50
0
0
0
0
66
4.0000
0
100
30
100
40
0
1.0000
0
100
20
90
40
0
0.2500
0
100
0
70
0
0
0.0625
0
95
0
40
0
0
0.0156
0
0
0
0
0
0
67
4.0000
10
100
40
100
30
70
1.0000
0
100
0
100
20
0
0.2500
0
100
0
70
0
0
0.0625
0
60
0
0
0
0
0.0156
0
50
0
0
0
0
68
4.0000
0
100
40
100
80
20
1.0000
0
100
20
90
0
0
0.2500
0
100
0
70
0
0
0.0625
0
60
0
30
0
0
0.0156
0
20
0
0
0
0
69
4.0000
50
100
0
100
100
30
1.0000
10
100
0
100
20
20
0.2500
0
100
0
100
0
0
0.0625
0
90
0
0
0
0
0.0156
0
90
0
0
0
0
70
1.0000
20
100
100
100
100
100
0.2500
10
100
20
70
100
0
0.0625
0
70
0
10
0
0
0.0156
0
20
0
0
0
0
0.0040
0
0
0
0
0
0
71
4.0000
20
100
50
100
100
50
1.0000
0
100
20
90
100
20
0.2500
0
100
0
80
50
0
0.0625
0
100
0
50
0
0
0.0156
0
40
0
0
0
0
72
1.0000
0
100
30
60
0
70
0.2500
0
95
0
50
0
20
0.0625
0
70
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
73
1.0000
0
100
30
90
50
20
0.2500
0
100
0
60
30
10
0.0625
0
70
0
10
0
0
0.0156
0
40
0
0
0
0
0.0040
0
0
0
0
0
0
74
1.0000
20
100
0
100
100
70
0.2500
0
100
0
40
50
40
0.0625
0
95
0
20
0
0
0.0156
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
75
1.0000
0
100
50
90
50
0
0.2500
0
100
30
80
20
0
0.0625
0
85
0
40
0
0
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
76
1.0000
0
100
20
90
100
0
0.2500
0
100
0
70
0
0
0.0625
0
95
0
40
0
0
0.0156
0
70
0
0
0
0
0.0040
0
0
0
0
0
0
77
4.0000
80
100
30
100
0
20
1.0000
20
100
30
100
0
10
0.2500
0
100
0
80
0
0
0.0625
0
95
0
70
0
0
0.0156
0
95
0
40
0
0
78
1.0000
10
100
100
100
100
60
0.2500
0
100
30
80
20
0
0.0625
0
100
0
70
20
0
0.0156
0
80
0
20
0
0
0.0040
0
0
0
0
0
0
79
1.0000
20
100
10
100
50
0
0.2500
10
95
0
30
0
0
0.0625
0
85
0
30
0
0
0.0156
0
10
0
0
0
0
0.0040
0
0
0
0
0
0
80
1.0000
20
100
0
100
100
0
0.2500
0
100
0
0
40
0
0.0625
0
100
0
0
0
0
0.0156
0
10
0
0
0
0
0.0040
0
0
0
0
0
0
81
1.0000
30
100
30
100
70
0
0.2500
0
90
30
80
0
0
0.0625
0
85
20
60
0
0
0.0156
0
0
0
40
0
0
0.0040
0
0
0
20
0
0
82
1.0000
0
100
20
50
0
0
0.2500
0
100
0
50
0
0
0.0625
0
40
0
0
0
0
0.0156
0
40
0
0
0
0
0.0040
0
0
0
0
0
0
83
1.0000
0
100
0
30
0
0
0.2500
0
70
0
0
0
0
0.0625
0
20
0
0
0
0
0.0156
0
20
0
0
0
0
0.0040
0
0
0
0
0
0
86
1.0000
0
100
0
0
0
0
0.2500
0
20
0
0
0
0
0.0625
0
0
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
87
1.0000
10
100
0
0
0
0
0.2500
0
80
0
0
0
0
0.0625
0
20
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
88
1.0000
10
100
0
70
80
0
0.2500
0
100
0
0
0
0
0.0625
0
50
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
00
0
0
0
0
89
4.0000
10
100
10
90
0
0
1.0000
0
100
0
50
0
0
0.2500
0
100
0
50
0
0
0.0625
0
60
0
0
0
0
0.0156
0
0
0
0
0
0
90
1.0000
0
100
0
0
0
0
0.2500
0
20
0
0
0
0
0.0625
0
0
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
91
1.0000
20
90
0
0
0
0
0.2500
0
40
0
0
0
0
0.0625
0
10
0
0
0
0
0.0156
0
10
0
0
0
0
0.0040
0
0
0
0
0
0
93
1.0000
20
100
0
100
0
0
0.2500
10
100
0
80
0
0
0.0625
0
100
0
80
0
0
0.0156
0
80
0
20
0
0
0.0040
0
10
0
0
0
0
94
1.0000
20
100
0
100
0
40
0.2500
0
100
0
50
0
0
0.0625
0
80
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
95
1.0000
10
100
0
90
40
0
0.2500
0
100
0
70
30
0
0.0625
0
100
0
50
0
0
0.0156
0
0
0
30
0
0
0.0040
0
0
0
0
0
0
96
1.0000
0
100
10
100
50
20
0.2500
0
95
0
50
0
0
0.0625
0
30
0
40
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
97
1.0000
30
100
20
80
0
20
0.2500
20
100
0
30
0
0
0.0250
10
90
0
30
0
0
0.0156
0
80
0
30
0
0
0.0040
0
0
0
0
0
0
99
1.0000
0
100
0
90
0
0
0.2500
0
100
0
70
0
0
0.0625
0
85
0
50
0
0
0.0156
0
10
0
30
0
0
0.0040
0
0
0
0
0
0
100
1.0000
20
100
70
100
100
10
0.2500
10
100
0
40
90
0
0.0625
10
100
0
0
0
0
0.0156
10
80
0
0
0
0
0.0040
0
10
0
0
0
0
101
1.0000
20
100
0
90
100
20
0.2500
0
100
0
80
90
0
0.0625
0
95
0
20
0
0
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
102
1.0000
10
100
30
90
30
0
0.2500
0
100
10
60
0
0
0.0625
0
80
0
0
0
0
0.0156
0
70
0
0
0
0
0.0040
0
0
0
0
0
0
103
1.0000
0
100
10
70
0
10
0.2500
0
80
0
40
0
0
0.0625
0
10
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
100
4.0000
0
100
0
100
30
0
1.0000
0
100
0
100
0
0
0.2500
0
100
0
80
0
0
0.0625
0
90
0
0
0
0
0.0156
0
50
0
0
0
0
107
4.0000
20
100
30
90
100
0
1.0000
0
100
30
80
30
0
0.2500
0
100
0
70
0
0
0.0625
0
80
0
50
0
0
0.0156
0
30
0
20
0
0
108
1.0000
0
100
30
90
80
0
0.2500
0
100
0
90
50
0
0.0625
0
95
0
70
0
0
0.1560
0
75
0
50
0
0
0.0040
0
0
0
0
0
0
109
4.0000
20
100
0
100
0
0
1.0000
0
100
0
100
0
0
0.2500
0
95
0
30
0
0
0.0625
0
90
0
20
0
0
0.0156
0
20
0
0
0
0
112
1.0000
0
100
50
100
100
0
0.2500
0
100
10
70
80
0
0.0625
0
100
0
40
40
0
0.0156
0
70
0
0
0
0
0.0040
0
0
0
0
0
0
113
1.0000
0
100
50
90
0
10
0.2500
0
70
20
70
0
0
0.0625
0
40
0
30
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
114
4.0000
30
100
0
100
90
0
1.0000
0
100
0
90
0
0
0.2500
0
100
0
70
0
0
0.0625
0
90
0
40
0
0
0.0156
0
20
0
0
0
0
115
1.0000
0
100
20
90
0
0
0.2500
0
95
0
60
0
0
0.0625
0
60
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
116
1.0000
0
100
60
100
30
20
0.2500
0
100
10
60
0
0
0.0625
0
85
0
40
0
0
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
117
1.0000
0
100
10
100
0
0
0.2500
0
100
0
90
0
0
0.0625
0
50
0
0
0
0
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
118
4.0000
0
100
0
80
100
0
1.0000
0
100
0
40
100
0
0.2500
0
80
0
10
100
0
0.0625
0
50
0
0
40
0
0.0156
0
0
0
0
0
0
120
4.0000
10
100
20
60
0
0
1.0000
0
100
0
0
0
0
0.2500
0
80
0
0
0
0
0.0625
0
60
0
0
0
0
0.0156
0
50
0
0
0
0
122
4.0000
0
100
100
100
100
50
1.0000
0
100
40
95
100
30
0.2500
0
100
0
90
100
30
0.0625
0
95
0
70
100
30
0.0156
0
95
0
30
50
30
123
4.0000
30
100
40
100
100
60
1.0000
20
100
0
100
60
0
0.2500
0
100
0
100
0
0
0.0625
0
100
0
80
0
0
0.0156
0
90
0
40
0
0
124
4.0000
40
100
40
100
50
40
1.0000
30
100
40
100
0
0
0.2500
30
100
30
100
0
0
0.0625
0
80
0
50
0
0
0.0156
0
60
0
20
0
0
125
4.0000
10
100
50
100
100
100
1.0000
0
100
40
90
100
100
0.2500
0
100
0
80
100
0
0.0625
0
60
0
50
0
0
0.0156
0
20
0
20
0
0
126
1.0000
0
100
40
100
0
20
0.2500
0
100
20
70
0
10
0.0625
0
95
20
60
0
0
0.0156
0
70
0
30
0
0
0.0040
0
0
0
0
0
0
127
4.0000
30
100
10
100
0
80
1.0000
0
100
0
90
0
0
0.2500
0
95
0
50
0
0
0.0625
0
95
0
50
0
0
0.0156
0
50
0
0
0
0
128
4.0000
0
100
50
100
—
—
1.0000
0
100
20
100
0
—
0.2500
0
95
0
70
0
—
0.0625
0
95
0
30
0
—
0.0156
0
70
0
0
0
—
129
1.0000
0
100
10
30
0
0
0.2500
0
30
0
0
0
0
0.0625
0
0
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
138
1.0000
10
100
0
0
0
0
0.2500
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90
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0
0
0
0.0625
0
50
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
142
4.0000
0
100
0
100
30
80
1.0000
0
100
0
90
30
30
0.2500
0
90
0
40
20
0
0.0625
0
70
0
20
0
0
0.0156
0
50
0
0
0
0
143
4.0000
0
100
0
100
60
60
1.0000
0
100
0
90
0
30
0.2500
0
100
0
70
0
30
0.0625
0
100
0
50
0
20
0.0156
0
0
0
40
0
0
144
4.0000
30
100
0
100
0
0
1.0000
0
100
0
100
0
0
0.2500
0
100
0
30
0
0
0.0625
0
95
0
0
0
0
0.0156
0
30
0
0
0
0
145
1.0000
0
90
0
70
50
20
0.2500
0
80
0
40
0
0
0.0625
0
30
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
146
1.0000
0
100
0
70
40
0
0.2500
0
100
0
0
0
0
0.0625
0
30
0
0
0
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0.0156
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30
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0
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0.0040
0
0
0
0
0
0
147
1.0000
0
100
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0
20
30
0.2500
0
30
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0
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0.0625
0
20
0
0
0
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0.0156
0
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0
0
0
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0.0040
0
0
0
0
0
0
148
1.0000
0
100
0
10
0
20
0.2500
0
50
0
0
0
0
0.0625
0
0
0
0
0
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0.0156
0
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0
0
0
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0.0040
0
0
0
0
0
0
151
1.0000
0
100
30
0
30
0
0.2500
0
95
0
0
0
0
0.0625
0
20
0
0
0
0
0.0156
0
20
0
0
0
0
0.0040
0
20
0
0
0
0
152
1.0000
0
100
0
70
0
0
0.2500
0
100
0
70
0
0
0.0625
0
50
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
153
1.0000
0
100
0
30
20
10
0.2500
0
70
0
0
0
0
0.0625
0
0
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
156
1.0000
0
100
0
60
0
0
0.2500
0
70
0
30
0
0
0.0625
0
50
0
0
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
162
4.0000
80
100
100
100
100
1.0000
20
100
100
100
100
0.2500
0
100
100
100
100
0.0625
0
100
100
80
0
0.0157
163
4.0000
60
100
70
100
1.0000
40
100
100
100
0.2500
40
100
100
100
0.0625
10
100
0
70
0.0157
0
95
0
0
164
4.0000
60
100
100
100
1.0000
50
100
30
100
0.2500
20
100
0
100
0.0625
10
100
0
50
0.0157
10
70
0
20
165
4.0000
100
100
100
100
1.0000
60
100
90
100
0.2500
40
100
50
100
0.0625
20
100
50
100
0.0157
0
100
0
30
166
4.0000
40
100
20
100
1.0000
30
100
0
100
0.2500
20
100
0
70
0.0625
0
80
0
50
0.0157
0
80
0
0
167
4.0000
50
100
100
100
1.0000
50
100
0
100
0.2500
40
100
0
100
0.0625
30
100
0
80
0.0157
20
100
0
60
168
4.0000
60
100
100
100
100
30
1.0000
20
100
100
100
100
30
0.2500
0
100
90
90
70
0
0.0625
0
90
80
90
20
0
0.0157
0
70
0
50
0
0
169
4.0000
40
100
100
100
100
1.0000
0
100
90
95
100
0.2500
0
100
0
90
100
0.0625
0
99
0
50
100
0.0157
0
80
0
30
100
170
4.0000
10
100
0
100
100
1.0000
0
100
0
90
100
0.2500
0
100
0
90
70
0.0625
0
100
0
60
0
0.0157
0
60
0
0
0
171
4.0000
10
100
100
100
100
1.0000
0
100
100
100
100
0.2500
0
100
70
70
40
0.0625
0
100
50
30
0
0.0157
0
75
0
0
0
172
4.0000
50
100
100
100
100
50
1.0000
20
100
60
100
100
30
0.2500
10
100
40
90
50
20
0.0625
0
100
30
80
50
0
0.0157
0
100
30
60
0
0
173
4.0000
30
100
70
100
100
1.0000
0
100
0
100
100
0.2500
0
100
0
70
0
0.0625
0
100
0
60
0
0.0157
0
40
0
0
0
174
4.0000
0
100
10
100
100
1.0000
0
100
0
100
100
0.2500
0
100
0
70
100
0.0625
0
0
0
20
0
0.0157
0
0
0
0
0
175
4.0000
40
90
10
100
100
20
1.0000
30
90
0
70
0
10
0.2500
30
50
0
20
0
0
0.0625
10
10
0
0
0
0
0.0157
10
0
0
0
0
0
176
4.0000
50
100
30
100
1.0000
30
100
0
100
0.2500
20
100
0
100
0.0625
20
100
0
60
0.0157
0
100
0
30
177
4.0000
30
100
80
100
100
1.0000
10
100
80
100
100
0.2500
10
100
60
100
100
0.0625
0
100
30
70
0
0.0157
0
60
30
0
0
178
4.0000
30
100
50
100
100
1.0000
0
100
50
100
100
0.2500
0
100
30
90
100
0.0625
0
95
30
0
0
0.0157
0
30
0
0
0
179
4.0000
0
100
30
100
100
1.0000
0
100
30
80
100
0.2500
0
60
0
20
100
0.0625
0
10
0
0
0
0.0157
0
0
0
0
0
180
4.0000
20
100
30
100
100
1.0000
0
100
20
100
100
0.2500
0
90
20
50
100
0.0625
0
20
0
0
100
0.0157
0
0
0
0
0
181
4.0000
10
100
0
100
100
0
1.0000
0
100
0
100
100
0
0.2500
0
98
0
90
90
0
0.0625
0
80
0
80
0
0
0.0157
0
60
0
40
0
0
183
4.0000
30
100
20
100
70
1.0000
0
100
20
100
0.2500
0
100
10
100
0.0625
0
30
0
0
0
0.0157
0
0
0
0
0
185
4.0000
10
100
10
100
1.0000
0
100
0
100
0.2500
0
100
0
100
0.625
0
90
0
0
0.0157
0
0
0
0
186
4.0000
10
100
0
95
1.0000
0
100
0
30
0.2500
0
100
0
0
0.0625
0
100
0
0
0.0157
0
10
0
0
187
4.0000
30
100
20
90
1.0000
20
100
0
60
0.2500
10
100
0
0
0.0625
0
80
0
0
0.0157
0
0
0
0
189
4.0000
80
100
100
100
1.0000
40
100
100
100
0.2500
0
100
100
100
0.0625
0
100
0
100
0.0157
0
100
0
40
190
4.0000
50
100
100
100
100
1.0000
20
100
100
100
100
0.2500
0
100
60
100
100
0.0625
0
100
0
90
100
0.0157
0
100
0
90
0
191
4.0000
40
100
70
100
100
1.0000
0
100
50
95
100
0.2500
0
100
30
80
100
0.0625
0
100
0
80
100
0.0157
0
85
0
0
0
192
4.0000
10
100
60
100
100
1.0000
0
100
50
100
100
0.2500
0
100
30
100
0
0.0625
0
80
20
20
0
0.0157
0
30
0
0
0
193
4.0000
20
100
10
100
1.0000
20
100
0
100
0.2500
0
100
0
100
0.0625
0
95
0
30
0.0157
0
10
0
0
194
4.0000
20
100
0
100
1.0000
10
100
0
100
0.2500
10
70
0
20
0.0625
0
30
0
0
0.0157
0
0
0
0
195
4.0000
40
100
100
100
100
1.0000
20
100
60
100
100
0.2500
20
100
0
70
100
0.625
0
95
0
0
50
0.0157
0
30
0
0
0
196
4.0000
40
100
100
100
100
1.0000
30
100
100
100
100
0.2500
20
100
20
100
100
0.0625
0
100
10
40
100
0.0157
0
60
0
20
0
197
4.0000
50
100
50
100
1.0000
30
100
30
100
0.2500
30
100
20
100
0.0625
20
100
0
70
0.0157
0
100
0
50
198
4.0000
0
100
40
100
100
1.0000
0
100
40
100
100
0.2500
0
100
40
100
0
0.0625
0
60
0
10
0
0.0157
0
30
0
0
0
199
4.0000
20
100
100
100
100
40
1.0000
0
100
50
100
100
0
0.2500
0
100
50
100
100
0
0.0625
0
95
30
80
20
0
0.0157
0
60
30
30
0
0
200
4.0000
0
100
0
100
100
60
1.0000
0
100
0
100
100
0
0.2500
0
100
0
90
50
0
0.0625
0
70
0
50
0
0
0.0157
0
50
0
40
0
0
201
4.0000
0
100
30
100
100
0
1.0000
0
100
0
100
100
0
0.2500
0
80
0
80
40
0
0.0625
0
70
0
60
40
0
0.0157
0
60
0
40
0
0
202
4.0000
20
100
100
100
100
1.0000
0
100
0
100
100
0.2500
0
80
0
60
100
0.0625
0
60
0
0
0
0.0157
0
0
0
0
0
203
4.0000
30
100
0
100
100
20
1.0000
20
100
0
95
50
0
0.2500
10
75
0
50
0
0
0.0625
10
30
0
30
0
0
0.0157
0
20
0
0
0
0
204
4.0000
20
100
40
100
100
20
1.0000
0
100
40
90
100
10
0.2500
0
100
30
90
100
10
0.0625
0
85
30
70
30
0
0.0157
0
40
0
0
0
0
205
4.0000
30
100
50
100
100
20
1.0000
30
100
0
95
100
0
0.2500
30
100
0
95
50
0
0.0625
20
80
0
80
0
0
0.0157
10
40
0
20
0
0
206
4.0000
20
100
40
100
100
30
1.0000
0
100
30
90
100
0
0.2500
0
100
10
90
70
0
0.0625
0
100
10
80
0
0
0.0157
0
50
0
0
0
0
207
4.0000
0
100
20
100
100
30
1.0000
0
100
10
100
100
0
0.2500
0
100
0
90
100
0
0.0625
0
80
0
90
0
0
0.0157
0
60
0
50
0
0
208
4.0000
10
100
20
100
100
20
1.0000
0
100
20
90
30
0
0.2500
0
70
10
80
0
0
0.0625
0
60
0
20
0
0
0.0157
0
0
0
0
0
0
209
4.0000
0
100
10
100
50
0
1.0000
0
100
10
100
50
0
0.2500
0
70
0
70
50
0
0.0625
0
50
0
40
0
0
0.0157
0
50
0
20
0
0
210
4.0000
20
100
100
100
1.0000
20
100
100
100
0.2500
10
80
100
95
0.0625
0
0
0
30
0.0157
0
0
0
30
211
4.0000
0
90
0
0
0
0
1.0000
0
80
0
0
0
0
0.2500
0
70
0
0
0
0
0.0625
0
0
0
0
0
0
0.0157
0
0
0
0
0
0
212
4.0000
40
100
40
100
100
0
1.0000
20
100
40
90
100
0
0.2500
10
100
30
70
70
0
0.0625
0
95
20
20
70
0
0.0157
0
80
0
0
0
0
213
4.0000
0
100
30
80
30
0
1.0000
0
100
20
70
0
0
0.2500
0
90
10
0
0
0
0.0625
0
60
0
0
0
0
0.0157
0
0
0
0
0
0
214
4.0000
0
100
10
100
0
0
1.0000
0
100
0
90
0
0
0.2500
0
95
0
40
0
0
0.0625
0
70
0
0
0
0
0.0157
0
0
0
0
0
0
216
4.0000
0
100
40
50
0
0
1.0000
0
100
20
0
0
0
0.2500
0
60
10
0
0
0
0.0625
0
30
0
0
0
0
0.0157
0
20
0
0
0
0
218
4.0000
10
100
40
100
0
0
1.0000
0
100
20
80
0
0
0.2500
0
100
10
70
0
0
0.0625
0
90
0
30
0
0
0.0157
0
30
0
0
0
0
219
4.0000
0
100
0
10
0
0
1.0000
0
80
0
0
0
0
0.2500
0
0
0
0
0
0
0.0625
0
0
0
0
0
0
0.0157
0
0
0
0
0
0
220
4.0000
0
100
80
100
100
60
1.0000
0
95
0
0
90
0
0.2500
0
60
0
0
0
0
0.0625
0
0
0
0
0
0
0.0157
0
0
0
0
0
0
221
1.0000
80
100
100
100
100
90
0.2500
0
100
100
90
100
80
0.0625
0
100
60
90
100
0
0.0156
0
95
20
60
0
0
0.0040
0
20
0
0
0
0
222
1.0000
80
100
100
100
—
70
0.2500
70
100
100
100
—
60
0.0625
20
100
40
90
—
30
0.0156
0
70
10
80
—
0
0.0040
0
30
0
40
—
0
223
4.0000
100
100
100
100
100
0
1.0000
60
100
100
100
100
0
0.2500
20
100
100
100
0
0
0.0625
0
100
50
80
0
0
0.0156
0
30
0
30
0
0
224
1.0000
0
100
100
90
—
50
0.2500
0
100
60
90
—
10
0.0625
0
95
10
80
—
0
0.0156
0
40
0
50
—
0
0.0640
0
0
0
0
—
0
225
1.0000
30
100
100
90
—
50
0.2500
30
100
100
90
80
20
0.0625
0
80
20
80
80
0
0.0156
0
60
0
50
70
0
0.0040
0
0
0
20
0
0
226
1.0000
70
100
100
90
—
60
0.2500
40
100
100
80
90
30
0.0625
0
85
30
80
40
0
0.0156
0
50
10
50
0
0
0.0040
0
0
0
20
0
0
227
4.0000
100
100
100
100
0
100
1.0000
50
100
100
100
0
100
0.2500
30
100
100
90
0
100
0.0625
0
100
100
90
0
40
0.0156
0
90
40
70
0
0
228
1.0000
40
100
100
100
100
60
0.2500
10
100
70
90
100
40
0.0625
0
90
0
50
0
10
0.0156
0
30
0
0
0
0
0.0040
0
0
0
0
0
0
229
1.0000
65
100
100
100
—
70
0.2500
0
100
90
90
—
50
0.0625
0
80
30
70
—
20
0.0156
0
30
0
40
0
0
0.0040
0
0
0
20
0
0
230
4.0000
80
100
100
100
100
0
1.0000
60
100
100
100
100
0
0.2500
20
100
40
90
100
0
0.0625
20
100
0
80
20
0
0.0156
20
90
0
50
0
0
231
4.0000
90
100
100
100
100
100
1.0000
90
100
100
100
100
100
0.2500
70
100
100
100
100
60
0.6250
0
100
100
100
100
30
0.0156
0
70
40
60
0
9
232
1.0000
65
100
100
100
—
50
0.2500
30
100
100
90
—
50
0.0625
0
100
100
90
—
0
0.0156
0
90
50
80
50
0
0.0040
0
70
10
50
0
0
233
1.0000
65
100
100
90
—
80
0.2500
20
100
50
90
60
50
0.0625
0
95
10
70
—
0
0.0156
0
80
0
70
0
0
0.0040
0
0
0
20
0
0
234
1.0000
60
100
100
100
100
70
0.2500
20
100
100
100
100
50
0.0625
0
100
60
100
100
20
0.0156
0
80
10
30
0
0
0.0040
0
30
0
0
0
0
235
1.0000
0
100
30
100
100
50
0.2500
0
100
0
90
20
20
0.0625
0
95
0
80
0
0
0.0156
0
30
0
10
0
0
0.0040
0
0
0
0
0
0
236
4.0000
60
100
100
100
100
100
1.0000
50
100
100
100
100
100
0.2500
30
100
60
100
0
100
0.0625
10
80
40
60
0
0
0.0156
0
60
0
40
0
0
237
1.0000
60
100
100
100
100
70
0.2500
10
100
100
100
100
50
0.0625
0
100
40
100
100
30
0.0156
0
95
0
80
0
0
0.0040
0
60
0
20
0
0
238
1.0000
50
100
100
100
100
100
0.2500
20
100
80
100
90
60
0.0625
0
100
30
60
0
0
0.0156
0
60
0
20
0
0
0.0040
0
0
0
0
0
0
239
4.0000
100
100
100
100
100
50
1.0000
50
100
100
100
100
30
0.2500
20
100
30
100
100
0
0.0625
0
90
20
60
20
0
0.0156
0
20
0
30
0
0
240
1.0000
10
100
60
100
100
60
0.2500
0
100
30
90
0
0
0.0625
0
90
0
70
0
0
0.0156
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
241
1.0000
10
100
40
90
100
60
0.2500
0
95
10
90
10
10
0.0625
0
90
0
90
0
0
0.0156
0
60
0
10
0
0
0.0040
0
0
0
0
0
0
242
1.0000
20
100
60
100
100
60
0.2500
10
100
0
100
80
40
0.0625
0
80
0
40
0
10
0.0156
0
50
0
10
0
0
0.0040
0
0
0
0
0
0
243
1.0000
40
100
100
90
100
50
0.2500
10
100
90
90
100
0
0.0625
0
100
10
90
0
0
0.0156
0
90
0
30
0
0
0.0040
0
0
0
0
0
0
244
1.0000
20
100
60
100
70
90
0.2500
0
100
40
50
50
0
0.0525
0
100
0
30
40
0
0.0156
0
50
0
0
0
0
0.0040
0
0
0
0
0
0
245
1.0000
20
100
100
90
100
0
0.2500
0
100
100
90
100
0
0.0625
0
95
30
70
80
0
0.0156
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
246
1.0000
50
100
100
100
—
60
0.2500
30
100
50
90
—
60
0.0625
10
95
0
80
80
30
0.0156
0
40
0
40
—
0
0.0040
0
10
0
20
0
0
247
1.0000
50
100
100
100
100
80
0.2500
0
100
70
90
100
40
0.0625
0
100
40
70
0
10
0.0156
0
80
10
40
0
0
0.0040
0
60
0
10
0
0
248
1.0000
70
100
100
100
100
90
0.2500
10
100
100
90
90
40
0.0625
0
100
50
90
80
20
0.0156
0
95
20
80
0
0
0.0040
0
80
0
10
0
0
249
1.0000
20
100
100
100
100
40
0.2500
10
100
50
100
30
30
0.0625
0
100
50
100
0
30
0.0156
0
70
50
50
0
30
0.0040
0
50
50
50
0
0
250
1.0000
10
100
100
100
100
40
0.2500
0
100
100
100
100
40
0.0625
0
80
50
80
100
20
0.0156
0
50
30
50
0
10
0.0040
0
0
0
10
0
0
251
1.0000
10
100
70
90
100
20
0.2500
0
90
50
90
100
60
0.0625
0
60
0
20
0
0
0.0560
0
60
0
0
0
0
0.0040
0
0
0
0
0
0
252
1.0000
20
100
100
100
—
20
0.2500
20
90
70
90
0
0
0.0625
10
80
20
80
0
0
0.0156
0
60
0
80
0
0
0.0040
0
0
0
30
0
0
253
4.0000
70
100
100
100
100
100
1.0000
40
100
100
100
100
90
0.2500
0
100
30
80
100
50
0.0625
0
100
0
70
30
0
0.0156
0
60
0
40
0
0
254
4.0000
50
100
100
100
100
100
1.0000
40
100
80
100
100
100
0.2500
20
100
50
90
0
0
0.0625
0
95
0
40
0
0
0.0156
0
50
0
0
0
0
255
1.0000
20
100
50
100
100
60
0.2500
10
100
20
90
100
0
0.0625
0
90
0
70
0
0
0.0156
0
40
0
30
0
0
0.0040
0
40
0
0
0
0
256
4.0000
60
100
100
100
100
0
1.0000
0
100
50
100
100
0
0.2500
0
100
0
60
0
0
0.0625
0
80
0
20
0
0
0.0156
0
0
0
0
0
0
257
1.0000
0
100
40
100
100
0
0.2500
0
100
20
90
100
0
0.0625
0
95
0
40
0
0
0.0156
0
40
0
10
0
0
0.0040
0
0
0
0
0
0
258
1.0000
10
95
10
90
0
20
0.2500
0
80
0
40
0
10
0.0625
0
70
0
10
0
0
0.0156
0
0
0
0
0
0
0.0040
0
0
0
0
0
0
259
4.0000
70
100
100
100
100
90
1.0000
50
100
100
100
100
60
0.2500
20
90
40
70
0
0
0.0625
0
80
0
30
0
0
0.0156
0
80
0
0
0
0
260
4.0000
90
100
100
100
100
100
1.0000
80
100
100
100
100
80
0.2500
50
100
90
100
100
50
0.0625
20
100
40
70
40
0
0.0056
0
60
0
0
0
0
261
4.0000
100
100
100
100
100
90
1.0000
90
100
100
100
100
0
0.2500
20
90
90
60
100
0
0.0625
0
70
30
20
100
0
0.0156
0
0
0
0
0
0
262
2.0000
0
100
0
100
50
50
0.5000
0
100
0
100
20
0
0.1250
0
100
0
90
0
0
0.0310
0
60
0
30
0
0
0:0080
0
20
0
0
0
0
263
4.0000
0
100
20
100
100
50
1.0000
0
100
0
100
100
0
0.2500
0
100
0
100
100
0
0.0625
0
95
0
100
50
0
0.0156
0
80
0
30
0
0
264
4.0000
90
100
100
100
100
100
1.0000
80
100
100
100
100
90
0.2500
60
100
100
90
50
80
0.0625
10
100
100
90
30
30
0.0156
0
70
20
70
0
0
265
1.0000
50
100
100
100
—
80
0.2500
10
100
60
90
—
0
0.0625
0
95
10
90
—
0
0.0156
0
80
0
70
—
0
0.0040
0
20
0
60
—
0
266
1.0000
100
100
100
100
—
90
0.2500
0
100
90
90
—
60
0.0625
0
100
20
90
90
20
0.0156
0
70
10
80
0
0
0.0040
0
30
0
60
0
0
267
1.0000
10
100
50
90
—
80
0.2500
0
100
40
80
—
0
0.0625
0
95
30
80
70
0
0.0156
0
60
0
50
0
0
0.0040
0
0
0
0
0
0
268
1.0000
40
100
100
90
—
60
0.2500
0
100
90
90
—
40
0.0625
0
95
10
80
60
30
0.0156
0
65
0
70
0
0
0.0040
0
20
0
50
0
0
269
1.0000
70
100
90
100
—
80
0.2500
10
100
30
80
—
50
0.0625
0
95
0
80
—
10
0.0156
0
70
0
80
0
0
0.0040
0
0
0
40
0
0
270
1.0000
90
100
100
100
—
80
0.2500
50
100
30
90
—
50
0.0265
30
100
20
80
—
10
0.0156
10
70
10
80
0
0
0.0040
0
20
10
60
0
0
271
1.0000
10
100
90
90
—
80
0.2500
0
100
50
80
—
0
0.0625
0
90
10
70
60
0
0.0156
0
70
0
60
—
0
0.0040
0
0
0
50
0
0
272
1.0000
50
100
100
100
100
60
0.2500
0
100
30
80
20
0
0.0625
0
100
0
70
20
0
0.0156
0
70
0
20
0
0
0.0040
0
0
0
0
0
0
273
1.0000
50
100
100
100
—
90
0.2500
20
100
100
90
—
70
0.0625
0
100
30
90
60
20
0.0056
0
70
20
80
30
0
0.0040
0
30
0
30
30
0
274
1.0000
60
100
100
100
—
100
0.2500
0
100
100
100
—
90
0.0625
0
100
30
90
—
40
0.0156
0
80
30
80
80
0
0.0040
0
60
0
50
0
0
275
1.0000
20
100
100
100
—
70
0.2500
0
100
50
90
—
50
0.0625
0
90
10
80
50
10
0.0156
0
70
0
50
0
0
0.0040
0
0
0
30
0
0
276
1.0000
20
100
706
100
—
70
0.2500
0
100
30
90
—
20
0.0625
0
95
20
80
—
0
0.0156
0
75
0
50
—
0
0.0040
0
20
0
40
0
0
277
1.0000
20
100
10
100
0
50
02500
0
95
0
90
0
10
0.0625
0
30
0
70
0
0
0.0156
0
30
0
50
0
0
0.0040
0
0
0
0
0
0
278
1.0000
0
100
90
90
50
50
0.2500
0
80
70
90
—
0
0.0625
0
75
10
70
—
0
0.0156
0
50
0
50
0
0
0.0040
0
10
0
20
0
0
279
4.0000
90
100
100
100
100
100
1.0000
80
100
100
100
100
70
0.2500
10
100
90
80
100
50
0.0625
0
90
70
70
40
30
0.0156
0
60
0
30
0
0
280
4.0000
100
100
100
100
100
60
1.0000
40
100
100
90
100
50
0.2500
10
100
100
90
100
0
0.0625
0
90
30
30
0
0
0.0056
0
20
0
0
0
0
281
4.0000
40
100
100
100
70
0
1.0000
20
100
100
100
0
0
0.2500
0
90
0
40
0
0
0.0625
0
70
0
0
0
0
0.0156
0
20
0
0
0
0
282
4.0000
0
100
40
90
0
0
1.0000
0
100
0
50
0
0
0.2500
0
60
0
0
0
0
0.0625
0
40
0
0
0
0
0.0156
0
0
0
0
0
0
283
4.0000
70
100
100
100
100
0
1.0000
30
100
100
100
100
0
0.2500
0
100
50
100
100
0
0.0625
0
90
0
90
100
0
0.0156
0
90
0
20
10
0
284
4.0000
80
100
100
100
100
0
1.0000
40
100
100
100
100
0
0.2500
0
100
0
100
100
0
0.0625
0
80
0
80
100
0
0.0156
0
80
0
0
0
0
285
4.0000
80
100
100
100
100
100
1.0000
50
100
100
100
100
100
0.2500
40
100
90
90
100
100
0.0625
30
100
60
80
60
60
0.0156
0
60
0
50
0
0
286
4.0000
80
100
100
100
100
0
1.0000
40
100
40
100
100
0
0.2500
20
100
30
90
90
0
0.0625
0
80
20
80
20
0
0.0156
0
60
0
50
10
0
287
4.0000
60
100
100
100
100
100
1.0000
40
100
80
100
100
100
0.2500
30
100
40
100
50
100
0.0625
0
80
30
100
30
100
0.0156
0
80
0
60
30
50
288
4.0000
50
100
40
90
50
0
1.0000
0
100
0
40
0
0
0.2500
0
90
0
0
0
0
0..0625
0
50
0
0
0
0
0.0156
0
10
0
0
0
0
289
4.0000
0
80
0
40
100
60
1.0000
0.2500
0.0625
0.0156
290
4.0000
100
100
100
100
100
80
1.0000
40
100
100
100
100
80
0.2500
10
100
100
100
100
50
0.0625
0
100
50
70
40
0
0.0155
0
70
0
20
0
0
291
4.0000
100
100
100
100
100
0
1.0000
40
100
100
100
100
0
0.2500
10
100
0
100
100
0
0.0625
0
100
0
80
100
0
0.0156
0
80
0
0
0
0
292
4.0000
60
100
100
100
100
0
1.0000
30
100
100
100
100
0
0.2500
0
100
0
50
0
0
0.0625
0
95
0
0
0
0
0.0156
0
20
0
0
0
0
293
4.0000
70
100
100
100
100
90
1.0000
0
100
100
100
30
90
0.2500
0
100
100
100
30
0
0.0625
0
100
0
80
20
0
0.0156
0
50
0
20
0
0
294
4.0000
50
100
90
100
100
40
1.0000
20
100
60
100
20
—
0.2500
0
100
30
80
0
—
0.0625
0
80
0
80
0
0
0.0156
0
0
0
70
0
0
As can be seen from Table 8, the compounds of the present invention have high herbicidal activity against a wide spectrum of weeds and are very selective, e.g., they do not harm rice plants.
While the invention has been described with respect to the specific embodiments, it should be recognized that various modifications and changes may be made by those skilled in the art to the invention which also fall within the scope of the invention as defined by the appended claims.
|
Herbicidal fluorovinyloxyacetamide compounds of formula (I) are useful for protecting crops from weeds:
wherein:
R 1 is a phenyl group optionally having one or more substituents selected from the group consisting of C 1-6 alkyl, halogen-substituted C 1-6 alkyl, C 1-6 alkoxy and halogen;
R 2 is a C 1-6 alkyl; or
R 1 and R 2 together with the nitrogen atom to which they are bound form a 5-, 6- or 7-membered nitrogen heterocycle optionally having one or more ring oxygen atoms, double bonds and C 1-6 alkyl substituents;
R 3 is a phenyl or thiophen-2-yl group optionally having one or more substituents selected from the group consisting of C 1-6 alkyl, halogen-substituted C 1-6 alkyl, C 1-6 alkoxy, methylenedioxy and halogen; and
R 4 is a perfluoro C 1-6 alkyl group.
| 2
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CROSS REFERENCE TO RELATED APPLICATIONS
This is the U.S. National Phase Application under §371 of International Application No. PCT/JP2008/063161, filed Jul. 23, 2008, which claims the benefit of Japanese Application No. 2007-192378, filed Jul. 24, 2007 each of which is hereby incorporated by reference in its entirety herein. The International Application was published in the Japanese language on Jan. 29, 2009 as WO 2009/014134 A1 under PCT Article 21(2).
FIELD OF THE INVENTION
The present invention relates to a dual pressure sensor for detecting, through two sensor units, two pressures to be measured.
BACKGROUND OF THE INVENTION
There is a known “Semiconductor Pressure Sensor,” disclosed in, for example, Japanese Unexamined Patent Application Publication H5-52691, which is hereby incorporated by reference in its entirety, as a dual pressure sensor for measuring a pressure between two points. The semiconductor pressure sensor measures the differential pressure in fluids by detecting two pressures separately using respective pressure-sensitive diaphragm chips and then subtracting these measured pressures. Because of this, the semiconductor pressure sensor is provided with not only two pressure-sensitive diaphragm chips, but also with an airtight container for sealing the chip airtightly, and a substrate, whereon are disposed each of the pressure-sensitive diaphragm chips, provided within the airtight container. A shared pressure reference chamber for the two pressure-sensitive diaphragm chips is formed within the airtight container. The outputs of the individual pressure-sensitive diaphragm chips are connected to the outside of the airtight container through terminals. The substrate is provided with two pressure connecting tubes that connect the pressures to be measured to the respective pressure-sensitive diaphragm chips.
However, the semiconductor pressure sensor disclosed in Japanese Application Publication H5-52691 is structured from many components: two pressure connecting tubes for connecting to the fluid to be measured, two pressure-sensitive diaphragm chips for measuring the respective pressures to be measured, a substrate upon which the individual pressure-sensitive diaphragm chips are mounted, and two terminals for connecting electrically the respective pressure-sensitive diaphragm chips through wire bonding. Because of this, the component count is high, and thus there is a problem in that the assembly operations are time-consuming, and the efficiency of the assembly operations is low.
In addition, because, in particular, the two pressure-sensitive diaphragm chips are disposed in common on a single substrate, if either of the pressure-sensitive diaphragm chips fails for some reason, both of the chips must be replaced by the substrate unit, or in other words, the entire unit must be replaced. This means that the pressure-sensitive diaphragm chip that is functioning normally must be discarded, which is uneconomical. Additionally, the two pressure guide tubes must be fabricated separately and attached passing through a lid portion of the airtight container, and thus there is a problem in that this requires an attachment with a high level of airtightness.
SUMMARY OF THE INVENTION
The present invention is to solve the conventional problems set forth above, and the object thereof is to provide a dual pressure sensor capable of improving the assembly operability and airtightness along with enabling simplification through the reduction of the component counts.
The dual pressure sensor as set forth in the present invention, by which to achieve the object set forth above, comprises an airtight container having two through paths and having a pressure reference chamber formed on the inside thereof; and two pressure sensor units, disposed arranged lined up within the pressure reference chamber, for detecting two pressures to be measured; wherein: the two pressure sensor units each comprise respective substrates and respective pressure-sensitive diaphragm chips for detecting respective pressures to be measured by converting into electrical signals displacements of diaphragms due to the respective application of the pressures to be measured; and the substrate of each individual pressure sensor unit comprises: a substrate main unit that has a small hole and has a connecting duct formed therein, and wherein a pressure-sensitive diaphragm chip is secured so as to block the small hole; and a pressure connecting portion, provided formed integrally with the substrate main unit and protruding therefrom, having a pressure connecting hole for connecting to the connecting hole, wherein one end extends to the outside of the airtight container from the through paths, to connect the individual pressure to be measured through the connecting duct to the diaphragm of the pressure-sensitive diaphragm chip.
In the present invention, the pressure connecting portion may be integrated with the substrate, making it possible to reduce the number of components, enabling the sensor to be simplified, facilitating the sensor assembly operations, and enabling an improvement in the ease of assembly operations. Additionally, the pressure connecting portion need not be secured to an airtight container, and all that is necessary is for the pressure connecting portions to penetrate through a seal material at the through holes, enabling the assembly of the seal structure between the pressure connecting portion and the through holes to be simplified, enabling an improvement in productivity. Additionally, because the two pressure sensor units are independent of each other, if either of the pressure sensor units were to fail, then there would be no need to change the entirety of the dual pressure sensor, but rather only that particular pressure sensor unit need be replaced with a new pressure sensor unit.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the present invention will be more readily apparent from the following detailed description and drawings of illustrative embodiments of the invention in which:
FIG. 1A is a front view of a dual pressure sensor as set forth in the present invention.
FIG. 1B is a plan view of a dual pressure sensor as set forth in the present invention.
FIG. 1C is a side view of a dual pressure sensor according to the present invention.
FIG. 2 is a cross-sectional diagram along the section II-II of FIG. 1B .
FIG. 3 is a cross-sectional diagram along the section in FIG. 2 .
FIG. 4 is a cross-sectional diagram illustrating one example of a flow controlling valve provided with a dual pressure sensor as set forth in the present invention.
Like reference numerals are used in the drawing figures to connote elements of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained in detail based on the example of embodiment illustrated in the drawings. In FIG. 1A through FIG. 1C , FIG. 2 , and FIG. 3 , the dual pressure sensor 1 comprises: an airtight container 2 ; two pressure sensor units 3 A and 3 B that are housed within the airtight container 2 ; a substrate 4 ; and the like.
The airtight container 2 is structured from a case 7 that is made out of a synthetic plastic, or the like, in the shape of a box that has a bottom but that is open at the top, and a lid 8 that covers, airtightly, the top opening portion of the case 7 , made out of the same synthetic plastic, or the like. Within the airtight container 2 is formed a pressure reference chamber 9 shared by the two pressure sensor units 3 A and 3 B. The case 7 is formed as a rectangular box, open at the top, having a bottom panel 7 a , and side panels 7 b through 7 b that are provided integrally along each edge of the bottom plate 7 a , where the ratios of the lengths of two intersecting sides are essentially 2 to 1. In the case 7 there are two pressure sensor units 3 A and 3 B that are arranged in intimate contact with each other. Triangular prism positioning protruding portions 10 for positioning and preventing the movement of the respective pressure sensor units 3 A and 3 B are provided in each of the core portions of the inner surfaces of the case 7 and in the center portions in the lengthwise direction of the inner surfaces of the opposing long-edge side panels 7 d and 7 e . Two through holes 11 a and 11 b are formed corresponding to the respective pressure sensor units 3 A and 3 B on the bottom panel 7 a.
The lid 8 is formed in the shape of a flat panel having a shallow indented portion 12 on the bottom surface thereof, and is secured to the top surface of the case 7 through screws through a seal material, not shown, to seal the top surface open portion of the case 7 airtightly. In the center of the lid 8 is formed a through hole 8 a through which the outside signal line 13 passes to the outside. Additionally, in the center of the top surface of the lid 8 is provided a connector portion 14 that closes the through hole 8 a airtightly and to which is connected one end of the outside signal line 13 .
The pressure sensor unit 3 A is structured from a substrate 15 A, a pressure-sensitive diaphragm chip 16 A, and an output correcting circuit 17 A.
The substrate 15 A is formed as a single unit from a synthetic plastic, formed from a substrate main unit 15 A- 1 and a pressure connecting portion 15 A- 2 that is provided integrally and protruding from the center portion of the bottom surface of the substrate main unit 15 A- 1 . The substrate main unit 15 A- 1 is formed in a thin box shaped which, in its planar view, is rectangular, and which essentially matches half the size of the interior shape of the case 7 . In the inside of the case 7 is formed a connecting duct 21 a . On the top surface of the case 7 is formed a small hole 22 a for connecting the pressure to be measured P 1 to the pressure-sensitive diaphragm chip 16 A. The corner portions of the substrate main unit 15 A are cut away at a 45° angle so as to fit tightly with the side surfaces of the positioning protruding portions 10 . The substrate main unit 15 A- 1 is formed so as to be large, to cause the volume of the connecting duct 21 a to be large. The reason for causing the volume of the connecting duct 21 a to be large is to absorb the sudden variations in pressure of the pressure to be measured P 1 to thereby prevent the diaphragm of the diaphragm chip 16 A from being damaged due to sudden variations in pressure.
The pressure connecting portion 15 A- 2 is formed in a cylindrical shape, and the bottom end portion thereof protrudes to the outside of the case from the hole 11 a of the case 7 . On the inside of the pressure connecting portion 15 A- 2 is formed a pressure guiding hole 23 a for connecting the pressure to be measured P 1 to the pressure-sensitive diaphragm chip 16 A through the connecting duct 21 a of the substrate main unit 15 A- 1 and to the small hole 22 a.
A semiconductor pressure sensor is used as the pressure-sensitive diaphragm chip 16 A. Because of this, the pressure-sensitive diaphragm chip 16 A is provided with a semiconductor substrate (silicon) wherein is formed a thin the pressure-sensitive portion (diaphragm), and a diffusion-type deformation gauge for detecting and converting into a signal the deformation, due to the pressure to be measured P 1 , of the diaphragm, using the piezoresistance effect, formed through impurities, or through an ion implantation technique, in the semiconductor substrate. This type of pressure-sensitive diaphragm chip 16 A is known through, for example, Japanese Unexamined Patent Application Publication H06-213743, which is hereby incorporated by reference in its entirety. The pressure-sensitive diaphragm chip 16 A is secured on the top surface of the substrate main unit 15 A- 1 , and the pressure to be measured P 1 is applied to one surface of the diaphragm through the small hole 22 a . The reference pressure within the airtight container is applied to the surface of the other diaphragm. Furthermore, the pressure-sensitive diaphragm chip 16 A is connected electrically to electrical circuitry on the substrate 4 through bonding wires 25 a.
The output correcting circuit 17 A has a temperature measuring resistive element, not shown, and is a circuit for correcting the pressure to be measured P 1 that is detected by the pressure-sensitive diaphragm chip 16 A based on the change in the resistance value of this temperature measurement resistive element. This circuit 17 A is secured to the top surface of the substrate main unit 15 A- 1 , and is connected electrically to the pressure-sensitive diaphragm chip 16 A through bonding wires 26 a.
The pressure sensor unit 3 B is formed with a structure that is identical to that of the pressure sensor unit 3 A, and thus identical structural components and parts are indicated by replacing the respective number suffixes “A,” “a,” and “- 1 ” with “B,” “b,” and “- 2 ,” respectively, and explanations thereof are omitted.
These pressure sensor units 3 A and 3 B are arranged in intimate contact with each other in the case 7 , and thus, as illustrated in FIG. 3 , the substrate main units 15 A- 1 and 15 B- 1 of the substrates 15 A and 15 B are positioned by the inner surface of the case and the positioning protruding portions 10 . Because of this, the mutually facing side surfaces 20 a of the substrate main units 15 A- 1 and 15 B- 1 are in contact with each other, and the remaining three side surfaces 20 b through 20 d are each in contact with the inside surfaces of the case 7 . Furthermore, the bottom surfaces of the substrate main units 15 A- 1 and 15 B- 1 are in contact with the inside surface of the bottom panel 7 a . Furthermore, the pressure connecting portions 15 A- 2 and 15 B- 2 of the respective substrates 15 A and 15 B protrude through O-rings to below the case 7 through the through holes 11 a and 11 b of the bottom panel 7 a to connect, respectively, to the pressure connecting tubes 24 A and 24 B. Causing the side surfaces 20 a of the two substrate main units 15 A- 1 and 15 B- 1 to contact each other in this way makes it possible to equalize the temperatures of the two substrates 15 A and 15 B. Note that the individual pressure sensor units 3 A and 3 B are contained in the case 7 and are secured by screws.
The substrate 4 , after the bonding wires 25 a and 25 b have been bonded, is contained within the case 7 together with the pressure sensor units 3 A and 3 B, and is secured, by a plurality of screws, to the positioning protruding portions 10 , and lead lines 28 are connected to the connector portion 14 of the lid 8 .
This type of dual pressure sensor 1 is used in combination with a flow controlling valve 100 , as illustrated in FIG. 4 , to be used in measuring the flow of a fluid 102 that flows within the valve body 101 .
The flow Q of the fluid 102 that flows within a flow path 103 of the flow controlling valve 100 can be calculated using the following Equation (1). In Equation (1), A is a constant, Cv is a flow factor that is determined by the opening of the valving element, and Δ P is the pressure differential between the upstream side and the downstream side of the fluid.
Q=A·Cv·√ΔP (1)
Typically, in a flow controlling valve 100 , the throttling effect will vary depending on the opening of the valving element 104 , making it possible to measure flows over a wider range than when compared to a differential pressure flow meter that uses a fixed orifice. Furthermore, it is possible to know the pipe pressure at the flow controlling valve unit, and to use that information in not only measuring the flow, but also in diagnostics such as identifying pressure problems.
When the dual pressure sensor 1 is attached to the flow controlling valve 100 , the pressure connecting portion 15 A- 2 of the substrate 15 A for one of the pressure sensor units 3 A is connected through the pressure connecting tube 24 A and the flow path 50 on the upstream side at the flow controlling valve 100 , to apply to the diaphragm of the pressure-sensitive diaphragm chip 16 A the pressure to be measured P 1 on the upstream side of the valving element 104 . The pressure connecting portion 15 B- 2 of the substrate 15 B for the other pressure sensor unit 3 B is connected through the pressure connecting tube 24 B and the flow path 50 on the downstream side at the flow controlling valve 100 , to apply to the diaphragm of the pressure-sensitive diaphragm chip 16 B the pressure to be measured P 2 on the downstream side of the valving element 104 . Because of this, the diaphragms of the respective pressure-sensitive diaphragm chips 16 A and 16 B deform in accordance with the applied pressures P 1 and P 2 , changing the output voltage of the diffusion-type deformation gauges in accordance with these deformations, to measure the pressures P 1 and P 2 . In this case, the pressure within the airtight container 2 is applied as the reference pressure to the diaphragm, and thus the output voltages of the individual pressure-sensitive diaphragm chips 16 A and 16 B are the output voltages for the absolute pressures corresponding to the respective pressures to be measured P 1 and P 2 . Furthermore, the output voltages of the individual pressure-sensitive diaphragm chips 16 A and 16 B are sent to the output correcting circuits 17 A and 17 B. The output correcting circuits 17 A and 17 B perform temperature compensation based on the temperature measuring resistive element resistance voltages of the respective circuitry therein, and then send the respective measured pressures P 1 and P 2 , for which the outputs have been corrected, through the outside signal lines 13 to the flow calculating means 61 . The flow calculating means 61 then calculate, through a calculation process. the differential pressure Δ P (P 1 −P 2 ) from the respective output-corrected measured pressures P 1 and P 2 that have been received, and substitute the pressure differential Δ P into the aforementioned Equation 1 to measure the flow Q of the fluid 102 that flows through the flow controlling valve 100 . Note that in FIG. 4 : 60 is the flow opening detecting means for detecting the opening of the valving element 104 ; 62 is a valve shaft; 63 is an upstream seat ring; 64 is an upstream retainer; 65 is a downstream seat ring; and 66 is a downstream retainer.
The dual pressure sensor 1 , structured in this way, has the pressure connecting portions 15 A- 2 and 15 B- 2 disposed protruding integrally from the respective substrates 15 A and 15 B, making it possible to reduce the part count. Additionally, when the pressure connecting portions 15 A- 2 and 15 B- 2 are fabricated from discrete components, as with the pressure sensor disclosed in Japanese Unexamined Patent Application Publication H5-52691, it may be necessary to position them and secured them airtightly to the bottom of the case 7 , but in the dual pressure sensor 1 according to the present invention, the pressure connecting portions 15 A- 2 and 15 B- 2 merely need protrude through a seal component, such as an O-ring, through the through holes 11 a and 11 b , simplifying the assembly operations for the pressure connecting portions 15 A- 2 and 15 B- 2 , enabling an improvement in the sensor assembly productivity.
Additionally, because the dual pressure sensor 1 as set forth in the present invention is provided with two individual and independent pressure sensor units 3 A and 3 B, if either one should fail then it is necessary to swap only the sensor unit that has failed, and not necessary to swap the sensor in its entirety, which has economic benefits.
While the invention has been particularly shown and described with reference to a number of preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. Accordingly, the invention is to be limited only by the scope of the claims and their equivalents.
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A dual pressure sensor using a reduced number of parts to simplify its structure and having increased ease of assembly and improved air tightness. The dual pressure sensor has an airtight container, two pressure sensor units received in the airtight container so as to be in intimate contact with each other and a substrate. The pressure sensor units has two bases, two pressure sensing diaphragm chips, and an output correction circuit. The pressure sensing diaphragm chips are secured to the bases, respectively. The bases are constructed respectively from base bodies having communication paths formed inside them and also respectively from pressure introduction sections integral with and projecting from the base bodies. The pressure introduction sections respectively project outward from insertion holes formed in the airtight container.
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RELATED APPLICATIONS
[0001] The instant application claims the benefit of U.S. Provisional Patent Application No. 61/558,275, filed Nov. 10, 2011, which application is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The embodiments disclosed herein are directed toward control optimization methods and apparatus for thermal energy storage. The disclosed embodiments are more particularly directed toward control optimization for thermal energy storage in a cascaded phase change material thermal energy storage system associated with a concentrated solar power generation system.
BACKGROUND
[0003] Many electrical power providers are incorporating concentrated solar power generation facilities into their mix of electricity sources. In these facilities concentrated solar energy provides the heat required to drive conventional steam turbines for power generation. Most existing concentrated solar power generation facilities are operated only when the sun is not obscured by cloud cover and is sufficiently positioned above the horizon to provide adequate light for plant operation. Thus, many existing concentrated solar power generation facilities can not operate in the evening or in periods of intermittent cloud cover.
[0004] Shifting plant operation away from strict solar dependence has many economic benefits, including a potentially extended operational period each day. To properly operate through periods of cloud cover or in the evening, a plant must have the ability to store energy in some form at a low cost. Thermal energy storage is the most economically feasible way for a plant to accomplish the required energy storage. To date, many forms of thermal energy storage have been investigated, including: two tank, thermocline, chemical, solid media, and phase change material storage. Presently, no one technology has emerged as a dominant storage strategy. On the contrary, each technology has recognized advantages and disadvantages. Phase Change Material (PCM) based thermal energy storage systems are of great interest for high temperature concentrated solar power applications because of the potential for enhanced performance at relatively low material cost.
[0005] The basic phase change material thermal energy storage concept features the use of a material with a melting temperature in between the hot and cold side temperatures of a solar field as a thermal energy storage medium. When the system is operated in a “charge” mode, heat transfer fluid from the solar field is cooled by melting the phase change material. In a “discharge” mode, relatively cool heat transfer fluid is heated by running it in reverse through the thermal energy storage system thus solidifying the phase change material. The benefit of a phase change material based system is the high energy density realized by exploiting the latent heat of a suitable material in addition to utilizing the sensible heat. The energy storage density of a suitable energy storage material can typically be doubled by adding latent heat storage over a 100° C. temperature range.
[0006] Phase change material based thermal energy storage systems must include multiple types of salts with different melt temperatures to effectively store and discharge energy over a temperature range of 100° C. or more. In a multiple-material design, the total amount of energy that can be stored for a given storage mass over the 100° C. temperature differential can be greatly increased. The forgoing arrangement of linearly arrayed phase change material groups, (with each group or container of a given phase change material being known as a “bucket”) is called a cascade and can be thought of like a cascading waterfall, with the highest melt temperature at the top followed by progressively lower melt temperatures to the bucket at the bottom.
[0007] A phase change material thermal energy storage system having a sufficient number of buckets provides for energy storage at the highest temperature possible. A theoretical best case phase change material system would have an exceptionally large number of phase change material buckets with different melt temperatures spread equally through the range of expected heat transfer fluid temperatures. Implementing an exceptionally large number of distinct phase change material buckets is not practical however, in part because there are a limited number of suitable phase change material choices. It is generally more feasible to utilize 3-5 phase change materials with melt temperatures spread as evenly as possible throughout the designed storage temperature range.
[0008] Nearly all thermal energy storage systems can be described as belonging to one of two categories: active and passive. An active system is classified as a system that actively engages its storage material with the system's heat transfer fluid, typically through mechanical interactions. For example, a two-tank molten salt system is classified as an active system because the molten salt is actively pumped. Passive systems do not have mechanical interaction. A common example of a passive system is concrete storage where the storage material encases heat transfer fluid pipes and passively accepts and gives thermal energy to the working fluid. A phase change material thermal energy storage system as described above is a type of passive storage system.
[0009] Certain physical limitations cause difficulty controlling a passive phase change material storage system for optimal transient performance. First, the salts used as phase change materials have very low heat transfer rates compared to the heat transfer fluid. The lower heat transfer rate of a phase change material occurs in part because the material is stationary and also because suitable phase change materials conduct heat poorly. Low heat transfer rates cause power output from the storage system to be lower even if the total energy storage is large. Second, phase change materials accept and release heat isothermally over the melting region whereas heat transfer fluid accepts and releases heat over a range of temperatures. Therefore, in a manageable system of three to five phase change material buckets in a cascade, the highest temperature bucket will have a substantially lower temperature than the maximum heat transfer fluid temperature.
[0010] In addition, day-to-day repeatability presents a significant difficulty in the operation of a passive thermal energy storage system. Problems arise from driving temperature differences during charge and discharge in combination with variable solar field outlet temperature and variation in heat transfer fluid flow rates. For example, in a cascading phase change material system with four phase change material buckets, a third bucket may have a driving temperature difference of nearly 30° C. during charge compared to only a 10° C. temperature difference during discharge. These temperature differences are constrained by the availability of materials with desired melt temperatures. Furthermore, a bucket sees a varying mass heat transfer fluid flow rate that may fluctuate between 0 kg/s and a maximum rate during charge operation compared to a constant mass flow rate at or near the maximum during discharge. In addition, the heat transfer characteristics for a given phase change material salt are different for charge and discharge. These and potentially other factors combine to make the charging transient response of any system quite different from that of the discharge transient response.
[0011] The foregoing considerations become a problem when attempting to design a thermal energy storage system that will properly exploit the beneficial energy characteristics of phase change in nearly 100% of the phase change material provided. For example, a system that is able to melt 100% of the phase change material during charge may only be able to solidify 50% of the phase change material during discharge. The next day, this system might melt the remaining 50% solid during charge and continue to superheat the phase change material sensibly during the remainder of the charge. Now, during discharge the system will only be able to solidify 25% of the phase change material. This process will continue until only a small portion of the phase change material is going through a phase change every day. Thus, the storage system has lost a significant portion of its energy storage density.
[0012] The embodiments disclosed herein are directed toward overcoming one or more of the problems discussed above.
SUMMARY OF THE EMBODIMENTS
[0013] One embodiment is a solar power generation system including a heat transfer fluid circuit, a solar energy concentrator and a thermal energy storage system. The thermal energy storage system comprises a cascaded series of multiple buckets of phase change material all in thermal communication with the heat transfer fluid circuit. In this embodiment an outlet from one of the buckets of the thermal energy storage system is in direct communication through a secondary branch of the heat transfer fluid circuit with an inlet into a power block steam train component. The secondary branch provides for the routing of some or all of the heat transfer fluid flowing from the solar field to the power block through a storage bucket during active energy production.
[0014] In this embodiment, the bucket in direct thermal communication with the power block may be a high temperature bucket containing a phase change material that has a melting temperature greater than the phase change materials contained in other buckets of the cascaded series.
[0015] A related embodiment is a cascaded thermal energy storage system having multiple buckets of phase change material connected in series by a heat transfer fluid circuit. This embodiment further includes a secondary branch of the heat transfer fluid circuit connecting an outlet of one or more buckets directly to a power block inlet. The foregoing connection is made through the secondary branch while producing energy within the power block.
[0016] Another related embodiment is a method of utilizing solar energy comprising the following steps; providing a heat transfer fluid circuit, a solar energy concentrator, a cascaded thermal energy storage system and a power block all connected by a primary heat transfer fluid circuit. The method further includes flowing heat transfer fluid from the solar energy concentrator outlet through a bucket of phase change material and then flowing heat transfer fluid from the bucket through a secondary branch of the heat transfer fluid circuit to the power block while producing energy with the power block. In the foregoing embodiment, the bucket may be a high temperature bucket containing a phase change material that has a melting temperature greater than the phase change materials contained in other buckets of the cascaded series.
[0017] Another embodiment is a solar power generation system generally as described above but further comprising an inlet to one or more selected buckets of the thermal energy storage system in direct communication through a secondary branch of the heat transfer fluid circuit with an outlet from a power block component. In addition, an outlet from the one or more selected buckets is in direct communication through the heat transfer fluid circuit with the solar energy concentrator or the power block. This configuration provides for heat transfer fluid flow to be preheated after at least one bucket of the thermal energy storage system has been substantially discharged but before the thermal energy system is recharged. In this embodiment, the buckets of the thermal energy storage system in communication with the power block outlet may be colder temperature buckets containing a phase change material that has a lower melting temperature than the phase change materials contained in at least one other bucket of the cascaded series.
[0018] A related embodiment includes a cascaded thermal energy storage system as generally described above but further comprising at least one secondary branch of the heat transfer fluid circuit connecting an outlet from the power block to the inlet to one or more buckets of the cascaded thermal energy storage system.
[0019] A related embodiment includes a method of preheating a solar energy system comprising the step of flowing heat transfer fluid from a power block outlet through one or more partially discharged buckets of the thermal energy storage system prior to charging the thermal energy storage system. The method thus provides for preheating heat transfer fluid which may then be flowed to the solar energy concentrator and the power block before active power generation commences.
[0020] An alternative embodiment includes a solar power generation system as generally described above but further comprising multiple secondary heat transfer fluid circuit branches directly connecting at least two buckets of the thermal energy storage system to at least two corresponding steam train components. The secondary heat transfer fluid branches provide for direct heat transfer fluid injection between individual phase change material buckets and corresponding steam train components during the discharge phase of power generation. In this embodiment, the melting temperature of the phase change material in each bucket may correspond to the designed operating temperature of the corresponding steam train component.
[0021] A related embodiment includes a cascaded thermal energy storage system as generally described above but further comprising multiple secondary branches of the heat transfer fluid circuit connecting outlets from at least two buckets to inlets to at least two steam train components during discharge of the thermal energy storage system. In this embodiment, the melting temperature of the phase change material in each bucket may correspond to the designed operating temperature of the corresponding steam train component.
[0022] A related embodiment includes a method of utilizing solar energy comprising the step of flowing heat transfer fluid from at least two selected buckets of phase change material to the inlet of at least two corresponding steam train components while discharging the thermal energy storage system. This method provides for direct heat transfer fluid injection between individual phase change material buckets and corresponding steam train components during the discharge phase of power generation.
[0023] Another embodiment includes a solar power generation system generally as described above but further comprising secondary branches of the heat transfer fluid circuit connecting one or more buckets of the thermal energy storage system with an outlet from the power block and further connecting the one or more buckets with the solar energy concentrator. This embodiment provides for heat transfer fluid flowing in the heat transfer fluid circuit to be heated by partial discharge of the thermal energy storage system during periods of insufficient insolation to charge the thermal energy storage system.
[0024] In the foregoing embodiment, the one or more buckets of the thermal energy storage system in communication with the power block outlet may be colder temperature buckets containing a phase change material that has a lower melting temperature than the phase change materials contained in other buckets of the cascaded series.
[0025] A related embodiment includes a cascaded thermal energy storage system generally as described above but further comprising one or multiple secondary branches of the heat transfer fluid circuit connecting the power block to an inlet to one or more buckets during periods of insufficient insolation to charge the thermal energy storage system.
[0026] A related embodiment is a method of utilizing solar energy comprising the step of partially discharging the thermal energy storage system during periods of insolation too low to charge the thermal energy storage system by flowing heat transfer fluid from the power block outlet through one or more buckets of the thermal energy storage system.
[0027] Another embodiment includes a solar power generation system as generally described herein comprising any combination of secondary branches of the heat transfer fluid circuit extending between selected phase change material buckets and selected steam train components and/or any combination of secondary branches of the heat transfer fluid circuit extending between selected phase change material buckets and the solar field.
[0028] A related embodiment is a cascaded thermal energy storage system generally as described above further comprising any combination of secondary branches of the heat transfer fluid circuit extending between selected phase change material buckets and selected steam train components and/or any combination of secondary branches of the heat transfer fluid circuit extending between selected phase change material buckets and the solar field.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is schematic diagram representation of a prior art concentrated solar power generation system operating in charge mode.
[0030] FIG. 2 is schematic diagram representation of a prior art concentrated solar power generation system operating in discharge mode.
[0031] FIG. 3 is schematic diagram representation of an improved concentrated solar power generation system operating to produce energy.
[0032] FIG. 4 is schematic diagram representation of an improved concentrated solar power generation system during warm-up operations prior to charging and after discharge.
[0033] FIG. 5 is schematic diagram representation of an improved concentrated solar power generation system operating in discharge mode.
[0034] FIG. 6 is schematic diagram representation of an improved concentrated solar power generation system operating in a partial discharge mode.
[0035] FIG. 7 is schematic diagram representation of a concentrated solar power generation system featuring a combination of improvements.
DETAILED DESCRIPTION
[0036] Unless otherwise indicated, all numbers expressing quantities of ingredients, dimensions, reaction conditions and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”.
[0037] In this application and the claims, the use of the singular includes the plural unless specifically stated otherwise. In addition, use of “or” means “and/or” unless stated otherwise. Moreover, the use of the term “including”, as well as other forms, such as “includes” and “included”, is not limiting. Also, terms such as “element” or “component” encompass both elements and components comprising one unit and elements and components that comprise more than one unit unless specifically stated otherwise.
[0038] A conventional concentrated solar energy power generation system 100 is schematically illustrated in FIGS. 1 and 2 . Various embodiments of solar powered generation systems having enhanced thermal energy storage control methods and apparatus are disclosed herein and illustrated in FIGS. 3-7 . The enhanced thermal energy storage embodiments disclosed herein are improvements upon the basic design of FIGS. 1 and 2
[0039] The solar power generation system 100 of FIGS. 1 and 2 may be considered to have multiple functional blocks including; one or more solar energy concentrators 102 , one or more thermal energy storage systems 104 and one or more power blocks 106 . A commercially implemented solar power generation system 100 will generally have many solar energy concentrators 102 in a solar field for each thermal energy storage system 104 or power block 106 .
[0040] The solar energy concentrator elements 102 may be of any known type, including but not limited to, parabolic trough reflectors, heliostat based solar energy towers or similar apparatus. In all cases the solar concentrator element 102 concentrates reflected sunlight upon the surface of a tube or other receiver structure within which heat transfer fluid is circulated. The heat transfer fluid is thus heated by the concentrated sunlight to a temperature sufficient to drive a steam turbine generator as described below.
[0041] In the various embodiments disclosed herein, the solar energy concentrator 102 , thermal energy storage system 104 and power block 106 are each maintained in thermal communication through a heat transfer fluid circuit 108 . The heat transfer fluid circuit 108 as shown on FIGS. 1 and 2 is referred to herein as the primary heat transfer fluid circuit. The heat transfer fluid circuit 108 has heat transfer fluid flowing within pipes, valves, pumps, heat exchange elements and other structures of the circuit 108 . The heat transfer fluid flowing in the circuit 108 is typically heat transfer oil or other liquid having appropriate chemical, thermal and physical qualities.
[0042] The power block 106 includes various steam train components 110 which provide for heat exchange between heat transfer fluid flowing in the heat transfer fluid circuit 108 and water flowing in a steam circuit 112 . Typically, the power block 106 includes at least the following steam train components; a pre-heater 114 , an evaporator 116 and a super-heater 118 , arranged in order from lesser to greater operational temperature. In the various steam train components 110 , heat is exchanged between the heat transfer fluid circuit 108 and the steam circuit 112 resulting in the production of super heated steam which may be used to drive a steam turbine 120 for power generation. It is important to note that a commercially implemented power block is substantially more complex than schematically illustrated in FIG. 1 .
[0043] The thermal energy storage system 104 includes a series of multiple buckets, each containing a phase change material having a selected melting temperature. In the schematic illustrations of FIGS. 1-7 , phase change material buckets 122 , 124 , and 126 respectively are illustrated in a cascaded series. It is important to note however, that a commercially implemented thermal energy storage system may have more than or less than 3 buckets. In addition, a commercially implemented system may have multiple containers of any shape or size holding a specific type of phase change material. In this case, each collection of interlinked containers holding the same phase material constitutes one functional bucket.
[0044] The buckets 122 , 124 , 126 are arranged in a cascade. As defined herein, a “cascade” or “cascaded” phase change material thermal energy storage system is one where the various phase change material buckets are arranged in a thermally decreasing series. For example, as shown on FIG. 1 , the phase change material bucket 122 nearest the outlet from the solar field is designated as a “hot” phase change material bucket. This bucket contains a phase change material having a melting point temperature higher than the phase change materials contained in other buckets in the series. A heat transfer fluid circuit outlet from the hot phase change material bucket 122 leads to an inlet to a medium phase change material bucket 124 . An outlet from the medium temperature phase change material bucket 124 leads to a cold bucket 126 and so on until a complete cascade from the highest temperature bucket to lowest temperature bucket is complete. In each bucket, relatively simple or more complex heat exchange apparatus provides for heat exchange between the heat transfer fluid flowing in the heat transfer fluid circuit 108 and the phase change material contained within each bucket.
[0045] The solar power generation system 100 may be operated in two modes with respect to the thermal energy storage system 104 ; charge mode and discharge mode. Operation in the charge mode is schematically represented in FIG. 1 . In the charge mode, incident solar radiation falling upon a solar energy concentrator 102 is concentrated by reflection upon a portion of the heat transfer fluid circuit 108 flowing through or near the concentrator. Thus, in charge mode relatively cooler heat transfer fluid enters a solar field inlet 128 in the heat transfer fluid circuit 108 and flows to a solar field outlet 130 on the opposite side of a solar energy concentrator 102 while being heated by concentrated sunlight. Upon exit from the solar energy concentrator 102 the heated heat transfer fluid is routed to the power block 106 and/or the thermal energy storage system 104 . In the power block 106 , the heat transfer fluid flows through various steam train components to create super-heated steam for power generation as described above. The cooled heat transfer fluid is then returned in the heat transfer fluid circuit 108 to the solar field for additional heating.
[0046] Simultaneously, or alternatively, a portion of the heat transfer fluid in the heat transfer fluid circuit 108 may be routed through the thermal energy storage system 104 . In the charge mode, heat transfer fluid flows first into the phase change material hot bucket 122 , then into the medium temperature bucket 124 and finally into the coldest temperature bucket 126 . In each bucket, heat exchange with the phase change material causes heat energy to be transferred to the phase change material. Ideally, heat is transferred to the phase change material until the phase change material becomes fully molten. Since the melting point of the material in the “hot” bucket 122 is higher than the melting point in the “medium” bucket 124 the somewhat cooled heat transfer fluid exiting bucket 122 still is sufficiently hot to melt the material in bucket 124 and so on. As noted above, it is typically not desirable to add a significant amount of additional sensible heat to a given bucket of phase change material after the phase change material contained therein has fully melted. Thus, when all phase change materials in all buckets have melted, the thermal energy storage system may be described as “charged” or fully charged. Upon exiting the coldest phase change material bucket 126 , the then cooled heat transfer fluid may be routed back to the solar energy concentrator 102 for reheating by solar energy.
[0047] A solar energy power generation system 100 may be operated in charge mode at the discretion of the system operator provided sufficient insolation is available to heat the heat transfer fluid flowing through the solar energy concentrators 102 to a sufficiently high temperature to melt the phase change material in each bucket.
[0048] The thermal energy storage system 104 provides the system 100 with the ability to generate power for a period of time after the sun has set or when the sun is obscured by cloud cover. When the solar power generation system 100 is operated without solar input, the system is defined herein as being operated in a “discharge” mode. Operation of the basic system in the discharge mode is schematically illustrated in FIG. 2 . As shown in FIG. 2 , heat transfer fluid flowing in the heat transfer fluid circuit 108 flows through the steam train components 110 in the same direction to accomplish the same steam and power production steps described above. In discharge mode however, the high temperature heat transfer fluid is obtained by flowing cooled heat transfer fluid in reverse order through the cascaded buckets of phase change material. In particular, cooled heat transfer fluid is flowed through the cold phase change material bucket 126 , the medium temperature phase change bucket 124 and the hot phase change material bucket 122 in that order. As the phase change material in each bucket solidifies, heat is transferred to the heat transfer fluid. When all phase change materials in all buckets have solidified, the thermal energy storage system may be described as fully “discharged” and typically it is inefficient or impossible to further extract sensible heat from the system for additional power generation.
[0049] As noted above, day-to-day repeatability presents a significant difficulty in the operation of a thermal energy storage system such as shown in FIGS. 1 and 2 . In particular, the charging transient response of the system is quite different from that of the discharge transient response. This become a problem when attempting to design a system such as that illustrated in FIG. 1 and FIG. 2 that will properly exploit the beneficial energy characteristics of phase change in nearly 100% of the phase change material provided.
[0050] FIG. 3 schematically illustrates an improved method and apparatus for optimizing the control of a thermal energy storage system 104 to improve transient performance. The enhanced method illustrated in FIG. 3 includes routing some or all of the heat transfer fluid flow from the solar field through a phase change material bucket before the heat transfer fluid is routed to the power block 106 . This re-routing occurs during active energy production. In particular, some or all of the heat transfer fluid taken from the solar field outlet 130 over a selected period of time may be routed through the hot phase change material bucket 122 before sending it to the power block. When this strategy is employed, the hot bucket 122 can charge fully even when the charge driving temperature difference is much lower than the discharge driving temperature difference. Implementation of the control improvement strategy illustrated in FIG. 1 requires at least one secondary branch to the heat transfer fluid circuit, for example an additional pipe 132 or other conduit and associated valves be added to the heat transfer fluid circuit between an outlet from a bucket, for example, hot bucket 122 and the inlet of the steam train 110 , for example before the super-heater element 118 .
[0051] An alternative control improvement method and apparatus is schematically illustrated in FIG. 4 . This embodiment includes preheating the system 100 in the morning or when the system is otherwise cold by more fully discharging one or more relatively colder temperature buckets, for example bucket 126 . Because the melt temperatures of the one or more cold buckets are too low to heat the heat transfer fluid sufficiently to run the power block after the hot bucket 122 has fully discharged, the thermal energy storage system 104 and power block 106 must typically be shut down when there is still some latent energy available in the colder buckets. This energy can be used to improve overall plant performance by discharging it to preheat the solar field and power block 106 before the commencement of power generation operations.
[0052] The startup period for a concentrated solar power plant is traditionally long, on the order of an hour. This period is required to warm up the turbines and the heat transfer fluid in the heat transfer fluid circuit pipes. Using the cold buckets to do some portion or all of the required preheating will allow the system 100 to begin power production earlier in the day, thus increasing total power output. In addition, this method and apparatus causes the cold buckets to become fully discharged so the thermal energy storage system 104 can more efficiently be charged during the day. Implementation of the method of pre-heating the colder buckets requires the addition of one or more secondary branches to the heat transfer fluid circuit, for example pipe 134 leading from the power block to bucket 126 and then on to the inlet 128 of the solar field or back to the power block. Although only one additional pipe 134 is shown on FIG. 4 , this embodiment could be implemented with any combination of pipes that exit the colder temperature buckets and bypass the hot bucket 122 .
[0053] An alternative control improvement method and apparatus is schematically illustrated in FIG. 5 . This embodiment includes direct heat transfer fluid injection between individual phase change material buckets and corresponding steam train components during the discharge phase of power generation. The heat transfer fluid temperature at the outlet of the phase change material cascade during discharge is required to be slightly less than the designed maximum power block inlet temperature; otherwise the heat transfer fluid at the maximum power block inlet temperature could not effectively charge the hot bucket 122 . Therefore, the steam train 110 can not receive the designed maximum heat input during discharge operation. At this off-design condition, it is may be favorable to overload some steam train heat exchangers on the heat transfer fluid side to increase the heat flow to the steam train and in addition to more accurately balance the phase change material discharge rates.
[0054] Although the various buckets in the thermal energy storage system may be linked through heat transfer circuit inlet and outlet pipes with any of the steam train components, it is desirable to match the discharge temperature of a selected bucket with the optimum operating temperature of the corresponding steam train component. For example, the melting temperature of the phase change material in a given bucket may be approximately equal to the designed operating temperature of the corresponding steam train component.
[0055] As illustrated in FIG. 5 , this embodiment may be implemented with one or more secondary branches to the heat transfer fluid circuit, for example, pipes 136 and 138 leading from intermediate buckets to corresponding steam train components. In addition, secondary heat transfer fluid pipes 140 and 142 may be required leading from the steam train back to the next warmest bucket
[0056] An alternative control improvement method and apparatus is schematically illustrated in FIG. 6 . This embodiment features partial discharge of the thermal energy storage system 104 during periods of low insolation. Thus, as the sun goes down but still provides some light to the solar concentrators or as clouds partially obscure the sun, heat transfer fluid flow from the solar field to the power block 106 is supplemented with heat transfer fluid flow from the thermal energy storage system 104 to maintain the optimum power block inlet flow rate. Because the colder buckets in a thermal energy storage system 104 (for example buckets 124 and 126 ) typically have excess stored energy when compared to the hot bucket 122 , it is possible to discharge the colder buckets 124 , 126 first while maintaining full charge in the hot bucket. Thus, this embodiment features the routing of heat transfer fluid flow from the outlet of the steam train through one or two cold buckets to preheat it before sending it to the solar field for final solar heating to an operational temperature. The implementation of this improvement requires one or more secondary branches to the heat transfer fluid circuit, for example pipes 144 and 146 as shown on FIG. 6 . Pipe 144 leads from the outlet of bucket 124 to the solar field inlet 128 and pipe 146 leads from the outlet of bucket 126 to the solar field inlet 128 .
[0057] Each of the embodiments for enhanced thermal storage system control described above could be implemented alone, or in combination with other alternative embodiments. For example, FIG. 7 schematically illustrates a system 100 featuring each of the control enhancements described herein in combination. The FIG. 7 embodiment includes, but is not limited to a solar power generation system or thermal energy storage system, that comprises both the primary heat transfer fluid circuit of FIGS. 1 and 2 , in particular heat transfer fluid circuit element 108 and various secondary heat transfer fluid circuit branches. The secondary heat transfer fluid circuit branches can be implemented in any combination and include but are not limited to pipes 132 , 134 , 136 , 138 , 140 , 142 , 144 and 146 . The implementation of each improvement disclosed herein in any combination provides a concentrated solar power generation system operator with a great deal of flexibility over the charge and discharge management of a cascaded phase change material thermal energy storage system.
[0058] Various embodiments of the disclosure could also include permutations of the various elements recited in the claims as if each dependent claim was a multiple dependent claim incorporating the limitations of each of the preceding dependent claims as well as the independent claims. Such permutations are expressly within the scope of this disclosure.
[0059] While the embodiments disclosed herein have been particularly shown and described with reference to a number of alternatives, it would be understood by those skilled in the art that changes in the form and details may be made to the various configurations disclosed herein without departing from the spirit and scope of the disclosure. The various embodiments disclosed herein are not intended to act as limitations on the scope of the claims. All references cited herein are incorporated in their entirety by reference.
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Concentrating solar power (CSP) systems and methods are disclosed featuring the use of a solid-liquid phase change heat transfer material (HTM). The systems and methods include a solar receiver configured to receive concentrated solar flux to heat a quantity of the solid HTM and cause a portion of the solid HTM to melt to a liquid HTM. The systems and methods also include a heat exchanger in fluid communication with the solar receiver. The heat exchanger is configured to receive liquid HTM and provide for heat exchange between the liquid HTM and the working fluid of a power generation block. The heat exchanger further provides for the solidification of the liquid HTM. The systems and methods also include a material transport system providing for transportation of the solidified HTM from the heat exchanger to the solar receiver.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a composite structure of wood and reinforced concrete. It also relates to a composite girder including a composite structure of wood and reinforced concrete. It also relates to a dome shaped load bearing structure including such composite structure of wood and reinforced concrete.
2. DESCRIPTION OF THE PRIOR ART
At the present time there is generally the requirement to use materials of wood in an increased manner for halls, hangers and other supporting structures having long spans. A known building procedure includes the use of girders of laminated wooden boards having large cross sections at high surface loads. Forces encountered in such structures are highly concentrated. This concentration can lead to problems at joints and junctions because the magnitude of allowable forces at joints and junctions of wooden structures is limited. Further known are framework or lattice, respectively, structures which, however, necessitate complicated and intrinsic jointing elements. Wooden structures pose, furthermore, the problem that the individual elements of the structure must be laid out prior to the final assembling in order to allow the dimensions of the individual members and of the bores to be exactly matched to each other for the mutual connections. These procedures are intrinsic and time consuming and need a large precision. And in spite thereof it is still necessary to make further adjustments during the final assembly and building.
Structures made of reinforced concrete are known for a long time, including their advantages and drawbacks. The drawbacks of such reinforced concrete structures are the need to construct corresponding time and cost consuming intrinsic false works and that the structures themselves are of a large weight.
SUMMARY OF THE INVENTION
It is, therefore, a general object of the invention to provide a composite structure, in which the respective advantages of wooden constructions and reinforced steel constructions complete each other in such a manner that it is possible to design therewith building structures having small momentums of their own weight, without complicated false works and without high demands regarding precise dimensions of the individual members or elements, respectively.
A further object is to provide a composite structure of wood and reinforced concrete which comprises structural members of wood and structural members of reinforced concrete and interconnecting members which interconnect the structural members of wood and the structural members of reinforced concrete and are arranged in such a manner that they project through the cross sections of the structural members of wood and are molded into at least one cross section of reinforced concrete. Yet a further object is to provide a composite girder having a composite structure of wood and reinforced concrete including structural members of wood and structural members of reinforced concrete and interconnecting members which interconnect the structural members of wood and the structural members of reinforced concrete and are arranged in such a manner that they project through the cross sections of the structural members of wood and are molded into at least one cross section of reinforced concrete, which composite girder comprises an upper plate made of reinforced concrete, and at least one girder of laminated wooden boards at its bottom side, which at least one girder of laminated wooden boards is mounted by means of fitted set bolts to the plate made of reinforced concrete or to longitudinal ribs made of concrete formed at the plate made of reinforced concrete.
Yet a further object is to provide a dome shaped load bearing structure including a composite structure of wood and reinforced concrete having structural members of wood and structural members of reinforced concrete and interconnecting members which interconnect the structural members of wood and the structural members of reinforced concrete and are arranged in such a manner that they project through the cross section of the structural members of wood and are molded into at least one cross section of reinforced concrete, and having at least one tension arch structure of a catenary shape resting at its respective ends on the supports, which tension arch structure comprises as structural members of wood tension spars extending in the direction of the arch, which tension spars include tension plates at tension junctions, between which tension plates a respective disc of reinforced concrete is located, which tension junctions or tension spars, respectively, are anchored by means of fitted set bolts at said disc of reinforced concrete.
The connection between the structural members of wood themselves or between the structural members of wood and the structural members of reinforced concrete is made by fitted set bolts which as such are already known. The wooden members, into which initial bores for these fitted set bolts have previously been made, can be connected in a force locked manner to a body of reinforced concrete preferably after the assembling and the mounting of the bolts in that concrete is poured into the corresponding cross sections. The advantage of this procedure and design is, among others, that any deviations regarding dimensions at the structures of wood and of the earlier made bore holes for the fitted set bolts are taken up by the concrete. A preferred embodiment includes respective twin cross section members and reinforced concrete arranged between such members such that the portion of wood which swells and also which shrinks can be reduced to less than half. Furthermore, it is possible to adjust the connection to the forces to be connected or transferred, respectively, by selecting the number of cross sections which are equipped with fitted set bolts. A further advantage is that at junctions of members connecting forces occur which act only in the direction of the fibers of the wood. Accordingly, it is possible to connect the structural members of wood by a simple design also for relatively large forces.
The composite structure design finds use for various structures or building structures, respectively.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings, wherein:
FIG. 1 illustrates a composite girder made up of structural members of wood and structural members of reinforced concrete;
FIG. 2 illustrates a section of a span of a bridge extending over a plurality of supports and having no false work;
FIG. 3 is a cross section of the bridge according to FIG. 2 at a supporting column;
FIG. 4 illustrates a junction of a lattice girder and the corresponding cross sections;
FIG. 5 is a cross section through the tension arch structure of a dome shaped load bearing structure;
FIG. 6 is a cross section through a pressure arch structure located adjacent the tension arch structure of FIG. 5;
FIG. 7 illustrates one of the trusses located between the tension arch structure and the pressure arch structure;
FIG. 8 is a section along line IV--IV of FIG. 7;
FIG. 9 illustrates the joint between a tension spar and one of the supporting discs of concrete;
FIG. 10 illustrates the joint between a pressure spar and a supporting disc of concrete;
FIG. 11 illustrates the connection between a truss and a supporting disc of concrete;
FIG. 12 illustrates a tension junction of tension spars;
FIGS. 13 g, h, k are sections along the lines g, h, k of FIGS. 9 and 12;
FIG. 14 illustrates a pressure junction of pressure spars;
FIGS. 15 b, c, d, e are sections along the lines b, c, d, e of FIG. 10;
FIGS. 16 b', c', d', m are sections along the lines b', c', d', m of FIG. 11; and
FIG. 17 illustrates on an enlarged scale a view of the gable roof like super structure shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a T beam structured as composite girder made of structural members of wood and reinforced concrete. The structures .Of wood consist substantially of two girders 31 of laminated wooden boards and cross beams 32 extending between the girders 31. Casing supports 33 which support a wooden casing 34, i.e. concrete mold, lie on the cross beams 32.
Fitted set bolts 11 are anchored in the girders of laminated wooden boards. After this above described structure has been assembled, a roadway plate 30 of reinforced concrete is poured into the wooden casing 34. The anchoring of the roadway plate to the girders of laminated wooden boards is made via the fitted set bolts 11. Tension steel rods 35 adapted to take up tension forces are located within the structures such as illustrated in FIG. 1, which tension steel rods 35 are tensioned after the pouring of the concrete.
FIGS. 2 and 3 illustrate a corresponding composite structure with reference to a bridge extending over a plurality of supporting coles and without any false work. FIG. 2 is a cross section through a bay section of the bridge and FIG. 3 a cross section at a support. The structure of this bridge contains similar to the design of FIG. 1 structural members of wood in form of girders 31 made of laminated wooden boards, which in this embodiment are designed as twin cross section structures.
Also here cross beams 32 extend between the two twin cross section girders 31 of laminated wooden boards, which girders 31 support via casing supports 33 the wooden casing 34, i.e. mold for the concrete to be poured. The roadway plate which is a reinforced concrete structure positioned on the wooden casing 34 includes two longitudinally extending ribs 36. In the final mounted or assembled, respectively, state the girders 31 of each twin cross section are anchored by means of fitted set bolts 11 laterally at a respective rib 36. Connecting brackets 38 projecting into the roadway plate 30 are provided at the area of the ribs. The concrete supports 39 (FIG. 3) extend also between the girders 31 of laminated wooden boards of each twin cross section structure. These girders 31 are anchored at the supports by means of fitted set bolts 11 or fitted screw bolts 11', respectively, along their entire height. In order to additionally take up tension forces tension steel rods 35 extend also here at the side of the girders 31 of laminated wooden boards.
As already mentioned above, it is possible to initially assemble and mount the wooden structure, whereafter the roadway plate 30 of concrete is poured and the tension steel rods 35 are tensioned. A specific preciseness regarding the arrangement of the interconnecting fitted set bolts 11 is thereby not necessary.
FIG. 4 illustrates an embodiment, in which the longitudinally extending ribs are structured as lattice girders of wood. FIG. 4 depicts specifically a joint at a lattice girder where a support 40, a strut 41 and a lower chord 42 of the girder are Joined and additionally the sections a-a, b-b and c-c are designed, too. The junction 43 of the lower chord is, thereby, preferably located in this joint. The support 40, strut 41 and lower chord 42 are designed as twin cross section members made of structural members of wood, such as clearly visible in the illustrated cross sections thereof. Now, a disc 44 of reinforced concrete and including reinforcing baskets or rebar 45 is located at the area of this joint or junction, respectively. The anchoring of the twin cross sections of wood at the reinforcing disc 44 proceeds by means of fitted set bolts 11 and fitted screw bolts 11'. Two tension plates 46 are located at the sides of the twin cross section of the lower chord 42 at the area of the junction, which tension plates 46 interconnect two wooden members of the lower chord 42 abutting each other and are anchored via fitted threaded bolts in the disc 44 of reinforced concrete. The number of fitted set bolts and fitted screw bolts, respectively, is selected in accordance with the forces to be transmitted at the Joint. The forces intersect each other in the joint exactly at its center of gravity. In the wooden members connecting forces are present which act only in the longitudinal direction of the fibers. At the joints the cross sections of the wooden men, bets and structures can be selected to be rather slim, such that the influence of the swelling and shrinking of the wood can be reduced.
The following embodiment refers to a hall or hangar, respectively, having a span width of e.g. 70 m, which hall can be used as indoor riding court, covered playing field (example: Astro-Dome) or similar applications. This riding hall is illustrated in FIGS. 5 to 7 at a scale of about 1:500, whereas the FIGS. 8 and 17 are designed on a scale of about 1:200 and the other figures on a scale of about 1:50. The width of the hall is given by the number of adjacently located tension and pressure arches, of which each has a width of about 15 meters. It shall, however, be distinctly noted that these dimensions are given by example only and not by way of restriction and that it is possible to design halls of a still larger width in accordance with the here illustrated structural procedure.
The dome shaped load bearing structure of FIGS. 7 and 8 includes a tension arch 1 (FIGS. 5 and 8) of a catenary shaped pattern which is connected to a support 3 at both its ends via a respective supporting disc 2 made of concrete. This support 3 may be integrated in the structure of a grandstand.
Immediately adjacent this tension arch 1 a pressure arch 4 (FIGS. 6 and 8) is provided, which is also connected via the supporting discs 2 of concrete to the supports 3.
A truss 5 (FIGS. 7 and 8) is located between the respective tension arches and pressure arches. The truss 5 is mounted at the one side to a movable and at the other side to a stationary support.
FIG. 8 illustrates in section the tension arch 1 of FIG. 5 the pressure arch 4 of FIG. 6 which re interconnected by the truss 5. FIG. 8 illustrates furtheremore that the tension arch 1 includes tension spars 6 made of wood or of hollow steel profile members which are designed as twin cross sections and extend in the direction of the arch, which tension spars 6 absorb the tension forces. The tension spars 6 rest on beams 7 extending perpendicularly thereto between two adjacent trusses 5. The roof casing of the tension arches 1 can consist of translucent plates 8, e.g. of transparent corrugated roof plates which do not absorb tension forces on their own. Accordingly skylights are formed at the tension arches 1 which extend in the direction of the arch. The wooden tension spars 6 of the tension arches 1 may be connected directly to the supporting discs 2 of concrete such as specifically clearly shown in FIGS. 9 and 14. Hereto cross sections 9 of tension-reinforced concrete are foreseen between the twin cross sections of wood and tension plates 10 made of wood or of steel are placed laterally at the twin cross sections of the tension spars 6, which tension plates 10 are connected to each other by means of fitted set bolts or fitted screw bolts 11, respectively. A corresponding connection is foreseen at the tension junctions of the tension spars 6 such as illustrated in FIG. 12. The cross sections of concrete which are tension-reinforced pass into the concrete supporting disc 2. By this design the tension forces of the own weight and of the live load can be transferred via relatively small cross sections directly to the supports.
FIGS. 8, 14 and 15 illustrate that the pressure arches 4 are of a similar design. Pressure spars 12 of wood extend here in the direction of the arch and form together with the casing (mold) and the lateral trusses 13 a structure having a high resistance to buckling. The pressure forces are transmitted via the pressure spars 12 directly into the supporting discs of concrete, such as illustrated in FIG. 10 and by the sectional views b, c, d and e of FIG. 15. At the side of every pressure spar 12 plates 14 of wood or steel are mounted and connected by means of fitted set bolts or screw bolts 11. Between the plates 14 a tension reinforced concrete cross section 15 is foreseen, which passes into the supporting disc 2 of concrete. FIG. 14 illustrates a pressure Junction between the pressure spars which correspondingly includes two lateral plates 14 which are interconnected by fitted set bolts, whereby the pressure Junction itself is formed by a concrete cross section 15.
Finally, the trusses 5 are structured of wooden members in accordance with generally known procedures and their connections to the supporting discs 2 of concrete are illustrated in FIG. 11 and the corresponding cross sections b', c', d', g and m in accordance with FIGS. 13 and 16.
The pressure members 16 which are made of wood are designed here also as twin cross sections, between which a respective tension reinforced concrete cross section 17 is foreseen at the area of the joint, whereby plates 18 of wood or steel are located at the sides of the twin cross section and are connected by means of fitted set bolts 11, respectively. The connection of the tension members 19 of the truss 5 proceeds correspondingly. At the section m (FIG. 16) the laterally located tension plates 21 are anchored in the supporting disc 2 of concrete by means of fitted set bolts 20.
In FIG. 5 it can be seen that the tension arch has at its center area a low inclination or slope, respectively, towards the center. This inclination is lower than the prescribed minimal value of 15%, which is necessary for a sufficient self-cleaning of the transparent corrugated roof plates and simultaneously for a safe guiding away of water on the roof. For this reason a superstructure in shape of a gable roof 22 is foreseen at this center area, of which the roof has the prescribed inclination and can also be covered by transparent corrugated roofing boards 8. FIG. 17 illustrates that this superstructure 22 on the roof is connected at the area of a lower beam 7 to the tension spars 6, i.e. it is bolted thereto between the twin cross section. Thereby gutters and down spouts 23 for the water of the tension arch and also of the superstructure 22 on the roof are foreseen at the connection area.
In order to build or assemble, respectively, the described dome shaped load bearing structure, the trusses are installed firstly and thereafter the tension arches and pressure arches installed before the supporting discs of concrete are poured, i.e. the cross sections of concrete of the joints and junctions are poured. The corresponding fitted bolts, fitted screw bolts and fitted set bolts are placed prior to the pouring of the concrete. By this procedure any deviations from precise dimensions of the members of wood are taken up by the concrete, which simplifies considerably the installation of the connections of the tension arches and pressure arches. After the supporting discs of concrete have been made, the trusses are lowered such that the tension arches and pressure arches support their own weight and transmit the corresponding forces into the supporting discs 2 of concrete.
The described structure consists essentially of wooden members having a cross section of 8×50 cm, of which the tension forces and pressure forces, respectively, are transferred individually into the supporting discs of concrete. This allows an avoiding of large concentrations of forces. The tension arches form translucent strips, which can be completed by window openings in the trusses, such that no artificial light is needed during daytime.
The explained embodiments illustrate the large variety of possibilities of applications of the inventive composite structure. Corresponding further applications are obvious for the person skilled in the art. By means of this composite structure the advantages of reinforced concrete structures can be combined with the advantages of wooden structures. It is possible to realize buildings having smaller momentums of their own weight, whereby high demands regarding precise dimensions of the individual members of the structure are not needed and which structures can be mounted and assembled without any intrinsic false works.
In case of smaller widths it is possible to use in the illustrated structures bolts having correspondingly small diameters, i.e. to use nails.
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.
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The composite structures are composed of wooden members such as girders of laminated wooden boards and members of reinforced concrete such as a plate of reinforced concrete which form for instance a composite load supporting structure designed as pedestrian walkway or similar structure. In order to interconnect the members of wood themselves or to members made of reinforced concrete fitted set bolts or fitted screw bolts, respectively, are arranged in such a manner that they extend through the cross sections of the wooden members and are anchored at least in one cross section of reinforced concrete. The parts consisting of reinforced concrete are poured as a rule after the assembling of the wooden structure such that deviations of dimensions can be equalized or taken up, respectively, quite easily. This allows a combining of the advantages of wooden structures and of structures made of reinforced concrete.
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PRIORITY CLAIM/INCORPORATION BY REFERENCE
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/589,559 entitled “Golf Tee” that was filed on Jan. 23, 2012 and names Lon Klein as inventor. The entirety of that application is hereby expressly incorporated by reference into this application.
BACKGROUND
[0002] In golf, a tee is normally used for the first stroke of each hole, and the area from which this first stroke is hit is informally known as the teeing box, also known as the teeing ground. Normally, teeing the ball is allowed only on the first shot of a hole, called the tee shot, and is usually not allowed for any other shot. Teeing gives a considerable advantage for drive shots, so it is highly desirable whenever allowed. A standard golf tee is 2.750″ (two and three quarter inches) long, but both longer and shorter tees are permitted and are preferred by some players.
SUMMARY
[0003] An elevation tube comprising a substantially cylindrical body having a first end configured to hold a golf ball and a second end configured to insert into the ground. The second end includes a tapered portion, a bullet-like shaped portion, a spike-like shaped portion, a serrated edge, a regularly curved edge or an irregularly curved edge. An elevation tube comprising a substantially cylindrical body having a first end configured to hold a golf ball, the elevation tube being coupleable to a conventional golf tee, wherein when the elevation tube is coupled to the conventional golf tee, the first end of the elevation tube holds the golf ball to the exclusion of a golf ball holding means of the conventional tee.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows an elevation tube that is used as a golf tee or a portion of a golf tee according to an exemplary embodiment.
[0005] FIG. 2 shows a second exemplary embodiment of an elevation tube.
[0006] FIG. 3 shows a third exemplary embodiment of an elevation tube.
[0007] FIG. 4 shows a fourth exemplary embodiment of an elevation tube.
[0008] FIG. 5 shows a fifth exemplary embodiment of an elevation tube.
[0009] FIG. 6 shows a sixth exemplary embodiment of an elevation tube.
DETAILED DESCRIPTION
[0010] The exemplary embodiments may be further understood with reference to the following description and appended drawings, wherein like elements are referred to with the same reference numerals. The exemplary embodiments describe a golf tee that may be implemented to hold a golf ball for a tee shot by a player.
[0011] FIG. 1 shows an elevation tube 10 that is used as a golf tee or a portion of a golf tee. In the example of FIG. 1 , the elevation tube 10 includes a first end 12 and a second end 17 . The first end 12 is designed to hold the ball, while the second end 17 is designed for insertion either into the ground and/or into another portion of the tee. The other portion of the tee may be a core section that is fully described in U.S. patent application Ser. No. 12/956,310. Thus, the elevation tube 10 described herein may be used with or without the core section. When used with the core section, the elevation tube 10 is used in generally the same manner as described in the above-described patent application. In addition, the materials and general construction of the elevation tube 10 is the same as the described elevation tube in the above-described patent application, except for the modifications described herein.
[0012] However, when the elevation tube 10 is used without the core section, the elevation tube will be inserted directly into the ground of the tee box. As shown in FIG. 1 , this exemplary embodiment of the elevation tube 10 includes a taper 20 at the second end 17 to aid in the insertion into the ground of the tee box. The taper 20 is generally shown as having an approximately 45 degree taper angle. However, the taper angle may be varied to any angle to aid in the insertion. The variance of the taper angle may depend on any number of factors including the structural rigidity required for the insertion into the tee box, the structural rigidity of the material(s) used for the construction of the tee, etc. In fact, the elevation tube 10 may be provided to consumers with varying taper angles, so consumers may select the elevation tube 10 with the taper angles that they desire. During the manufacturing process, the elevation tube 10 may be manufactured initially as a long tube that may be cut into multiple elevation tubes 10 with different taper angles.
[0013] As shown in FIG. 1 , the total length of the elevation tube 10 is the length of the taper 20 (T) plus the length of the remainder of the elevation tube 10 (H). The length T of the taper 20 is preferably not to exceed ½″. Those skilled in the art will understand that the taper 20 may aid in the insertion of the elevation tube 10 into the ground. That is, the taper 20 results in the second end 17 having a pointed or wedge-shaped portion, which may allow for a more easy insertion into the ground than a blunt end.
[0014] FIG. 2 shows a second exemplary embodiment of an elevation tube 30 . The elevation tube 30 is similar to elevation tube 10 described above, except that elevation tube 30 includes a second end 37 that includes a bullet-like shape to aid in insertion into the ground of the tee box. Again, the angles of the bullet shape from the body of the elevation tube 30 may be varied, and the lengths discussed above are similar for this elevation tube. In FIG. 2 , the outer walls 38 of elevation tube 30 having the bullet-like shape are illustrated using straight lines. However, those skilled in the art will understand that the outer walls 38 may also be curved either concavely or convexly. Furthermore, the bottom 39 of the bullet-like shape is shown as a closed point. It is possible that the second end 37 is cut or formed such that it stops, for example, at the location of line 36 , meaning that if the elevation tube 30 were generally hollow, the second end 37 would also include a hole in the area of line 36 .
[0015] In addition, it is possible to stack multiple elevation tubes 30 within each other to vary the height of the tee. For example, a first elevation tube 30 may be placed into the tee box. However, the golfer may desire that the tee have a greater height than the height of the first end 32 . In this case, the golfer may place the second end 37 of a second elevation tube 30 into the first end 32 of the elevation tube 30 that is currently in the tee box. As should be apparent from the figure, the bullet-like shape of the second end 37 of the second elevation tube 30 will be received into the first end 32 of the first elevation tube 30 . When the non-tapered cylinder portion of the second elevation tube 30 reaches an insertion point approximately equal to the first end 32 of the first elevation tube 30 a mechanical fit will be created between the two elevation tubes 30 . This results in a stack of two elevation tubes 30 having a height that is greater than a single elevation tube 30 . Additional elevation tubes 30 may also be stacked to achieve any height desired by the golfer. While this stacking example is provided with respect to elevation tube 30 , those skilled in the art will understand that any of the elevation tubes disclosed herein may be designed to be stackable.
[0016] It is further noted that the second end 37 or a portion thereof may further include a coating material that may be applied on the external or internal surface of the second end. The coating material is designed to make the second end 37 more rigid and/or more durable for insertion into the ground. The coating material may be any material that makes the second end more rigid and/or durable such as a plastic coating material or synthetic coating material. It is also noted that while the coating of the second end 37 is described with respect to this particular embodiment, any of the second ends for any of the described embodiments may include such a coating material.
[0017] In a further exemplary embodiment, the second end 37 may also include a separate tip piece that may be constructed from a different material than the remainder of the elevation tube 30 . For example, referring to FIG. 2 , the tip piece may be added to the second end 37 in the area from the line 36 to the bottom point 39 . This tip piece may be constructed from a material such as a plastic material or a synthetic material that is more rigid and durable than the material used to construct the remainder of the elevation tube 30 . Again, since the second end 37 is designed to be placed into the ground, the rigid and durable tip piece will aid in placing the elevation tube 30 into the ground, especially where the tee box is hard. In one exemplary embodiment, the elevation tube 30 is a complete piece, e.g., the elevation tube 30 material extends all the way to bottom point 39 . In this embodiment, the tip piece may be placed over the material of the elevation tube 30 and coupled thereto such as by gluing or other known fastening means. In another exemplary embodiment, the elevation tube 30 material ends in the are of the line 36 resulting in a hole in the bottom of the elevation tube 30 . In this embodiment, the tip piece may be coupled to the end of the elevation tube 30 in the area of the hole, either on the exterior or interior surface of the elevation tube 30 . It is again noted that while the additional tip piece is described with respect to this particular embodiment, a similar tip piece may be coupled to the second ends of any of the described embodiments.
[0018] FIG. 3 shows a third exemplary embodiment of an elevation tube 40 . The elevation tube 40 is similar to elevation tube 10 described above, except that elevation tube 40 includes a second end 47 that includes a spike-like shape to aid in insertion into the ground of the tee box. Again, the angles of the spike-like shape from the body of the elevation tube 40 may be varied, and the lengths discussed above are similar for this elevation tube.
[0019] FIG. 4 shows a fourth exemplary embodiment of an elevation tube 50 . The elevation tube 50 is similar to elevation tube 10 described above, except that elevation tube 50 includes a second end 55 that includes a serrated end to aid in insertion into the ground of the tee box. Again, the angles and number of serrations of the elevation tube 50 may be varied, and the lengths discussed above are similar for this elevation tube.
[0020] FIG. 5 shows a fifth exemplary embodiment of an elevation tube 60 . The elevation tube 60 is similar to elevation tube 10 described above, except that elevation tube 60 includes a second end 67 that includes a regular or irregular curved shape to aid in insertion into the ground of the tee box. Again, the lengths discussed above are similar for this elevation tube.
[0021] FIG. 6 shows a sixth exemplary embodiment of an elevation tube 70 . In this embodiment, the elevation tube 70 is a cylinder that may be placed over a conventional wooden or plastic tee 80 . That is, the conventional tee 80 is placed into the ground and the elevation tube is placed over the portion of the conventional tee that would normally hold the ball. The elevation tube 70 may be secured to the conventional tee 80 in any manner, e.g., friction fit, protrusions that rest on the conventional tee, etc. Thus, in this embodiment, the elevation tube 70 holds the ball, rather than the conventional tee 80 . It is also noted that the elevation tube 70 may be inserted onto the conventional tee 80 by pushing the elevation tube 70 in the direction 90 .
[0022] In an alternative embodiment, the elevation tube 70 may be placed onto the conventional tee 80 by pulling in the direction 95 . In such an embodiment, the elevation tube 70 may be pre-attached to the convention tee 80 such as in the area of the shaft 82 of the conventional tee 80 . After the conventional tee 80 is inserted into the ground, the elevation tube 70 may be pulled up in the direction 95 to result in the configuration shown in FIG. 6 .
[0023] It should be noted that while the above exemplary embodiments described inserting the elevation tubes directly into the teeing ground, it is also possible that the golfer will have a tool to prepare the ground for receiving the elevation tubes. For example, the tool may soften the teeing ground or create a hole or indent in the teeing ground into which the elevation tube may be inserted.
[0024] It will be apparent to those skilled in the art that various modifications may be made in the present invention, without departing from the spirit or the scope of the invention. Thus, it is intended that the present invention cover modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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An elevation tube comprising a substantially cylindrical body having a first end configured to hold a golf ball and a second end configured to insert into the ground. The second end includes a tapered portion, a bullet-like shaped portion, a spike-like shaped portion, a serrated edge, a regularly curved edge or an irregularly curved edge. An elevation tube comprising a substantially cylindrical body having a first end configured to hold a golf ball, the elevation tube being coupleable to a conventional golf tee, wherein when the elevation tube is coupled to the conventional golf tee, the first end of the elevation tube holds the golf ball to the exclusion of a golf ball holding means of the conventional tee.
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The Government has rights in this invention pursuant to Contract CPE 8015591 awarded by the National Science Foundation.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for the delignification and pulping of lignocellulosic materials such as softwoods, hardwoods and derivatives or substrate materials related thereto, and the delignification liquor employed therein.
2. Description of the Prior Art
An economic, safe and nonpolluting process for the delignification of lignocellulosic materials such as wood and wood derivatives has long been sought, as the resultant pulp is widely employed, in both the paper industries and newly developed biomass industries as the raw product therefore. A conventional delignification process, commonly referred to as the "Kraft" process, involves the cooking of chipped lignocellulosic materials in a treatment liquor of sodium hydroxide and sodium sulfide. Such treatments are undesirable in that the pulping process inevitably degrades a significant portion of the desired cellulose component, substantially reducing the pulp yield of the process. Additionally, processes of this type which rely on sulfide components in the treatment liquors present the problem of the disposal of sulfide pollutants, which requires further expensive processing.
In an effort to avoid the loss of cellulose experienced in conventional processes, other treatment liquor components have been employed, such as ethylenediamine or aqueous ethanol, see U.S. Pat. Nos. 2,218,479 and 3,585,104, respectively. However, these components alone, have not been effective in avoiding substantial cellulose degradation. Accordingly, in order to secure sufficiently high yields of pulp, it has been common practice to incorporate in these treatment liquors sulfide components, such as sodium sulfide with ethylenediamine and ammonium sulfide with aqueous alcohols (U.S. Pat. No. 4,329,200). Although these processes give substantially higher pulp yields with correspondingly low lignin content, the problem presented by the presence of sulfide pollutants not only remains, but is aggravated thereby.
In order to minimize the effect of sulfide pollutants, U.S. Pat. No. 4,012,280 proposes delignification of lignocellulosic materials by treatment with an aqueous sodium hydroxide solution in the presence of a cyclic keto compound such as anthraquinone. This process is free of sulfur and is stated to have the advantage of producing no polluting or odor producing sulfur compounds. However, it results in only a very marginal gain in pulp yield, due to substantial degradation of cellulosic material.
While some of the aforementioned delignification processes could provide a viable system to inhibit the degradation of cellulose, it has never been possible to avoid the use of pollutants such as inorganic sulfides. Similarly, while some other processes provided a delignification process alleviating the pollution problems, they failed to inhibit the degradation of the cellulose.
It is therefore an object of the present invention to provide a selective delignification process while at the same time significantly retarding degradation of cellulosic components.
It is another object of this invention to provide a process for the delignification of lignocellulosic materials which avoids the presence of sulfide pollutants.
It is yet a further object of this invention to provide treatment liquors which can be practically recovered and reused in the above-identified processes.
These and other objects may be secured by the invention described below.
SUMMARY OF THE INVENTION
Lignocellulosic materials may be delignified and pulped in a reactor vessel containing a pulping liquor comprised of aliphatic amines and/or polyamines and aqueous lower aliphatic alcohols, further in the presence of anthraquinone and/or one or more of its derivatives, an azine, or their combination. The material to be pulped is cooked in the above liquor for a period of time sufficient to delignify the material, and thereafter the resultant cellulosic pulp is recovered from the reactor, for instance by separating it from the spent liquor and then steam stripping or hot water washing to remove the entrapped solvents. The recovered spent liquor and washings can be recycled back to effect the delignification of a new batch of lignocellulosics until a considerable concentration of lignin is achieved in the spent liquor. The organic solvents can then be recovered by distilling the concentrated spent liquor in the presence of sodium hydroxide and effectively reutilizing the removed material for further delignification application. It is the discovery of the present invention that aliphatic polyamines such as ethylenediamine in combination with aqueous alcohols such as ethanol in the presence of catalyst like anthraquinone provide an effective and efficient pulping agent for the selective removal of lignin while protecting the cellulosic materials from degradation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic illustration of the effects of varying amounts of ethylenediamine in this invention.
FIG. 2 is a graphic illustration of the effects of variation of catalyst amounts in this invention.
FIG. 3 is a graphic illustration of the effects of varying amounts of alcohol in this invention.
FIG. 4 is a graphic comparison of this invention with art-recognized processes.
FIG. 5 is a graphic illustration of the effects of pulping liquor recycling in this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Lignocellulosic materials, such as soft- and hardwoods and their derivatives, may be delignified and otherwise pulped by cooking them in a closed reactor vessel in the organic solvent mixture (hereinafter, pulping liquor) of this invention. Surprisingly high yields of pulp, of up to 13% or more (percentage expressed on original lignocellulosic material) than that derived from the conventional "Kraft" process can be achieved.
By softwood is meant species such as pine, spruce and balsam fir. By hardwood is meant species such as birch, aspen, maple and sweet gum.
The pulping liquor solution employed is comprised of volatile alcohols such as ethanol or methanol, ethylenediamine or related aliphatic polyamines and water. For purposes of clarity, this invention will be further described with reference to the use of ethanol and ethylenediamine. However, as is discussed below, the invention is not so limited. Broadly, the ethanol, ethylenediamine and water should each be present in amounts of 1-12 parts by volume. When treating softwoods, an equally effective but more economical mix may be employed, and the ethanol, ethylenediamine and water should each be present in amounts from 1-5 parts by volume. A particularly preferred composition is comprised of ethanol, ethylenediamine and water in a volume ratio of 1:5:5, respectively. However, for hardwoods the preferred composition for the same components is comprised of ethanol, ethylenediamine and water in a volume ratio of 1:7.5:11.5 respectively. The above-described pulping liquor is cooked with the lignocellulosic material in the ratio of grams lignocellulosic material to milliliters pulping liquor in the range of 1:4 to 1:15. In a particularly preferred process, the ratio of grams of lignocellulosic material to pulping liquor is 1:4-1:12.
This reaction is catalyzed by the presence of anthraquinone, or its derivatives, azines, or both. Although the present invention is demonstrated with anthraquinone, other members of the quinone family are equally effective. Naphthaquinone, methylanthraquinone, amino-anthraquinone are among preferred species. The amount of anthraquinone required can be determined by the amount of lignocellulosic material present, and should generally be 0.1 to 10% of the lignocellulosic material, by weight, preferably in the range of 0.5-1.5%. These ratios and percents are based upon the oven dry weights of the lignocellulosic material. As will occur to one of ordinary skill in the art, the amounts of each component of the reaction mixture are interdependent, and anthraquinone required can be varied by varying the amount of pulping liquor. Accordingly, the anthraquinone catalyst should be present in amounts of grams of catalyst per milliliter of pulping liquor on the order of from 0.001-0.1:4 to 0.001-0.1:15, and preferably 0.005-0.015:4 to 0.005-0.015:12.
The above reaction mixture is cooked in a closed reactor vessel at temperatures from 140° C.-200° C., for from 50-360 minutes. Particularly preferred temperatures and times for softwood range between 170°-190° C., and from 60-120 minutes, respectively. Preferred temperature and times for hardwood range between 160°-175° C. and from 60-100 minutes, respectively.
When equal amounts of identical lignocellulosic materials are cooked in the above process and by the above-described conventional Kraft process, surprisingly, superior yields are secured by the instant process. Thus, the total pulp yield from southern yellow pine according to the instant process is on the order of 57.75% at 28.5 kappa number. The corresponding values for the Kraft process are 45.80 and 36.5 respectively. Similarly, the total pulp yield according to the instant process for sweet gum is on the order of 59.9% at 19.2 kappa number. Corresponding values for the Kraft pulping of sweet gum are 52.0 and 32.8 respectively. It can therefore be seen that the combination of ethylenediamine and aqueous ethanol in the presence of anthraquinone gives dramatically superior protection and preservation of the cellulose pulp component of the lignin-containing material.
Although the inventors do not wish to be bound by this theory, it appears that the ethylenediamine present retards attack on the mannans, while ethanol seems to preserve the xylans.
It will also be observed that the instant process, by totally eliminating inorganics from the pulping liquor and the delignification system, avoids the sulfide pollution problems of the prior art. Moreover, as the solvent mixture of the instant process boils at approximately 115° C., a very high recovery of the solvent mixture is possible by simple distillation, making the process and solvent mixture even more economically superior. Thus almost 99.0% of ethylenediamine charged and 95-97% ethanol charged were recovered by simple distillation in the presence of sodium hydroxide.
An important feature of the spent liquor is its continued delignification potentiality. The spent liquor, after adjusting the concentration of ethylenediamine, ethanol or anthraquinone can be recycled back to delignify more lignocellulosic material. Although gradual deterioration occurs in its capacity to delignify the wood, it is possible to precipitate the lignin from the 2-3 times recycled and concentrated (in lignin) spent liquor, thereupon making it possible to reuse the liquor in the pulping process. In this particular and preferred embodiment, the process is explained using a closed reactor. However, the process is also suitable for a continuous reactor such as a Kamyr digester, when lignocellulosic material and pulping liquor are fed in a counter-current fashion.
The pulp in unbeaten form produced by treatment of lignocellulosic material with the pulping liquor of the instant process produces a paper with greater tear strength than that produced from unbleached and unbeaten Kraft pulp. The unbeaten Kraft pulp will afford a tear factor of 219±5% while the aqueous ethylenediamine-ethanol-anthraquinone pulp in accordance with the present invention gives a tear factor of 261±5%. Beating the pulp reduces the tear factor in both instances to about the same level of 175±5% at 600 C.S.F. (Canadian Standard Freeness) level.
Further features and characteristics of paper and pulp produced according to the present invention are of value. For example, the operating pressure of the digester is 140 psig and is significantly lower than the typically high operating pressure (approx. 500 psig) for the ethanol or ethanol-ammonium sulfide processes cited above.
Thus, the process is distinct from the commercial Kraft process and the more recent organosolv sulfide methods although borrows some technology from each. Both the components of the reaction mixture in the Kraft process, viz. sodium hydroxide and sodium sulfide, are detrimental to the process. While sodium hydroxide severely degrades the cellulosic components, losing considerable amounts of pulp yield, sodium sulfide poses a serious environmental pollution problem. The instant process avoids sodium hydroxide by using the mixture of ethanol and ethylenediamine. Similarly, anthraquinone replaces sodium sulfide resulting in a novel pollution free, high yield process.
The invention is illustrated by the following examples and its objects, features and advantages will become apparent in these examples and accompanying figures. However, it should be noted that these examples are illustrative only and the scope of the invention is not thereby limited. Despite the fact that the inventions are carried out using a mixture of ethanol-ethylenediamine and in the presence of anthraquinone, the mixture prepared by permutation-combination of the following classes of compounds would also be effective.
Class A--Aliphatic amines and polyamines such as ethylenediamine, propylenediamine, hexamethylenediamine, methylaniline, ethylamine, etc.
Class B--Lower aliphatic alcohols like methanol, ethanol, butanol, pentanol, etc.
Class C--Quinones and azines, such as benzoquinone, anthraquinone, naphthaquinone, phenazine and their derivatives.
In the examples, the kappa number and analysis of ethanol, ethylenediamine, carbohydrate analysis were carried out by the following art-recognized methods.
______________________________________Kappa number Tappi-T236 OS-76Ethanol analysis Gas chromatography methodEthylenediamine Potentiometric TitrationCarbohydrate analysis Tappi - T249 PM-75______________________________________
In the following examples, pulping was carried out in stainless steel pressure vessels of either one of the following two types: (1) 30 ML capacity shaking bomb reactor in an oil bath and (2) 1.5 liter capacity electrically heated Parr reactor equipped with a stirrer. While charging the shaking bomb reactor, 2.194 grams of air dry southern yellow pine wood meal (equivalent to 2.0 grams of oven dry substance) passing through #10 U.S. mesh and retained on #30 mesh was used. However, 114.9 g of air dry industrial size chips (equivalent to 100.0 g of oven dry wood) were employed in the electrically heated Parr reactor. The oil heated bomb takes one and one-half minutes to reach the pulping temperature and is maintained to within ±0.5° C. of said maximum, while the electrically heated Parr reactor needs 40 minutes to reach the present maximum and is maintained with ±2° C. of said maximum to the end of the cooking period.
Upon completion of the cooking period the pulp mixture was brought to room temperature and spent liquor was separated from the pulp first by suction filtration and then by washing the pulp with water.
EXAMPLE 1
Seven samples of southern yellow pine chips were subjected to the pulping treatment described in the invention. The ethylenediamine component of the pulping liquor is varied while maintaining other factors constant. The condition employed and the results of the effect of variation of ethylenediamine on the rate of delignification of pine are shown in Table 1 and FIG. 1.
TABLE 1__________________________________________________________________________EFFECT OF VARIATION OF EDA INEDA/ETOH/H.sub.2 O--AQ PULPING SYSTEMLIQUOR/WOOD RATIO = 10/1 AQ % ON WOOD = 1.0 ETOH ML/G WOOD = 3.47COOKING TEMP = 180° C. TIME @ TEMP = 100 MTS BOMB IN SHAKER OIL BATHCOOK EDA ML/G H.sub.2 O ML/G % RESIDUAL % LIGNIN KAPPANUMBER WOOD WOOD PULP YIELD FREE YIELD NUMBER__________________________________________________________________________10 0 6.53 85.87 -0 11611 .68 5.85 84.59 -0 95.512 2.03 4.5 78.29 67.78 87.213 3.38 3.15 75.72 66.89 75.7 6 4.05 2.48 72.72 65.66 6314 4.74 1.79 75.2 66.85 72.115 6.53 0 76.35 67.05 79.1__________________________________________________________________________ % lignin free yield = % residual pulp yield (1 - K × 0.154/100)
EXAMPLE 2
Six samples of southern yellow pine chips were subjected to the pulping treatment according to the present invention. In these experiments, the charge of anthraquinone is varied while keeping other factors constant. FIG. 2 shows the variation in lignin content of aqueous ethanol-ethylenediamine-anthraquinone pulp expressed in terms of kappa number along the vertical axis, and anthraquinone content of the treatment liquor expressed in terms of percent by weight anthraquinone of the oven dry weight of wood along the horizontal axis.
EXAMPLE 3
Six samples of southern yellow pine chips were subjected to the pulping treatment according to the invention. The ML ethanol charged per oven dry wood was varied while holding other variables constant. Cooking experiments were carried out using the same digester and procedures as in Example 1. Three samples were also treated with pulping liquor according to the invention but by substituting methanol for ethanol. The results are indicated in FIG. 3.
EXAMPLE 4
Ten samples of southern yellow pine chips were subjected to pulping experiments according to the present invention. Cooking was carried out using the digester and similar procedures as in Example 1. The effects of variation in cooking temperature and time and liquor:wood ratio on the delignification of southern yellow pine is shown in Table 2.
TABLE 2__________________________________________________________________________EFFECT OF VARIATION OF LIQUOR:WOOD RATIO, COOKING TEMP. AND TIME INAQUEOUSETHYLENEDIAMINE-ETHANOL-ANTHRAQUINONE PULPING OF SOUTHERN YELLOW PINELiquor composition = Ethylenediamine/Ethanol/Water = 5/1/5Shaker bomb reactor in oil bath; chips size = -10 + 30 U.S. mesh Liquor:Wood % AQ. on Cooking Cooking Time Total Pulp YieldCook Number Ratio (MLig) Wood Temp. °C. Minutes Kappa Number % on Wood__________________________________________________________________________1 5:1 1.0 190 100 34.7 59.422 7:1 1.0 190 100 32.3 59.873 9:1 1.0 190 100 31.8 58.94 11:1 1.0 190 100 33.6 58.945 11:1 1.5 180 100 47.8 64.466 11:1 1.5 190 100 31.3 58.937 11:1 1.5 200 100 24.0 57.648 11:1 1.5 190 60 43.4 65.009 11:1 1.5 190 120 30.3 59.6510 11:1 1.5 190 140 39.6 61.13__________________________________________________________________________
FIG. 4 is a graph of residual pulp yield of southern yellow pine prepared in accordance with the present invention along the vertical axis; with the lignin content expressed in terms of kappa number along the horizontal axis. For comparison, selectivity plots of aqueous ethylenediamine anthraquinone (without ethanol) and Kraft pulping for the same lignocellulosic material, ethanol ammonium sulfide pulping of hemlock and ethylenediamine-ammonium sulfide pulping of red spruce are also shown. The invented process clearly demonstrates superior selectivity over all of the delignification processes currently known.
EXAMPLE 5
One sample of industrial size chips of southern yellow pine was also subjected to the pulping experiments in accordance with the present invention using an electrically heated Parr reactor equipped with stirrer, while a second sample is subjected to the conventional Kraft pulping. The pulping conditions and the results are indicated in Table 3. Pulps obtained from these experiments were subjected to carbohydrate analysis and the results are shown in Table 4.
EXAMPLE 6
Four samples of southern yellow pine chips were subjected to the pulping experiments according to the present invention. Cooking experiments were carried out in the similar digester as detailed in Example 1. The spent liquor from the pulping experiment were analyzed for the recoverable ethanol and ethylenediamine. Also the ethylenediamine lost to the pulp was estimated. The results are shown in Table 5.
TABLE 3______________________________________COMPARISON OF EDA--ETOH--H.sub.2 O--AQ PULPINGWITH KRAFT PULPING METHOD USING 1.5LITER BOMB DIGESTERSystem: Batch DigestorCOOK # EEAQ KRAFT______________________________________Active alkali -- 23as Na.sub.2 O % on woodSulfidity -- 31.55Liq/wd ratio 7/1 5/1(ml/g)Ethanol 0.64 --ml/g woodEDA 3.18 --ml/g woodAQ % on wood 0.75 --Cooking temp °C. 190 170Cooking time (mts) 115 140Total pulp 57.75 45.80yld % on woodLignin free 55.22 43.2pulp yld% on woodKappa number 28.5 36.5______________________________________
TABLE 4______________________________________CARBOHYDRATE AND LIGNIN ANALYSIS OFSOUTHERN YELLOW PINE WOOD AND PULPS Wood Kraft EEAQ______________________________________Kappa number -- 36.5 31.10Residual pulp -- 45.80 58.67yield %(on wood)Klason lignin% (on pulp) -- 5.62 3.75% (on wood) 28.30 2.57 2.20Araban% (on pulp) -- 0.50 0.30% (on wood) 1.16 0.23 0.18% lost* -- 80.18 84.48Xylan% (on pulp) -- 6.20 3.94% (on wood) 5.71 2.84 2.31% lost -- 50.37 59.54Mannan% (on pulp) -- 9.44 18.75% (on wood) 12.17 4.32 11.00% lost -- 64.47 9.60Glucan% (on pulp) -- 79.36 73.11% (on wood) 45.05 36.34 42.90% lost -- 19.30 4.80______________________________________ *% Lost based on original content in the wood. T1 TABLE 5-MATERIAL BALANCE IN EDA--ETHANOL--AQ PULPING? -Liquor/Wood Ratio=11/1 EDA/Wood= 5/1 Ethanol/Wood= 1/1? - AQ % on O D Wood= 1.0 Shaker Oil Bath (Batch)? -? ? ? ? ? Control?-Cook?????W/O? -Number? EEB1? EEB2? EEB3? EEB4? Chips? -Cooking 190 190 190 200 190 -temp °C. -Cooking time 60 80 100 100 100 -(mins) -% EDA 0.1 0.1 0.09 0.09 --?-lost to -pulp (on -charged- EDA) -% EDA in 99.91 99.06 98.93 99.06 99.23 -spent liquor -(on charged -EDA) -% EDA 99.24 98.48 98.00 97.93 99.87 -recovered -after NaOH -distillation -% Ethanol 93.5 95.9 94.8 94.5 --? -recovered -Kappa 54.9 47.4 39.7 25.6 --? -number -Res. pulp 66.7 64.54 62.33 59.12 --? -yield %? -
EXAMPLE 7
Several samples of southern yellow pine chips were subjected to pulping experiments according to the present invention. Cooking was carried out in the shaker bomb reactor in oil bath as in Example 1. The spent liquor obtained from this set of experiments was adjusted for the original concentration of ethylenediamine, ethanol and anthraquinone. The spent liquor so adjusted for concentration was used as pulping liquor for further pulping experiments. The spent liquor was recycled several times. The results of the effect of recycling spent liquor on the extent of delignification of southern yellow pine in aqueous ethylenediamine-ethanol-anthraquinone are shown in FIG. 5.
EXAMPLE 8
Twelve samples of sweet gum chips were subjected to pulping experiments according to the present invention. Cooking was carried out in the digester as in Example 1. The effects of several variables of the pulping on the delignification of sweet gum is shown in Table 6. For comparison, typical results of Kraft pulping of sweet gum are also shown.
Although the above process and pulping liquor have been described with reference to particular and preferred embodiments, particularly with regard to the compositions employed and parameters observed, they are illustrative only. Variations will occur to those of ordinary skill in the art without the exercise of inventive faculty which remain within the scope of the invention as claimed below.
TABLE 6__________________________________________________________________________PULPING OF SWEET GUM (HARDWOOD) IN ACCORDANCE WITH THE INVENTED PROCESSChips Size - (-10 + 30); Wood Used Per Digester = 2.0 g (oven dry)Shaker Bomb Reactor in Oil Bath; Liq:Wood Ratio ML/g = 10:1 Cooking Time Mg. TotalCook Number Cooking Temp. °C. Minutes ML EDA ML Ethanol Anthraquinone Kappa Number Pulp__________________________________________________________________________ Yld.1 160 80 7.5 0.0 20 35.2 60.72 160 80 7.5 1.0 20 37.3 63.63 160 80 7.5 2.5 20 45.0 66.24 160 80 7.5 1.0 0 79.8 68.65 160 80 7.5 1.0 4 65.0 65.46 160 80 7.5 1.0 10 56.6 64.37 170 80 7.5 1.0 10 54.3 63.68 172 80 7.5 1.0 10 42.3 60.99 175 80 7.5 1.0 10 23.7 57.310 172 60 7.5 1.0 10 43.7 61.011 172 95 7.5 1.0 10 19.2 59.912 Kraft pulping with 23% active alkali at 170° C. for 90 mts; 32.8 52.0__________________________________________________________________________
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A pulping liquor for the delignification of lignocellulosic materials is disclosed which avoids the use of sodium hydroxide and so avoids degradation of substantial portions of the cellulose component, and simultaneously avoids the use of sulphide or other environmental pollutants. The cooking process employing this liquor can advantageously include recycling of the liquor to provide sustained delignification from the same original liquor provided, and distillation of spent liquor to recover the essential components thereof.
The liquor is comprised of alcohol, an amine and water, each present in amount of 1-12 parts by volume. The liquor is further used in the presence of a quinone and/or azine catalyst.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of U.S. Ser. No. 09/939,065, filed Aug. 24, 2001, now U.S. Pat. No. 6,884,613, which claims the benefit of U.S. Provisional Application No. 60/227,986, filed Aug. 25, 2000. The contents of the prior applications are incorporated herein by reference in their entirety.
STATEMENT AS TO FEDERALLY SPONSORED RESEARCH
This invention was made with Government support under Grant 28528 awarded by the National Institutes of Health and under Grant BE9800617 awarded by the National Science Foundation. The Government may have certain rights in the invention.
FIELD OF THE INVENTION
The invention relates to methods and compositions for purifying and concentrating viruses.
BACKGROUND OF THE INVENTION
Gene therapy involves the transfer of genetic material encoding one or more therapeutic genes and the sequences necessary for their expression to target cells to alter their genetic makeup for some desired therapeutic effect. Gene therapy is being tested in a wide variety of applications, including the treatment of complex genetic disorders such as cancer and infectious diseases such as AIDS, and in tissue engineering. Often, the genetic material is transferred ex vivo to tissue that has been removed from a patient. After gene transfer, the tissue is cultured and expanded in vitro, and then re-implanted into the patient. If the target tissue cannot be removed or cultured in vitro (e.g., brain, heart, lungs), the genetic material is instead injected directly into the patient.
Recombinant retroviruses are the most common gene transfer vector used in human gene therapy clinical trials. However, transduction efficiency is often too low to achieve the desired biological effect in many potential human gene therapy situations. Attempts to improve transduction efficiency by concentrating the retroviruses (e.g., by centrifugation, ultrafiltration, tangential flow, or hollow fiber filtration) have not been very successful. Although retrovirus preparations concentrated by these methods contain higher concentrations of infectious virus, they nonetheless do not transduce significantly more target cells than the unconcentrated stocks. The development of methods that improve transduction efficiency is therefore necessary.
Methods for increasing the sensitivity of assays used to detect disease-causing viruses are also needed. The number of viral particles in a patient's tissue (i.e., viral load) generally correlates well with the rate of progression of associated diseases. To obtain earlier and more accurate diagnoses, and thereby improve patient prognosis, medical personnel need to be able to detect lower viral loads than can be detected with the analytical methods that are currently in widespread use.
SUMMARY OF THE INVENTION
The invention provides new methods for purifying and concentrating viruses. The inventors have discovered that one reason that concentration of retroviruses by the methods described above has not been successful is that high molecular weight proteoglycans present in retroviral stocks are co-concentrated with retroviruses (Le Doux et al., Biotechnology and Bioengineering, 58(1):23-34, 1998). The co-concentrated proteoglycans inhibit retroviral transduction. The new purification and concentration methods feature treatment of virus stock with an anionic polyelectrolyte and a cationic polyelectrolyte, followed by centrifugation. The new methods minimize the amount of proteoglycan co-precipitated with the infectious virus.
In general, the invention features a method for purifying viruses from solution (e.g., solutions containing viruses and other components such as proteoglycans). The method includes the steps of (a) combining the solution with an anionic polyelectrolyte; (b) combining the solution with a cationic polyelectrolyte; and (c) centrifuging the solution to obtain a supernatant and a virus-containing pellet. Steps (a) and (b) can be carried out in forward or reverse order, or simultaneously.
The anionic polyelectrolyte can include, for example, a glycosaminoglycan or a polysaccharide, either of which may be sulfated. Examples include chondroitin sulfates, heparin, heparan sulfate, keratan sulfate, carrageenans, fucoidan, poly-L-glutamic acid, poly-L-aspartic acid, other anionic peptides or proteins, poly(glycolic acid), poly(lactic acid), poly(lactic-co-glycolic acid).
The cationic polyelectrolyte can include, for example, a cationic polymer that complexes with the anionic polyelectrolyte. For example, the cationic polyelectrolyte can be (diethylamino)ethyl dextran, a histone, protamine, poly-L-arginine, poly-L-histidine, poly-L-lysine, or another cationic peptide or protein.
The methods can also include the step of separating the pellet from the supernatant, and then resuspending the pellet in a resuspension buffer (e.g., phosphate buffered saline, cell culture medium, or a buffer suitable for injection into a patient (e.g., a pharmaceutically acceptable carrier such as a solution that does not cause allergic or other adverse reaction with the patient upon injection), for example, in a volume of resuspension buffer no greater than one-tenth or one-hundredth the volume of the solution, thereby resulting in at least a ten-fold or one-hundred-fold concentration of the virus, respectively.
The virus to be purified can be, for example, an enveloped virus, such as a lentivirus, Moloney murine leukemia virus (MMLV), herpes simplex virus (HSV), Epstein-Barr virus (EBV), human cytomegalovirus (CMV), an influenza virus, a poxvirus, an alphavirus, or human immunodeficiency virus (HIV) or other retrovirus; or a non-enveloped virus such as an adenovirus, a parvovirus, or a poliovirus.
Another embodiment of the invention features a method for preparing a formulation for administering a nucleic acid molecule to a patient. The method includes the steps of (a) obtaining a solution containing a virus that includes a nucleic acid molecule to be administered to a patient; (b) combining the solution with an anionic polyelectrolyte; (c) combining the solution with a cationic polyelectrolyte; (d) centrifuging the solution to obtain a supernatant and a virus-containing pellet; (e) separating the supernatant from the pellet; and (f) resuspending the pellet in a resuspension buffer suitable for injection into a patient. The method can also include the step of separating the virus from the polyelectrolytes. Steps (a) and (b) can be carried out in forward or reverse order, or simultaneously.
Still another embodiment of the invention features an assay method for detecting the presence of a virus in a sample. The method includes the steps of (a) obtaining a sample to be assayed for the presence of a virus; (b) combining the sample with an anionic polyelectrolyte; (c) combining the sample with a cationic polyelectrolyte; (d) centrifuging the sample to obtain a supernatant and a pellet (where the pellet includes the virus, if any); and (e) assaying the pellet for the presence of the virus. The method can optionally include the step of resuspending the pellet in a buffer solution, and/or the step of separating the virus from the polyelectrolytes. Steps (a) and (b) can be carried out in forward or reverse order, or simultaneously.
Yet another embodiment of the invention features a kit for use in concentrating or purifying viruses. The kit includes a tube of a suitable size and shape for use in a centrifuge; an anionic polyelectrolyte; and a cationic polyelectrolyte. Optionally, the kit can also include instructions for use. The polyelectrolytes can be supplied in a single tube or in two separate tubes.
The invention provides several advantages. For example, the invention can be scaled up for use in a large-scale manufacturing process. The invention also has many applications in the emerging commercial field of gene therapy that make use of recombinant retroviruses, as well as in any area of research in which cells or tissues are genetically modified using recombinant retroviruses. The methods of the invention can moreover be rapidly performed in a tabletop centrifuge, thus increasing convenience and efficiency and eliminating losses in infectivity due to thermal decay of the viruses.
The new methods advantageously allow rapid concentration and purification of retroviruses without destroying their biological activity and without placing the retroviruses in a solution that is toxic to the target cells to which they will be applied. The invention allows the virus buffer to be rapidly and easily exchanged for a buffer more suitable to the target cells. This can be important where the cell culture medium used to produce virus particles (e.g., DMEM with 10% bovine calf serum) is not suitable for cell types that are potential targets for gene therapy.
The new methods can be used to concentrate viruses to any desired level. The ability to concentrate viruses would substantially improve the effectiveness of many gene therapies, such as those that rely on lentivirus vectors. Lentivirus vectors are of significant interest for use in gene therapy because they can permanently and stably transfer genes into cells and tissues by direct injection in vivo. Lentivirus vectors often fail to achieve the desired therapeutic effect, however, because they have relatively low gene transfer efficiencies and are produced at low titers. Concentrated forms are needed for injection to achieve the desired biological effect. This invention can be used to manufacture stocks of lentivirus vectors that have a high enough concentration to achieve the desired therapeutic effect.
The new methods not only increase transduction efficiency by increasing the concentration of the viruses, they unexpectedly increase transduction by an additional factor of two to three or more beyond the concentration factor, possibly by increasing the encounter frequency of the viruses with the cells.
This invention will also significantly improve the sensitivity of assays designed to detect pathological viruses in large volumes of fluid such as blood or plasma by precipitating the viruses into a small pellet and to a concentration high enough to be detected by current assays. For example, blood or plasma samples can be treated with charged polymers as described above, and the resulting precipitate pelleted and assayed for the presence of pathological viruses. Because the concentration of the pathological viruses would be substantially increased in the pellet, the overall sensitivity of the screening process would be greatly increased, and, as a result, the safety of the tested blood supply improved.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.
Other features and advantages of the invention will be apparent from the following detailed description, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plot of relative virus concentration, indicated by the concentration of capsid protein p30, in a retrovirus solution before mixing with POLYBRENE® and chondroitin sulfate C (“Before”), in the retrovirus solution after mixing with POLYBRENE® and chondroitin sulfate C (“After”), in the supernatant resulting from centrifuging the retrovirus solution (“SN”), and in a solution resulting from resuspending to original volume in phosphate-buffered saline (PBS) the pellet resulting from centrifuging the retrovirus solution. The y-axis represents optical density at 490 nm (OD 490 ).
FIG. 2 is a plot of the biological activity of viruses taken from the four samples described in FIG. 1 . The y-axis represents virus titer (colony-forming units per milliliter (cfu/ml)).
FIG. 3 is a plot of relative concentration of serum proteins in the four samples described in FIG. 1 , as indicated using a Coomassie Blue Protein Assay. The y-axis represents OD490.
FIG. 4 is a plot of relative cell number (represented by OD 490 on the y-axis) versus concentration of POLYBRENE® used alone (-−-), chondroitin sulfate C used alone (-□-), and POLYBRENE® and chondroitin sulfate C used at the same time (-●-).
FIG. 5 is a plot of transduction efficiency of viruses taken from the four samples described in FIG. 1 , with the exception that the “Pellet” sample was resuspended to only ⅛ of its original volume. The dotted line represents the expected transduction efficiency corresponding to 8-fold concentration. The y-axis represents BGAL activity virus titer (colony-forming units per milliliter (cfu/ml)).
FIG. 6 is a plot of secreted KGF accumulated in the culture medium of control unmodified fibroblasts (Control unmodified cells, -●-), fibroblasts that have been modified with a standard stock of unconcentrated keratinocyte growth factor (KGF) retrovirus to which POLYBRENE® alone (8 μg/ml) has been added (KGF virus with polybrene, -∘-), and fibroblasts that have been genetically modified with precipitated KGF virus that was resuspended in one-tenth the original volume (10× precipitate of KGF virus, -▾-), as a function of time, as described in Example 5.
DETAILED DESCRIPTION
This invention describes a simple and facile method to rapidly and selectively concentrate retroviruses.
The New Methods
In a typical method of the invention, virus stocks are combined with 1 μg/ml to 100 μg/ml of anionic polyelectrolyte (e.g., chondroitin sulfate C; “CSC”), optionally incubated (e.g., for 10 minutes or longer) at 4° C. to 37° C., and then combined with 1 μg/ml to 100 μg/ml of a cationic polyelectrolyte (e.g., POLYBRENE®-brand hexadimethrine bromide), and optionally incubated (e.g., for 0 to 10 minutes, or longer) at 4° C. to 37° C. Alternatively, the cationic polyelectrolyte can be added before, or at the same time as, the anionic polyelectrolyte. Subsequently, a visible pellet is typically formed by low speed centrifugation (e.g., 10,000 rpm for 5 minutes) in a tabletop centrifuge.
The cell culture supernatant that contains the unpelleted material can be removed and the pellet resuspended in a buffer optimized for the culture and transduction of the target cells. The final concentration of the viruses, and the number of therapeutic gene copies that are ultimately delivered to the target cells, are controlled by the volume of buffer used to resuspend the pellet. The pellet can be, for example, resuspended in a volume that is 10- to 100-fold less than the initial volume of the virus stock, so that the final concentration of the viruses is 10- to 100-fold greater than the concentration of the viruses in the original, unpelleted, virus stock.
To transduce the target cells, the cells can be incubated (e.g., at 37° C. for several hours) with the concentrated virus solution (which also contains the polyelectrolytes). Significantly, the efficiency with which the cells transduced in these experiments is 2- to 3-fold higher than expected based on the increased concentration of the viruses alone, as described in Example 1. In other words, if the virus solution is concentrated 10-fold by this technique, the efficiency with which the cells are transduced is 20- to 30-fold higher than the original, unpelleted, virus stock. This unexpected increase in transduction efficiency is probably due to a higher frequency of encounters between the target cells and the viruses due to sedimentation of viruses complexed with polyelectrolytes. That is, the rate at which the virus complexes precipitate onto the cells may occur at a higher rate than would occur between viruses and cells in the absence of polyelectrolytes.
Viruses that can be concentrated by the new methods include retroviruses (e.g., enveloped retroviruses) such as human immunodeficiency virus (HIV), lentiviruses, and Moloney murine leukemia virus (MMLV). The method can also be used to concentrate other enveloped viruses, including herpes simplex virus (HSV), Epstein-Barr virus (EBV), human cytomegalovirus (CMV), influenza viruses, poxviruses, and alphaviruses; or non-enveloped viruses such as adenoviruses, parvoviruses, or polioviruses. Lentivirus vectors are of special interest, because they are able to transfer genes to cells that are not dividing. This ability can provide a major advantage for in vivo gene therapy. The new methods can be used to provide lentiviruses at high enough concentrations to achieve the desired biological effect.
Use of the New Methods in Gene Therapy Applications
Retroviruses can be raised in packaging cell lines, and then harvested. The new methods should be useful with any packaging cell line, including, for example, ψCRIP, FLYA13, and PHOENIX® amphotropic packaging cell lines. Retroviruses can be harvested as follows: Packaging cell lines are grown to confluence. The cell culture medium is removed and replaced with fresh medium and the cells are incubated at 37° C. After a sufficient time (e.g., about 12, 18, 24, or 30 hours), the cell culture medium is removed, filtered (0.45 μm), and frozen for later use as a virus stock. The virus stocks can be mixed with polyelectrolyte solutions according to the methods of the invention (e.g., to increase transduction efficiencies and/or to rapidly concentrate and purify the virus particles from the cell culture medium in which they were grown). After the viruses are precipitated with the polymers and centrifuged to form a pellet, they can be resuspended in any suitable buffer, including phosphate buffered saline (PBS), tris-buffered saline, or basal cell culture medium (e.g., Dulbecco's modified Eagle medium, “DMEM”). Resuspended virus particles can be injected into a tissue to be treated, administered orally, nasally, rectally, intravenously, intramuscularly, using a gene gun or other intradermal methods, or by other routes used for drug delivery. A major advantage of this method is that less than 3 percent of non-viral proteins are precipitated with the virus particles, affording a dramatic reduction in, or elimination of, natural inhibitors of retrovirus transduction such as proteoglycans or TGF-β.
Use of the New Methods in Analytical Applications
Current methods for detecting viruses typically assay blood plasma for the presence of markers for a particular virus. In the case of human immunodeficiency virus, for example, these markers include viral RNA and HIV p24 antigen (a virus capsid protein). Viral RNA has traditionally been the marker of choice, in part because RNA assays can make use of the polymerase chain reaction (PCR) to amplify the analyte and are, therefore, generally more sensitive than the enzyme-linked immunosorbent assays (ELISAs) use to detect the antigens such as HIV p24. Although RNA assays tend to be more sensitive, however, they are also more expensive and are not as easy to perform as ELISAs. Cost and sensitivity issues aside, both types of assays have proved to be valuable predictors for certain aspects of the progression of diseases such as AIDS. RNA assays, for example, appear to be better predictors of the clinical progression of the disease, whereas p24 antigen assays appear to be better predictors of the patient's chance of survival.
The new methods can be used to concentrate viruses present in tissue samples before the samples are analyzed, effectively increasing the sensitivity of the analytical methods. Advantageously, the polymers used for virus precipitation in the new methods do not block the ability of standard protocol assays such as ELISAs to detect retrovirus proteins, and should not interfere with PCR reagents.
Polyelectrolytes
In general, any pair or system of charged polymers that can bind to the viruses or otherwise interact with viruses so as to cause them to aggregate or otherwise precipitate rapidly under low speed centrifugation can be used to concentrate viruses.
Preferably, the charged polymers are not toxic to the cells and do not inactivate the viruses. If the charged polymers are cytotoxic, they must be able to be separated from the viruses prior to their application to the target cells. For example, the virus can be dissociated from the polymers using a high-salt buffer that reduces the electrostatic attraction between the virus and polymers. Alternatively, the virus can be dissociated from the polymers by enzymatically degrading one or both of the polymers. For example, CSC can be degraded into individual disaccharides by treating the solution with chondroitinase ABC. Once the polymers have been degraded or dissociated from the virus, the virus can be isolated (e.g., using a gel filtration spin column).
Chondroitin sulfate C and POLYBRENE® together form an examplary pair of polyelectrolytes that can form complexes that can be used to concentrate viruses. However, any pair of polyelectrolytes that includes an anionic polymer (e.g., sulfated glycosaminoglycans or polysaccharides such as chondroitin sulfate A, B, D, or E, heparin, heparan sulfate, keratan sulfate, iota carrageenan, kappa carrageenan, and fucoidan; anionic peptides and proteins such as poly-L-glutamic acid and poly-L-aspartic acid; or biodegradable polymers such as poly(lactic acid), poly(glutamic acid), and poly(lactic-co-glycolic acid)) and a cationic polymer that can complex with the anionic polymer (e.g., POLYBRENE®, (diethylamino)ethyl dextran (DEAE dextran), histones, protamine, or cationic peptides and proteins such as poly-L-lysine, poly-L-arginine, and poly-L-histidine) can be used instead of this exemplary pair. For example, polymer pairs iota carrageenan and DEAE dextran; heparan sulfate and protamine; and L-glutamate and L-lysine can be used.
Virus Concentration Kits
Optionally, the new methods can be carried out using a reagent kit. The kit can include suitable reagents and optionally vessels for carrying out the new methods. Such a kit can be produced and sold in various sizes. For example, a kit for concentrating small volumes of virus-containing medium (e.g., less than about 25 ml) can include a plastic or glass tube, which can contain a solution of a suitable anionic polymer or into which such a polymer can be added from another supplied vessel. The tube can be, for example, a standard centrifuge tube or a similarly sized and shaped tube. After introducing the virus-containing medium into the tube, the tube can be sealed (e.g., using a supplied screw cap), shaken to ensure thorough mixing, and incubated for a suitable time. After incubating, the tube can be opened and a solution containing a suitable cationic polymer can be added (e.g., using a pipettor) to the tube. The tube can then be re-sealed, shaken, and incubated again. Alternatively, the contents of the tube can be decanted after the first incubation step into a second tube that already contains a suitable cationic polymer. The second tube can likewise be sealed, shaken, and incubated. In either case, the tube can be loaded into a centrifuge (or its contents can be decanted into a centrifuge tube and loaded into a centrifuge) after the second incubation step, and spun at a suitable speed. The supernatant resulting from the centrifugation step can then be decanted, being careful not to disrupt the pellet. The pellet might then be washed using an optionally supplied wash solution, and possibly resuspended in a supplied resuspension buffer.
The kits can optionally include enzymes or small spin columns to eliminate or separate, respectively, the viruses from the polymers. The kits can also include a dye, or the polymers can be conjugated to a dye, to make the precipitated virus easy to see with the naked eye, thereby facilitating the resuspension of small volumes of virus. The kit can also include a resuspension buffer optimized for transducing particular cell types or for injection in vivo.
Numerous other embodiments of suitable kits are also contemplated, including kits for use with both tabletop and larger centrifuges.
EXAMPLES
The invention is further described in the following examples, which do not limit the scope of the invention described in the claims.
Example 1
Concentration of MMLV
Stocks of Moloney murine leukemia virus (MMLV) were brought to 80 μg/ml of chondroitin sulfate C, incubated for 10 minutes at 37° C., and then brought to 80 μg/ml of POLYBRENE®, and incubated for an additional 10 minutes at 37° C. The retroviruses, when mixed with POLYBRENE® and chondroitin sulfate C(CSC), were visibly pelleted by low speed centrifugation (i.e., 10,000 rpm for 5 minutes) in a tabletop centrifuge. The visible pellet was resuspended to its original volume with phospate buffered saline (PBS). As shown in FIG. 1 , the solution resulting from resuspension of the pellet was then tested for the presence of a virus capsid protein (p30) by ELISA (black bar/“Pellet”). The concentration of p30 in the supernatant was determined after centrifugation (cross hatched bar/“SN”), as was the concentration of p30 in non-centrifuged virus stocks before (white bar/“Before”), and after (speckled bar/“After”) POLYBRENE® and CSC were added.
The solution resulting from the resuspension of the pellet in PBS was tested for its biological activity, using a virus titer assay. The pelleted retroviruses were found to have retained most of their biological activity, as illustrated by the black bar (“Pellet”) in FIG. 2 . The biological activity in the supernatant (cross hatched bar/“SN”) was also determined, as was the biological activity in non-centrifuged virus stocks before (white bar/“Before”) and after (speckled bar/“After”) POLYBRENE® and CSC were added.
The solution resulting from the resuspension of the pellet in PBS was tested for total protein concentration. The virus pellets were found to contain very few serum proteins, as illustrated by the black bar (“Pellet”) in FIG. 3 . The total protein concentration in the supernatant (cross hatched bar/“SN”) was also determined, as was the total protein concentration in non-centrifuged virus stocks before (white bar/“Before”) and after (speckled bar/“After”) POLYBRENE® and CSC were added.
As indicated in FIG. 4 , POLYBRENE® and CSC are not cytotoxic when used together. The data plotted in FIG. 4 were determined by adding various concentrations of POLYBRENE® and CSC to culture medium and then applying it to NIH 3T3 cells plated the previous day at 5000 cells per well in a 96 well plate. The cells were grown for two days, and then were fixed and stained in the Orange G assay for cell number.
The results show that virus concentrated by pelleting with POLYBRENE® and CSC efficiently transduces cells. A solution resulting from the resuspension of the pellet to ⅛th its original volume with cell culture medium was used to transduce NIH 3T3 cells. The results are represented by the black bar (“Pellet”) in FIG. 5 . Cells were also transduced with virus stocks before the stocks were centrifuged and before (white bar/“Before”), and after (speckled bar/“After”) POLYBRENE® and CSC were added to them. Cells were also transduced by the supernatant (cross hatched bar/“SN”) of a virus stock after it had been brought to 80 μg/ml POLYBRENE® and 80 μg/ml CSC and centrifuged. Also shown in FIG. 5 is the expected transduction efficiency of a virus stock that is concentrated 8-fold, given that the concentrated virus does not saturate the cells, no inhibitors were co-concentrated with the viruses, and the viruses are not inactivated by the concentration process (dotted line).
In summary, less than 3 percent of non-viral proteins were concentrated into the pellet ( FIG. 3 ), giving rise to a pellet that contained active viruses ( FIGS. 2 and 5 ) and the polyelectrolyte complexes but almost no spent medium or other substances that might interfere with retrovirus transduction. Importantly, a solution that contains high concentrations of POLYBRENE® and chondroitin sulfate C is not cytotoxic to cells ( FIG. 4 ).
Example 2
Concentration of Lentivirus
The new methods can also be used with lentivirus vectors in a manner similar to that described in Example 1. As described for MMLV in Example 1, stocks of lentiviruses are brought to 80 μg/ml of chondroitin sulfate C, incubated for 10 minutes at 37° C., and then brought to 80 μg/ml of POLYBRENE®, and incubated for an additional 10 minutes at 37° C. The complex of chondroitin sulfate C, POLYBRENE®, and the lentivirus particles is concentrated by low speed centrifugation (e.g., 10,000 rpm for 5 minutes) in a tabletop centrifuge ( FIG. 1 ). The pellet is resuspended in phosphate buffered saline or any other buffer suitable for injection in vivo. The volume of the buffer used to resusupend the viruses is chosen based on the desired final concentration of virus needed to achieve a therapeutic effect. Typically, the pellet is resuspended in a volume that is about 10- to 100-fold less than the initial volume of the virus stock, so that the final concentration of the viruses is 10- to 100-fold greater than the concentration of the viruses in the original virus stock. The virus-polymer solution is then delivered in vivo in such a way as to maximize the transfer of genes to the target cells. For example, to target airway epithelial cells, the virus-polymer solution is injected into the lungs of a patient in the form of an aerosol. The number of genes transferred by this method is substantially higher than with traditional methods because the virus is at a higher concentration and the polymer mixture enhances the efficiency of gene transfer 2- to 3-fold or more.
Example 3
Use of the New Methods in Gene Therapy
The new methods are scalable for large-scale purification and concentration of recombinant retroviruses for use in human gene therapy protocols. Large-scale purification and concentration is important for the ultimate success of many human gene therapy protocols because large numbers of genes generally must be transferred to achieve a desired therapeutic effect. It is estimated that up to 1 liter of retrovirus stocks may have to be used for a typical gene therapy clinical trial to achieve the desired effect. To administer this amount of virus to a patient using traditional methods, the patient is treated several times with smaller volumes of virus. The new methods of the invention can be used not only to enhance the activity and concentration of the virus stocks as described in Examples 1 and 2, but also to reduce the number of times the viruses must be administered to patients to achieve the desired therapeutic effect. Large volumes of retroviruses, produced by standard large-scale cell culture techniques (e.g., microcarrier bioreactors or stirred-tank bioreactors), are brought to appropriate concentrations of cationic and anionic polymers as described in Examples 1 and 2. The virus precipitates are then mechanically separated from the fluid portion of the virus stock on a large scale using sedimenting centrifuges and/or centrifugal classifiers. These machines separate particles from fluid streams in a continuous process and allow the new methods to be used on a large scale to produce retrovirus precipitates useful for human gene therapy protocols.
Example 4
Use of the New Methods to Improve Assay Sensitivity
The new methods are also useful for improving the sensitivity of assays designed to detect pathological viruses in blood or plasma. Blood and plasma samples are often screened for the presence of HIV using PCR to detect the RNA genome of HIV or using an ELISA to detect p24, an HIV capsid protein. The number of HIV particles (viral load) in the blood of AIDS patients is often determined in order to follow the course of the disease. The new methods are used to enhance the sensitivity of these assays. Enhanced sensitivity increases the likelihood of detecting blood or plasma products that are contaminated with HIV and reduces the likelihood that a patient is misdiagnosed as HIV negative due to the poor sensitivity of a diagnostic test for HIV. Blood or plasma samples are brought to 80 μg/ml of CSC and POLYBRENE®, and the resulting precipitates are pelleted by low speed centrifugation as described in Example 1. The pellet is resuspended in 1/10 to 1/100 the original volume, effectively concentrating the HIV antigens 10- to 100-fold. The resuspended sample is tested by any of several currently available ELISA kits that test for the presence of HIV antigens. Because the samples are concentrated 10- to 100-fold, and because the polymers do not interfere with ELISAs, the sensitivity of the HIV test is enhanced 10- to 100-fold. Assuming that the polymers do not interfere with PCR reactions, the sensitivity of kits that detect HIV by PCR is also expected to be enhanced 10- to 100-fold.
Example 5
Precipitation and Concentration of a Recombinant Retrovirus Encoding Keratinocyte Growth Factor (KGF)
The new methods were used to precipitate and concentrate a recombinant retrovirus encoding KGF to improve gene transfer and increase the level of KGF secreted by transduced cells.
A stock of amphotropic KGF retrovirus was harvested from a packaging cell line and filtered through a 0.4 micron filter. The stock was brought to 80 μg/ml CSC and 80 μg/ml POLYBRENE®, and the resulting complex was pelleted by centrifugation and resuspended in cell culture medium to one-tenth the original volume. This 10× concentrated KGF virus suspension was used to transduce human diploid fibroblasts overnight. Afterwards, the cells were washed with culture medium, and then allowed to grow to confluence.
To measure the levels of secreted KGF, the genetically modified human fibroblasts were split into new 10 cm dishes, and grown to confluence. The spent medium was replaced with fresh culture medium (30 ml), and aliquots (1 ml) were removed over time. The levels of KGF secreted by the cells were quantitated using an ELISA specific for KGF. FIG. 6 is a plot of secreted KGF accumulated in the culture medium of control unmodified fibroblasts (Control unmodified cells, -●-), fibroblasts that have been modified with a standard stock of unconcentrated KGF retrovirus to which POLYBRENE® alone (8 μg/ml) has been added (KGF virus with polybrene, -∘-), and fibroblasts that have been genetically modified with precipitated KGF virus that was resuspended in one-tenth the original volume (10× precipitate of KGF virus, -▾-), as a function of time. A small amount of KGF is naturally secreted by control diploid human fibroblasts. As illustrated by FIG. 6 , this level is enhanced when the cells are transduced with the KGF virus in the conventional manner, and is greatly enhanced when the same virus is precipitated with CSC and POLYBRENE® and resuspended in one-tenth the original volume.
Since KGF is known to stimulate the growth of epidermal keratinocytes of the skin, genetically modified cells (e.g., dermis cells, keratinocytes, epidermal cells) secreting KGF may have uses in promoting wound healing (including, for example, healing of chronic wounds such as diabetic wounds). For example, such cells can be administered to tissue in the vicinity of the wound (e.g., by injection or implantation, optionally together with a pharmaceutically acceptable carrier, optionally containing other pharmaceutical substances), or topically applying the cells to the wound (e.g., in a dressing, film (e.g., a polyurethane film), a hydrocolloid (e.g., hydrophilic colloidal particles bound to polyurethane foam), a hydrogel (e.g., cross-linked polymers containing about at least 60% water), a hydrophilic or hydrophobic foam, or another carrier, e.g., a pharmaceutically acceptable gel, cream, powder, suspension, solution, ointment, salve, lotion, or biocompatible matrix, e.g., a petroleum jelly formulation, optionally containing other pharmaceutical substances such as an antibiotic). The cells can be used to promote healing by, for example, stimulating growth of keratinocytes for use, for example, in wound healing methods (e.g., those described in U.S. Pat. No. 6,197,330). Higher levels of KGF secretion can enhance the therapeutic effectiveness of these cells. Higher levels of KGF secretion can enhance the therapeutic effectiveness of these cells.
OTHER EMBODIMENTS
It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, advantages, and modifications are within the scope of the following claims.
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The invention provides new methods for purifying and concentrating viruses. The inventors have discovered that high molecular weight proteoglycans present in retroviral stocks are co-concentrated with the retroviruses, and can inhibit retroviral transduction. The new purification and concentration methods feature treatment of virus stock with an anionic polyelectrolyte and a cationic polyelectrolyte, followed by centrifugation. The new methods minimize the amount of proteoglycan co-precipitated with the infectious virus.
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BACKGROUND OF THE INVENTION
This invention relates to playthings in general, and more particularly relates to a doll apparatus that is constructed to simulate motion of babies during the process of natural birth.
Many teaching aids and toys have been devised to simulate the birth of babies, both human and animal. In particular, [French patent publication No. 2 554 360 ] discloses a manually operated pusher to move a fetal doll shaped as a human along a birth canal and deliver same through an exit at one end of the canal. In [U.S. Pat. No. 4,237,649, ] issued Dec. 9, 1980 to A. E. Goldfarb and E. Dantzer for Toy Animal Figures Representing Parent Animal and Offspring, a continuous conveyor belt is used to simulate delivery of a fetal doll in the shape of a foal. The birthing simulations achieved through operation of the devices disclosed in the aforesaid French Pat. No. 2 554 360 and U.S. Pat. No. 4,237,649 do not approach actual delivery conditions in that consideration is not given to the characteristic motion for a baby during delivery thereof. That is, the motion of a baby during delivery is relatively slow and pulsates at a low rate. Such motion may be termed chugging along.
Simulation of this chugging or pulsating characteristic is addressed in the prior art by [U.S. Pat. No. 3,822,486 ] which issued July 9, 1974 to C. F. knapp and G. S. Zeades for A Dynamic Childbirth Simulator For Teaching Maternity Patient Care. According to such U.S. Pat. No. 3,822,468, the slow pulsating motion of delivery is simulated by precisely controlling delivery of pressurized air to a bladder system. Air pressure is varied by a relatively expensive electronic controller and the bladder is a relatively complicated structure, making the overall cost so high that use of those teachings found in U.S. Pat. No. 3,822,486 is restricted essentially to expensive apparatus used for giving instructions to nurses and doctors.
SUMMARY OF THE INVENTION
According to the instant invention, simulation of the slow pulsating motion characteristic of the birthing process is achieved in an economical and reliable manner. More particularly, in accordance with the instant invention, one or more fetal dolls are stored in an elongated cylinder in a chamber between the front open end of the cylinder and a piston that is mounted within the cylinder for longitudinal movement. A fluid seal is interposed between the piston and cylinder at the cylindrical interface therebetween, and a spring biases the piston forward or in the delivery (birthing) direction. As the piston moves forward in its working stroke, a metering orifice at the otherwise closed back end of the cylinder permits air to bleed slowly into an expandable chamber behind the piston. The metering orifice is so small that forward motion of the piston under the influence of the spring is retarded through the formation of a partial vacuum in the expandable chamber. The spring, the metering orifice and the frictional engagement between the seal and interior wall of the cylinder combine to create a condition such that movement of the piston in the birthing direction is at a relatively slow speed that pulses at a slow rate thereby simulating the characteristic motion of the delivery process.
Accordingly, the primary object of the instant invention is to provide a novel, inexpensive and reliable mechanism for simulation a birthing process.
Another object is to provide a mechanism of this type which achieves a relatively slow motion that pulsates at a slow rate.
Still another object is to provide a mechanism of this type that is purely mechanical.
A further object is to provide a mechanism of this type in which motion of a piston, closely fitted within a cylinder, is retarded through buildup of a partial vacuum in the cylinder as a result of limiting introduction of fluid into an expandable chamber of the cylinder located between the piston and the closed end of the cylinder.
Another object is to provide novel means to simulate multiple as well as individual births.
BRIEF DESCRIPTION OF THE DRAWINGS
These objects as well as other objects of this invention shall become readily apparent after reading the following description of the accompanying drawings in which:
FIG. 1 is a diagrammatic view in side elevation of a mother animal that is provided with a delivery or birthing mechanism constructed in accordance with teachings of the instant invention.
FIG. 2 is a longitudinal cross-section of the delivery mechanism in FIG. 1.
FIGS. 3A and 3B are enlarged fragmentary cross-sectons through the "check valve" inlet in FIG. 2. In FIG. 3A, the piston is moving rearward to recharge the spring while in FIG. 3B the piston is moving forward in its working stroke.
FIG. 3C is a fragmentary cross-section through line 3C--3C of FIG. 3A looking in the direction of arrows 3C--3C.
FIG. 4 is a fragmentary longitudinal cross-section of a delivery mechanism constructed in accordance with a second embodiment of this invention.
FIG. 5 is a fragmentary longitudinal cross-section of a delivery mechanism constructed in accordance with a third embodiment of this invention.
FIG. 6 is an elevation looking at the closed rear end of the cylinder in FIG. 5 looking in the direction of arrows 6--6.
FIG. 7 is a fragmentary perspective looking at the closed end of the cylinder which forms the birth canal of the birthing mechanism of FIGS. 5 and 6.
FIG. 8 is a partially sectioned elevation of a fetal doll within an egg.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now referring to the figures and more particularly to FIGS. 1-3C wherein body 10 simulates the torso of an animal. Disposed therein is a delivery or birthing mechanism 15 including elongated plastic cylinder 11 which is open at its front end, shown at the left in FIG. 1. The rear or right end of cylinder 11 is closed by disk-like cap 41 having annular undercut protrusion 43 at the front thereof which is received with a snap fit by an annular groove in the interior surface of cylinder 11. To assure an airtight connection between cap 41 and cylinder 11, a sealant may be applied at the interface therebetween. For a reason to be explained hereinafter, cap 41 is provided with metering orifice 44.
Extending from the center of cap 41 at the front thereof is projection 47 having latching formation or tip 48 at the free end thereof. The latter is received by chamber 49 at the rear of plastic piston 40 which is disposed for longitudinal movement within cylinder 11. Tip 48 is normally in engagement with interior shoulder 51 at the entrance to chamber 49. Extending axially from the center of cap 41 at the rear thereof is lever 52 that is engageable by dog or cam 53 as the latter is driven counterclockwise by motor 54. Dog 53 drives the free end of lever 52 downward with respect to FIG. 2 thereby flexing cap 41 so that latching tip 48 moves upward with respect to FIG. 2 to clear shoulder 51 and thereby release piston 40. With piston 40 not being held by latching tip 48, the force of spring 21 moves piston 40 forward in a working or delivery stroke that terminates when O-ring seal 61 falls into interior locking groove 62 of cylinder 11 at the front thereof. O-ring seal 61 is carried by piston 40, being mounted in annular groove 63 thereof.
As seen best in FIGS. 3A and 3B, groove 63 is oversized as compare with seal 61. That is, the cross-sectional diameter of seal 61 is substantially less than the distance between front and rear boundary walls 64, 65 of groove 63 and the internal diameter of seal 61 is substantially greater than the diameter of groove defining wall 66 that connects walls 64 and 65. When piston 40 moves in the forward direction indicated by arrow F in FIG. 3B, seal 61 provides a complete 360° seal between the interior surface of cylinder 11 and rear wall 65. Further, when piston 40 moves rearward, as indicated by arow R in FIG. 3A, it is in 360° engagement with the interior surface of cylinder 11 and is also in contact with front wall 64.
However, the latter is provided with at least one notch 67 of substantial size which now provides part of a pneumatic communication path between the front and rear of piston 40, such path also including the space between seal 61 and rear 65, the space between seal 61 and wall 66 and the space between the outside wall of piston 40 and the inside wall of cylinder 11. Thus, seal 61 acts as the movable member of a check valve which closes as pistion 40 moves forward F and opens when pistion 40 moves to the rear R. This permits piston 40 to be moved rapidly in the rearward direction R while forward movement F is retarded because air can bleed only slowly through small diameter metering orifice 44 of cap 41 into the expandable chamber 69 between cap 41 and the rear of piston 40. Coiled compression spring 21 disposed within chamber 69 biases piston 40 in the forward direction F. The portion of cylinder 11 in front of piston 40 constitutes a birth canal wherein a plurality of fetal dolls (pups) 39 are disposed when piston 40 is held in its reset position by latch 48. At this time, the front of cylinder 11 is closed temporarily by removable frictionally held plug 28 which also closes opening 27 in body 10.
The birthing process takes place by using knob 73, disposed outside of body 10 at the free end of rod 72, to wind and thereby charge spring motor 54. When the energy stored in motor 54 is released, say by pulling upward on rod 72, dog 53 on motor output shaft 74 rotates counterclockwise and in moving past extension 52 moves same to disengage latch tip 48 from piston 40 so that the latter may be moved forward by spring 21. Initial forward motion of piston 40 causes O-ring 61 to move to its sealing position against rear wall 65 of groove 63. Now the sole path for entry of air into expandable chamber 69 is through orifice 44.
The rate at which air bleeds into chamber 69 is so low that forward movement of piston 40 is greatly retarded by partial vacuum developed within chamber 69. Forward motion of piston 40 is also retarded by the friction force developed between the internal surface of cylinder 11 and seal 61 as the latter slides and/or rolls along the interior surface of cylinder 11. The net effect of these vacuum and friction forces acting in opposition to the force of spring 21 is to retard forward movement of piston 40 and results in a characteristic of speed versus position for piston 40 that is not smooth. Instead, this characteristic exhibits pulsations at a slow rate at least in part because the pressure level within expandable chamber 69 rises and falls but remains below ambient so that the vacuum force that opposes the biasing force provided by spring 21 pulsates. Further, the friction force at the interface between O-ring seal 61 and cylinder 11 varies for different positions of seal 61 along the length of cylinder 11. Thus, motion of piston 40 is step-like with a pause between steps, i.e. an intermittent, non-uniform advancement, in what may be termed chugging motion. That is, forward motion of piston 40 is relatively slow and pulstes at a slow rate, and during each pulse forward movement is relatively rapid. This forward motion of piston 40 pushes fetal dolls 39 to exit from torso 10 through opening 27 with a motion that simulates actual birthing motion.
The outside of torso 10 is covered with pile fabric 90 which is the same in color and other appearance characteristics as the covering 91 for the rear of plug 28. At the beginning of the birthing process, fetal dolls 39 moving through cylinder 11 engage plug 28 and force it to separate from cylinder 11. Now opening 27 is clear and remains so until the birthing process is complete, at which time opening 27 is closed by covering 92 on the rear of piston 40. Covering 92 is made of the same pile fabric that body skin 90 and covering 91 on plug 28 are made of.
In the embodiment of FIG. 4, latching tip 48 is intended to be released manually by applying a force in the direction of arrow A to arm 83 of the L-shaped extension which projects from the rear of cap 81. The other arm of the L-shaped extension is connected to cap 81 at the center thereof and extends parallel to the axis of cylinder 11. Grommet-like member 84 mounted in a complementary opening of cap 81 constitutes the movable element of a check valve that permits air to leave expandable chamber 85 rapidly. As piston 99 moves forward, check valve element 84 closes so that entry of air into chamber 85 is limited by metering orifice 44.
In the embodiment of FIGS. 5-7, the rear of cylinder 11 is closed by disk-like cap 12 that is held in place by snap-fitted ring formation 13. Rubber slide 14 mounted to the outer surface of cap 12 is guided by essentially parallel undercut strips 16, 16 formed integrally with cap 12. Slide 14 normally covers relatively large aperture 17 in cap 12. Slide 14 is provided with very small diameter metering orifice 18 that is selectively positionable in alignment with aperture 17 to permit air to enter cylinder 11 at a very slow rate. Slide 14 functions as a check-valve in that slide 14 is flexible enough to permit air to be expelled readily from cylinder 11 through aperture 17 when piston 20 is moved toward cap 12, yet most of aperture 17 is sealed by slide 14 when air is being drawn into cylinder 11 through metering orifice 18. Coiled compression spring 21 is interposed between circular ridge 22 of piston 20 and the rear of cap 12 to bias piston 20 forward or toward the open end of cylinder 11. Annular flap-type seal 24 is mounted to piston 20 at the front thereof and is self-biased against the interior wall of cylinder 11.
With slide 14 in its normal inactive position shown in FIG. 6, the check valve action of flexible slide 14 seals aperture 17 so that forward movement of piston 20 under the influence of spring 21 will be resisted by creation of a reduced pressure or vacuum condition within expandable chamber 29 that is formed within cylinder 11 between closure cap 12 and the rear of piston 20.
To commence the birthing process, utilizing its projection 89, slide 14 is moved to the left with respect to FIG. 6 until engaging stop 95. Now metering orifice 18 is aligned with aperture 17 so that air may bleed into chamber 29 to raise the pressure therein, thereby reducing the vacuum force acting in opposition to the force of biasing spring 21. This permits piston 20 to move forward and force fetal dolls 39 within cylinder 11 through opening 27.
As in the embodiment of FIGS. 1-3C, even though air is permitted to bleed into expandable chamber 29, the rate at which this occurs is so low that forward movement of piston 20 is retarded greatly and the characteristic of speed versus position for piston 20 is not smooth. Instead, this characteristic exhibits pulsations at a slow rate because the pressure level within expandable chamber 29 rises and falls but remains below ambient so that the vacuum force that opposes the biasing force provided by spring 21 pulsates. The retarding force in piston 20 is enhanced by the frictional engagement of seal 24 with the interior of cylinder 11. The force of spring 21 opposed by the vacuum and friction forces acting on piston 20 moves the latter forward with a relatively slow motion that pulsates at a slow rate, and by so doing the motion of fetal dolls 39 as they exit through opening 27 simulates actual birthing motion.
While disposed within the simulated delivery canal, each fetal doll may be enclosed within an individual egg shell of the type shown in FIG. 8 wherein shell 101 encloses fetal doll 102 in the form of a snake. Shell 101 is formed of two sections 103, 104 that mate at interface 105 and may be constructed of water soluble material. After delivery, shell 101 is placed in water and will weaken to the point where the load spring (not shown) within doll 102 causes shell 101 to break so that doll 102 may be removed. As alternatives to constructing shell 101 of paper mache or other water soluble material, shell sections 103, 104 may be held together directly by a water soluble cement or by tape 106 that is water soluble and/or is coated with a water soluble cement.
It is noted that motor 54 (FIG. 1) may include a speed reducer so that shaft 74 rotates slowly to introduce a substantial delay from the time operation of motor 54 commences to the time piston 40 is unlatched to commence the birthing process. A time delay may also be introduced by electrical means, say by utilizing a solenoid (not shown), acting against a dashpot to operate arm 52 (FIG. 2), arm 83 (FIG. 4) and slide 14 (FIG. 6). Such solenoid may be operated remotely and may also operate an audio device (not shown). In the case of the birthing process for dogs, such audio device may emit a loud bark from the mother to signal that delivery is about to commence, and as the pups (fetal dolls 39) pass through opening 27, yelping sounds may be emitted. Further, elements 14, 52 and/or 83 may be operated to initiate the birthing process by moving (i.e. twisting, pulling) part of the mother, such as her ear, tongue, tail or nose, with movement of such part being mechanically coupled to such elements 14, 52 and/or 83.
After delivery, the apparatus may be reset by using a rod to push pistons 20, 40 and 99 to the rear. Such rod may be integrated with a nest that is adapted to store the mother doll. As an alternative, resetting may be accomplished by utilizing a filament (not shown) attached to piston 40 and extending outside of cylinder 11 through metering aperture 44. Such filament may be pulled directly. To gain a mechanical advantage, such filament may be wound with a crank mechanism (not shown) that is automatically disengaged when the piston is held by latch 48.
Although the present invention has been described in connection with a plurality of preferred embodiments thereof, many other variations and modifications will now become apparent to those skilled in the art. It is preferred, therefore, that the present invention be limited not by the specific disclosure herein, but only by the appended claims.
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Toy apparatus is provided with delivery structure constructed to simulate a natural birthing process by imparting slow pulsating delivery motion to fetal dolls as they exit from a simulated birth canal. Such delivery structure includes an elongated cylinder which constitutes a birth canal, a piston mounted for longitudinal movement within the cylinder, a spring that biases the cylinder forward to push fetal dolls in a delivery direction through the open front end of the cylinder, and retarding structure acting on the piston in opposition to the spring. The retarding structure includes a seal function alloy engaged with the cylinder and carried by the piston, and metering structure to create a vacuum behind the piston by limiting the rate at which air is drawn into the cylinder behind the piston while the latter moves forward.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a Continuation application of PCT Patent Application PCT/EP2012/062197 filed on Jun. 25, 2012, which claims the priority benefit of Turkish Patent Application Serial No. 2011/02838, filed Apr. 28, 2011, which is hereby incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to asphalt recycling systems which provide the asphalt layer (RAP), which is desired to be recycled by being removed from the place thereof, to be converted into recycled asphalt concrete (RAC), and particularly relates to asphalt recycling systems with respect to the prior art part of Claim 1 .
BACKGROUND
[0003] As known, asphalt concrete obtained from the aggregate and bitumen mixture is used in the form of different layers like corrosion layer, binder, straightening layer and base layers on road's upper structure. Each of these layers is produced by means of recipes prepared in laboratory with respect to the methods of international standards in order to provide different performance requirements. Different performances expected from each layer are provided by means of recipes prepared by different maximum particle dimension, different gradation and different bitumen proportions. These performance requirements are valid also for the layers to be realized using the recycled asphalt concrete (RAC).
[0004] Asphalt concrete which is applied to roads should be removed after certain usage duration (after the asphalt concrete completes the lifetime thereof). Today, because of the environmental conditions, removed asphalt concrete should be recycled and used in the production of new asphalt concrete. Moreover, recycling of the removed asphalt concrete (hereafter it will be called RAP) and the usage thereof in the production of new asphalt concrete provides economic advantages. As the removed asphalt proportion used in the production of new asphalt concrete increases, the economic advantage provided increases more.
[0005] Thus, in the related technical field, recycling can be realized by the usage of removed (RAP) asphalt concrete in the production of new asphalt concrete. In the present art, there are pluralities of technological recycling methods used for the recycling of asphalt.
[0006] Whatever the recycling method, the recycling of the RAP and the proportion of the RAP in the new mixture depends on maximum granule dimension, gradation and the bitumen proportion included and the results of the measurement of the aging and fatigue characteristics of the bitumen included. The removed asphalt concrete can be added with the proportion that the new mixture can provide the desired performance characteristics.
[0007] One of the most frequently used recycling method is the adding of the removed asphalt concrete, in hot form and in determined proportions, to the new asphalt mixture realized in the asphalt plant mixer. This method is called hot recycling. Here the important factors are the RAP amount and the method of mixing the RAP to the aggregate. The RAP should be mixed to the aggregate in a slow and controlled manner and at the optimum temperature.
[0008] In the patent application U.S. Pat. No. 4,279,592, a heat exchanger is disclosed which is used for pre-heating intake air for rotary drier. In the pre-heating hopper provided in the subject matter invention, air is circulated and afterwards, said air is transferred to the air inlet of the combustion hopper by means of a pipe. Said pre-heating hopper is assembled above the rotary drier and it has a curved form.
[0009] In the patent application JP2005290685, a deodorizing drier is disclosed. Said drier is used in deodorization of gas which is exhausted from a heating drum for heating and regenerating paving aggregate waste in a recycle plant. Here, deodorizing drier carries out continuous deodorization over a long period of time and at the same time carries out heating and drying of the paving aggregate. Accordingly, the deodorizing drier comprises a storage hopper arranged in some midpoint of an exhaust channel regarding the exhaust gas exiting the heating drum; a paving aggregate feeder for feeding the paving aggregate to the storage hopper; a paving aggregate discharging device for discharging the paving aggregate in a predetermined amount from the storage hopper; and a control mechanism in order for the paving aggregate feeder to control the feeding amount of the paving aggregate such that the storage hopper stores therein a constant amount of the paving aggregate. The deodorizing drier carries out deodorization of the exhaust gas by the paving aggregate in the storage hopper and carries out heating and drying of the paving aggregate in the storage hopper by waste heat of the exhaust gas.
SUMMARY OF THE INVENTION
[0010] The present invention is a hot asphalt recycling system, which eliminates the abovementioned problems and which brings new advantages to the related technical field.
[0011] An object of the present invention is to obtain recycled asphalt concrete, in order to be used in new asphalt concrete production, by providing the RAP to be heated by consuming less power and in a more regular manner and by joining RAP with hot aggregate.
[0012] Another object of the present invention is to provide a system which brings the RAP and aggregate to the process temperature and which takes the humidity in the RAP or in the aggregate and thereby which provides the RAP or aggregate to be dried.
[0013] In order to realize all of the abovementioned objects, the present invention is a hot asphalt recycling system comprising a mixing hopper where the hot aggregate, exiting the drier, and the RAP are mixed; and a pouring hopper which is opened to said mixing hopper from one end thereof and from whose other end RAP is poured, in order to obtain recycled asphalt concrete which is to be used in the production of one of the asphalt layers by using RAP. Said system comprises an air inlet pipe whose one end is connected to the heat source and whose other end is opened to the pouring hopper in order to transfer hot air, which is heated by a heat source, inside the pouring hopper; and at least one drying box in order to provide the RAP inside the pouring hopper to be poured to the mixing hopper in a sequenced manner and step by step.
[0014] In a preferred embodiment of the subject matter invention, there is a separator which is positioned between the pouring hopper and the air outlet pipe, in order to provide the precipitation and accumulation of the RAP particles in powder form existing inside the pouring hopper.
[0015] In a preferred embodiment of the subject matter invention, there is a separator which is positioned between the pouring hopper and the air outlet pipe, in order to provide the precipitation and accumulation of the RAP particles in powder form existing inside the pouring hopper.
[0016] In another preferred embodiment of the subject matter invention, said drying boxes are sequenced one under the other on the first line and on the second line of the pouring hopper so that at least some parts thereof will coincide in the vertical axis in the pouring hopper.
[0017] In another preferred embodiment of the subject matter invention, said drying boxes are sequenced one under the other on the first line of the pouring hopper.
[0018] In another preferred embodiment of the subject matter invention, said drying boxes are positioned one under the other on the second line so as to correspond between the drying boxes which are positioned one under the other on the first line.
[0019] In another preferred embodiment of the subject matter invention, said drying boxes are connected inside the pouring hopper so that the drying boxes will move in the pouring direction around a shaft from the middle part thereof.
[0020] In another preferred embodiment of the subject matter invention, there is a drive member which drives the shaft, in order to partially rotate the drying boxes, existing on the first line, in the pouring direction and in order to bring the drying boxes from the waiting position to the pouring position or from the pouring position to the waiting position.
[0021] In another preferred embodiment of the subject matter invention, there are pluralities of openings at the bottom part of the drying box, in order to provide heating of the RAP by circulating the hot air through the drying box.
[0022] In another preferred embodiment of the subject matter invention, there is a comb which has pluralities of teeth entering between said openings, in order to remove the RAP accumulated between the openings.
[0023] In another preferred embodiment of the subject matter invention, the drying boxes, existing on the first line, are partially rotated by a drive motor and said drying boxes are brought to the pouring position from the waiting position and the RAP is poured onto the drying boxes which exist in waiting position on the second line.
[0024] In another preferred embodiment of the subject matter invention, the drying boxes, existing on the second line, are partially rotated by a drive motor and said drying boxes are brought from the waiting position to the pouring position and the RAP is poured onto the drying boxes which exist in waiting position on the first line.
[0025] In another preferred embodiment of the subject matter invention, there is a sensor which measures the temperature of the mixture which exits from said pouring hopper and which is accumulated in the mixture hopper.
[0026] In another preferred embodiment of the subject matter invention, there is a control unit which adjusts the waiting duration of the drying box in the waiting position according to the temperature value received from the sensor; and which provides the RAP to be heated more or less.
[0027] In another preferred embodiment of the subject matter invention, the hot air is provided from a waste hot gas.
[0028] In another preferred embodiment of the subject matter invention, the hot air is heated using the exhaust output of the drier.
[0029] In another preferred embodiment of the subject matter invention, there is a rotary valve which provides the RAP to be poured from the RAP depot into the pouring hopper in a controlled manner and without cold air intake.
[0030] In another preferred embodiment of the subject matter invention, said rotary valve comprises a RAP input compartment facing the RAP depot and a RAP output compartment facing the pouring hopper.
[0031] The present invention is a hot asphalt recycling method, in order to obtain the RAC, which is to be used in the production of one of the asphalt layers, by using RAP, characterized by comprising the steps of:
a) The RAP, exiting the RAP feeding unit, is carried onto the pouring hopper; and said RAP is fed into the pouring hopper in a controlled manner, b) The hot air, which is heated from a heat source, is applied into the pouring hopper; and said hot air is drawn by means of a vacuum from the bottom so that the hot air enters into the pouring hopper, c) The RAP is poured into the mixing hopper step by step so that the RAP is waited inside said pouring hopper for a limited duration, d) The air inside the pouring hopper is exhausted through the exhaust outlet of the drier, e) The RAP, which is heated while it is being poured from the pouring hopper, is mixed in the mixing hopper with the aggregate exiting the drier.
[0037] In another preferred embodiment of the subject matter method, said step (a) comprises the following process step: the temperature of the mixture, which exits the pouring hopper and which is accumulated from the mixing hopper, is measured by a sensor.
[0038] In another preferred embodiment of the subject matter method, said step (a) comprises the following process step: according to the temperature value received from the sensor, the waiting duration of the drying box in the waiting position is adjusted, and by a control unit, the heating (less heating or more heating) of the RAP is controlled.
[0039] In another preferred embodiment of the subject matter method, said step (c) comprises the following process step: the RAP, which exists inside the drying box hopper positioned one under the other on the first line of the pouring hopper, is poured into the drying box hopper positioned on the second line and said RAP is transferred to the mixing hopper step by step.
[0040] In another preferred embodiment of the subject matter method, said step (c) comprises the following process step: the drying boxes are sequenced one under the other on the first line of the pouring hopper.
[0041] In another preferred embodiment of the subject matter method, said step (c) comprises the following process step: the drying boxes are positioned one under the other on the second line so as to correspond between the drying boxes which are positioned one under the other on the first line.
[0042] In another preferred embodiment of the subject matter method, said step (e) comprises the following process step: before hot air is exhausted through the exhaust outlet, the RAP powder particles are precipitated and they are accumulated in a separator.
[0043] In order for the embodiment and the advantages of the subject matter invention to be understood in the best manner with the additional elements, it has to be evaluated with the figures explained below.
BRIEF DESCRIPTION OF THE FIGURES
[0044] In FIG. 1 a, a representative view of the heating method of the subject matter asphalt recycling system is given.
[0045] In FIG. 1 b, a representative view of the alternative embodiment of the heating method of the subject matter asphalt recycling system is given.
[0046] In FIG. 2 a , the detailed view of the inner part of the pouring hopper is given.
[0047] In FIG. 2 b , the representative view of the movements of the drying boxes is given.
DETAILED DESCRIPTION OF THE INVENTION
[0048] In this detailed description, the embodiment of the subject matter hot asphalt recycling system is explained with references to the annexed figures without forming any restrictive effect in order to make the subject more understandable.
[0049] With reference to FIG. 1 , the subject matter hot asphalt recycling system's hot RAP and hot aggregate mixing system and mixing method in an asphalt plant ( 10 ) is described. First of all, the aggregate, existing inside the aggregate silos (not illustrated in the figure) in the aggregate feeding unit, is transferred into a drier ( 50 ) by means of a conveyor. Inside said drier ( 50 ), there is a rotary drum and the aggregate is heated by applying hot air into the drum. The aggregate, exiting the drier ( 50 ), is poured into the mixing hopper ( 60 ).
[0050] For the RAP, there is a pouring hopper ( 20 ) where the RAP is carried by means of a conveyor ( 23 ) from the RAP silo (not illustrated in the figure) existing in the RAP feeding unit, and where the RAP is poured downwardly in the vertical direction into the mixing hopper ( 60 ). One end of the pouring hopper ( 20 ) is opened to the mixing hopper ( 60 ). The pouring hopper ( 20 ) extends upwardly in the vertical direction from the mixing hopper ( 60 ). The pouring hopper ( 20 ) can have a cylindrical form or in the form of a rectangular prism. The RAP is poured from the pouring hopper ( 20 ) to the mixing hopper ( 60 ) in a controlled manner so as to wait for certain duration. In order to provide this, there are drying boxes ( 22 ) which are positioned inside the pouring hopper ( 20 ).
[0051] In the subject matter application, there is a heating system ( 30 ) for heating the RAP. Said heating system ( 30 ) comprises an air inlet pipe ( 31 ) for directing the hot air, exiting from a heat source ( 80 ), to the pouring hopper ( 20 ). The air inlet pipe ( 31 ) is connected to the heat source ( 80 ) from one end thereof ( 312 ). The other end thereof ( 311 ) is opened towards the pouring hopper ( 20 ). The hot air advances towards the mixing hopper ( 60 ) from the upper part of the pouring hopper ( 20 ). In order to provide this, there is a vacuum under the pouring hopper ( 20 ) and the hot air is drawn by means of vacuum. By means of this, the hot air advances by passing through each point of the pouring hopper ( 20 ) and through inside, upper side and lateral side of the drying boxes ( 22 ) inside the pouring hopper ( 20 ).
[0052] There is a directing part ( 211 ) on the wall ( 21 ) of the pouring hopper ( 20 ). The directing part ( 211 ) directs the hot air towards the end part ( 311 ) of the air inlet pipe ( 31 ). There is a curved part ( 314 ) at the end part of the air inlet pipe ( 31 ). The hot air enters the pouring hopper ( 20 ) through said curved part ( 314 ).
[0053] Particles, which are in powder form, exit the RAP heated inside the pouring hopper ( 20 ). There is a separator ( 40 ) for precipitating and accumulating said powder particles. Said separator ( 40 ) is positioned in a vertical manner at the lateral part of the pouring hopper ( 20 ). The separator ( 40 ) comprises an inlet part ( 41 ) which is opened to the pouring hopper ( 20 ). The hot air passes to the separator ( 40 ) through the pouring hopper ( 20 ) by means of said inlet part ( 41 ). The cross section of the separator ( 40 ) is wider than the cross section of the pouring hopper ( 20 ); by means of this, when hot air enters into the separator ( 40 ), because of the cross section width, the speed of the hot air decreases and the powder particles, which move together with air, are precipitated. The separator ( 40 ) has a rectangular prism form. However, it can also have a helical form. There is an accumulation hopper ( 43 ) on the lower part of the separator ( 40 ); and the precipitated powder particles are accumulated here. Said powder particles are transferred to the mixing hopper ( 60 ) by means of a transfer pipe ( 44 ). The hot air exits from the outlet part ( 42 ) of the separator ( 40 ). The outlet part ( 42 ) is opened to the air outlet pipe ( 32 ). By means of this, the hot air passes through the separator ( 40 ) and afterwards, the hot air arrives at the exhaust outlet ( 51 ) of the drier ( 50 ) through the air outlet pipe ( 32 ). There is a filter at the exhaust outlet ( 51 ). By means of this, the hot air is filtered through the filter and it is given out to the atmosphere. Thus, the dirty air output to the atmosphere is prevented.
[0054] After hot RAP and hot aggregate are mixed in the mixing hopper ( 60 ); by means of a vertical elevator ( 70 ), the mixture is taken and it is carried to the mixer of the asphalt plant ( 10 ). Thus, the RAP is heated in the desired manner and it is mixed with hot aggregate.
[0055] With reference to FIGS. 2 a and 2 b , the abovementioned drying box ( 22 ) has a basket-like form and it comprises a hopper form wherein some of the RAP can be accumulated. The drying boxes ( 22 ) are sequenced so as to be mutual and so as to be one above the other inside the pouring hopper ( 20 ) in the distance from the upper part of the pouring hopper ( 20 ) until the mixing hopper ( 60 ). The drying boxes ( 22 ), existing on the first line ( 21 a ) and the second line ( 21 b ) of the pouring hopper ( 20 ), are sequenced so that some parts thereof will coincide in the vertical direction. The drying boxes ( 22 ) are connected onto a shaft ( 221 ) by means of a hinge from the middle points thereof on the first line ( 21 a ). When a force is applied to the shaft ( 221 ) by means of the drive member ( 92 ), the drying box ( 22 ) rotates in the pouring direction (X). When the RAP is poured into the pouring hopper ( 20 ) from the upper part thereof, the RAP is accumulated in the hopper of the drying box ( 22 ). After certain time duration, the drying box ( 22 ) is rotated as much as required in the pouring direction (X), the RAP inside is provided to be poured into the hopper of the drying box ( 22 ) which exists at the bottom. Afterwards, the drying box ( 22 ) whereon RAP is poured is again rotated in the pouring direction (X) after certain time duration; and the RAP inside the hopper is provided to be poured into the hopper of the drying box ( 22 ) which exists at the bottom. The RAP continues these processes in a sequenced manner, and it finally reaches the mixing hopper ( 60 ). The drying boxes ( 22 ) are sequenced so as to be mutual and so as to be one under the other on the first and second line ( 21 a, 21 b ) of the pouring hopper ( 20 ). The drying boxes ( 22 ) on the first line ( 21 a ) firstly stay in the waiting position. Afterwards, by means of a drive motor, the drying boxes ( 22 ) existing on the first line ( 21 a ) are rotated in the pouring direction (X) as required, and thereby the drying boxes ( 22 ) are brought to the pouring position. The RAP, existing inside the drying boxes ( 22 ), is poured into the hopper of the drying boxes ( 22 ) which are sequenced on the second line ( 21 b ) and which stay in the waiting position. Afterwards, the drying boxes ( 22 ), existing on the second line ( 21 b ), are rotated from the waiting position towards the pouring position by means of a drive motor. In this case, the RAP, existing in the hopper of the drying box ( 22 ) existing on the second line ( 21 b ), is poured onto the drying boxes ( 22 ) which stay in the waiting position on the first line ( 21 a ). By means of this, the RAP passes from the drying boxes ( 22 ) which are sequenced on the first line ( 21 a ) to the drying boxes ( 22 ) which are sequenced on the second line ( 21 b ) and afterwards, the RAP passes from the drying boxes ( 22 ) existing on the second line ( 21 b ) to the drying boxes ( 22 ) existing on the first line ( 21 a ); and the RAP advances until the mixing hopper ( 60 ) in a sequenced manner.
[0056] The hopper of the drying box ( 22 ) is in the form of a grid with holes through which hot air can pass. After RAP is poured to the hopper of the drying box ( 22 ), hot air, which is drawn by hot vacuum, is passed through said grid holes, and the hot air moves inside the pouring hopper ( 20 ) in the flow direction. The back part of the drying box ( 22 ) has a perforated form. The hot air passes through the holes on said back part and it easily advances inside the pouring hopper ( 20 ). When the RAP, which exists inside the drying box ( 22 ), is poured into the drying box ( 22 ) which exists at the bottom, the RAP can enter into the grid holes of the drying box ( 22 ) and can remain there. There are combs for removing the RAP entering between the grid holes. Said combs enter into the grid holes, and RAP is provided to be removed from between the grid holes. The number of combs is equal to the number of grid holes.
[0057] In order to provide the RAP to discharge into the pouring hopper ( 20 ) in a controlled manner, the RAP is transferred to a RAP depot ( 11 ) from the conveyor ( 23 ). The RAP depot ( 11 ) is positioned at the upper part of the pouring hopper ( 20 ). The RAP is firstly transferred to the RAP depot ( 11 ), afterwards, it is poured into the pouring hopper ( 20 ) from here. There is a rotary valve ( 12 ) which provides the RAP to be stopped and to be poured again while the RAP is being poured from the RAP depot ( 11 ) to the pouring hopper ( 20 ). The rotary valve ( 12 ) has compartments facing the RAP depot ( 11 ) and the pouring hopper ( 20 ). The RAP, flowing from the conveyor ( 23 ), fills in the compartments of the valve ( 12 ) in sequence. While the rotary valve ( 12 ) rotates around the own axis thereof, the RAP, which fills in the compartments thereof, is transferred inside the pouring hopper ( 20 ) in sequence. By means of this, for instance when the drying boxes ( 22 ) existing on the first line ( 21 a ) are in waiting position, RAP is transferred to the drying boxes ( 22 ) from the compartment of the rotary valve ( 12 ). Afterwards, when the drying boxes ( 22 ) are in pouring position, the rotary valve ( 12 ) rotates as required and the inlet part of the RAP depot ( 11 ) is covered and thus the RAP does not flow. By means of the rotary valve ( 12 ), while the drying boxes ( 22 ) are in pouring position, the RAP flow from the RAP depot ( 11 ) is prevented. By means of the rotary valve ( 12 ), the pouring hopper ( 20 ) and the RAP depot ( 11 ) are connected in an air-tight manner, and feeding is provided without cold air input to the pouring hopper ( 20 ).
[0058] There is a sensor ( 91 ) which measures the temperature of the aggregate and of the RAP accumulated in the mixing hopper ( 70 ). Said sensor ( 91 ) is in connection with a control unit ( 90 ). The control unit ( 90 ) adjusts the waiting time duration of the drying boxes ( 22 ), which are in waiting position, according to the temperature of the mixture in the mixing hopper. For instance, if the temperature of the mixture is not at the desired temperature value, the drying boxes ( 22 ) stay in the waiting position for longer time duration. Thus, the optimum temperature value is provided.
[0059] In the subject matter application, hot air, which exits the drier ( 50 ), is used as the heat source ( 80 ). However, in alternative embodiments, hot air may not be provided by the drier ( 50 ), and it may be provided by another heat source ( 80 ). For instance, temperature can also be provided by the hot air coming from the waste air exhaust gas outlet or temperature can also be provided by a separate heat source ( 80 ) which is embodied for this process.
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Hot asphalt recycling system having a mixing hopper where the hot aggregate, exiting the drier, and the RAP are mixed; a pouring hopper which is opened to said mixing hopper from one end thereof and from whose other end RAP is poured, in order to obtain recycled asphalt concrete which is to be used in the production of one of the asphalt layers by using RAP. Said system comprising an air inlet pipe whose one end is connected to the heat source and whose other end is opened to the pouring hopper in order to transfer hot air, which is heated by a heat source, inside the pouring hopper; and at least one drying box in order to provide the RAP inside the pouring hopper to be poured to the mixing hopper in a sequenced manner and step by step.
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FIELD OF THE INVENTION
The invention relates to a method for encasing a body of an exhaust gas system with a housing, wherein the body has an outer envelope surface with a circumference and the housing is formed from at least one single-piece metal strip with a width and a length.
BACKGROUND OF THE INVENTION
Such bodies serve to filter diesel exhaust or for catalytic cleaning of exhaust from internal combustion engines and have a monolithic sintered body. The housing enables a connection to the exhaust system of the internal combustion engine. The mounting and fixation of the monolithic body in the housing is problematical, since the porous ceramic substance has only a limited mechanical strength. It is therefore not possible to exert rather large clamping forces on the body to accomplish its secure and firm mounting.
A further difficulty in the mounting results from the need to compensate for the relatively large cross section tolerances of the body which occur during the fabrication, as well as the differences in thermal expansion which occur as a result of different coefficients of thermal expansion of the body material and the metal housing.
In the special field of exhaust catalytic engineering for automobiles, there are basically three main designs of catalysts, namely, tube catalysts, housing catalysts, and wound catalysts. The present invention refers to wound catalysts.
In DE 102 57 651 A1 is described a winding method for a catalyst body, in which at first a metal plate or a metal strip is deformed. This metal strip, hereinafter generally called a blank, is bent into a cylinder, so that its two opposite end regions overlap. After a monolith coated with a catalytically active material, especially one in ceramic form, has been wrapped in a support mat, the combination of monolith and mounting mat, here called the body, is shoved into the winding of the housing envelope. This winding is then stretched so that it firmly surrounds the body in the required manner. The winding, stretched in this way into its end shape, forms a housing or in general a housing envelope of the catalyst housing and is tacked with spot welds for fixation to certain places. At the end face, entry and exit funnels are arranged, being designed according to requirements for fastening to an exhaust pipe. The fastening of the entry and exit funnels is done each time by means of a circular weld seam along the edges of the housing envelope. To accomplish an optimal sealing of the catalyst housing, the exterior edge of the winding or housing envelope is joined by means of a weld seam to the underlying portion of the winding or housing envelope, i.e., the overlap is welded shut.
In DE 10 2006 026 814 A1 is described a housing in which a metal sheet as the housing envelope is wound onto the two end sheets at the entry and exit end. The long thin sheet is wound in several layers on the end sheets and then joined to them. The thin sheet can be easily wound. The multiple layers produce an excellent noise suppression, so that such housings give off practically no mechanical vibrations. Furthermore, the multiple layers at the same time act as a labyrinth seal, so that a simple fixation of the outer end of the metal sheet is entirely adequate, such as by a few weld spots.
In WO 9914119 (A2) is described a device for closing a housing in which spacers with a special surface are arranged in the circumferential direction about the housing so that they are fitted to the surface of the housing. The spacers here are contained in a circular mat that is enclosed around the housing in the circumferential direction,
According to DE 601 07 267 T2, a housing is formed by sheet metal elements that are joined together in the axial direction by roll-seam welding.
In JP 08284656 A is described a housing consisting of two metal strips arranged one on the other, which are partly overlapping in the circumferential direction.
SUMMARY OF THE INVENTION
The problem of the present invention is to provide a method in which a metal strip of the housing can be wound around the body in a single work step and at the same time it is possible to adapt the inner diameter of the body to the size of the body during the process and without measuring the body.
The problem is solved by a winding method in which the body is placed in a loop formed by a belt-shaped conveyor element that can be driven in at least one conveyor device, wherein the conveyor element is seated against the outer envelope surface at a wrapping angle of at least 270 degrees. Starting with a first edge, the metal strip is then introduced in a conveyor device between the body and the conveyor element. After this, the metal strip is drawn into a gap between the body and the conveyor element and at the same time it is wound around the body with the drawn-in portion of the metal strip. The conveyor element is operated until the body is encased at least twice by the metal strip.
The method ensures that the multiple encasing of the body with a metal strip occurs continuously in a single work step and the radial pressure required by the housing is produced in the perpendicular direction to the envelope surface of the body during the winding process Wrapped at least twice means that at least two complete 360-degree layers of strip are arranged about the body and the body is fully encased in strip at least twice. In other embodiments, up to six layers of strip can be provided, depending on the strip thickness.
Since in this method the pressure of the housing on the body is adjusted solely by the tension of the continuously moving conveyor element, the tolerances of the body due to manufacturing need not be taken into account, since the conveyor element in the case of bodies of different size produces the same radial pressure by the housing, due to the same tension.
Thanks to the continuous movement of the conveyor element, a relative movement of the individual layers of the metal strip is possible. The degree of the relative movement depends on the number of layers of the metal strip and the particular wrap angle.
Preferably, the length dimension of the metal strip encircling the body is 2.2 to 6.6 times the circumferential dimension of the body. In this way, it is possible to vary the rigidity of the housing and adjust different strip thicknesses The strip thickness can be reduced with the number of layers.
It is advantageous in this method that the body is formed at least from a sintered body and at least one mounting mat arranged about the sintered body, wherein the mounting mat is compressed to an adjustable degree by turning the body in the conveyor element before feeding the metal strip. In it important in this winding method that the adjusting of the pressure of the housing on the body, which is necessary for a secure mounting is possible both in regard to the dimensional tolerances of the sintered body and in regard to the thickness tolerances of the mounting mat, without having to take measurements of the tolerances in advance. Accordingly, it is possible to encase bodies that do not have a completely round cross section. This includes sintered bodies with an oval or rounded cross section.
This method can also be used to produce mufflers, in which the body constitutes the inner structure of a muffler which is encased with a metal strip, constituting the housing.
Basically, the conveyor element is arranged to be driven by an electric motor or a manual crank indirectly across one or two drive shafts. The drive system also produces the necessary tension of the conveyor element for the winding process.
Moreover, it is advantageous that the radial pressure of the conveyor element in the direction perpendicular to the envelope surface can be held constant or varied during at least part of the process by the torque generated on the drive shafts. The degree of variation in the tension of the conveyor element is dependent on the property and surface texture of the material of the metal strip. By the continuous rolling of the body in the continuously moving conveyor element, an extremely accurate adjusting of the radial pressure is possible. The pressure is preferably adjusted by regulated motors, by which the conveyor element is rolled on and off or moved.
It is of special importance to the present invention that the edge region of the metal strip stands out from the body in the direction axial to the axis of rotation and during the wrapping of the body it is wound at the same time onto a diameter-adjustable expanding mandrel or onto a spacer with a nonvariable diameter. This ensures that the diameter of the housing is also kept sufficiently constant in the edge region.
It is of special importance to the present invention that the metal strip is at least partly coated with a lubricating and/or adhesive and/or sealing compound. By the use of a lubricating compound, it is possible to more easily adjust the radial pressure of the housing, because thanks to the improved sliding properties between the layers of the metal strip the tension of the conveyor element can be reduced. With a sealing compound, corrosion between the layers is primarily prevented, since no corrosive agents can get in between the layers. With an adhesive compound, the strength of the housing can be improved, because the individual layers are fixed relative to each other. Preferably, an agent will be used that fulfills all three properties. Such an agent can slide during the winding process and hardens at a later time, retaining its sealing property.
After the wrapping of the body, the second edge of the metal strip, which forms the end of the metal strip, is joined at least partly to the portion of the metal strip already wrapped around the body. In this way, the housing is enclosed and the tension of the housing is fixed at the end of the process.
In connection with the invented configuration and arrangement of the method, a winding device for the encasing of a body of an exhaust system with a metal strip as the housing is advantageous that has at least two parallel arranged side pieces and several axles and shafts mounted in the side pieces and able to rotate. The side pieces and the axles and shafts form a machine housing. The width of the machine housing corresponds at least to the width of the metal strip. Furthermore, a belt-shaped conveyor element is provided, which is mounted on the axles and shafts and can be driven in at least one of the directions of conveyance by at least one driving device of the winding device, provided on the shafts. The conveyor element forms the core of the winding process. Between the side pieces are provided two deflection elements, arranged parallel to the axles, forming a gap running parallel to the axles, with the conveyor element mounted on them. The gap forms the feed opening for the metal strip. Thus, a winding space is formed beneath the gap, bounded by the axles and situated between the side pieces. The belt-shaped conveyor element projects on either side of the gap beyond the two deflection elements into the winding space and forms a loop in the winding space, in which the body being wrapped can be placed.
Moreover, it is advantageous that the conveyor element is closed endlessly or open, and at least two axles and at least two shafts are provided, around which the conveyor element is passed, while at least one shaft can be driven directly or indirectly via the drive device. The shaft configured as the drive shaft can be driven by a motor or a manual tool from outside the two side pieces.
Moreover, it is advantageous that the winding device has a tensioning device and the tension of the conveyor element can be adjusted directly or indirectly via the tensioning device and the tension can be used to vary or hold constant the radial pressure of the conveyor element in the direction perpendicular to the envelope surface of the body. The radial pressure exerted by the conveyor element is critical to the winding tension of the metal strip and to the ultimate diameter of the housing that is formed by the closed metal strip. Drive motors of the shafts on which the conveyor element is wound by its respective end are also provided as tensioning devices.
In one preferred embodiment for a series manufacturing, it is advantageous that the open conveyor element has two ends, while the respective end is wound each time on one of the shafts and the respective end is driven each time by a regulated motor. For the tensioning of the conveyor element, both shafts are driven and braked at least partly with different speed and/or different torque, in order to avoid a separate tensioning device.
It is essentially advantageous that the spacing forming the gap between the two deflection elements can be varied for placing the body in and taking it out. Preferably, the spacing of at least two axles and/or shafts arranged opposite each other in relation to the gap is also variable for placing the body in and taking it out. Because the spacing can be reduced once more after the body has been placed in it, the wrap angle of the conveyor element about the body can be maximized, so that a precise pressure adjustment is possible for the wrapping. It is also advantageous that the width of the gap for wrapping the body can be varied in a range between 2 mm and 30 mm. The wrap angle is increased by a very small gap width, but it is also possible to increase the gap depending on the strip thickness and the bending capacity of the metal strip.
This simplifies the mounting of the axles and shafts, since the bearings of the individual axles and shafts do not have to be moved directly for the body to be placed in and taken out.
Finally, it is advantageous that the respective side piece is configured as a two-part piece and forms two housing pieces each time, and the two housing pieces can be displaced or swiveled to vary the spacing relative to each other in at least one direction and also fixed relative to each other by an end stop. The fixation serves to maintain the tension in the conveyor element during the winding process, so that the two housing pieces are not shoved apart by the tension.
Furthermore it is advantageous that an expanding mandrel of adjustable diameter or a spacer with a nonvariable diameter is provided, which is arranged coaxial to the body and can be wound onto the edge region of the metal strip. This ensures that the diameter of the housing is also held sufficiently constant in the edge region.
It is also advantageous that guide elements for the conveyor element are provided on at least two axles or on at least two shafts, forming an end stop for the conveyor element in the axial direction. The metal strip and the body, as well as the conveyor element, must be adjusted relative to each other in the directions perpendicular to the axis of rotation. Thanks to the guide elements, the position of the conveyor element is constant in the axial direction.
The object of invention is also a structural part for an exhaust system, consisting of a body with a round or oval or rounded cross section in relation to the direction of flow and a circumference, as well as a housing surrounding the body with a round or oval or rounded cross section. The housing is formed from at least one single-piece metal strip. The length of the metal strip in the circumferential direction about the body corresponds to 2.2 to 6.6 times the dimension of the circumference of the body and the housing is formed from several layers of the metal strip wound about the body. For this, it is advantageous for the metal strip to have a thickness between 0.2 and 0.3 mm.
Moreover, it is advantageous to provide a lubricating and/or adhesive and/or sealing compound between the individual layers of the metal strip. With such a compound, thanks to its sliding properties in a still liquid or paste-like state, the individual layers of the metal strip slide against each other. This sliding is accomplished by the tension applied by the conveyor element, which in turn produces a particular diameter of the housing. The better the sliding properties, the less tension needed for the precise adjustment of the diameter. Furthermore, the compound accomplishes a continuous sliding of the individual layers proportionately to the tension of the conveyor element.
The compound can also prevent corrosion in the gap between the individual layers, since the compound seals off the gap. Furthermore, the dried compound, depending on its elasticity, influences the elasticity of the housing. Precisely when a very thin-walled metal sheet is used, the compound can produce the necessary elasticity, as well as the necessary stability of the housing. Thus, the housing is a multilayered part consisting of the metal strip and the compound.
In order to close the housing or the winding of metal strip, the edge at the end of the metal strip is joined at least partly to a portion of the metal strip that is wrapped around the body. The wrapping is fixed in place by this and the gap between the uppermost and the second partial region of the metal strip is closed.
Preferably, the body is formed from a sintered body and a mounting mat arranged about the sintered body. The sintered bodies are used as converters, filters or catalysts. However, this type of housing can also be used for mufflers in which the body is formed from sheet metal parts such as pipes and walls and has neither a sintered body nor a mounting mat.
BRIEF DESCRIPTION OF THE DRAWINGS
Further benefits and details of the invention are explained in the patent claims and the specification and represented in the figures. There are shown;
FIG. 1 a schematic view of a metal strip;
FIG. 2 a perspective view of a round sintered body;
FIG. 3 a perspective view of a metal strip wound about a sintered body with a mounting mat;
FIG. 4 a schematic of part of an exhaust system with a device according to FIG. 3 ;
FIG. 5 a perspective view of a wound metal strip;
FIG. 6 a side view of a body prior to the winding process;
FIG. 7 a side view of a body during the winding process;
FIG. 8 a side view of a winding device with a closed conveyor element;
FIG. 9 a perspective view of a winding device according to FIG. 8
FIG. 10 a front view of a winding device per FIG. 9 with two shafts driven by motors and an open conveyor element
FIG. 11 an inside view of a winding device with a guide plate and an end stop;
FIG. 12 a front view of a winding device from above with a feed for the metal strip and end stops for the conveyor element;
FIG. 13 a cross sectional representation of an expanding mandrel with the housing and the conveyor element according to the cross sectional view of FIG. 14 ; and
FIG. 14 a cross sectional view of a wound body in a loop formed by the conveyor element.
DETAILED DESCRIPTION OF THE INVENTION
With the method of the invention, a body 10 [ FIG. 2 ] of an exhaust system 1 [ FIG. 4 ] is wrapped in a metal strip 20 such that the wound metal strip 20 forms a housing 2 . In FIG. 1 , a metal strip 20 with a thickness of 0.2 mm and two edges 21 , 22 is shown, being used for the method. The two longitudinal sides of the metal strip 20 have an edge region 26 which can project beyond the sintered body 11 at the side after the wrapping, depending on the ratio of the length 14 of the sintered body 11 to the width 24 of the metal strip 20 . In the sample embodiment described, the width 24 of the metal strip 20 is 25% greater than the length 14 of the sintered body 11 .
The length 25 of the metal strip 20 is around four times the circumference of the body 10 , consisting of the sintered body 11 and a mounting mat 12 . The circumferential dimension as usual corresponds to the product of a diameter 15 and π. The diameter 15 varies according to the thickness of a mounting mat 12 and the diameter of a sintered body 11 .
In FIG. 2 the sintered body 11 is shown, being wrapped in a mounting mat 12 according to FIGS. 3 and 4 . The sintered body 11 preferably has a channel structure, in which the exhaust gas is catalytically treated and/or filtered. The body 10 consisting of the sintered body 11 wrapped with the mounting mat 12 is wrapped with the metal strip 20 according to the method of the invention, using a winding device 5 according to FIGS. 8 to 10 . In this process, the metal strip 20 starting with the edge 21 is wrapped several times about the body 10 , so that several layers 23 [ FIG. 5 ] are formed. The mounting mat 12 is compressed by the winding of the metal strip 20 , so that the sintered body 11 is fixed in place. Depending on the tension of the metal strip 20 , the mounting mat 12 is more or less compressed.
In FIG. 4 is shown a sample embodiment in which the body 10 is configured as a converter and integrated in one part of an exhaust system 1 . The metal strip 20 wrapped about the body 11 forms the housing 2 for the body 11 or for the converter. The wound metal strip 20 is joined at both end faces of the housing 2 to exhaust pipes 19 across nozzles 18 . These constitute part of the exhaust system 1 .
In FIG. 5 is shown a perspective view of a wound metal strip 20 . Thanks to the winding, between three and five layers 23 are formed in this sample embodiment, depending on the circumferential position. A larger or smaller gap 40 is formed between the layers, depending on the winding density, into which a lubricating or adhesive or sealing compound can be introduced in a later process.
FIG. 6 shows a side view of the body 10 prior to the winding process. The metal strip 20 is introduced into the gap 4 between the conveyor element 3 and the body 10 and lies with its edge 21 or underside in front, tangentially against the circumferential surface of the mounting mat 12 of the sintered body 11 . The circumferential surface of the mounting mat 12 at the same time forms the envelope surface 16 of the body 10 . By its top side, the metal strip 20 lies against the conveyor element 3 . For reasons of clarity, the conveyor element 3 is shown at a distance from the body 10 , although there is no spacing during the winding.
As shown in the side view of FIG. 7 , the body 10 is wrapped repeatedly with the metal strip 20 . By means of the mounting mat 12 , the sintered body 11 is mounted and fixed in place in the housing 2 formed by the metal strip 20 in the axial and radial direction, individually adapted to the particular dimension tolerance of the sintered body 11 .
In FIGS. 8 to 10 are shown preferred sample embodiments of winding devices 5 for the wrapping of a body 10 of an exhaust system 1 with a metal strip 20 . The winding devices 5 basically have two parallel arranged side pieces 50 , 51 and several axles and shafts arranged perpendicular to the side pieces 50 , 51 and mounted in the side pieces 50 , 51 so as to rotate. In the sense of the invention, a shaft unlike an axle is driven in rotation.
Of the winding devices 5 shown in FIG. 8 , only the rear side piece 51 and the axles 511 - 516 , 562 , 563 , 569 as well as the shafts 520 , 521 , 560 , 561 along with other parts yet to be described more closely are shown in cross section.
According to the sample embodiments of FIGS. 8 and 9 , an endless belt-shaped conveyor element 3 able to move in at least one direction of conveyance 33 is mounted on the axles 511 - 516 , 562 and the shaft 520 . Thanks to several braces 58 arranged parallel to the axles 511 - 516 , 562 and perpendicular to the two side pieces 50 , 51 , the two side pieces 50 , 51 are arranged at a parallel distance AS from each other, which is greater than the width of the conveyor element 3 or the width 24 of the metal strip 20 . The distance AS corresponds at least to the length 14 of the body 10 , shown in FIG. 2 . The braces 58 and the axles 511 - 516 produce a machine housing 57 , in which the winding process occurs.
The belt-shaped conveyor element 3 is deflected by each of the axles 511 - 516 and at the same time driven by the shaft 520 . For this, the shaft 520 is coordinated with a manual drive device 52 , which drives the conveyor element 3 in a direction of conveyance 33 of the winding device 5 . The drive device 52 comprises a toothed drive wheel 522 , arranged on the drive shaft 520 , for a toothed belt 523 . The toothed belt 523 connects the drive wheel 522 to a gear 524 , arranged on an intermediate drive shaft 521 . On the intermediate drive shaft 521 the driving torque for the drive shaft 520 is introduced by a lever 500 per FIG. 9 . The two gears 522 , 524 have different diameters, so that the drive torque in the direction of the drive shaft 520 is reduced. The toothed belt 523 is stretched across a roller 504 , which is arranged on an auxiliary axle 503 able to move parallel to the drive shaft 520 and mounted in an oblong hole 506 . The displacement of the auxiliary axle 503 with the roller 504 in the oblong hole 506 occurs by an adjustment mechanism 525 , arranged between the two side pieces 50 , 51 .
A tensioning device 56 is provided for tensioning the conveyor element 3 . The tension of the conveyor element 3 is produced by the auxiliary axle 562 , on which the conveyor element 3 is deflected. For this, the auxiliary axle 562 is movably mounted in an oblong hole 507 and can be adjusted by a pulling device 564 in the horizontal direction in the oblong hole 507 .
The pulling device 564 is guided by form fit or frictional locking around a tensioning shaft 560 and moved by the tensioning shaft 560 in the oblong hole 507 in the pulling direction. The pulling device 564 deflected by the tensioning shaft 560 is pretensioned in the pulling direction upstream from the tensioning shaft 560 by a weight 565 hanging freely from the pulling device 564 . For this, the pulling device 564 is deflected by two deflection axles 563 , 569 arranged one behind the other in the direction of the conveyor element 3 and between the tensioning shaft 560 and the weight 565 .
The tensioning shaft 560 is connected by a toothed belt 523 to an intermediate shaft 561 . For this, a gear 566 is arranged on the tensioning shaft 560 and a gear 567 on the intermediate shaft 561 . The toothed belt 523 can be adjusted by an adjustment mechanism 568 , arranged between the two side pieces 50 , 51 .
In the sample embodiment of FIG. 10 , an open conveyor element 3 is provided, whose ends are each wound on one of the two drive shafts 520 , 620 . The two drive shafts 520 . 620 are each driven by an electric motor 60 , 61 , which is positioned on the side piece 50 at the shaft head and regulated by a controller 610 , 621 . Depending on the control system of the two electric motors 60 , 61 , the tension of the conveyor element 3 or the radial pressure on the body 10 necessary for the winding process is generated.
For the winding process, the body 10 is placed in a loop 30 formed by the conveyor element 3 . For this, the two side pieces 50 , 51 are divided in the horizontal direction and each pair of side pieces 50 , 51 forms a front housing part A or a rear housing part B. The two housing parts A, B can be shoved apart in the horizontal direction A, so that the body 10 can be placed in the loop 30 between the two housing parts A, B. After the body 10 is put in place, the two housing parts A, B are shoved together once more and fixed to each other in direction R. For this, end stops 508 , 518 are provided on the housing parts A, B according to FIG. 10 , by which the housing parts A, B lie against each other in a direction R. The housing parts A, B thus have a definite spacing 510 .
The stretched conveyor element 3 lies, as shown in FIG. 8 as an example, against the circumferential surface of the body 10 . Between the body 10 and the conveyor element 3 , the metal strip 20 is introduced. The conveyor element 3 is driven in one or both directions of conveyance 32 , 33 , depending on the sample embodiment, and the metal strip 20 is drawn in continuously.
The drawing in of the metal strip 20 and the shaping of the metal strip 20 by the conveyor element 3 becomes more precise and easy when a wrap angle u of the conveyor element 3 about the body 10 is as large as possible. The wrap angle u is increased by the arrangement of two deflection elements 530 , 531 , which are disposed parallel to the axles 511 - 516 . The deflection elements 530 , 531 form two opposite sliding edges, arranged across the entire width of the conveyor element 3 , by which the conveyor element 3 slides or is deflected. The deflection elements 530 , 531 are adjustable relative to the side pieces 50 , 51 in the horizontal direction for changing the wrap angle u and they form a gap 54 with a width 540 , beyond which the conveyor element 3 projects into a winding space 55 .
The shafts and axles are in part mounted by bearings 59 in the side pieces 50 , 51 .
FIG. 11 shows one of two opposite guide plates 110 . The guide plates 110 position the body 10 in the direction of the axis of rotation 100 within the winding space 55 . Below the guide plate 110 there is an end stop 111 for the body 10 .
FIG. 12 shows a feed 9 by which the metal strip 20 is introduced into the winding device 5 . Thanks to the feed 9 , the metal strip 20 is oriented and checked one last time for tolerances. Furthermore, guide elements 8 are provided on the two axles 512 , 513 , across which the conveyor element 3 runs immediately before and after the winding space 55 , by which the conveyor element 3 is guided in the axial direction.
As shown in FIG. 4 , the metal strip 20 is broader, or the housing 2 is longer than the body 10 . The edge region 26 of the metal strip 20 projects beyond the edge of the body 10 . During the winding process, one must ensure that the inner diameter of the housing 2 is constant over the entire length. FIGS. 13 and 14 show an expanding mandrel 70 , which can be adapted in its diameter 71 to the nominal diameter 15 of the body. The expanding mandrel 70 is arranged coaxially to the body 10 per FIG. 14 and rotates along with the body 10 during the winding process. The edge region 26 of the metal strip 20 is wound onto the expanding mandrel 70 , as shown in the cross section I-II of FIG. 14 according to FIG. 13 , thus preventing the housing 2 from getting into the edge region 26 .
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A method for encasing a body of an exhaust gas system with a housing which is wound around the body. Using a winding method, the body is placed in a loop formed by a belt-shaped conveyor element that can be driven in a conveyor device, wherein the conveyor element is seated against the outer casing face at a wrapping angle u of at least 270 degrees. Starting with a first edge, the metal strip is then introduced in a conveyor device between the body and the conveyor element, is drawn into the gap between the body and the conveyor element and is bent around the body until the body is encased at least twice by the metal strip.
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FIELD OF THE INVENTION
The present invention relates to a variable speed rotary drive mechanism. More specifically, the present invention includes a drive mechanism useful in operating display sign elements, such as those on prismatic displays, so as to vary the speed of rotation from a maximum velocity occurring during the changing of display surfaces to a minimum velocity occurring as the position corresponding to the display of the desired surface is approached.
BACKGROUND OF THE INVENTION
There are several known kinds of convertible signs, one type of which creates a display arrangement comprising single or multiple prisms, each of which are mounted at opposite longitudinal ends and rotatable about their longitudinal axis. in the case of multiple prisms, each prism is part of an equal sequence in a frame, the prisms residing beside each other. The sides of the prism are oriented in a permanently occurring sequence forming a number of displays corresponding to the number of side surfaces of the single prism. Such a sign necessarily includes a drive motor for synchronous rotation of the prisms via a transmission.
Displays of this type usually comprise triangular aluminum prisms, which rotate in an aluminum frame and show three displays in permanently recurring sequence. The prisms can be dismounted and exchanged. Due to the triangular shape of the prisms, three different views can be shown. The display arrangement can be mounted with its frame standing free, on walls or on roofs of buildings. Also, single prism signs are typically found on scoreboards in arenas or the like.
Known display arrangements of this type are typically driven by an electric motor, and the prisms are rotated synchronously by a gear transmission in such a manner that the sides of the respective prisms belonging to the same picture are shown simultaneously and form a display. The gear transmission ensures synchronous rotation of each prism.
A gear transmission, however, involves certain disadvantages. A desirable characteristic of most convertible signs is that they operate noiselessly, particularly when the displays are mounted on buildings. A gear transmission for operating noiselessly requires good lubrication. This requirement would be difficult to attend to at many sign locations, because of the need for periodic service and such signs in most cases are positioned in places of difficult access. The problem of access has created a need for mechanisms of high durability and reliability, along with the continuing requirement for accurate registration of the sign elements and the constant need to start, rotate and stop the sign display. Experience in the field has demonstrated the need to convert this inherently complex mechanical operation into one having as much reliability and simplicity as possible.
A recent solution to these problems is disclosed in commonly assigned U.S. Pat. No. 5,343,645, issued to Huber. There is disclosed a chain driven gear drive system, including off-center gear elements. These gear elements are rotated to translate various potential speeds to a mounting gear, on which a sign member is mounted. As a result of this structure, the sign member rotates through successive 120° turns while varying the speed of rotation from a maximum velocity occurring during the changing of display surfaces to a minimum velocity occurring as the position corresponding to the new display surface of the sign member, of the sign is approached.
What is needed is an alternate drive mechanism for driving display sign arrangements and other devices that require frequent start and stops.
SUMMARY OF THE INVENTION
The present invention provides an alternate variable speed rotary drive mechanism for operating display sign elements, such as those on prismatic displays, so as to vary the speed of rotation from a maximum velocity occurring during the changing of display surfaces to a minimum velocity occurring as the position corresponding to the display of the desired surface is approached. The variable speed rotary drive mechanism can also be used to drive other devices requiring frequent starts and stops, such as conveyors.
In one embodiment in accordance with the invention, a convertible sign mechanism is provided which comprises a convertible sign member that is rotatable about an axis. A drive means is connected to the convertible sign member for rotating the convertible sign member at a variable velocity, with the drive means operating continuously throughout the rotation of the convertible sign member. The drive means includes a motor, a drive shaft operatively connected to the motor, a cam follower operatively connected to the drive shaft, a member configured to receive the cam follower in a slidable engagement, an output gear operatively connected to the member; and a drive gear operatively connected to the output gear and to the convertible sign member. The output gear and the drive gear provide a reduction ratio of at least 2:1.
These and various other advantages 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 obtained by its use, reference should be made to the drawings which form a further part hereof, and to the accompanying description, in which there is described a preferred embodiment of the invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of the convertible sign mechanism in accordance with the invention;
FIG. 2 is a side view of the of the mechanism, with the motion transmission device in a first position;
FIG. 3 is a schematic view of the motion transmitting device in a first position;
FIG. 4 is a schematic view of the motion transmitting device in a second position;
FIG. 5 is a schematic view of the motion transmitting device in a third position; and
FIG. 6 is a schematic view of the motion transmitting device in a fourth position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a convertible sign mechanism according to the principles of the invention is shown generally at 10 . The convertible sign mechanism 10 includes a multifaceted prismatic display member 12 , which can have two or three sides, but in the specific example is shown to have three-sides 14 , 16 , 18 . The sides 14 , 16 , 18 typically contain different information, and when in a multiple prismatic sign, are typically ganged or combined together with similar display members in a coordinated manner to form the desired sign. The mechanism 10 further includes a drive mechanism 20 for rotating the display member 12 about its central axis so that each side 14 , 16 , 18 is periodically brought into view.
With reference now to FIGS. 1 and 2, the drive mechanism 20 generally includes a suitable electric motor 22 having a drive shaft 24 with a pinion gear 26 fixed thereto, such that the pinion gear 26 is rotatably driven by the motor 22 . The motor 22 is typically timed by conventional timing devices or the motor can be under computer control. An endless chain 28 is disposed over the drive gear 26 and an input gear 30 that is fixed to an input shaft 32 which forms the input to a variable speed, motion transmitting device 34 . An output shaft 36 extends from the device 34 and has an output gear 38 fixed thereon so as to rotate with the output shaft 36 . A second endless chain 40 is disposed over the output gear 38 and a large diameter drive gear 42 that is fixed to a shaft 44 which is connected to the display member 12 .
When the motor 22 is activated, the drive shaft 24 rotates the pinion gear 24 which drives the endless chain 28 . The endless chain 28 in turn drives the input gear 30 , thereby rotating the input shaft 32 . The motion transmitting device 34 continuously varies the rotational speed input by the input shaft 32 , so that the rotational speed of the output shaft 36 and the output gear 38 are continuously varied. The rotation of the output gear 38 is transmitted by the endless chain 40 to the large diameter drive gear 42 which drives the shaft 44 thereby causing the display member 12 to rotate so as to change the side 14 , 16 , 18 that is viewed.
A concern when driving members that are periodically stopped and started, such as prismatic display members and conveyor systems which stop and start at fill stations, is that the initial start of movement from a fully stopped condition be gradual. The movement speed should eventually build up to a maximum, and then gradually decrease as the driven member starts approaching its next intended position. Applicant's have found that this gradual increase and gradual decrease of movement speed avoids the shock of abrupt starts and stops, and minimizes wear on components.
In order to accomplish the gradual increase and gradual decrease of the rotational speed of the display member 12 , the motion transmitting device 34 is specifically designed to convert the constant speed rotational input provided by the input shaft 32 into a smooth, cyclically varying speed, accelerating-decelerating rotational output to the output shaft 36 .
With reference specifically to FIG. 2, it is seen that the motion transmitting device 34 includes a pair of spaced side walls 46 , 48 , each of which includes a bearing 50 , 52 associated therewith for rotatably supporting the respective shafts 32 , 36 . A cam follower arm 54 is suitably fixed to the end of the input shaft 32 , such as by a key, so as to rotate with the input shaft 32 . A follower 56 , such as a rotating bearing or a sliding bearing, is fixed to the follower arm 54 and is spaced radially of the axis of the input shaft 32 . A cam arm 58 is suitably fixed at one end thereof to the end of the output shaft 36 , such as by a key, whereby the cam arm 58 is eccentrically mounted. The cam arm 58 includes a slot 60 formed therein which extends longitudinally the length of the cam arm 58 , and the follower 56 is slideably received within the slot 60 . Thus, as the input shaft 32 rotates, the output shaft 36 rotates as a cyclically varying speed due to the cam and follower arrangement.
Preferably, the follower 56 is spaced from the axis of the input shaft 32 a distance slightly greater than the distance between the axes of the input and output shafts. Thus, as the input shaft 32 rotates, the cam follower arm 54 and the follower 56 rotate therewith. Rotation of the follower arm 54 and follower 56 causes the cam arm 58 and the output shaft 36 to rotate. The rotational speed of the input shaft 32 can be assumed to be constant, and therefore due to the arrangement of the device 34 , the rotational speed of the output shaft 36 will vary from a maximum when the follower arm/follower 54 , 56 and the cam arm 58 are in the position shown in FIGS. 2 and 3, to a minimum when the follower arm/follower and cam arm are displaced 180° to the position shown in FIG. 5 . The transition between maximum and minimum rotational speeds of the output shaft 36 occurs in an extremely smooth manner due to this arrangement, such that abrupt starts and stops are avoided.
The variation in rotational speed occurs based upon the distance of the follower 56 from the axis of the output shaft 36 . Referring now to FIGS. 3-6, when the follower 56 is at its maximum distance from the output shaft axis, as illustrated in FIG. 3, the torque acting on the cam arm 58 is greatest since the moment arm D of the force acting on the cam arm is at its maximum. As the elements rotate to the position shown in FIG. 4, the follower 56 is moving toward the output shaft 36 , and thus the rotational speed of the output shaft 36 is continuously decreasing. When the elements reach the position shown in FIG. 5, the follower 56 has moved to its closest distance to the output shaft axis. Therefore, the torque acting on the cam arm 58 is at its minimum, since the moment arm of the force is at its minimum. As the elements rotate from the position shown in FIG. 5 to the position shown in FIG. 6, the follower 56 moves away from the output shaft 36 so that the rotational speed thereof gradually increases.
It is important that the follower 56 be spaced from the axis of the input shaft 32 a distance slightly greater than the distance between the axes of the input and output shafts, i.e. the axis of the follower 56 , should not coincide with the axis of the output shaft 36 . This prevents binding of the follower 56 in the cam arm 58 , which would stop rotation of the output shaft 36 and possibly damage the components.
Assuming that the display member 12 is initially at rest and the side 14 is currently viewable, then to view the side 16 the display member 12 must be rotated about its axis. This is accomplished by activating the motor 22 , which drives the input shaft 32 in the suitable direction. Initially, the follower 56 and cam arm 58 are in their minimum rotational speed position (FIG. 5 ). When the input shaft 32 is rotated, the follower arm 54 /follower 56 start driving the cam arm 58 , with the rotational speed gradually increasing as the follower 56 and cam arm 58 move away from the minimum speed position (FIG. 6 ). Concurrently, the display member 12 starts to gradually rotate from its stopped position.
Continued rotation causes the follower 56 and cam arm 58 to reach their maximum speed position (FIG. 3 ), at which point the display member 12 is being driven at its maximum speed and the side 16 is partially visible. As the follower 56 and cam arm 58 move from the maximum speed position, the speed of the display member 12 starts decreasing as the side 16 of the display member is starting to approach its fully viewed position (FIG. 4 ). When the side 16 reaches its fully viewed position, the follower 56 and cam arm 58 will be back at their minimum speed position (FIG. 6 ). To stop the display member 12 in position, one need only to deactivate the motor 22 at the minimum speed position.
Ideally, for a three-sided (prismatic) display member 12 , the output gear 38 and the large diameter drive gear 42 are sized to provide a 3:1 reduction ratio, such that a complete cyclic speed variation provided by the motion transmitting device 34 occurs for every 120° rotation of the display member 12 . This ensures that the display member 12 goes through the cycle of gradual speed increase, maximum speed, and gradual speed decrease to minimum speed each time a new side is to be viewed. For a two sided display member a 2:1 reduction ratio would be provided.
While the invention has been described herein as driving a display member, the invention could also be used to drive any member requiring frequent starts and stops, such as conveyors with containers thereon which stop and start at fill stations to fill the containers. The gradual increase and decrease of speed provided by the motion transmitting device described herein would prevent the containers on the conveyor from tipping over, with the maximum speed between starting and stopping maintaining efficient operation of the conveyor.
The above specification provides a complete description of the manufacture and use of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.
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A convertible sign mechanism is provided which comprises a convertible sign member that is rotatable about an axis. The convertible sign member is capable of rotating at a variable velocity. A motor is operatively connected to a drive shaft, which is connected to a cam follower. The cam follower is slidably connected to a member receiving the cam follower, with the receiving member being connected to an output gear. The output gear is connected to a drive gear, which together provide a reduction ratio of at least 2:1.
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TECHNICAL FIELD
[0001] The present invention generally relates to aircraft display systems and methods and, more particularly, to systems and methods for enhanced display of symbology on a see-through display.
BACKGROUND
[0002] Computer generated aircraft displays have become highly sophisticated and capable of displaying a substantial amount of flight management, navigation, and control information that gives flight crews more effective control of the aircraft and a reduction in workload. In this regard, electronic displays, such as head-up displays (HUDs) and head-down displays (HDDs), are used in aircraft as Primary Flight Displays to display important flight management, navigation, and control information to flight crews.
[0003] As an example, a HUD typically projects flight information onto a combiner located within the general viewing area (e.g., the cockpit window) of the aircraft pilot. The HUD system can combine critical flight instrumentation (e.g., altitude, attitude, heading, airspeed, vertical speed instruments) and primary engine instrument indicators into a single, readily interpretable display. As a result, HUD systems have become effective visual tools for controlling aircraft, reducing pilot workload, increasing situational awareness, and improving overall flight safety.
[0004] However, the amount of flight information provided onto the combiner of a conventional HUD system is generally limited to permit simultaneous viewing of the flight information and the environment beyond the cockpit window. Since the combiner overlays the information onto a view of the actual environment, any information having a particular position on the environment may not be accurately displayed in some instances. For example, if the information is symbology representing an airport, and the airport is located behind a mountain, conventional HUD systems could render the airport without regard to the intervening terrain, thereby producing an image that appears as if the airport extends through the mountain. It is therefore desirable to improve the accuracy of the information presented to the flight crew.
[0005] Accordingly, it is desirable to provide systems and methods with enhanced display of symbology, particularly an enhanced display of geo-referenced symbology. Furthermore, other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
BRIEF SUMMARY
[0006] In accordance with an exemplary embodiment, a see-through display system includes a processing unit configured to receive data representative of geo-referenced symbology and terrain data, to compare the geo-referenced symbology to the terrain data, and to generate display commands associated with the geo-referenced symbology based on the terrain data. The system further includes a display device coupled to the processing unit and configured to receive the display commands from the processing unit and to display the geo-referenced symbology.
[0007] In accordance with another exemplary embodiment, a see-through display system is associated with a user at a viewing perspective. The system includes a processing unit configured to receive data representative of first geo-referenced symbology and terrain data, the terrain data including data associated with a first terrain feature, the processing unit further configured to supply display commands associated with the first geo-referenced symbology. The system further includes a display device coupled to the processing unit, and configured to receive the display commands from the processing unit and to display the geo-referenced symbology such that the first geo-referenced symbology appears at least partially obscured by the first terrain feature from the viewing perspective.
[0008] In accordance with another exemplary embodiment, a method is provided for displaying geo-referenced symbology in a see-through display for a user at a viewing perspective. The method includes determining a position for geo-referenced symbology; receiving terrain data that includes a terrain feature in front of the position of the geo-referenced symbology from the viewing perspective of the user; generating display control signals associated with the geo-referenced symbology; and displaying the geo-referenced symbology based on the display control signals such that the terrain feature at least partially obscures the geo-referenced symbology.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
[0010] FIG. 1 is a functional block diagram of an aircraft display system according to an exemplary embodiment;
[0011] FIG. 2 depicts an exemplary image that may be rendered by the aircraft display system of FIG. 1 ; and
[0012] FIG. 3 is a flowchart depicting a display method according to an exemplary embodiment.
DETAILED DESCRIPTION
[0013] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
[0014] Broadly, exemplary embodiments described herein provide visual display systems and methods. More specifically, the visual display systems and methods display images that include enhanced geo-referenced symbology such as waypoints and runways. The appearance of the geo-referenced symbology is based on terrain data even though the terrain data may not be displayed itself.
[0015] FIG. 1 depicts a block diagram of an exemplary head-up display (HUD) system 100 for displaying enhanced geo-referenced symbology. Although the system 100 described herein as a HUD system, the system 100 may also be a near-to-eye (NTE) display system or any other type of see-through display. The system 100 may be incorporated into an aircraft or other type of vehicle, or carried or worn by the user, for example, in a helmet. In the exemplary embodiment shown, the HUD system 100 includes a processing unit 102 , a database 104 , a flight management system 106 , and a display device 108 . In one embodiment, the display device 108 includes a projector, and a combiner, although any suitable display unit or combination of units may be provided. Notably, it should be understood that although the HUD system 100 appears in FIG. 1 to be arranged as an integrated system, the HUD system 100 is not so limited and can also include an arrangement whereby one or more of the processing unit 102 , the database 104 , the flight management system 106 , a projector 112 , and a combiner 116 is a separate component or a subcomponent of another system located either onboard or external to an aircraft. Also, for example, the HUD system 100 can be arranged as an integrated system or a subsystem of a more comprehensive aircraft system (e.g., flight management system, navigation and control system, target aiming and control system, collision alert and/or avoidance system, weather avoidance system, etc.). The HUD system 100 can be utilized in an aircraft, such as a helicopter, airplane, or unmanned vehicle. Moreover, exemplary embodiments of the HUD system 100 can also be utilized in spacecraft, spacesuits, ground- and air-based helmets, ships, submarines, fixed wing and rotor aircraft, such as helicopters, as well as other types of vehicles, including automobiles, military vehicles and the like. For simplicity, embodiments are described below with reference to “aircraft.”
[0016] The processing unit 102 can be any type of computer processor associated with a visual display system. Generally, the processing unit 102 receives and/or retrieves flight management information (e.g., from the flight management system 106 ) and landing, target and/or terrain information (e.g., from database 104 ). The processing unit 102 generates display control signals associated with the flight management information, which may include symbology such as a zero pitch reference line, heading indicators, tapes for airspeed and altitude, terrain information, flight path information, RNP information, and any other information desired by a flight crew. The processing unit 102 then sends the generated display control signals to a display device 108 . More specific functions of the processing unit 102 will be discussed below.
[0017] Database 104 is coupled to processing unit 102 and can be a memory device (e.g., non-volatile memory, disk, drive, tape, optical storage device, mass storage device, etc.) that can store digital landing, waypoint, and target location as either absolute coordinate data or as a function of an aircraft's position. Database 104 can also include, for example, a terrain data, which includes the locations and elevations of natural and manmade terrain. Generally, the term “terrain” represents any 3D object within the environment. More specifically, the terrain data in the database 104 can also include the locations and elevations of natural terrain obstacles such as mountains or other elevated ground areas, and also the locations and elevations of man-made obstacles such as radio antenna towers, buildings, bridges, etc. The terrain data in the database 104 can be up-linked from an external source or populated in real time from an onboard device that senses and maps terrain, such as, for example, a Forward Looking Infrared (FLIR) sensor, or an active or passive type of radar device.
[0018] The flight management system 106 is coupled to processing unit 102 , and can provide navigation data associated with the aircraft's current position and flight direction (e.g., heading, course, track, etc.) to the processing unit 102 . The navigation data provided to the processing unit 102 can also include information about the aircraft's airspeed, altitude, pitch, and other important flight information. In exemplary embodiments, the flight management system 106 can include any suitable position and direction determination devices that are capable of providing the processing unit 102 with at least an aircraft's current position (e.g., in latitudinal and longitudinal form), the real-time direction (heading, course, track, etc.) of the aircraft in its flight path, the waypoints along the flight path, and other important flight information (e.g., pitch, airspeed, altitude, attitude, etc.). Information can be provided to the processing unit 102 by, for example, an Inertial Reference System (IRS), Air-data Heading Reference System (AHRS), and/or a global positioning system (GPS). In other embodiments, the flight management system 106 can be replaced with a general positioning and/or mission management system.
[0019] The HUD system 100 also includes the display device 108 coupled to the processing unit 102 . The processing unit 102 executes one or more algorithms (e.g., implemented in software) for determining the position of the various types of desired information. The processing unit 102 then generates a plurality of display control signals representing this data, and sends display control signals for display on the display device 108 . The display device 108 and/or processing unit 102 may include a graphics display generator for generating the appropriate symbology, as discussed in greater detail below. The display device 108 may be a color LCD type projection unit that images a variety of symbology onto a combiner in pre-determined color formats, patterns, shading, and the like, in response to instructions from the processing unit 102 . As noted above, any type of display device 108 may be incorporated into the system 100 , including an OLED, LCD, or scanning laser projected onto or into the edge of a combiner.
[0020] FIG. 2 depicts an exemplary visual display 200 that may be rendered by the HUD system 100 of FIG. 1 . As noted above, the visual display 200 is displayed over actual terrain 214 as the flight crew looks through the combiner 116 ( FIG. 1 ). The visual display 200 may include symbology that may be useful to the flight crew. In this embodiment, the symbology of the visual display 200 includes, among other things, computer generated symbols representing a zero pitch reference line (e.g., commonly referred to as a horizon line) 202 , an airspeed scale or tape 210 , an altitude scale or tape 212 , and a roll scale 216 .
[0021] In addition, and as will now be described in more detail, the visual display 200 in FIG. 2 may also selectively render geo-referenced symbology 220 , 222 , 224 , 226 , 228 . The geo-referenced symbology 220 , 222 , 224 , 226 , 228 corresponds to a particular position in the actual terrain 214 . In this particular exemplary embodiment, the geo-referenced symbology includes waypoints 220 , 222 , airport 224 , enhanced building symbology 226 , and target 228 . Waypoint 220 is located behind the buildings in the terrain 214 and waypoint 222 is between two mountains. At least part of airport 224 is behind a hill. Building 226 and target 228 are similarly behind terrain 214 . Other examples of geo-referenced symbology can include flight path information, required navigation performance (RNP) information, conformal symbology, restricted airspace designations, landing pads, and any type of ground referenced targets.
[0022] Conventional systems merely overlay the symbology onto the actual terrain by mapping the geo-referenced symbology onto the designated position of the perspective view, without regard to the actual elevation and characteristics of the terrain. For example, in a conventional system, the waypoint 220 would appear in front of or within the buildings, waypoint 222 would appear in front or within both mountains, and airport 224 would appear to go through the hill. In accordance with an exemplary embodiment, the HUD system 100 ( FIG. 1 ) considers the terrain such that the geo-referenced symbology 220 , 222 , 224 , 226 , 228 appears more accurately relative to the terrain 214 .
[0023] Any number of techniques can be used to ensure that the geo-referenced symbology 220 , 222 , 224 is properly displayed on the visual display 200 . One such method is shown in FIG. 3 , and additional reference is made to FIGS. 1 and 2 . In a first step 310 , the processing unit 102 generates display control signals for the LCD projector 112 for the non-geo-referenced symbology, including the zero pitch reference line 202 , flight path marker 206 , airspeed tape 210 , altitude tape 212 , and roll scale 216 . In a second step 320 , the processing unit 102 generates display control signals for the geo-referenced symbology, including the waypoints 220 , 222 , airport 224 , building 226 , and target 228 . In a third step 330 , the processing unit 102 receives terrain data from the database 104 , and in a fourth step 340 , the processing unit 102 compares the position and characteristics of the geo-referenced symbology 220 , 222 , 224 to the actual terrain data from the database 104 . In one exemplary embodiment, this comparison can be a pixel by pixel comparison, although any suitable comparison technique can be used. In a fifth step 350 , the processing unit 102 modifies the display control signals for the geo-referenced symbology as necessary for accurate depiction relative to the actual terrain 214 . In a sixth step 360 , the processing unit 102 sends the geo-referenced symbology 220 , 222 , 224 , 226 , 228 and the non-geo-referenced symbology to the display device 108 . This method results in an accurate visual display (e.g., display 200 ) for viewing geo-referenced symbology 220 , 222 , 224 , 226 , 228 relative to the actual terrain 214 .
[0024] Other mechanisms for modifying the visual display 200 relative to the terrain 214 may also be used. For example, in an alternate embodiment, display signals corresponding to terrain symbology are provided to the display device 108 for display. However, the display device 108 displays the terrain symbology in a color that will not be visible to the viewer on the see-through display, such as for example, a “clear” color such as black. In this way, the terrain symbology is not visible, but since it is drawn onto the display device 108 , it acts as a mask to modify the appearance of the geo-referenced symbology 220 , 222 , 224 , 226 , 228 from the perspective of the viewer such that it is accurately displayed relative to the real terrain 214 . This results in the system 100 , in effect, performing a per-pixel calculation and clearing the object pixels where the terrain at issue would normally be rendered. In a further embodiment, the terrain may be rendered with an off-screen 3D buffer, for example, a buffer that contains depth and height information that is used as a 3D mask when rendering objects. In a further embodiment, a ray tracing algorithm can be utilized to determine which portion of the symbology 220 , 222 , 224 , 226 , 228 should be displayed.
[0025] While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
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A see-through display system includes a processing unit configured to receive data representative of geo-referenced symbology and terrain data, to compare the geo-referenced symbology to the terrain data, and to generate display commands associated with the geo-referenced symbology based on the terrain data. The system further includes a display device coupled to the processing unit and configured to receive the display commands from the processing unit and to display the geo-referenced symbology.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a National Stage Application of International Application No. PCT/CH2005/000116 filed Mar. 1, 2005, which published as WO 2005/083050 on Sep. 9, 2005, the disclosure of which is expressly incorporated by reference herein in its entirety. Further, the present application claims priority under 35 U.S.C. §119 and §365 of Netherland Application No. 1025609 filed Mar. 1, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a container for barley to be steeped, with a floor that is provided with passageways for passing water between the underside of the floor and the barley to be steeped in the container.
[0004] 2. Background Description
[0005] As known to the expert, brewing beer requires that barley be cleaned and steeped prior to the malting process, wherein the barley grains are moved to more or less of an extent in order to germinate. Known here is the use of a so-called steeping cistern provided with a double, flat floor. The top floor of the double floor is here perforated, wherein the perforated passageways are small enough to prevent barley grains brought from above onto the top floor of the double floor from passing through these perforated passageways. The distance between the two floors of the double floor normally measures at least about 80 cm.
[0006] While the barley is cleaned and steeped in the known steeping cistern, the barley is introduced into the cistern on the top floor of the double floor. In the steeping cistern, the barley is subjected to a treatment primarily involving two alternating and repeating phases. During the first phase, the barley is supplied with water via the double floor, wherein not just the barley, but also the dual floor is submerged under the water. Also referred to as the wet steeping phase, this phase typically lasts about 2 to 5 hours. In the second phase that follows the wet steeping phase, which is also referred to as dry steeping phase, and generally lasts for about 10 hours, the water is drained from the steeping cistern, wherein the water that was above the first floor of the double floor during the wet steeping phase flows through the perforations in the top floor of the double floor.
[0007] During the steeping process, the moisture content in the (living) grains increases, thereby accelerating the conversions into the grains necessary for sustaining life. In these conversions, starch compounds are enzymatically converted in water and carbon dioxide, for which purpose oxygen is additionally needed from the environment. During the wet steeping phase, the water is aerated to supply oxygen and expel carbon dioxide. In the dry steeping phase, the air between the grains is freshened through aeration, which expels carbon dioxide and supplies oxygen.
[0008] One important objection associated with using a flat steeping cistern with a double floor is the significant level of water consumption, since the double floor is of necessity filled with water during the wet steeping phase. The typical quantities that here play a role fill the double floor with about 300 m 3 of water (rule of thumb: about 0.7 m3 per m 2 of steeping cistern surface), wherein about 450 m 3 of water is present above the top floor of the double floor during the wet steeping phase (rule of thumb: about 1 m 3 per ton of barley). There are only a limited number of options for reducing the height of the double floor, since a minimum height is required to evacuate a sufficient amount of carbon dioxide from the mass of barley grains during the steeping phase. Another important objection associated with the use of known flat steeping cisterns is that cleaning it when no barley grains are present in the flat steeping cistern is very time consuming and work intensive, and there is a risk that contaminants will nonetheless remain behind, an undesirable prospect given the type of end product, specifically beer.
SUMMARY OF THE INVENTION
[0009] The invention now intends to offer a solution, or at least improvement, for the set of problems described above. To this end, the device according to the invention is characterized in that a water line network under the floor is directly adjacent to passageways in order to pass water through these passageways. Using such a water line network eliminates the necessity of using a double floor, which must be filled with water during the wet steeping phase. As a result, a significant savings in water consumption can be realized.
[0010] In order to expand the functionality of the water line network, it is preferred that the water line network be set up for diverting water via the passageways starting at the barley to be steeped.
[0011] As an alternative or in combination, it is preferred that the water line network be set up for supplying water via the passageways to the barley to be steeped through the passageways starting at the underside of the floor.
[0012] To keep the water line network relatively simple in design, it is desirable to limit the number of passageways through which water is passed from or to the barley to be steeped, making it necessary to provide the passageways with a traversable surface that is significantly larger than the traversable surface of the perforation passageways in the top floor of the double floor of the flat steeping cistern according to prior art. In this case, passageways with a traversable surface of at least 50 cm 2 , and further of at least 100 cm 2 , are preferred. In order to now prevent barley grains from passing through these passageways, the passageways should preferably be provided with sieve units.
[0013] The container preferably has a round head shape in the top view, wherein the passageways are arranged in radially oriented rows. The advantages associated with this are primarily structural in nature.
[0014] In order to subject the barley grains in the container to the action of the water supplied through the passageways as homogeneously as possible, it is preferred that the passageways be distributed over the surface of the floor in a primarily uniform fashion. This general rule might be less applicable, if at all, near the circumferential edge given the deviating behavior near the circumferential edges of the floor. In addition, the advantage to a uniform distribution of passageways over the surface of the floor is that, as will be explained further on, if these passageways are also used for aerating the barley grains, the barley grains can be set in motion with a minimum number of passageways, thereby generating a growing, dirt-removing and pressure-compensating effect. The barley grains will pass straight through the passageways perpendicularly upward, while a downwardly flowing stream of barley grains is obtained at some radial distance between the passageways, for example at a radial distance of between 20 and 50 centimeters, thereby yielding a more or less toroidal pattern of motion, wherein the barley grains are continuously circulated. This pattern of motion is also referred to as a recirculating effect. As already mentioned, the number of passageways must here be limited, wherein a compromise must be found between the traversable surface of the passageways, the density of passageways on the floor, and the recirculating effect. The density of the passageways on the floor is preferably less than 10, or more preferably less than 5 passageways per m 2 . In order to achieve the homogeneous distribution during the use of radially oriented rows as effectively as possible, even near the midpoint of the round head shape, it is preferred that adjacent, radially oriented rows vary in length.
[0015] It is very preferred that the water line network under the floor be provided with a series of shared water line elements, and with water branch line elements, between a shared water line element and a passageway. This limits the tube length required for the water line network.
[0016] When using radially oriented rows of passageways, it is preferred that the shared water line elements be radially oriented, so that the orientation of rows, passageways and shared water line elements coincide, and the water branch line elements in between can be essentially uniform in design.
[0017] It is here further preferred that the shared water line elements be arranged between two adjacent radially oriented rows of passageways viewed from above, so that the water branch line elements can be connected right next to the passageways of the two adjacent, radially oriented rows at one end, and right next to the same shared water line element at their opposite end.
[0018] In order to also limit the tube length necessary for the water line network, it is further preferred that a number of shared water line elements be connected to a water main line element.
[0019] One important advantage in terms of the simplicity with which the device can be cleaned in the interim is achieved by providing a container for cleaning agents that is connected by a cleaning agent valve with the water line network, so that cleaning agents can be added to the water line network when desired. It must here be kept in mind that the amount of water the water line system can hold is many times less than the volume of the double floor of the flat steeping cistern according to prior art. As already mentioned, the latter volume usually measures 300 m 3 , while a typical volume for the inside of the water line system measures 5 m 3 , so that the application of a container for cleaning agents with which the so-called clean-in-place process can be performed lies within the realm of possibility. It also holds true that using a water line system inside the water line system enables far higher flow rates, which also already yields an improved cleaning effect.
[0020] In addition, there are major advantages to directly connect a carbon dioxide line system to the passageways under the floor in order to remove carbon dioxide from the barley to be steeped via these passageways. Even though these passageways can in principle relate to passageways other than the passageways used to supply air from the water line system to the barley to be steeped (wherein the dimensions and number of passageways for the carbon dioxide and passageways for the water can deviate from each other, if needed), it is here preferred that the same passageways be used for supplying (and potentially discharging) water that were used to evacuate the carbon dioxide from the barley mass during the dry steeping phase.
[0021] In order to limit the necessary tube length for realizing the carbon dioxide line system, the latter is preferably provided under the floor with a number of shared carbon dioxide line elements and carbon dioxide branch line elements between a shared carbon dioxide line element and a passageway. The advantages to a shared carbon dioxide line element and carbon dioxide branch line element are comparable to the application of shared water line elements and water branch line elements.
[0022] From the same standpoint, it is further preferred that a number of shared carbon dioxide line elements be connected to a carbon dioxide main line element. Connecting this carbon dioxide main line element to a vacuum source can generate a reduced pressure inside the entire carbon dioxide line system to evacuate the carbon dioxide via the corresponding passageways.
[0023] An efficient use of the used line elements is achieved by having the shared water line elements and shared carbon dioxide line elements be formed at least in part by the same shared line elements.
[0024] An identical advantage comes into play when the water branch line elements and carbon dioxide branch line elements are formed at least in part by the same branch line elements. The same branch line elements can be used for both supplying (and potentially discharging) water and removing carbon dioxide, since supplying (or discharging) water does not take place simultaneously with carbon dioxide removal.
[0025] In order to now prevent carbon dioxide from inadvertently getting into the water main line elements during the use of shared line elements, it is preferred that a water valve be provided between the shared line elements and water main line element.
[0026] For a comparable reason, namely to prevent water from penetrating into the carbon dioxide main line element, it is preferred that carbon dioxide valves be provided between the shared line elements and the carbon dioxide main line element.
[0027] It is also very much preferred for an air line system to be connected to the passageways under the floor, so that air can be supplied to the barley to be steeped via these passageways. As in the case of the passageways for the carbon dioxide, it also holds true that the passageways for air (or oxygen) can in principle be passageways other than the passageways for passing through water, and hence can also deviate in terms of number and dimensions, but that the passageways intended for supplying air to the barley preferably be the same as the passageways for passing through water and/or the passageways for removing carbon dioxide.
[0028] In order to limit the tube length required for realizing the air line system, the air line system is preferably provided with a number of shared air line elements and air branch line elements between a shared air line element and a passageway. In addition, it is preferred within this framework that a number of shared air line elements be connected to an air main line element. Connecting the air main line element to a compressor or the like makes it possible to realize an elevated pressure inside the air line system in order to supply air to the barley to be steeped.
[0029] It is preferred that air valves be provided between the shared air line elements and air main line element, so that passageways can be provided in groups for air.
[0030] It is here advantageous to provide a control system suitable for the individual or group operation of various air valves.
[0031] In order to remove contaminants or the like that circulate on the water in the container, it is preferred that the container be provided near its upper side with a scraper, so that the elements circulating on the water can be scraped off while shifting the scraper in a displacement direction along the surface of the water.
[0032] To facilitate the shifting of undesired particles, such contaminants, to the surface of the water in the container, air can be supplied as a stimulus through the air supply passageways. Since the scraper is only effective directly on its front side, another preferred embodiment of the device according to the invention is characterized in that the control system is suitable for opening one or more air valves located in the displacement direction on the front side of the scraper viewed from above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] The invention will be explained in greater detail based on the description of a preferred embodiment of a steeping device according to the invention drawing reference to the following figures:
[0034] FIG. 1 shows a perspective view of a steeping cistern (partially transparent view);
[0035] FIG. 2 shows a detailed perspective view of part of the steeping cistern according to FIG. 1 ;
[0036] FIG. 3 shows a detailed portion of FIG. 2 ;
[0037] FIG. 4 shows a top view of a possible distribution pattern of passageways on the floor of the steeping cistern according to FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0038] FIG. 1 shows a steeping cistern 1 for steeping barley for the malting process, e.g., for brewing beer. For example, the steeping cistern 1 can be arranged at the top on a malting tower, which is advantageous from a logistical standpoint, since the steeped barley is subjected to ensuing steps in the malting process after steeping.
[0039] The steeping cistern 1 encompasses a container in the form of a cylindrical container 2 with a perpendicular wall 3 and a flat floor 4 abutting the lower side of this perpendicular wall 3 with a diameter of 24 meters. The container 2 is meant to be filled through its open upper side with barley 5 to be steeped, and also to be filled with water during the wet steeping phase.
[0040] Located in the middle of the container 2 is a cylindrical support 27 with a central, perpendicular rotational axis 28 for a bridge 29 , which extends between the support 27 and the perpendicular wall 3 of the container 2 . Connected to the underside of the bridge 29 is a curved scraper body 30 provided with a scraping wall 31 located at the level of the water surface in the container 2 during the wet steeping phase. Situated in the trough of the scraper body 30 is a capstan 32 for removing material, moved by the scraper body 30 from the surface of the water in container 2 in the direction of the support 27 . To this end, the support 27 is provided with passageways (not shown in greater detail) for removing the material through the inside of the support 27 .
[0041] The floor 4 of the container 2 is provided with a number of passageways 6 for passing through agents like water, air/oxygen and carbon dioxide, which play a role in the steeping process. The passageways 6 are arranged in radial rows 7 ( FIG. 4 ), which vary in length. In particular, the long rows 7 a extend over nearly the entire radius of the floor 4 , and the short rows 7 b extend only on the outer half of the radius of the floor 4 . The passageways 6 are situated among each other in every radial row 7 spaced roughly the same distance apart. The angle formed by the adjacent rows 7 with each other measures about 6 to 7 degrees. The optimal angle depends on the diameter of the floor. This yields a regular pattern of passageways 6 , wherein the distribution of passageways 6 over the surface of the floor 4 is uniform. The density of the passageways 6 averages about 1 passageway per m 2 of floor area (see, e.g., FIG. 4 ).
[0042] The diameter of each passageway 6 measures about 10 cm. In order to prevent barley grains from passing through the passageways 6 , the latter are provided with sieve material 8 , as shown in FIG. 3 . As illustrated in FIGS. 2 and 3 , the passageways 6 are formed from the upper side of a conical accumulator 9 on the inclined lateral wall, from which one air branch line 10 is connected, and to which a combined branch-on line 11 is connected centrally in the middle on the bottom side. On the side opposite the accumulator 9 , the air branch line 10 connects to a shared air line 12 , to which the air branch lines 10 belonging to other passageways 6 in the same series 7 and an adjacent row 7 are connected. The combined branch lines belonging to the passageways 6 of the same radial rows 7 connect to a shared combined line on their side lying opposite the accumulator 9 . In the top view, the various shared air lines 12 and the various shared combined lines 13 are located between two adjacent radial rows 7 . Just as the rows 7 , the shared air lines 12 and the shared combined lines 13 therefore also extend in a radial direction, wherein the shared air lines 12 are located over the accompanying shared combined lines 13 . The diameter of the shared combined lines 13 tapers off toward the middle, so that enough pressure can also be exerted near the middle of the floor when water is supplied to the passageways 6 via the shared combined lines 13 .
[0043] On the outside of the container 2 , the shared air lines 12 connected to an annular air main line element 14 , which is hooked up to a compressor 34 to increase the pressure inside the air line system, which consists of the air main line element 14 , the shared lines 12 and the air branch lines 10 . The air pressure inside the air line system can hence be increased to a pressure exceeding the static pressure owing to the water column (e.g., 0.5 bar or more) in order to supply air to the barley 5 through passageways 6 . The air valves 23 between the shared air lines 12 and the air main line element 14 must be open for supplying air.
[0044] The outside of the shared combined lines 13 connect with a water main line element 15 or a CO 2 main line element 16 . As with the air main line element 14 , the water main line element 15 is annular, and extends all around the periphery of the container 2 on its bottom side. In the water line system comprised of the water line main line element 15 , the shared combined line 13 and the combined branch line 11 , water can be supplied via the supply line 17 by opening the water valve 19 and connecting the water valve 20 to the barley 5 via passageways 6 , while water can also be discharged via the same water line system from the container 2 through passageways after closing the water valve 19 and opening the water valve 20 via discharge line 18 . The water valves 21 between the shared combined lines 13 and the water main line element 15 must here be opened, while the CO 2 valves 22 between the shared combined lines 13 and the CO 2 main line elements 16 must be closed. The water main line element 15 is connected to a reservoir 25 via cleaning liquid valves 26 . The reservoir 25 contains cleaning liquid, e.g., lye, which can be supplied to the water in the water main line element 15 with the cleaning liquid valve 26 open.
[0045] A total of four CO 2 main line elements 16 are provided, wherein each traverses a quarter circle around the periphery of the container 2 . The CO 2 main line elements 16 have an increasing diameter, wherein a vacuum pump 24 is provided on the side of the largest diameter (see FIG. 1 ). The action of the fans 24 makes it possible to remove CO 2 from the barley via the carbon dioxide line system consisting of the four carbon dioxide main line elements 16 , the shared combined lines 13 and the combined branch lines 11 .
[0046] The arrangement of passageways 6 in the sieve material 8 of the floor 4 is preferably optimized via flow simulation.
[0047] The passageways 6 are arranged in rows 7 (and 7 a, 7 b ) in the exemplary embodiment, wherein these rows are simultaneously designed as a support for the floor 4 , and discharge the floor load.
[0048] The passageways 6 could also be arranged between the rows 7 , however.
[0049] The CO 2 main line element 16 can be arranged as shown on FIG. 1 , or closer to the floor 4 or at the upper edge of the container 2 .
[0050] In addition to evacuating CO 2 from the barley 5 via the passageways 6 or accumulators 9 , compressed air can also be introduced into the barley 5 via the air branch line 10 . To this end, each line connection is provided with a check valve between the air branch line 10 and accumulator 9 (not explicitly shown) to prevent water from penetrating. This improves sanitation.
[0051] Air branch lines 10 and branch-in lines 11 are preferably flexible or elastic in design.
[0052] The accumulators 9 constitute part of the floor 5 , and preferably lased like the holes in the sieve jacket.
[0053] The combined lines 13 form an inlet and outlet, while the main line is only used as an inlet for the air branch lines 10 .
[0054] The floor 4 and sieve material 8 in the example are designed in such a way that gridirons are arranged between the rows 7 , 7 a, 7 b, and the floor abuts the rows 7 , 7 a, 7 b as a perforated plate with the sieve openings.
[0055] The steeping cistern 1 functions as follows: Starting from an unfilled state of the container 2 , the barley 5 is introduced into the container 2 . Water is then supplied via the water line system to the barley 5 through the passageways 6 , so that the barley 5 is completely immersed in the water. This state of the wet steeping phase is retained for several hours, for example two or three hours. Because the passageways 6 are arranged in radial rows 7 and separate air valves 23 that can be individually opened and closed by a control system (not shown in any greater detail) are used per row, it is possible during the wet steeping phase to selectively provide rows 7 with air during the rotation of the scraper body 30 in a rotational direction 33 directly preceding the scraper body 30 with viewed from above, so that dirt there floats up locally to more of an extent, and can be removed via the scraping wall 31 through the capstan 32 .
[0056] After the steeping phase, the water is again allowed to drain from the container 2 via passageways 6 by opening the water valve 20 . The barley 5 then allowed to dry to more or less of an extent during the so-called dry steeping phase. During this dry steeping phase, which lasts five hours, for example, the barley grains swell and respire faster, to which end the barley grains absorb oxygen, and the barley grains release CO 2 . In order to keep this process going, oxygen is supplied to the barley as part of the air via the oxygen line system, while the CO 2 is evacuated from the barley through fans 24 with the CO 2 valves 22 open and water valves 21 closed. The combined branch lines 11 and shared, combined lines 13 are here both used for supplying and discharging water, and for evacuating CO 2 . The wet steeping phase and dry steeping phase described above can alternate a few times until steeping has reached a sufficient level, and the steeped barley is suitable for the malting process.
[0057] For cleaning the steeping cistern 1 , and above all for cleaning the water line system, this water line system can be rinsed thoroughly with water provided with cleaning liquid from the reservoir 25 . The type of line system here enables the realization of relatively high flow rates for the cleaning liquid, so that cleaning can take place effectively, while the necessary quantity of cleaning liquid remains limited due to the restricted quantity relative to the water line system. The expert will know that the passageways 6 and primarily their sieve materials 8 and the floor 4 can be exposed to the action of the cleaning liquid in this way, wherein only a thin layer of cleaning liquid has to be applied to the floor 4 to this end. The cleaning efficiency can be further increased significantly by aerating the cleaning liquid, which imparts motion to the cleaning liquid.
REFERENCE LIST
[0000]
1 Steeping cistern
2 Container
3 Wall
4 Floor
5 Barley
6 Passageway
7 Row
7 a Long row
7 b Short row
8 Sieve material
9 Accumulator
10 Air branch line
11 Branch-in line
12 Air line
13 Combined line
14 Air main line element
15 Water main line element
16 CO2 main line element
17 Supply line
18 Discharge line
19 Water valve
20 Water valve
21 Water valve
22 CO2 valve
23 Air valve
24 Vacuum valve
25 Reservoir
26 Cleaning liquid valve
27 Support
28 Rotational axis
29 Bridge
30 Scraper body
31 Scraping wall
32 Capstan
33 Rotational direction
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A device for steeping barley having a container for containing the barley to be steeped. The container has a floor and the floor has passageways for flowing at least one of steeping water and gases through the passageways. The device further includes a water line system under the floor directly connected to the passageways.
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BACKGROUND OF THE INVENTION
The present invention relates to surface covering tiles having integral connecting elements. The tiles are particularly useful to construct portable floor or ground coverings.
Persons who must support themselves on the ground, whether for rest or work, often wish to have a clean, dry, personal surface on which to do so. Further those who must stand for long periods of time on hard surfaces such as concrete flooring, whether interior or exterior, desire a relatively more resilient surface on which to support themselves to lessen the strain. Still further, campers often wish to provide a ground cover adjacent the doors of RV's or trailers or as a floor of a gazebo.
Previous surface covering tiles have allowed only limited portability as they are either too bulky or require too much effort to assemble and disassemble.
By way of example of prior art devices is Canadian patent No. 1,067,738 granted Dec. 11, 1979 to SOLAND relating to a ground covering of interconnections adjacently disposed plates. The plates are tensioned by cables and spaced apart by spacers of a specific construction to help lock adjacent plates from relative movement.
Canadian patent No. 1,145,784 granted May 3, 1983 to BERGQVIST relates to a surface covering and provides a surface covering for game courts and the like comprising a number of mutually detachable joined plates of a moldable resilient plastic. The plates are joined by telescoping peg elements.
Canadian patent No. 2,035,976 granted Mar. 22, 1994 to GElSEN ET AL relates to plates of plastic material for covering terraces and provides a tenon and groove--dovetail top--of connection between adjacent plates.
Canadian laid open application No. 2,077,335 of MacLEOD laid open on Sep. 3, 1991 relates to a cover for an area of ground for a stadium or the like having a plurality of units with vertical orientated male/female connectors and with spikes to support the unit above a grass surface aperture and the construction of the spikes permit for air circulation under the surface of the plates or units. The spikes provide a dangerous aspect to the handling of these units without skilled personnel.
The present invention seeks to provide a surface covering tiles which are easily connected, as portable, resilient and durable and which are easily stored without sharp spikes or the like which could cause injury in handling.
SUMMARY OF THE INVENTION
The foregoing aspects are achieved by a surface covering tile having a first and second surface in spaced relation with edges about its periphery. The edges have integral connecting elements which hingedly connect to adjacent surface covering tiles. The surface covering tile may be adapted to support a finishing surface.
The invention in one aspect provides a molded plastic tile having means for detachable securement to a like adjacent tile for covering a selected surface area. The tile comprises a top surface, an undersurface and a plurality of sides, at least one of the sides of the tile having at least one longitudinally bar-like bead adjacent a bottom edge thereof with the bead extending outwardly of the one side. At least another side of the tile has a plurality of recess means spaced longitudinally along a bottom edge thereof, the recess means extending outwardly and upwardly and adapted to receive a bar-like bead of another like confronting tile. The another side includes tongue means interspersed with the recess means and cooperating with the bar-like bead and recess means for detachably locking a bar-like bead of an adjacent tile in the recess means of the tile.
More particularly there is provided a molded plastic tile adapted to be detachably secured to other like plastic tiles to cover a selected surface area, the tile comprising a plate portion having an upper surface, an underside and peripheral sides extending downwardly generally perpendicular to the upper surface. At least one side of the tile has at least one longitudinal extending locking bead adjacent a bottom edge thereof. At least one second side of the tile has at least one female locking means, the female locking means including a longitudinally extending curved recess portion adjacent a bottom edge of the second side and at least one flexile locking tongue whereby two like tiles may be detachably secured together by the male bead of one tile being received in the female recess of the other tile, with the flexible tongue cooperating with the bead to detachably maintain the tiles in an interlocked position.
The upper surface of the tile may be defined by a peripheral rim and further includes a finishing surface element such as an air permeable carpet secured to the upper surface and within the rim.
Preferably there are two longitudinally spaced cylindrical locking beads adjacent the bottom edge of the one side and there are two sets of longitudinally spaced female locking means, spaced such that each locking bead is associated with a set of female locking means.
Each set of female locking means preferably includes a plurality of spaced female locking elements, each female locking element comprising a J-shaped element with an inner curvature compatible with the curvature of the bead. A flexible locking tongue is interspersed with adjacent lock elements.
The underside of the plate portion of the tile has an array of diagonally oriented walls defining substantially square triangular sections adjacent the sides of the tile and substantially rectangular portions inwardly thereof.
At least some of the bottom edges of the walls have upwardly directed recesses spaced from the adjacent posts whereby circulation of air is permitted between sections.
Preferably the plate portion has an array of small through apertures therein within at least some of the sections to permit air to circulate from above the tile to the underside.
The arrays of apertures preferably comprise a plurality of rows of apertures, adjacent apertures within a row being interspersed by a portion of the underside of reduced thickness.
Other features and aspects of the invention will become apparent from the detailed description of a preferred embodiment of the invention to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a tile, (with covering), from one corner showing male and female connectors and showing like tiles in phantom lines.
FIG. 2 is a top plan view of a tile without a cover.
FIG. 3 is a front (side) view of the tile shown in FIG. 2.
FIG. 4 is a sectional view along line 4--4 of FIG. 3 of a bead (male) member of the interconnecting elements.
FIG. 5 is a sectional view along lines 5--5 on FIG. 3 of a recess (female) member of the interconnection elements.
FIG. 6 is a sectional view along line 6--6 of FIG. 3 showing a tongue member of the intermediate elements.
FIG. 7 is a perspective view of portions of the connecting means of connected tiles, the tile with the male bead being shown partly in phantom.
FIG. 8 is a sectional view along lines 9--9 of FIG. 7.
FIG. 9 is a sectional view along the lines of FIG. 8 showing the connection of adjacent tiles.
FIG. 10 is a sectional view showing one method of separating adjacent tiles.
FIG. 11 is a sectional view showing another method of separating adjacent tiles.
FIG. 12 is a bottom plan view of a part of the tiles showing a section defined by interior support walls.
FIG. 13 is a sectional view along lines 13--13 of FIG. 12.
FIG. 14 is a sectional view along lines 14--14 of FIG. 2 showing a post and molding indentation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1, 2 and 3, there is shown a single tile 10 in perspective view with an air permeable covering 12 such as outdoor carpeting on the top or upper surface, which covering is of the indoor-outdoor carpet type. Adjacent tiles of the same construction are shown in phantom lines in order to make a platform of selected size. FIGS. 2 and 3 illustrate tile 10 in top view and side view without covering 12.
Tile 10 has an upper peripheral lip 14 to contain air permeable covering 12 and the height of the lip is comparable to the height of the covering. Under covering 12, tile 10 has upper surface 16.
Sides 20, 22 are mirror images of each other and sides 24, 26 are mirror images of each other so that only sides 20 and 24 will be further detailed.
Tile side 20, (as well as side 22), has a lower edge 30 with two longitudinal portions 32, 34 of the lower edge having a cylindrical, bar-like bead or male member 36 as more fully shown in section in FIG. 4. Bead 36 has a bottom 38 spaced a predetermined distance from lower edge 30.
Although two portions 32, 34 are shown, a variation of the invention would have a single longitudinal bar as shown in FIG. 2 with dotted line 40.
Tile side 24, (as well as side 26), has a lower edge 50, which is coplanar with lower edge 30 of side 20 and has two sections 52, 54 each with a plurality, (four are shown), of like outwardly, upwardly curving recesses defined by female elements 56. Elements 56 are flexible and are longitudinally spaced along side 24.
Intermediate the J-shaped elements 56, as shown in FIG. 3 and FIGS. 5-11, are flexible tongues 60 defined by slots 62 on either side thereof extending downwardly from an upper portion 64 of side 24, which construction permits tongues 60 to flex inwardly and outwardly slightly and return to a normal position, as shown in sectional views in FIGS. 5 and 6. Upper portion 64 is effectively a flexible hinge for tongue 60.
The lower front surface 66 of tongue 60 has a radius of curvature compatible with that of J-shaped elements 56 and bead 36.
FIGS. 7 and 8 illustrate in perspective and sectional views respectively how two like tiles 10a and 10b are connected, both of the tiles being shown in FIG. 7, only in part and one, 10b, in phantom lines. In connecting adjacent tiles, the tiles are moved relative to each other in a push/pull manner.
FIG. 9 illustrates the connection between two adjacent tiles in cross-section similar to FIG. 8. Tile 10a and tile 10b are moved relative to each other whereby bead 36 is pushed downwardly to flex tongue 60 inwardly, (as shown in dotted lines). Once bead 36 is within J-shaped element 56, tongue 60 flexes back to its natural or normal position as shown in FIG. 8. It will be apparent that to assemble two adjacent tiles, one tile 10a may be manually tilted slightly so that one end of bead 36 is forced into engagement with an adjacent J-shaped element 56 and this is repeated progressively along the length of the side of tile 106. The assembly or connection can also be achieved by placing tiles 10a and 10b on the ground, for example and aligning bead 36 above J-elements 56 and then standing on tile 10a to snap the beads 30 into the adjacent J-elements 56.
In separating the tiles, FIGS. 10 and 11 illustrate two methods, both simply being the angling of tiles 10a and 10b relative to each other. As shown in FIG. 10, tile 10a and 10b are twisted so that initially tongue 60 engages side 20 of tile 10a at 68 and then the peripheral rim 14 of both tiles touch at 70, (shown in dotted lines), whereupon further relative pivotal movement causes the two connectors to pivot relative to each other about pivot 70, bead 30 slipping out of the connector formed by tongue 60 and J-element 56 due to the flexibility of these elements. FIG. 11 illustrates twisting the two tiles 10a and 10b such that the end 74 of J-element 56 contacts the inner surface of side 20 at 76, again defining a pivot point about which further twisting or pivoting causes separation of bead 36 from the connector defined by tongue 60 and J-element 56.
FIGS. 12 and 14 illustrate in further detail, the molded construction of tile 10 to provide a lightweight, yet sturdy, tile which may be integrally molded without difficulty.
As previously noted, tile 10 has a peripheral lip 14 of a height to accommodate carpet-like material 12. The underside of tile 10 has a plurality of intersecting diagonal walls 80, 82, the juncture of which include cylindrical post elements 86. The bottom 88 of posts 86 are coplanar with the bottom edges 30 of side walls 20, 22, 24 and 26. Walls 80, 82 define an array of triangular border sections 90 with square interior sections 92, (FIG. 2). Within each section 90, 92, as seen in FIG. 3, is an array of square apertures 94 further shown in an enlarged view of a section 90 in FIG. 12 and in sectional view in FIG. 13. Also shown in FIGS. 12 and 13, (but not shown in FIG. 2), are reduced thickness portions 96 extending between adjacent apertures 94 in a selected longitudinal direction or row. Further, it will be noted that walls 80, as do walls 82, have a recess 98 therein formed by wall portions 100, 102, 104. The apertures 94, reduced thickness portions 96 and recesses 98 reduce material requirements but do not significantly affect the strength of tile 10. Moreover, the recesses 98 cause less "footprint markings" to be left on the surface on which the tile is used (such as grass). Further still, recesses 98 and apertures 94 permit the flow of air and moisture between sections and with that of the environment above the tile with an air permeable surface cover 12.
FIG. 14 illustrates post 86 with a slight depression 110 in the upper surface 16 (and attendant raised portion 112 on the underside) which are for reasons to facilitate molding the tile with reduced flashing, as is well known in the art.
With the type of connection provided by applicant's device, limited pivotal movement of the tiles relative to each other is provided and therefore the tiles will follow the contour of the underlying ground more effectively. As seen in FIGS. 10 and 11, two adjacent tiles will pivot upwardly about 25°, (FIG. 10) and downwardly about 40°, (FIG. 11).
In a prototype, applicant's square tiles 10 are about 193/16" square, with side edges 20, 22 about 5/8" in height. The female receiving elements 56 are about 3/4" wide with the locking tongues 60 about 3/8" wide. The beads 32 are about 45/8" long. The center to center distance between posts 86 is about 29/64" and apertures 94 are about 7/32" square.
Accordingly I have provided an easily molded tile for selective interconnection with like adjacent tiles to form a platform or the like which can be used outside an RV for deck chairs or the like, or adjacent dock areas levelled ground.
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A surface covering tile is disclosed having integral connecting elements about its edges to enable hinged interconnection between adjacent-like tiles. The connecting elements are longitudinally arranged about the peripheral edges of the tile and comprise semi-cylindrical curved female elements, protruding tongue elements and semi-cylindrical bar-like male elements. The elements are arranged such that the female and tongue elements cooperate to engage with the male elements of adjacent tiles. The tile is further adapted to receive a surface covering such as a carpet or mat, preferably an air permeable covering which will permit air to pass through apertures in the surface of the tile to the ground below.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/651,840, filed Aug. 29, 2003, which application claims priority under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application No. 60/406,841 filed Aug. 29, 2002; U.S. Provisional Patent Application No. 60/444,005, filed Jan. 31, 2003; U.S. Provisional Patent Application No. 60/447,383, filed Feb. 14, 2003; and U.S. Provisional Patent Application No. 60/462,435, filed Apr. 12, 2003; all of which are incorporated herein by reference. This application also claims priority under 35 U.S.C. § 119(e) from U.S. Provisional Patent Application No. 60/801,861, filed on May 19, 2006, which is also incorporated herein by reference.
STATEMENT REGARDING SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
REFERENCE TO SEQUENCE LISTING
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates generally to implantable devices for controlling at least one of shape and size of an anatomic structure or lumen.
[0006] 2. Description of Related Art
[0007] There is often a need to reduce the internal circumference of an orifice or other open anatomic structure to narrow or increase the size of the orifice or opening to achieve a desired physiologic effect. Often, such surgical procedures require interruption in the normal physiologic flow of blood, other physiologic fluids, or other structural contents through the orifice or structure. The exact amount of the narrowing or widening required for the desired effect often cannot be fully appreciated until physiologic flow through the orifice or structure is resumed. It would be advantageous, therefore, to have an adjustable means of achieving the narrowing or widening effect, such that the degree of narrowing or widening could be changed after its implantation, and after the resumption of normal flow in situ.
[0008] One example of a dysfunction within an anatomic lumen is in the area of cardiac surgery, and specifically valvular repair. Approximately one million open heart surgical procedures are now performed annually in the United States, and twenty percent of these operations are related to cardiac valves.
[0009] The field of cardiac surgery was previously transformed by the introduction of the pump oxygenator, which allowed open heart surgery to be performed. Valvular heart surgery was made possible by the further introduction of the mechanical ball-valve prosthesis, and many modifications and different forms of prosthetic heart valves have since been developed. However, the ideal prosthetic valve has yet to be designed, which attests to the elegant form and function of the native heart valve.
[0010] As a result of the difficulties in engineering a perfect prosthetic heart valve, there has been growing interest in repairing a patient's native valve. These efforts have documented equal long-term durability to the use of mechanical prostheses, with added benefits of better ventricular performance due to preservation of the subvalvular mechanisms and obviation of the need for chronic anticoagulation. Mitral valve repair has become one of the most rapidly growing areas in adult cardiac surgery today.
[0011] Mitral valve disease can be subdivided into intrinsic valve disturbances and pathology extrinsic to the mitral valve ultimately affecting valvular function. Although these subdivisions exist, many of the repair techniques and overall operative approaches are similar in the various pathologies that exist.
[0012] Historically, most valvular pathology was secondary to rheumatic heart disease, a result of a streptococcal infection, most commonly affecting the mitral valve, followed by the aortic valve, and least often the pulmonic valve. The results of the infectious process are mitral stenosis and aortic stenosis, followed by mitral insufficiency and aortic insufficiency. With the advent of better antibiotic therapies, the incidence of rheumatic heart disease is on the decline, and accounts for a smaller percentage of valvular heart conditions in the developed world of the present day. Commissurotomy of rheumatic mitral stenosis was an early example of commonly practiced mitral valve repair outside of the realm of congenital heart defects. However, the repairs of rheumatic insufficient valves have not met with good results due to the underlying valve pathology and the progression of disease.
[0013] Most mitral valve disease other than rheumatic results in valvular insufficiency that is generally amenable to repair. Chordae rupture is a common cause of mitral insufficiency, resulting in a focal area of regurgitation. Classically, one of the first successful and accepted surgical repairs was for ruptured chordae of the posterior mitral leaflet. The technical feasibility of this repair, its reproducible good results, and its long-term durability led the pioneer surgeons in the field of mitral valve repair to attempt repairs of other valve pathologies.
[0014] Mitral valve prolapse is a fairly common condition that leads over time to valvular insufficiency. In this disease, the plane of coaptation of the anterior and posterior leaflets is “atrialized” relative to a normal valve. This problem may readily be repaired by restoring the plane of coaptation into the ventricle.
[0015] The papillary muscles within the left ventricle support the mitral valve and aid in its function. Papillary muscle dysfunction, whether due to infarction or ischemia from coronary artery disease, often leads to mitral insufficiency (commonly referred to as ischemic mitral insufficiency). Within the scope of mitral valve disease, this is the most rapidly growing area for valve repair. Historically, only patients with severe mitral insufficiency were repaired or replaced, but there is increasing support in the surgical literature to support valve repair in patients with moderate insufficiency that is attributable to ischemic mitral insufficiency. Early aggressive valve repair in this patient population has been shown to increase survival and improve long-term ventricular function.
[0016] In addition, in patients with dilated cardiomyopathy the etiology of mitral insufficiency is the lack of coaptation of the valve leaflets from a dilated ventricle. The resultant regurgitation is due to the lack of coaptation of the leaflets. There is a growing trend to repair these valves, thereby repairing the insufficiency and restoring ventricular geometry, thus improving overall ventricular function.
[0017] Two essential features of mitral valve repair are to fix primary valvular pathology (if present) and to support the annulus or reduce the annular dimension using a prosthesis that is commonly in the form of a ring or band. The problem encountered in mitral valve repair is the surgeon's inability to fully assess the effectiveness of the repair until the heart has been fully closed, and the patient is weaned off cardiopulmonary bypass. Once this has been achieved, valvular function can be assessed in the operating room using transesophageal echocardiography (TEE). If significant residual valvular insufficiency is then documented, the surgeon must re-arrest the heart, re-open the heart, and then re-repair or replace the valve. This increases overall operative, anesthesia, and bypass times, and therefore increases the overall operative risks.
[0018] If the prosthesis used to reduce the annulus is larger than the ideal size, mitral insufficiency may persist. If the prosthesis is too small, mitral stenosis may result.
[0019] The need exists, therefore, for an adjustable prosthesis that would allow a surgeon to adjust the annular dimension in situ in a beating heart under TEE guidance or other diagnostic modalities to achieve optimal valvular sufficiency and function.
[0020] Cardiac surgery is but one example of a setting in which adjustment of the annular dimension of an anatomic orifice in situ would be desirable. Another example is in the field of gastrointestinal surgery, where the Nissen fundoplication procedure has long been used to narrow the gastro-esophageal junction for relief of gastric reflux into the esophagus. In this setting, a surgeon is conventionally faced with the tension between creating sufficient narrowing to achieve reflux control, but avoiding excessive narrowing that may interfere with the passage of nutrient contents from the esophagus into the stomach. Again, it would be desirable to have a method and apparatus by which the extent to which the gastro-esophageal junction is narrowed could be adjusted in situ to achieve optimal balance between these two competing interests.
[0021] Aside from the problem of adjusting the internal circumference of body passages in situ, there is often a need in medicine and surgery to place a prosthetic implant at a desired recipient anatomic site. For example, existing methods proposed for percutaneous mitral repair include approaches through either the coronary sinus or percutaneous attempts to affix the anterior mitral leaflet to the posterior mitral leaflet. Significant clinical and logistical problems attend both of these existing technologies. In the case of the coronary sinus procedures, percutaneous access to the coronary sinus is technically difficult and time consuming to achieve, with procedures which may require several hours to properly access the coronary sinus. Moreover, these procedures employ incomplete annular rings, which compromise their physiologic effect. Such procedures are typically not effective for improving mitral regurgitation by more than one clinical grade. Finally, coronary sinus procedures carry the potentially disastrous risks of either fatal tears or catastrophic thrombosis of the coronary sinus.
[0022] Similarly, percutaneous procedures which employ sutures, clips, or other devices to affix the anterior mitral leaflets to the posterior mitral leaflets also have limited reparative capabilities. Such procedures are also typically ineffective in providing a complete repair of mitral regurgitation. Furthermore, surgical experience indicates that such methods are not durable, with likely separation of the affixed valve leaflets. These procedures also fail to address the pathophysiololgy of the dilated mitral annulus in ischemic heart disease. As a result of the residual anatomic pathology, no ventricular remodeling or improved ventricular function is likely with these procedures.
[0023] The need exists, therefore, for a delivery system and methods for its use that would avoid the need for open surgery in such exemplary circumstances, and allow delivery, placement, and adjustment of a prosthetic implant to reduce the diameter of such a mitral annulus in a percutaneous or other minimally invasive procedure, while still achieving clinical and physiologic results that are at least the equivalent of the yields of the best open surgical procedures for these same problems.
[0024] The preceding cardiac applications are only examples of some applications according to the present invention. Another exemplary application anticipated by the present invention is in the field of gastrointestinal surgery, where the aforementioned Nissen fundoplication procedure has long been used to narrow the gastro-esophageal junction for relief of gastric reflux into the esophagus. In this setting, a surgeon is conventionally faced with the tension between creating sufficient narrowing to achieve reflux control, but avoiding excessive narrowing that may interfere with the passage of nutrient contents from the esophagus into the stomach. Additionally, “gas bloat” may cause the inability to belch, a common complication of over-narrowing of the GE junction. An adjustable prosthetic implant according to the present invention could allow in situ adjustment in such a setting under physiologic assessment after primary surgical closure.
[0025] Such an adjustable prosthetic implant according to the present invention could be placed endoscopically, percutaneously, or with an endoscope placed within a body cavity or organ, or by trans-abdominal or trans-thoracic approaches. In addition, such an adjustable prosthetic implant according to the present invention could be coupled with an adjustment means capable of being placed in the subcutaneous or other anatomic tissues within the body, such that remote adjustments could be made to the implant during physiologic function of the implant. This adjustment means can also be contained within the implant and adjusted remotely, i.e. remote control adjustment. Such an adjustment means might be capable of removal from the body, or might be retained within the body indefinitely for later adjustment.
[0026] The present invention and the methods for its use anticipate many alternate embodiments in other potential applications in the broad fields of medicine and surgery. Among the other potential applications anticipated according to the present invention are adjustable implants for use in the treatment of morbid obesity, urinary incontinence, anastomotic strictures, arterial stenosis, urinary incontinence, cervical incompetence, ductal strictures, and anal incontinence. The preceding discussions are intended to be exemplary embodiments according to the present invention and should not be construed to limit the present invention and the methods for its use in any way.
SUMMARY OF THE INVENTION
[0027] An object of the present invention is to provide an implantable device for controlling at least one of shape and size of an anatomical structure or lumen.
[0028] These and other objects of the present invention are achieved in an implantable device for controlling at least on of shape and size of an anatomical structure or lumen. An implantable device is provided that has an adjustable member configured to adjust the dimensions of the implantable device. In certain embodiments, a torqueable adjustment tool is configured to provide adjustment of the dimensions of the implantable device for a preferred dimension. In other embodiments adjustments for a preferred dimension may be accomplished remotely through activation of internal adjustment mechanisms.
[0029] In another embodiment of the present invention, an implantable device is provided for controlling at least one of shape and size of an anatomical structure or lumen that includes an implantable device has an adjustable member configured to adjust the dimensions of the implantable device, a particularly a preferred dimension. An adjustment tool is configured to provide adjustment of the dimensions of the implantable device, the adjustment tool providing translated motion through rotation.
[0030] In another embodiment of the present invention, an implantable device is provided for controlling at least one of shape and size of an anatomical structure or lumen. An implantable device has an adjustable member configured to adjust the dimensions of the implantable device and includes first and second bands. An adjustment tool is configured to provide adjustment of the dimensions of the implantable device for a preferred dimension.
[0031] In still another embodiment of the present invention, an implantable device is provided for controlling at least one of shape and size of an anatomical structure or lumen. An implantable device has an adjustable member configured to adjust the dimensions of the implantable device. The implantable device has an anterior portion, a posterior portion and dual threads that provide preferential adjustment of one side or the other of the implantable device. An adjustment tool is configured to provide adjustment of the dimensions of the implantable device.
[0032] In yet another embodiment of the present invention, an implantable device controls at least one of shape and size of an anatomical structure or lumen. An implantable device has an adjustable member configured to adjust the dimensions of the implantable device. An adjustment tool is configured to provide adjustment of the dimensions of the implantable device. The adjustment tool provides reciprocating action to provide for the adjustment.
[0033] In another embodiment of the present invention, an implantable device controls at least one of shape and size of an anatomical structure or lumen. An implantable device has an adjustable member configured to adjust the dimensions of the implantable device. An adjustment tool is configured to provide adjustment of the dimensions of the implantable device. The adjustment tool provides both course adjustment and fine adjustment.
[0034] Other features and advantages of the present invention will become apparent upon reading the following specification, when taken in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF FIGURES
[0035] FIG. 1 is a front view of a first embodiment of an implant for reducing the circumference of an anatomic orifice.
[0036] FIG. 2 is a front view of the implant of FIG. 1 secured to the annulus of a mitral valve, with the implant in an expanded position.
[0037] FIG. 3 is a front view of the implant of FIG. 1 secured to the annulus of a mitral valve, with the implant in a contracted position to reduced the size of the heart valve opening.
[0038] FIG. 4 is a perspective view of a second embodiment of an implant for reducing the circumference of an anatomic orifice, inserted through an open operative cardiac incision and secured around the mitral valve.
[0039] FIG. 5 is a perspective view of the implant of FIG. 4 , showing the cardiac incision closed, an adjustment tool extending through the closed incision, and adjustment of the implant possible after the patient has been taken “off pump.”
[0040] FIG. 6 is a perspective view of a first embodiment of an adjustment means for adjusting the circumference of an implant for reducing the circumference of an anatomic orifice.
[0041] FIG. 7 is a right side view of the adjustment means of FIG. 6 .
[0042] FIG. 8 is a left side view of the adjustment means of FIG. 6 .
[0043] FIG. 9 is a right side view of a second embodiment of an adjustment means for adjusting the circumference of an implant for reducing the circumference of an anatomic orifice.
[0044] FIG. 10 is a perspective view of a first alternate embodiment of an attachment means for the implant of FIG. 1 .
[0045] FIG. 11 is a perspective view of a second alternate embodiment of an attachment means for the implant of FIG. 1 .
[0046] FIG. 12 is a perspective view of a third embodiment of an implant for reducing the circumference of an anatomic orifice.
[0047] FIG. 13 is a perspective view of one end of the implant of FIG. 12 showing an optional keyed relationship between three coaxial cannulae to prevent relative rotation between the three components.
[0048] FIG. 14 is a perspective view of the implant of FIG. 12 showing the outer cannula extended to cover the implant.
[0049] FIG. 15 is a perspective view of the implant of FIG. 12 showing the outer cannula retracted to expose the implant.
[0050] FIG. 16 is a perspective view of the implant of FIG. 12 showing the middle cannula extended to unfold the implant.
[0051] FIGS. 17 and 18 are schematic views illustrating how extension of the middle cannula causes the implant to unfold, where FIG. 17 shows the implant in the folded position, and FIG. 18 shows the implant in the unfolded position.
[0052] FIG. 19 is a perspective view of the lower end of a touchdown sensor of the implant of FIG. 12 , showing the sensor in an uncompressed condition.
[0053] FIG. 20 is a perspective view of the lower end of the touchdown sensor of FIG. 19 , showing the sensor in a compressed condition.
[0054] FIG. 21 is a perspective end view of a fourth embodiment of an implant for reducing the circumference of an anatomic orifice.
[0055] FIG. 22 is a side view of the implant of FIG. 21 with the implant opened up to show its full length.
[0056] FIG. 23 is a side view of the adjustment mechanism of the implant of FIG. 21 .
[0057] FIG. 24 is a close-up view of two of the retention barbs of the implant of FIG. 21 .
[0058] FIG. 25 is a front view of a fifth embodiment of an implant for reducing the circumference of an anatomic orifice, with the implant shown in its expanded configuration.
[0059] FIG. 26 is a front view of the implant of FIG. 25 , with the implant shown in its contracted configuration.
[0060] FIG. 27 is an enlarged view of the area indicated by the circle 27 in FIG. 25 , with the outer body removed to show interior detail.
[0061] FIG. 28 is a schematic view showing the implant of FIG. 12 anatomically positioned at the mitral annulus in a heart with the implant in a fully expanded state.
[0062] FIG. 29 is a schematic view showing the implant of FIG. 12 anatomically positioned at the gastroesophageal opening with the implant in a fully expanded state.
[0063] FIG. 30 is a schematic view showing the implant of FIG. 29 implanted to reduce the circumference of the gastroesophageal opening.
[0064] FIG. 31 is a schematic view of an embodiment of an implantable device of the present invention.
[0065] FIG. 32A is a schematic view of another embodiment of an implantable device of the present invention.
[0066] FIG. 32B is a schematic view of a threaded member in an embodiment of an implantable device of the present invention.
[0067] FIG. 33 is a schematic view of an embodiment of an implantable device of the present invention with an outer tubing and an inner tubing in a relative first position.
[0068] FIG. 34 is a schematic view of an embodiment of an implantable device of the present invention with an outer tubing and an inner tubing in a relative second position.
[0069] FIG. 35 is a schematic view of an embodiment of an implantable device of the present invention with an outer tubing and an inner tubing in a relative third position.
[0070] FIG. 36 is a schematic view of an embodiment of an adjustable member of the present invention, with the distal tip of the adjustment tool coupled to the adjustment member.
[0071] FIG. 37 is a schematic view of an embodiment of an adjustment member of the present invention having an integrated pinion gear.
[0072] FIG. 38 is a schematic view of an embodiment of a flexible tube cover for an implant device.
[0073] FIG. 39 is a cross-section view of an assembled embodiment of an adjustable implant device.
[0074] FIG. 40 is a schematic view of an embodiment of a seal jacket for an adjustable member.
[0075] FIG. 41 is a schematic view of an embodiment of an adjustment band in the implantable member of the present invention.
[0076] FIG. 42 is a disassembled schematic view of part of the adjustment band and adjustment member of FIG. 41 .
[0077] FIG. 43 is an assembled view of the adjustment band and adjustment member of FIG. 42 .
[0078] FIG. 44 is a schematic view of an embodiment of the gearbox for the adjustment band of FIG. 41 .
[0079] FIG. 45 is a schematic view of an embodiment of the implantable device of the present invention with a sliding band that can be opened and closed to effect a preferential shape change.
[0080] FIG. 46 is a schematic view of an embodiment of the implantable device of the present invention with two adjustable screws used to achieve different pulling rates.
[0081] FIG. 47 is a schematic view of an embodiment of the implantable device of the present invention with reciprocating motion and a clover gear.
[0082] FIG. 48 is a schematic view of an embodiment of the implantable device system of the present invention with an adjustment tool having high column strength and stiffness.
[0083] FIG. 49 is a schematic view of an embodiment of the implantable device of the present invention shown in vivo with an adjustment tool having reduced column stiffness.
[0084] FIG. 50 is a cut-away view of an embodiment of the proximal portion of an adjustment tool.
[0085] FIG. 51 is a schematic view of an embodiment of the implantable device of the present invention with an articulated shape.
DETAILED DESCRIPTION OF THE INVENTION
[0086] Referring now to the drawings, in which like numerals indicate like elements throughout the several views, an exemplary implant 10 comprising an implant body 15 is shown in FIG. 1 . The implant body may be provided in a shape and size determined by the anatomic needs of an intended native recipient anatomic site within a mammalian patient. Such a native recipient anatomic site may be, by way of illustration and not by way of limitation, a heart valve, the esophagus near the gastro-esophageal junction, the anus, or other anatomic sites within a mammalian body that are creating dysfunction that might be relieved by an implant capable of changing the size and shape of that site and maintaining a desired size and shape after surgery.
[0087] The implant 10 of FIG. 1 comprises a circular implant body 15 which is provided with adjustable corrugated sections 20 alternating with intervening grommet-like attachment means 25 having narrowed intermediate neck portions. As can be seen in FIGS. 2 and 3 , the implant body 15 may be secured to the annulus of a heart valve 30 by a fixation means such as a suture 35 secured over or through the attachment means 25 . The corrugated sections 20 fold and unfold as the circumference of the implant body 15 shortens or lengthens. Adjustment of the implant 10 in situ may decrease the overall size of the heart valve 30 , increasing the coaptation of the valve leaflets 40 , and changing the configuration from that shown in FIG. 2 to that shown in FIG. 3 .
[0088] An additional exemplary embodiment 100 of the present invention is shown in FIGS. 4 and 5 , with an open operative cardiac incision 105 in a heart 110 shown in FIG. 4 , and closure of the cardiac incision 105 in FIG. 5 . As shown in FIG. 4 , the exemplary adjustable implant 100 according to the present invention comprises an implant body 115 with attachment means 120 that allows fixation to the annulus of a mitral valve 125 . The exemplary adjustable implant 100 is further provided with an adjustment means 130 that is controlled by an attached or coupled adjustment tool 135 . After closure of the myocardial incision 105 in FIG. 5 , the adjustment tool 135 remains attached or coupled to the adjustment means 130 , so that the size and shape of the implant 100 may further be affected after physiologic flow through the heart 110 is resumed, but with the chest incision still open. Once the desired shape and function are achieved, the adjustment tool 135 may be disengaged from the adjustment means 130 and withdrawn from the myocardial incision 105 . In various embodiments according to the present invention, the adjustment means 130 may be configured and placed to allow retention by or re-introduction of the adjustment tool 135 for adjustment following closure of the chest incision.
[0089] To use the implant 100 of FIGS. 4 and 5 , the physician makes the open operative incision 105 in the heart 110 , as shown in FIG. 4 , in the conventional manner. The implant 100 , mounted at the forward end of adjustment tool 135 , is then advanced through the incision 105 and sutured to the annulus of the mitral valve 125 . The adjustment tool 135 is then manipulated, e.g., rotated, depending upon the design of the adjustment means 130 , to cause the adjustment means to reduce the size of the implant body 115 , and hence the underlying mitral valve 125 to which it is sutured, to an approximate size. The myocardial incision 105 can now be closed, as shown in FIG. 5 , leaving the adjustment tool extending through the incision for post-operative adjustment.
[0090] Once the patient has been taken “off pump” and normal flow of blood through the heart 110 has resumed, but before the chest incision has been closed, further adjustments to the size of the mitral valve 125 can be made by manipulating the adjustment tool 135 .
[0091] FIGS. 6-8 show an exemplary adjustment means 200 for adjusting the circumference of an annular implant such as the implant 100 previously described. The adjustment means 200 comprises a rack and pinion system in which a first cam 205 with geared teeth 210 and an engagement coupler 215 turns on a first axel 220 . In this example, the first cam 205 engages a geared rack 225 on one or more surfaces of a first band 230 . The first band 230 passes between the first cam 205 and a second cam 235 that turns on a second axel 240 that is joined to a second band 245 . As shown in FIG. 8 , the first and second axels 220 , 240 are maintained in suitable spaced-apart relation by means of a bracket 250 formed at the end of the second band 245 .
[0092] The adjustment means 200 is preferably set within a hollow annular implant 100 of the type previously described, though it is possible to use the adjustment means in a stand-alone configuration wherein the first and second bands 230 , 245 are opposing ends of the same continuous annular structure. In either event, to adjust the length of an implant comprising the adjustment means 200 , a tool such as a hex wrench engages the engagement coupler 215 on the first cam 205 and rotates the first cam in a counterclockwise direction as shown in FIG. 7 , as indicated by the arrow 255 . Rotation of the first cam 205 causes the teeth 210 to drive the rack 225 to move the first band 230 toward the right, as indicated by the arrow 260 in FIG. 7 . This movement of the first band tightens the circumference of the annular implant. If the physician inadvertently adjusts the implant too tight, reversing direction of the engagement coupler 215 will loosen the implant.
[0093] In various embodiments according to the present invention, the first and second bands 230 , 245 may be separate structures, or they may be opposing ends of the same continuous structure. In such an embodiment, when motion is imparted to the engagement coupler 215 , the first cam 205 is rotated, causing the geared teeth 210 to engage the geared rack 225 , and causing the first band 230 to move with respect to the second band 245 to adjust the circumference of an implant.
[0094] FIG. 9 shows a somewhat different configuration of an exemplary engagement means 300 according to the present invention, in which there is no engagement coupler, and a bracket 350 is provided on both sides of the cams to maintain the first cam 315 and the second cam 320 in close approximation. In one proposed embodiment, the bracket is designed with close tolerances so as to press the first band 330 closely against the second band 345 , thereby to hold the bands in fixed relative position by friction. In another proposed embodiment, the brackets 350 are fabricated from an elastic material such that the cams 315 , 320 can be spread apart to insert the first band 330 between the cams, whereupon the cams are pulled back together with sufficient force to hold the bands 330 , 345 in fixed relative position by friction. In still another proposed embodiment involving an elastic mounting arrangement between the cams 315 , 320 , the lower edge of the first band 330 and the upper edge of the second band 345 have mating frictional or mechanical surfaces, whereby the cams 315 , 320 can be spread apart to permit relative movement between the bands or released to clamp the bands together in fixed relation.
[0095] FIG. 10 shows an exemplary attachment means 400 for an implant according to the present invention. The attachment means 400 could be used, for example, in place of the attachment means 25 of the implant 10 . The attachment means 400 takes the form of a grommet 410 comprising a wall 415 defining a lumen 420 and an attachment surface 425 . Such an attachment means would be used with the implant body extending through the lumen 420 and with fixation devices such as sutures or wires either tied over or affixed through the attachment surface 425 .
[0096] FIG. 11 shows another alternate embodiment of an attachment means 500 for an implant according to the present invention. The attachment means 500 could also be used, for example, in place of the attachment means 25 of the implant 10 . FIG. 11 shows an attachment means 500 in the form of a hollow tube or tube segment 510 comprising a wall 515 defining a lumen 520 , an outer surface 525 , and an attachment tab 530 . Such an attachment means would be used with the implant body extending through the lumen 520 and with fixation devices such as sutures or wires either tied or otherwise affixed over or through the attachment tab 530 . Such fixation devices might be placed through holes 535 provided in the attachment tab 530 . Alternately a solid attachment tab 530 might be provided, and the fixation devices might be passed through the solid tab. Modifications of these attachment means may be used in conjunction with a sutureless attachment system.
[0097] FIGS. 12-18 show another embodiment of a percutaneous annuloplasty device according to the present invention, in which an implant/delivery system array 600 includes a housing sheath 605 (not seen in FIG. 12 ), an actuating catheter 610 coaxially slidably mounted within the housing sheath 605 , and a core catheter 615 coaxially slidably mounted within the actuating catheter 610 . The core catheter has a central lumen 616 ( FIG. 13 ). The actuating catheter 610 and core catheter 615 may be round tubular structures, or as shown in FIG. 13 , either or both of the actuating and core catheters may be provided with one or more keyed ridges 618 , 620 respectively to be received by one or more reciprocal slots 622 , 624 within the inner lumen of either the housing sheath 605 or the actuating catheter 610 , respectively. Such keyed ridges 618 , 620 would limit internal rotation of an inner element within an outer element, should such restriction be desirable to maintain control of the inner contents from inadvertent displacement due to undersired rotational motion during use.
[0098] The implant/delivery system array 600 includes a distal tip 625 at the forward end of the core catheter 615 . One or more radial implant support arms 630 have their distal ends 632 pivotably or bendably mounted to the core catheter 615 adjacent its distal tip 625 . The proximal ends 634 of the radial implant support arms 630 normally extend along the core catheter 615 but are capable of being displaced outward away from the core catheter.
[0099] One or more radial support struts 636 have their proximal ends 638 pivotably or bendably mounted to the distal end of the actuating catheter 610 . The distal end 640 of each radial support strut is 636 pivotably or bendably attached to a midpoint of a corresponding radial implant support arm 630 . As the actuating catheter 610 is advanced with respect to the core catheter 615 , the radial support struts 636 force the radial implant support arms 630 upward and outward in the fashion of an umbrella frame. Thus the actuating catheter 610 , core catheter 615 , radial support struts 636 , and radial support arms 630 in combination form a deployment umbrella 642 .
[0100] A prosthetic implant 645 is releasably attached to the proximal ends 634 of the radial implant support arms 630 . Around the periphery of the prosthetic implant 645 and extending proximally therefrom are a plurality of retention barbs 646 . In addition, one or more of the radial implant support arms 630 comprise touchdown sensors 648 whose proximal ends extend proximal to the implant 645 . Extending through the central lumen 616 ( FIG. 13 ) of the core catheter 615 in the exemplary embodiment 600 and out lateral ports 650 ( FIG. 12 ) spaced proximally from the distal tip 625 are one or more release elements 660 , which serve to release the implant 645 from the delivery system, and one or more adjustment elements 665 which serve to adjust the implant's deployed size and effect. Because the release elements 660 and adjustment elements 665 extend through the proximal end of the core catheter 615 , as seen in FIGS. 14-16 , these elements can be directly or indirectly instrumented or manipulated by the physician. A delivery interface 670 ( FIGS. 12, 16 ) is defined in this example by the interaction of the deployment umbrella 642 , the release elements 660 , and the implant 645 . In the disclosed embodiment, the release elements 660 may be a suture, fiber, or wire in a continuous loop that passes through laser-drilled bores in the implant 645 and in the radial implant support arms 630 , and then passes through the length of the core catheter 615 . In such an embodiment, the implant 645 may be released from the delivery system at a desired time by severing the release element 660 at its proximal end, outside the patient, and then withdrawing the free end of the release element 660 through the core catheter 610 .
[0101] FIGS. 14-16 show the operation of the implant/delivery system array 600 , in which an umbrella-like expansion of the prosthetic implant 645 is achieved by sliding movement of the housing sheath 605 , the actuating catheter 610 , and the core catheter 615 . Referring first to FIG. 14 , the housing sheath 605 is extended to cover the forward ends of the actuating catheter 610 and core catheter 615 for intravascular insertion of the implant/delivery system array 600 . From this starting position, the housing sheath 605 is retracted in the direction indicated by the arrows 662 . In FIG. 15 the housing sheath 605 has been retracted to expose the forward end of the actuating catheter 610 and the collapsed deployment umbrella 642 . From this position the actuating catheter 610 is advanced in the direction indicated by the arrows 664 . This will cause the deployment umbrellas to expand in the directions indicated by the arrows 666 . FIG. 16 shows the expansion of the deployment umbrella 642 produced by distal motion of the actuating catheter 610 relative to the core catheter 615 . After the implant 645 has been positioned and adjusted to the proper size, the housing sheath 605 is advanced in the direction indicated by the arrows 668 to collapse and to cover the deployment umbrella 642 for withdrawal of the device from the patient.
[0102] FIGS. 17 and 18 are schematic views illustrating the radial implant support arms 630 and the radial support struts 636 of the implant/delivery system array 600 . In FIG. 17 , a radial support strut 636 is pivotably attached at its proximal end 638 at a first pivotable joint 670 to the actuation catheter 610 . The radial support strut 636 is attached at its distal end 640 to a second pivotable joint 672 at an intermediate point of a corresponding radial implant support arm 630 . The radial implant support arm 630 is attached at its distal end 632 by a third pivotable joint 674 to the core catheter 620 . FIG. 17 shows the assembly in a closed state. When the actuation catheter 610 is advanced distally over the core catheter 615 , as shown by the arrows 676 , the radial support strut 636 and the radial implant support arm 630 are extended by the motion at the first pivotable joint 670 , the second pivotable joint 672 , and the third pivotable joint 674 , as shown by the arrow 678 . This motion has the effect of expanding the deployment umbrella and folded implant (not shown in FIGS. 17 and 18 ), allowing it to achieve its greatest radial dimension, prior to engagement and implantation as previously discussed with reference to FIGS. 12-16 .
[0103] FIGS. 19 and 20 show further details of the touchdown sensors 648 shown previously in FIG. 12 . The touchdown sensor 648 of FIGS. 19 and 20 includes a distal segment 680 , an intermediate segment 682 , and a proximal segment 684 . The distal segment 680 is spring-mounted, so that it is capable of slidable, telescoping displacement over the intermediate segment 682 to achieve a seamless junction with the proximal segment 684 upon maximal displacement. When the touchdown sensor 648 is in its normal condition, the spring extends the proximal segment such that the sensor assumes the orientation shown in FIG. 19 . When the implant 645 ( FIG. 12 ) is seated against the periphery of an anatomical opening, the proximal segment 684 of the sensor 648 is compressed against the distal segment 680 , as shown in FIG. 20 . The distal segment 680 and the proximal segment 684 are both constructed of, are sheathed by, or otherwise covered with a radio-opaque material. However, the intermediate segment 682 is not constructed or coated with such a radio-opaque material. Therefore, when the distal segment 680 is at rest, it is fully extended from the proximal segment 684 , and the gap represented by the exposed intermediate segment 682 is visible on radiographic examination. However, when the distal segment 680 is brought to maximum closeness with the proximal segment 684 , no such radio-opaque gap is radiographically visible, and the touchdown sensor is said to be “activated”. This embodiment allows radiographic monitoring of the position of the touchdown sensor 648 with respect to the degree of extension of the distal catheter segment 680 . In the embodiment according to the present invention as shown, one or more touchdown detectors 648 are employed to ascertain that the delivery system for the prosthetic device is located in the proper position to deploy the implant into the mitral annulus. As this anatomic structure cannot be directly identified on fluoroscopy or standard radiographic procedures, such precise location could be otherwise difficult. At the same time, precise localization and engagement of the mitral annulus is critical for proper implant function and safety.
[0104] Touchdown detectors within the embodiments according to the present invention can have a multiplicity of forms, including the telescoping, spring-loaded, radio-opaque elements joined by a non-radio-opaque element as in the aforementioned examples. In embodiments employing magnetic resonance imaging, touchdown detectors according to the present invention may utilize metallic segments interposed by nonmetallic segments in a similar telescoping, spring-loaded array. Other embodiments include a visually-evident system with telescoping, spring-loaded elements with color-coded or other visual features for procedures in which direct or endoscopic observation would be possible. Still other embodiments of touchdown detectors according to the present invention include touchdown detectors provided with microswitches at their tips, such that momentary contact of sufficient pressure completes an electrical circuit and signals the activation of the touchdown detector to the operator. Still other touchdown detectors according to the present invention are provided with fiberoptic pathways for Rahmen laser spectroscopy or other spectral analytical techniques which are capable of detecting unique tissue qualities of the tissue at the desired site for implantation. In addition, still other embodiments according to the present invention include touchdown detectors containing electrodes or other electronic sensors capable of detecting and signaling the operator when a desired electrophysiologic, impedance, or other measurable quality of the desired tissue is detected for proper implantation. Such electrophysiologic touchdown detectors may include electrical circuits that produce visual, auditory, or other signals to the operator that the detectors are activated and that the implant is in the proper position for attachment.
[0105] In yet other embodiments according to the present invention, other intracardiac or extracardiac imaging techniques including, but not limited to, intravascular ultrasound, nuclear magnetic resonance, virtual anatomic positioning systems, or other imaging techniques may be employed to confirm proper positioning of the implant, obviating the need for the touchdown sensors as previously described.
[0106] FIGS. 21-24 show an implant 700 according to one embodiment of the present invention. In this embodiment, the implant body 705 is bandlike and flexible. Through much of its length, the implant body 705 is provided with a series of retention barbs 710 which are oriented to facilitate placement, retention, and removal of the device. The implant body 705 is also provided with an adjustable section 715 , which is provided in this example with a series of adjustment stops 720 . The adjustment stops 720 may be slots, holes, detents, dimples, ridges, teeth, raised elements, or other mechanical features to allow measured adjustment of the implant 700 in use. In the embodiment shown in FIGS. 21-24 , the adjustment stops 720 are engaged by a geared connector 725 . FIG. 21 is an end view, showing the implant body 705 curved on itself, with the retention barbs 710 to the exterior, and with the adjustable section 715 passing through its engagement with the geared connector 725 and curving internally within the implant body 705 to form a closed, round structure. FIG. 23 shows details of an exemplary geared connector 725 , in which a housing 730 is connected to the implant body 705 . The housing 730 contains and supports a mechanical worm 740 with an attached first geared head 750 which mates with a second geared head 755 . The second geared head 755 is attached to an adjustment stem 760 which is machined to receive a screwdriver-like adjustment element. The various embodiments according to the present invention may require a number of forms of adjustment elements. In the present example, the adjustment element is provided as a finely coiled wire with a distal tip machined to be received by a receiving slot in the adjustment stem 760 (not shown). The relationship between the distal tip of the adjustment element and the adjustment stem 760 is mechanically similar to a screwdriver bit and screwhead, such that torsion imparted to the adjustment means by the operator will result in the turning of the adjustment stem 760 and second geared head 755 allows motion of the first geared head 750 and worm 740 , which creates motion of the adjustable implant section 715 as the worm engages with the series of adjustment tops 725 . Excess length of the adjustable section 715 passes though a band slot 735 ( FIG. 23 ), thus allowing the band to move concentrically inside the closed implant body 705 . The adjustment element in this embodiment may be designed to remain in place after the deployment umbrella has been retracted and withdrawn. The connection between the adjustment element's distal tip and the adjustment stem 760 may be a simple friction connection, a mechanical key/slot formation, or may be magnetically or electronically maintained.
[0107] As further shown in FIG. 21 , the exemplary embodiment employs unidirectional retention barbs 710 which are attached to the outer perimeter of the implant body 705 . The retention barbs 710 are oriented in a consistent, tangential position with respect to the implant body 705 such that rotational motion of the implant body will either engage or release the retention barbs 710 upon contact with the desired tissue at the time of deployment. This positioning of the retention barbs 710 allows the operator to “screw in” the implant 700 by turning the implant 700 upon its axis, thus engaging the retention barbs 710 into the adjacent tissue. As shown in FIG. 24 , the retention barbs 710 may each be further provided with a terminal hook 775 at the end which would allow for smooth passage through tissue when engaging the retention barbs 710 by rotating the implant 700 , without permitting the implant 700 to rotate in the opposite direction, because of the action of the terminal hooks 775 grasping the surrounding tissue (much like barbed fish hooks). The terminal hooks 775 thus ensure the seating of the implant 700 into the surrounding tissue.
[0108] FIGS. 25-27 illustrate another embodiment of an implant 800 as contemplated according to the present invention. The implant 800 includes a band 805 ( FIG. 27 ), but the retention barbs of the previous example have been eliminated in favor of an outer fabric implant sheath 810 . The fabric sheath 810 can be sutured or otherwise affixed to the anatomic tissue in a desired location. The circumference of the implant body 800 is adjusted through a geared connector 825 similar to the geared connector of the bandlike implant array shown in FIG. 23 . More specifically, adjustment stops 820 on the band are engaged by a mechanical worm 840 with an attached first geared head 850 . The first geared head 850 mates with a second geared head 855 . The second geared head 855 is attached to an adjustment stem 860 which is machined to receive a screwdriver-like adjustment element.
[0109] FIG. 28 illustrates an example of the method of use of an implant/delivery system array 600 for positioning an implant 645 in a patient with ischemic annular dilatation and mitral regurgitation. Peripheral arterial access is obtained via conventional cutdown, arterial puncture, or other standard access techniques. After access to the arterial system is attained, guidewire placement is performed and intravascular access to the heart 900 is obtained using fluoroscopic, ultrasound, three-dimension ultrasound, magnetic resonance, or other real-time imaging techniques. The guidewire, deployment device, and implant are passed through the aortic valve in a retrograde fashion into the left ventricle 905 and then into the left atrium 910 . At this point, the operator retracts the housing sheath 605 , thus unsheathing the collapsed deployment umbrella 642 and implant 645 . The deployment umbrella 642 is then distended by the distal motion of the actuation catheter, causing the radial support arms and struts to fully distend. At this point, the touchdown detectors 648 are not in contact with any solid structures, and are fully extended with their radiolucent gaps visible on the imaging system. Once the deployment umbrella is distended, the entire assembly is pulled back against the area of the mitral valve 915 . At least two touchdown detectors 648 are employed in a preferred embodiment according to the present invention. When all touchdown detectors show the disappearance of their intermediate, non-opaque, intermediate segments and are thus activated, then the deployment umbrella must be in contact with the solid tissue in the region of the mitral annulus/atrial tissue, and further implant deployment and adjustment may proceed. However, if any one touchdown sensor is not activated, and a radiolucent gap persists, then the device is not properly positioned, and must be repositioned before further deployment. Thus, the touchdown sensor system may assist in the deployment and adjustment of prosthetic devices by the delivery system according to the present invention. Once properly positioned, the operator rotates the actuation catheter in a prescribed clockwise or counterclockwise manner to engage the retention barbs on the implant into the tissue in the region of the mitral annulus/atrial tissue. Should re-positioning be required, a reverse motion would disengage the retention barbs from the annular/atrial tissue, and repositioning may be performed, again using the touchdown detectors for proper placement. Once firmly seated, the adjustment element(s) are operated to achieve the desired degree of annular reduction. Real-time trans esophageal echocardiography, intravascular echocardiography, intracardiac echocardiography, or other modalities for assessing mitral function may then be employed to assess the physiologic effect of the repair on mitral function, and additional adjustments may be performed. Once a desired result has been achieved, the release elements are activated to detach the implant from the deployment umbrella. The operator then retracts the actuation catheter and extends the housing sheath, collapsing the deployment umbrella and covering the components for a smooth and atraumatic withdrawal of the device from the heart and vascular system.
[0110] If desired, the adjustment elements may be left in position after the catheter components are withdrawn for further physiologic adjustment. In yet other embodiments according to the present invention, a catheter-based adjustment elements may subsequently be re-inserted though a percutaneous or other route. Such an adjustment element may be steerably operable by the operator, and may be provided with magnetic, electronic, electromagnetic, or laser-guided systems to allow docking of the adjustment element with the adjustable mechanism contained within the implant. In still other embodiments, the adjustment mechanism may be driven by implanted electromechanical motors or other systems, which may be remotely controlled by electronic flux or other remote transcutaneous or percutaneous methods.
[0111] In the case of pulmonic valve repair, initial catheter access is achieved through a peripheral or central vein. Access to the pulmonary valve is also achieved from below the valve once central venous access is achieved by traversing the right atrium, the tricuspid valve, the right ventricle, and subsequently reaching the pulmonic valve.
[0112] In yet other embodiments according to the present invention, catheter access to the left atrium can be achieved from cannulation of central or peripheral veins, thereby achieving access to the right atrium. Then a standard atrial trans-septal approach may be utilized to access the left atrium by creation of an iatrogenic atrial septal defect (ASD). In such a situation, the mitral valve may be accessed from above the valve, as opposed to the retrograde access described in Example 1. The implant and a reversed deployment umbrella may be utilized with implant placement in the atrial aspect of the mitral annulus, with the same repair technique described previously. The iatrogenic ASD may then be closed using standard device methods. Access to the aortic valve may also be achieved from above the aortic valve via arterial access in a similar retrograde fashion.
[0113] Other embodiments of the adjustable implant and methods according to the present invention include gastrointestinal disorders such as gastro-esophageal reflux disease (GERD), a condition in which the gastro-esophageal (GE) junction lacks adequate sphincter tone to prevent the reflux of stomach contents into the esophagus, causing classic heartburn or acid reflux. This not only results in discomfort, but may cause trauma to the lower esophagus over time that may lead to the development of pre-cancerous lesions (Barrett's esophagus) or adenocarcinoma of the esophagus at the GE junction. Surgical repair of the GE junction has historically been achieved with the Nissen Fundoplication, an operative procedure with generally good results. However, the Nissen procedure requires general anesthesia and a hospital stay. Utilizing the devices and methods according to the present invention, an adjustable implant would obviate the need for a hospital stay and be performed in a clinic or gastroenterologist's office. Referring now to FIGS. 29 and 30 , an umbrella deployment device 600 with implant 645 is passed under guidance of an endoscope 1000 , through the patient's mouth, esophagus 1005 , and into the stomach 1010 , where the deployment device 600 is opened with expansion of the implant 645 and touchdown detectors 648 with a color-coded or otherwise visible gap. The touchdown detectors are then engaged onto the stomach around the gastroesophageal junction 1015 under direct endoscopic control until all touchdown detectors 648 are visually activated. The implant is then attached to the stomach wall, 1020 the umbrella 642 is released and withdrawn, leaving behind the implant 645 and the adjustment elements. The implant is then adjusted until the desired effect is achieved, i.e., minimal acid reflux either by patient symptoms, pH monitoring of the esophagus, imaging studies, or other diagnostic means. If the patient should suffer from gas bloat, a common complication of gastroesophageal junction repair in which the repair is too tight and the patient is unable to belch, the implant can be loosened until a more desirable effect is achieved.
[0114] In various embodiments anticipated by the present invention, the implant body may be straight, curved, circular, ovoid, polygonal, or some combination thereof. In various embodiments anticipated by the present invention the implant may be capable of providing a uniform or non-uniform adjustment of an orifice or lumen within the body. The implant body may further completely enclose the native recipient anatomic site, or it may be provided in an interrupted form that encloses only a portion of the native recipient anatomic site. In still other embodiments of the present invention, the implant body may be a solid structure, while in yet other embodiments the implant body may form a tubular or otherwise hollow structure. In one embodiment of the present invention, the body may further be a structure with an outer member, an inner member, and optional attachment members. In such an embodiment, the outer member of the implant body may serve as a covering for the implant, and is designed to facilitate and promote tissue ingrowth and biologic integration to the native recipient anatomic site. The outer member in such an embodiment may be fabricated of a biologically compatible material, such as Dacron, PTFE, malleable metals, other biologically compatible materials or a combination of such biologically compatible materials in a molded, woven, or non-woven configuration. The outer member in such an embodiment also serves to house the inner member. In this embodiment, the inner member provides an adjustment means that, when operated by an adjustment mechanism, is capable of altering the shape and/or size of the outer member in a defined manner.
[0115] In alternate embodiments according to the present invention, the adjustment means may be located external to or incorporated within the outer member. In yet additional alternate embodiments contemplated by the present invention, the implant body may consist of an adjustment means without a separate outer member covering said adjustment means.
[0116] In various embodiments according to the present invention, the adjustment means may include a mechanism which may be threaded or non-threaded, and which may be engaged by the action of a screw or worm screw, a friction mechanism, a friction-detent mechanism, a toothed mechanism, a ratchet mechanism, a rack and pinion mechanism, or such other devices to permit discreet adjustment and retention of desired size a desired position, once the proper size is determined.
[0117] In yet other embodiments according to the present invention, the adjustment means may comprise a snare or purse string-like mechanism in which a suture, a band, a wire or other fiber structure, braided or non-braided, monofilament or multifilament, is capable of affecting the anatomic and/or physiologic effects of the implant device on a native anatomic recipient site upon varying tension or motion imparted to said wire or fiber structure by a surgeon or other operator. Such an adjustment means may be provided as a circular or non-circular structure in various embodiments. Changes in tension or motion may change the size and/or shape of the implant.
[0118] In various embodiments according to the present invention, the adjustment means may be a metallic, plastic, synthetic, natural, biologic, or any other biologically-compatible material, or combination thereof. Such adjustment means may further be fabricated by extrusion or other molding techniques, machined, or woven. Furthermore, in various embodiments of the present invention, the adjustment means may be smooth or may include slots, beads, ridges, or any other smooth or textured surface.
[0119] In various embodiments of the present invention, the implant body may be provided with one or more attachment members such as grommets or openings or other attachment members to facilitate attachment of the implant to the native recipient site. In alternate embodiments, the implant body may attach to or incorporate a mechanical tissue interface system that allows a sutureless mechanical means of securing the implant at the native recipient site. In still other alternate embodiments, sutures or other attachment means may be secured around or through the implant body to affix the implant body to the native recipient site. In yet other embodiments of the present invention, mechanical means of securing the implant body to the native recipient site may be augmented or replaced by use of fibrin or other biologically-compatible tissue glues or similar adhesives.
[0120] In additional various embodiments according to the present invention, the adjustable implant may be employed to adjustably enlarge or maintain the circumference or other dimensions of an orifice, ostium, lumen, or anastomosis in which a disease process tends to narrow or constrict such circumference or other dimensions.
[0121] In various embodiments according to the present invention, an adjustment mechanism may be provided to interact with the adjustment means to achieve the desired alteration in the size and/or position of the adjustment means. Such an adjustment mechanism may include one or more screws, worm-screw arrays rollers, gears, frictional stops, a friction-detent system, ratchets, rack and pinion arrays, micro-electromechanical systems, other mechanical or electromechanical devices or some combination thereof.
[0122] In some embodiments as contemplated by the present invention, an adjustment tool may be removably or permanently attached to the adjustment mechanism and disposed to impart motion to the adjustment mechanism and, in turn, to the adjustment means to increase or decrease the anatomic effect of the implant on the native recipient site.
[0123] In alternate embodiments according to the present invention, micromotor arrays with one or more micro-electromechanical motor systems with related electronic control circuitry may be provided as an adjustment means, and may be activated by remote control through signals convey by electromagnetic radiation or by direct circuitry though electronic conduit leads which may be either permanently or removably attached to said micromotor arrays.
[0124] In still other various embodiments according to the present invention, the adjustment mechanism may be provided with a locking mechanism disposed to maintain the position of the adjustment means in a selected position upon achievement of the optimally desired anatomic and/or physiologic effect upon the native recipient site and the bodily organ to which it belongs. In other embodiments, no special locking mechanism may be necessary due to the nature of the adjustment means employed.
[0125] In yet other alternate embodiments according to the present invention, the adjustment means and/or the outer member structure may be a pliable synthetic material capable of rigidification upon exposure to electromagnetic radiation of selected wavelength, such as ultraviolet light. In such embodiments, exposure to the desired electromagnetic radiation may be achieved by external delivery of such radiation to the implant by the surgeon, or by internal delivery of such radiation within an outer implant member using fiberoptic carriers placed within said outer member and connected to an appropriate external radiation source. Such fiberoptic carriers may be disposed for their removal in whole or in part from the outer implant member after suitable radiation exposure and hardening of said adjustment means.
[0126] The present invention also provides methods of using an adjustable implant device to selectively alter the anatomic structure and/or physiologic effects of tissues forming a passageway for blood, other bodily fluids, nutrient fluids, semi-solids, or solids, or wastes within a mammalian body. Various embodiments for such uses of adjustable implants include, but are not limited to, open surgical placement of said adjustable implants at the native recipient site through an open surgical incision, percutaneous or intravascular placement of said implants under visual control employing fluoroscopic, ultrasound, magnetic resonance imaging, or other imaging technologies, placement of said implants through tissue structural walls, such as the coronary sinus or esophageal walls, or methods employing some combination of the above techniques. In various embodiments as contemplated by the present invention, adjustable implants may be placed and affixed in position in a native recipient anatomic site by trans-atrial, trans-ventricular, trans-arterial, trans-venous (i.e., via the pulmonary veins) or other routes during beating or non-beating cardiac surgical procedures or endoscopically or percutaneously in gastrointestinal surgery.
[0127] Furthermore, alternate methods for use of an adjustable implant device may provide for the periodic, post-implantation adjustment of the size of the anatomic structure receiving said implant device as needed to accommodate growth of the native recipient site in a juvenile patient or other changes in the physiologic needs of the recipient patient.
[0128] Adjustment of the adjustable implants and the methods for their use as disclosed herein contemplates the use by the surgeon or operator of diagnostic tools to provide an assessment of the nature of adjustment needed to achieve a desired effect. Such diagnostic tools include, but are not limited to, transesophageal echocardiography, echocardiography, diagnostic ultrasound, intravascular ultrasound, virtual anatomic positioning systems integrated with magnetic resonance, computerized tomographic, or other imaging technologies, endoscopy, mediastinoscopy, laparoscopy, thoracoscopy, radiography, fluoroscopy, magnetic resonance imaging, computerized tomographic imaging, intravascular flow sensors, thermal sensors or imaging, remote chemical or spectral analysis, or other imaging or quantitative or qualitative analytic systems.
[0129] In one aspect, the implant/delivery system of the present invention comprises a collapsible, compressible, or distensible prosthetic implant and a delivery interface for such a prosthetic implant that is capable of delivering the prosthetic implant to a desired anatomic recipient site in a collapsed, compressed, or non-distended state, and then allowing controlled expansion or distension and physical attachment of such a prosthetic implant by a user at the desired anatomic recipient site. Such a system permits the delivery system and prosthetic implant to be introduced percutaneously through a trocar, sheath, via Seldinger technique, needle, or endoscopically through a natural bodily orifice, body cavity, or region and maneuvered by the surgeon or operator to the desired anatomic recipient site, where the delivery system and prosthetic implant may be operably expanded for deployment. When desirable, the implant/delivery system according to the present invention is also capable of allowing the user to further adjust the size or shape of the prosthetic implant once it has been attached to the desired anatomic recipient site. The delivery system according to the present invention is then capable of detaching from its interface with the prosthetic implant and being removed from the anatomic site by the operator. The delivery system and prosthetic implant may be provided in a shape and size determined by the anatomic needs of an intended native recipient anatomic site within a mammalian patient. Such a native recipient anatomic site may be a heart valve, the esophagus near the gastro-esophageal junction, the anus, or other anatomic sites within a mammalian body that are creating dysfunction that might be relieved by an implant capable of changing the size and shape of that site and maintaining a desired size and shape after surgery.
[0130] In various embodiments contemplated by the present invention, the delivery system may be a catheter, wire, filament, rod, tube, endoscope, or other mechanism capable of reaching the desired recipient anatomic site through an incision, puncture, trocar, or through an anatomic passageway such as a vessel, orifice, or organ lumen, or trans-abdominally or trans-thoracically. In various embodiments according to the present invention, the delivery system may be steerable by the operator. The delivery system may further have a delivery interface that would retain and convey a prosthetic implant to the desired recipient anatomic site. Such a delivery interface may be operably capable of distending, reshaping, or allowing the independent distension or expansion of such a prosthetic implant at the desired recipient anatomic site. Furthermore, such a delivery interface may provide an operable means to adjust the distended or expanded size, shape, or physiologic effect of the prosthetic implant once said implant has been attached in situ at the desired recipient anatomic site. In various embodiments according to the present invention, such adjustment may be carried out during the procedure in which the implant is placed, or at a subsequent time. Depending upon the specific anatomic needs of a specific application, the delivery interface and the associated prosthetic implant may be straight, curved, circular, helical, tubular, ovoid, polygonal, or some combination thereof. In still other embodiments of the present invention, the prosthetic implant may be a solid structure, while in yet other embodiments the prosthetic implant may form a tubular, composite, or otherwise hollow structure. In one embodiment of the present invention, the prosthetic implant may further be a structure with an outer member, an inner member, and optional attachment members. In such an embodiment, the outer member of the prosthetic implant may serve as a covering for the implant, and is designed to facilitate and promote tissue ingrowth and biologic integration to the native recipient anatomic site. The outer member in such an embodiment may be fabricated of a biologically compatible material, such as Dacron, PTFE, malleable metals, other biologically compatible materials or a combination of such biologically compatible materials in a molded, woven, or non-woven configuration. The outer member in such an embodiment also serves to house the inner member. In this embodiment, the inner member provides an adjustment means that, when operated by an adjustment mechanism, is capable of altering the shape and/or size of the outer member in a defined manner.
[0131] In some embodiments according to the present invention, at least some portions of the adjustable inner or outer member may be elastic to provide an element of variable, artificial muscle tone to a valve, sphincter, orifice, or lumen in settings where such variability would be functionally valuable, such as in the treatment of rectal incontinence or vaginal prolapse.
[0132] In various embodiments according to the present invention, the delivery interface would have an attachment means to retain and convey the prosthetic implant en route to the native anatomic recipient site and during any in situ adjustment of the prosthetic implant once it has been placed by the operator. Such an attachment means would be operably reversible to allow detachment of the prosthetic implant from the delivery interface once desired placement and adjustment of the prosthetic implant has been accomplished.
[0133] In one embodiment of the present invention, illustrated in FIG. 31 , an implantable device system 1000 for controlling at least the size or shape of an anatomical structure or lumen includes an implantable device 1002 and an adjustment tool 1006 . The anatomical structure or lumen is an anatomic site with dysfunction that can be relieved by the implantable device 1002 to change a size or shape of the anatomic site.
[0134] The implantable device 1002 , in one exemplary embodiment, has a diameter no larger than 3.5 mm. In another embodiment the implantable device 1002 is configured to have variable size relative to its placement at an annulus of a heart valve. The implantable device 1002 has an adjustable member 1004 configured to adjust the dimensions of the implantable device 1002 . In one embodiment, the torqueable adjustment tool 1006 provides adjustment of the dimensions of the implantable device 1002 . The adjustable member 1004 , in some embodiments, may be oriented to receive the adjustment tool from a direction generally perpendicular to the primary plane defined by the implant device 1002 . Such an orientation is advantageous for intravenous access of the tool and in situ adjustment of the implant device 1002 . The implantable device 1002 can have a configuration where there are different pulling rates at different sections of the implantable device 1002 . The implantable device 1002 may optionally include a flexible tube ( 1032 , FIG. 38 ) and an outer fabric sheath ( 810 , FIGS. 25 and 26 ), which are not shown in the subsequent figures for clarity. The outer fabric sheath can be sutured, stapled, clipped, coiled, or otherwise affixed to anatomic tissue in a desired location. Generally the desired location is considered to be the internal surface of the area to be controlled, such as (for example) an interior wall of an organ, artery, or other internal anatomic passage. Also, while the implantable device 1002 is generally shown in the subsequent figures to have a “D”-shaped configuration, it should be understood that other shapes can be used in accordance with embodiments of the present invention.
[0135] Still referring to FIG. 31 , in certain embodiments, the adjustment tool 1006 is at least partially hollow, and in one specific embodiment at least 50% hollow. The adjustment tool 1006 may be an elongated tool, which has a proximal end and a distal end releasably attached to the adjustable member 1004 of implantable device 1002 . The adjustment tool 1006 may extend from its distal end coupled to the adjustable member 1004 to a control interface (e.g., handle) at the proximal end located preferably outside of the patient's body. The adjustment tool 1006 , when coupled to the adjustable member 1004 of implantable device 1002 , can provide a preferential shape change of the implantable device 1002 in planar and non-planar directions. The adjustment tool 1006 can adjust the implantable device 1002 in terms of narrowing or widening the dimensions of the implantable device 1002 .
[0136] FIG. 32A is a schematic of the implant device 1002 without showing an optional flexible outer tube and fabric sheath. The implantable device includes an adjustable member 1004 and adjustable tube portions 1013 a and 1013 b , which slide within hollow tube portions 1014 a and 1014 b , and retaining tube 1015 . FIG. 32B is a schematic of a disassembled portion of implantable device 1002 with retaining tube 1015 removed. As shown in FIG. 32B , in various embodiments, the implantable device 1002 includes a threaded rod 1008 threaded with right-hand helical grooves 1010 and left-hand helical grooves 1012 . Other embodiments may include a threaded rod 1008 with helical grooves in a single direction (e.g., all right-hand grooves or all left-hand grooves). Threaded rod 1008 may be a rigid material such as titanium, stainless steel, or a polymer. Adjustable tube portions 1013 a and 1013 b enclose at least a portion of grooves 1010 and 1012 so that pins 1016 a , 1016 b or protuberances on the inside diameter of the adjustable tube portions 1013 a , 1013 b are engaged by the grooves 1010 and 1012 , respectively. In other embodiments, pins 1016 a , 1016 b may be replaced by threads along the inside diameter of the adjustable tube portions 1013 a , 1013 b . Helical grooves 1010 and 1012 may be single channels or multiple channels to engage single pins 1016 a , 1016 b or multiple pins. Hollow tube portions 1014 a , 1014 b are relatively rigid to maintain curvature of the adjustable tube portions 1013 a , 1013 b regardless of the adjustment position.
[0137] The implantable device 1002 can have a coating including, but not limited to, heparin, and antibiotic, collagen, and an agent that promotes tissue in growth, PGLA, a de-calcification agent and the like. The implantable device 1002 can be made of a variety of materials including, but not limited to, a shape memory alloy (SMA), a shape memory polymer (SMP), titanium, stainless steel, polymer, a suture-based material, a biological material and the like.
[0138] In another embodiment of the present invention, illustrated in FIGS. 33 through 37 , the adjustable member 1004 provides translated motion through rotation. FIGS. 33 through 35 illustrate a theory of operation of an embodiment of the present invention, while FIGS. 36 and 37 shown details of the adjustment member 1004 .
[0139] Referring to now FIG. 33 , adjustable member 1004 of implantable device 1102 is shown including a docking port 1021 to receive the distal tip of the adjustment tool 1006 ( FIG. 31 ). In this embodiment, implant device includes a set of inner tubing 1028 a , 1028 b and a set of outer tubing 1026 a , 1026 b that can move relative to each other. The ends of the inner tubing 1028 a , 1028 b that do not engage the outer tubing 1026 a , 1026 b are secured to a set of hollow tubing 1014 a , 1014 b so that the inner tubing 1028 a , 1028 b does not move relative to the hollow tubing 1014 a , 1014 b . Although hollow tube portions 1014 a , 1014 b may be separate pieces that are permanently abutted when assembled, in some embodiments, the hollow tube portions 1014 a , 1014 b may be formed from a single tubing piece. An inner cable 1030 passes through the various tubing. Thus, the rigidity of the hollow tubing can be used to maintain the adjustable implant 1102 shape in certain dimensions so that adjustment of the device can be restricted to a preferred dimension, for example, an anterior-posterior dimension.
[0140] As shown in more detail in FIGS. 36 and 37 , adjustable member 1004 may also include a pinion gear 1022 (which may be integral to a docking port 1021 ) and a crown gear 1024 . FIG. 36 provides an isometric view of the adjustable member 1004 , and FIG. 37 provides a cut-away view of the adjustable member 1004 . As can be seen in the figures, the pinion gear 1022 engages the crown gear 1024 . In some embodiments, the pinion gear 1022 may be eliminated from adjustable member 1004 , and the distal tip of the adjustment tool 1006 may serve as the pinion gear when the tool is coupled to the docking port 1021 . When coupled to the docking port 1021 , the adjustment tool 1006 can rotate the pinion gear 1022 .
[0141] Referring back to FIG. 33 , the implantable device 1102 is shown generally at the middle of its adjustment range. Outer tubing 1026 a , 1026 b is affixed to the adjustable member 1004 and extends along a portion of the circumference of implantable device 1102 . Inner tubing 1028 a , 1028 b is affixed to hollow tubing 1014 a , 1014 b , respectively. Similar to the single threaded rod 1008 of FIG. 32B , threaded rods 1018 a , 1018 b sit inside the hollow tubing 1014 a , 1014 b and are threadedly engaged therewith. Threaded rods 1018 a , 1018 b may be a rigid material such as titanium, stainless steel, or a polymer. Hollow tube portions 1014 a , 1014 b enclose the threaded rods 1018 a , 1018 b such that rotation of the threaded rods 1018 a , 1018 b causes them to move axially within the hollow tube portions 1014 a , 1014 b . The threaded rod 1018 a may have right-handed threads, and the threaded rod 1018 b may have left handed threads. Other embodiments may include threaded rods 1018 a , 1018 b with threads in a single direction (e.g., all right-hand grooves or all left-hand threads).
[0142] The crown gear 1024 , and one end of each threaded rod 1018 a , 1018 b are all attached to an inner cable 1030 . Inner cable 1030 may be a cable or tube of any material with sufficient flexibility to conform to a shape of the implantable device 1102 while translating torque. For example, suitable material for inner cable 1030 may include titanium or stainless steel. As shown more clearly in FIGS. 36 and 37 , the rotation of crown gear 1024 imparts rotation to cable 1030 in the same direction.
[0143] Referring to FIG. 34 , when the handle of adjustment tool 1006 (not shown in this figure) is rotated clockwise in docking port 1021 , it causes clockwise rotation of the pinion gear 1022 (in FIG. 36 ). Rotation of the pinion gear 1022 in turn rotates crown gear 1024 . The rotation of crown gear 1024 causes rotation of inner cable 1030 , which imparts rotational movement to each threaded rod 1018 a , 1018 b . The rotation applied to the threaded rods 1018 a , 1018 b causes them to advance into their respective hollow tubing 1014 a , 1014 b in the directions A 1 , A 2 shown. As shown in FIG. 34 , when threaded rods 1018 a , 1018 b advance toward the middle of the hollow tubing 1014 a , 1014 b the overall circumference of the implant device 1002 is reduced. Advancing the threaded rods 1018 a , 1018 b drives the inner cable 1030 into the hollow tubing 1014 a , 1014 b . Translation of inner cable 1030 into the hollow tubing 1014 a , 1014 b causes the hollow tubing 1014 a , 1014 b to move towards adjustable member 1004 in the direction B 1 shown. Inner tubing 1028 a , 1028 b slides into outer tubing 1026 a , 1026 b to accommodate movement of the inner cable 1030 .
[0144] Referring to FIG. 35 , the handle of adjustment tool 1006 (not shown in this figure) is rotated counter-clockwise in docking port 1021 to cause counter-clockwise rotation of the pinion gear 1022 ( FIG. 36 ). Rotation of the pinion gear 1022 , in turn rotates crown gear 1024 . The rotation of crown gear 1024 causes rotation of inner cable 1030 , which imparts rotational movement to each threaded rod 1018 a , 1018 b . The rotation applied to the threaded rods 1018 a , 1018 b causes them to begin to withdraw from their respective hollow tubing 1014 a , 1014 b in the directions A 2 , A 1 shown. As shown in FIG. 35 , as threaded rods 1018 a , 1018 b withdraw from the middle of the hollow tubing 1014 a , 1014 b the overall circumference of the implant device 1002 is increased. Withdrawal of the threaded rods 1018 a , 1018 b pushes the inner cable 1030 out of the hollow tubing 1014 a , 1014 b . Translation of inner cable 1030 out of the hollow tubing 1014 a , 1014 b causes the hollow tubing 1014 a , 1014 b to move away from adjustable member 1004 in the direction B 2 shown. Inner tubing 1028 a , 1028 b telescopes out of outer tubing 1026 a , 1026 b to accommodate movement of the inner cable 1030 .
[0145] The inner tubing 1028 a , 1028 b , the outer tubing 1026 a , 1026 b , and the hollow tubing 1014 a , 1014 b may be covered by a flexible tube 1032 , such as a silicone tube, shown in FIG. 38 . In one embodiment, outer flexible tube 1032 is provided with no seam in the axial direction of the tube to allow for better tissue ingrowth after the implant procedure. In other embodiments inner tubing 1028 a , 1028 b may be eliminated, as shown in FIG. 39 .
[0146] FIG. 39 provides an assembled cross-section view of an implantable device 1202 according to an embodiment of the invention. The implant device includes the adjustable member 1004 , the outer tubing 1026 a , 1026 b , the hollow tubing 1014 a , 1014 b , the inner cable 1030 , and the threaded rods 1018 a , 1018 b as discussed in relation to FIGS. 33-35 . As shown in FIG. 39 , hollow tubing 1014 a , 1014 b may extend further along the length of inner cable 1030 than shown in other embodiments of FIGS. 33-35 to better maintain a preferred shape of the implant. Hollow tubing 1014 a , 1014 b may be threaded to receive the threaded rods 1018 a , 1018 b ; or hollow tubing may optionally include a threaded insert (spar 1019 a , 1019 b ) affixed to the inner diameter of hollow tubing 1014 a , 1014 b . In operation, as previously described, an adjustment tool may impart motion to the adjustable member 1004 . Gears in the adjustable member translate motion to the inner cable 1030 that, in turn translate motion to the attached threaded rods 1018 a , 1018 b . Depending on the direction of rotation, rotation of threaded rods 1018 a , 1018 b causes the threaded rods 1018 a , 1018 b to be drawn toward or away from the middle of the hollow tubing 1014 a , 1014 b , thus reducing or increasing the overall circumference of the implant device 1002 . The flexible outer tube 1032 and a seal jacket 1100 (also shown in FIG. 40 ) encapsulate the device so that no moving parts are exposed. The flexible outer tube 1032 provide sufficient rigidity to maintain a generally planar dimension, while allowing the device to adjust shape generally in a preferred dimension, such as the anterior-posterior dimension. As shown in FIG. 39 , the flexible outer tube 1032 may be further covered by an outer fabric sheath 1110 or thin sewing cuff. Elimination of the inner tubing ( 1028 a , 1028 b of FIG. 35 ) eliminates the need for telescoping parts and prevents the possibility of telescoping tubes being sutured or clipped together during attachment of the implant.
[0147] Referring to FIG. 40 , the adjustable member 1004 can include a seal jacket 1100 . FIG. 40 shows an embodiment of the seal jacket 1100 . The seal jacket 1100 may include a cover 1102 for the docking port 1021 ( FIG. 33 ) of the adjustable member 1004 . The cover 1102 may be in the form of a slit septum, flaps, elastic material or the like. The seal jacket cover 1102 may be included as part of a seal jacket 1100 that covers the entire housing of the adjustable member 1004 or a separate piece. In one embodiment, the seal jacket 1100 may be secured to the flexible tube 1032 . The seal jacket 1100 and flexible tube 1032 may be secured by an adhesive bond, a wrap, sutures, or the like. The cover 1102 provides access for an adjustment tool to couple to the docking port, while reducing the possibility of thrombus. In some embodiments, seal jacket cover 1102 and/or the seal jacket 1100 may be made of silicone, and covered by a polyester sewing layer or fabric sheath (e.g., 1110 of FIG. 39 ). In various embodiments, the seal jacket fits over the housing of the adjustable member 1004 that includes a crown gear coupled to a cable, can provide pinion access, and the like. In operation, the distal tip of an adjustment tool passes through the cover 1102 to engage the rotatable gear of adjustable member 1004 .
[0148] FIG. 41 shows an embodiment of implantable device 1302 including a first adjustment band 1042 a and a second adjustment band 1042 b . The first and second adjustment bands 1042 a , 1042 b can be overlapped, and the amount of overlap is effected by how the implantable device 1302 is sized. The first and second bands 1042 a , 1042 b can be slidable relative to each other. An adjustable member 1304 is coupled to the first band 1042 a and the second band 1042 b , and pulls or pushes them toward or away from each other. The first band 1042 a and the second band 1042 b can have flexible portions 1046 a , 1046 b configured to create a flexible zone at the primary bend regions 1047 a , 1047 b . The flexible portions 1046 a , 1046 b can have varying lengths and may also include one or more rigid portions 1044 . These rigid portions 1044 can include welded braids or bands, or have a higher durometer material than the flexible portions 1046 a , 1046 b . The flexible portions 1046 a , 1046 b and rigid portions 1044 may be part of the same material as the first and second bands 1042 a , 1042 b , or one or more portions may be separate material that is joined to form continuous piece.
[0149] The first and second bands 1042 a , 1042 b can have different sizes or the same sizes. In one specific embodiment, the first and second bands 1042 a , 1042 b are about 0.5 to 3 mm in thickness and about 5 to 10 mm in width. The first and second bands 1042 a , 1042 b can be made of a variety of materials including, but not limited to, an SMA, an SMP, titanium, stainless steel, polymer, a suture-based material, a biological material and the like. In one embodiment, the first and second bands 1042 a , 1042 b include a plurality of band layers. At least a portion of the first and second bands 1042 a , 1042 b may have superelastic properties. Implant 1302 may include a flexible, extruded outer layer (not shown) or hollow tube, such as flexible tube 1032 of FIG. 38 , to encase the structure formed by the first and second bands 1042 a , 1042 b flexible portions 1046 a , 1046 b , and rigid portions 1044 . The parts of the first and second bands 1042 a , 1042 b , that extend past adjustable member 1304 can be contained within the hollow interior of the outer layer.
[0150] FIG. 42 provides a more detailed schematic view of the unassembled adjustment bands and adjustment member of FIG. 41 . The first and second bands 1042 a , 1042 b may include a series of adjustment stops 1048 . Adjustment stops may be in the form of holes, detents, dimples, ridges, teeth, raised elements, other mechanical features or the like. These holes 1048 on each of the bands 1042 a , 1042 b are coupled to an adjustable member 1304 . The adjustable member 1304 may be generally cylindrical (such as a spool) with a series of teeth 1050 or protrusions radially positioned to engage the adjustment stops 1048 . Adjustable member 1304 may also include a docking port 1320 to receive an adjustment tool to trigger rotational movement of the adjustable member.
[0151] FIG. 43 provides an assembled view of the adjustment band and adjustment member of FIG. 42 . When mounted in a housing (not shown in FIG. 43 ), the adjustable member 1304 may be mounted on an axis to allow for rotational movement. The first and second bands 1042 a , 1042 b pass on either side of adjustable member 1304 so that the teeth 1050 engage the adjustment stops 1048 in each of the bands 1042 a , 1042 b . Rotating the adjustable member in turn tightens or loosens the bands.
[0152] FIG. 44 is a cut-away view of an embodiment of the gearbox for the adjustment band of FIG. 41 . In this embodiment, the adjustable member 1304 rests on a spring 1052 inside a housing 1040 for the adjustable member. The housing 1040 includes access and guidance for the first and second bands ( 1042 a , 1042 b of FIG. 43 ) to couple with the teeth 1050 of the adjustable member 1304 . The spring 1052 forces the adjustable member 1304 upward so that teeth 1056 on the top of the adjustable member 1304 engage with teeth 1058 on the inside upper surface of the housing 1040 . Engagement of the adjustable member teeth 1056 with the housing teeth 1058 locks the adjustable member 1304 in place to prevent rotational movement. Downward force, applied for example by an adjustment tool, against the spring 1052 disengages the teeth 1056 and 1058 so that the adjustable member 1304 can be rotated to adjust the size or shape of implantable device 1302 .
[0153] In another embodiment, FIG. 45 provides a schematic view of an implantable device 1402 of the present invention with a plurality of sliding bands that can be opened and closed to effect a shape change. As with the previous embodiments of FIGS. 41-44 , the first and second bands 1042 a , 1042 b pass on either side of adjustable member 1304 so that the teeth 1050 engage the adjustment stops 1048 in each of the bands 1042 a , 1042 b . Additional bands 1042 c may be incorporated to increase stiffness at different areas of the implant device 1402 to provide preferential shape change. The additional bands 1042 c may be secured to the first and second bands 1042 a , 1042 b using welds 1043 , adhesive or other mechanical techniques known in the art.
[0154] As illustrated in FIG. 46 , in one embodiment, an implantable device 1502 has an anterior portion 1060 , a posterior portion 1062 and dual threads that provide preferential adjustment of one side or the other of implantable device 1002 . The implantable device 1502 has two independently adjustable threaded portions 1064 a , 1064 b used to achieve different pulling rates and/or lateral dimensions. The adjustable threaded portions 1064 a , 1064 b can be connected to one or more adjustable member 1004 of the implantable device 1502 and positioned at either the posterior or anterior portions of the implantable device 1502 . In one embodiment, the posterior portion 1062 may be a rigid member which includes threaded hex screws 1066 a , 1066 b , internal threads or similar structures. In one embodiment, the hex screws 1066 a , 1066 b are attached in a manner that allows rotation of the hex screws so that the threads may engage adjustable threaded portions 1064 a , 1064 b . Rigid posterior portion 1062 may include one or more of adjustable members 1004 that can receive a tool to impart rotational motion through an inner tube or cable to one or more of hex screws 1066 a , 1066 b , as described above. Anterior portion 1060 may be a flexible tube to accommodate shape change as the anterior and posterior portions 1060 , 1062 move relative to each other.
[0155] In another embodiment, differently pitched threads or other mechanisms may be used to provide non-symmetrical shape change of the implant device. For example, referring to FIG. 46 , wider threads on threaded portion 1064 b , in relation to the threads of threaded portion 1064 a , would allow an adjustable member 1004 to expand or contract the implant 1502 more rapidly on the side of threaded portion 1064 b to provide preferential shape change for a selected region while using a single adjustable member.
[0156] FIG. 47 is a schematic view of an embodiment of an adjustable member 1604 for an implantable device. An adjustment tool may impart reciprocating motion to the adjustable member 1604 that includes a clover gear 1070 mounted in a housing 1072 . The inner cable 1030 ( FIG. 33 ) of the implantable device, for example, is affixed to the clover gear 1070 such that rotation of the clover gear transmits torque through the inner cable 1030 to a screw or other adjustable portion of the implantable device as previously disclosed. In this embodiment, the adjustment tool can provide reciprocating action to provide for adjustment. The adjustable member takes an axial force applied to the control portion at the proximal end of the adjustment tool and converts it to a rotational force applied to the inner cable 1030 of the implantable device. Reciprocating axial force may be provided from an adjustment tool by using spring-mounted buttons pressed by the user. Pressing a first button may transmit a downward axial motion to a first ribbon 1074 which engages the clover gear 1070 to cause clockwise rotation of the clover gear 1070 . A spring or other return force pushes the first ribbon back to its original position after each click or press of the button. Similarly, pressing a second button may transmit a downward axial motion to a second ribbon 1076 that engages the clover gear 1070 to cause counter-clockwise rotation of the clover gear 1070 .
[0157] In another embodiment, the adjustment tool provides coarse adjustment and fine adjustment. This varied adjustment can be achieved with the adjustment tool having screws with different threads.
[0158] FIG. 48 provides a schematic view of an embodiment of the implantable device system 1000 including an adjustment tool 1706 with high column strength and stiffness. The adjustment tool 1706 has a shaft 1794 and a handle 1096 with sufficient column strength to ensure a downward axial force on the handle 1096 provides proper engagement with the adjustable member 1004 of the implantable device 1002 . The handle 1096 may be a grip-like handle, as shown, or a smaller pen-type handle. The adjustment tool 1706 can include mechanical locking at the distal region 1782 to lock with the adjustable member 1004 . The mechanical locking is configured to provide engagement and disengagement tactile feel to the physician.
[0159] FIG. 49 is a schematic view of another embodiment of the implantable device system 1000 including an adjustment tool 1806 with reduced column stiffness. The adjustment tool 1806 has a handle 1096 a shaft 1080 with reduced column stiffness for greater flexibility and easier articulation of the adjustment tool 1806 . The handle 1096 may be a grip-like handle, as shown, or a smaller pen-type handle. The easier articulation offered by the this embodiment may facilitate user positioning of the device in vivo and clearing adjacent biological structures, particularly when it is docketed to the adjustable member 1004 of the implant 1002 . Flexibility may be varied along the length of the adjustment tool shaft 1080 . Flexibility may be increased at the distal region 1082 of the adjustment tool shaft 1006 , particularly in the region immediately proximal to the gear/fitting at the distal tip of the adjustment tool 1006 . This gear/fitting is constrained orthogonally to the adjustable member 1004 , and it is important that the adjustment tool 1006 be easy to insert/connect and remain clear of biological structures.
[0160] FIG. 50 provides a view of an embodiment of the proximal end of the adjustment tool 1006 . Referring to FIG. 50 , adjustment tool 1006 includes a flexible cable 1094 or similar structure that is affixed to and rotates with a handle 1996 . In other embodiments, the adjustment tool 1006 can have cables, a band, tubes, rods, and the like to impart rotational and/or axial motion from the proximal end to the distal tip of the tool 1006 . The flexible cable 1094 may be enclosed by a flexible, low-friction cable jacket 1098 that allows the cable 1094 to rotate freely within the jacket 1098 . In some embodiments, adjustment tool 1006 may also include a spring release mechanism to allow disengagement of the distal tip of the tool from the docking port 1021 ( FIG. 33 ) with minimal force being applied to the sutures (or other mechanisms) securing the implant device to the tissue of an anatomic orifice or lumen. As shown in FIG. 50 , in some embodiments, an e-clip 1099 or similar device may be used near the handle 1996 of the adjustment tool 1006 to secure the release mechanism in the docking station until adjustments are complete.
[0161] In one embodiment illustrated in FIG. 51 , the adjustment tool 1006 may be inserted inside a rigid sheath 1092 that reaches the implantable device 1002 . Thus, FIG. 51 is a schematic view of an embodiment of the implantable device system 1000 of the present invention with an articulated shape. The rigidness of the sheath 1092 provides the necessary column strength to support the flexible adjustment tool 1006 . An added benefit to this embodiment is that the sheath may be left in place, docked to the implantable device 1002 . The flexible adjustment tool 1006 may be removed and then reinserted at some future time to engage with the adjustable member 1004 of implantable device 1002 .
[0162] The adjustment tool 1006 can have a handle 1096 that can be adjustable. The handle 1096 can have a length of at least 8 inches, and in one embodiment at least 10 inches. Other embodiments may have a shorter or longer handle length. The handle 1096 may be thick to provide a hand-grip, or, in other embodiments, smaller to provide a pen-like grip. The handle can have a device to quantify a size change of the implantable device 1002 . For example, a half-turn of the adjustment tool handle can be correlated to a distance of travel of the threaded rods 1018 a , 1018 b ( FIG. 33 ) of an implant 1002 , thus allowing for measured adjustment of the implant. The handle may include a click-counter or other known device to measure rotational movement. In one embodiment, the adjustment tool 1006 may be included in a percutaneous delivery catheter.
[0163] A sensor, such as the touchdown sensor described in relation to FIGS. 12-18 above, can be coupled to the implantable device 1002 . A variety of different sensors can be utilized, including but not limited to, sensors that measure pressure, temperature and flow across the implantable device 1002 . Pacing leads are coupled to the sensor and the implantable device 1002 , and in this embodiment, the sensor is responsive to flow through the implantable device 1002 .
[0164] In another embodiment the implantable device system may include a micro-electromechanical motor system in conjunction with or instead of a separate adjustment tool to commence rotational movement in an adjustable member. Power and control of the micro-electromechanical motor system can be provided by electromagnetic radiation or through a direct wire connection and previously described herein.
[0165] Finally, it will be understood that the preferred embodiment has been disclosed by way of example, and that other modifications may occur to those skilled in the art without departing from the scope and spirit of the appended claims.
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An implantable device system for controlling the dimensions of internal anatomic passages corrects physiologic dysfunctions resulting from a structural lumen which is either too large or too small. Implantable devices are disclosed which employ various mechanisms for adjusting and maintaining the size of an orifice to which they are attached. Systems permit the implants to be implanted using minimally invasive procedures and permit final adjustments to the dimensions of the implants after the resumption of normal flow of anatomic fluids in situ.
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TECHNICAL FIELD
[0001] The present invention relates to a panel and related wall structure and in particular to a sound absorbing panel and structure which although not essentially but, preferably is used as a building panel such as a wall or ceiling panel.
BACKGROUND ART
[0002] Wall and ceiling panels made of a gypsum based material are well known. Such panels are often also called plaster board panels and consist of a core of gypsum material overlaid on each side by a paper sheet. Such panels are used placed against framing timber to provide a lining for an inferior surface of a room of a house or building or the like. Similarly suspended ceilings may be provided wherein the plasterboard is suspended from a framing structure to thereby reduce the degree of vibrational transmission of sound.
[0003] Such additional steps in providing a further sound proofing can however be costly and it is advantageous if a single sheet of a building panel can be provided wherein significant or adequate sound absorption effects are provided by that panel alone. It will be appreciated that the provision of intermediary sound absorbing members add steps to the installation procedure of lining a room of a building.
[0004] The sound transmission loss of wall-barriers is determined by physical factors such as mass and stiffness. In double layer assembly, as in gypsum wallboard on non-continuous wood framing, the depth of air space, the presence of sound absorbing material and the degree of mechanical coupling between layers critically affect sound transmission losses and therefore the sound transmission class (STC).
[0005] Renewed interest in reducing noise in living chambers has motivated research in structural-acoustic analysis. Sound is generated by creating disturbance of the air which sets up a series of pressure waves fluctuating above and below the air's normal atmospheric pressure. These pressure waves propagate in all directions from the source of the sound. There are many sources of sound in buildings: voices, human activities, external noises such as traffic, entertainment devices and machinery. They all generate small rapid variations in pressure about the static atmospheric pressure. These propagate through the air as sound waves. The nature of excitation may be unique to each chamber. The sound transmission loss of wall-barriers is determined by physical factors such as mass and stiffness. In double layer assembly, as in gypsum wallboard on non-continuous wood framing, the depth of air space, the presence of sound absorbing material and the degree of mechanical coupling between layers critically affect sound transmission losses and therefore the sound transmission class (STC). The internal sound field in the enclosed area is significantly affected by: the acoustic modal characteristics, the dynamic behaviour of the surrounding structure, and by the nature of the coupling of these two dynamic systems e.g. that created by wall and ceiling structures. In addition, depending upon the relative value of the wall panel and gap resonant frequencies, sound transmitted from one side of a wall to the other may be amplified rather than reduced.
[0006] It is common knowledge that for typical partitions, the transmission loss is much smaller for low frequency sounds than for high frequency sounds.
SUMMARY OF THE INVENTION
[0007] Accordingly it is an object of the present invention to provide a panel which overcomes the abovementioned disadvantages or which at least provides the public with a useful choice.
[0008] It is also an object of the present invention to provide a wall structure which has improved acoustic transmission properties over single panelled wall structures, or to at least provide the public with a useful choice.
[0009] Accordingly the present invention consists in a panel comprising a unitary wall or ceiling panel comprising
a first layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said first layer defining a first exterior major surface of the panel and a second layer of a solidified gypsum based material having a plurality of preferably substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface, said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor during its curing to a solidified state.
[0013] Preferably said second layer is engaged directly to said first layer.
[0014] Preferably a third layer is provided as part of said panel capturing said second layer between said first and third layer, said third layer being of a solidified gypsum based material of a non cavity defining structure and defining a second exterior major surface of said panel.
[0015] Preferably said third layer is substantially similar to said first layer.
[0016] Preferably said first, second and third layers are coextensive.
[0017] Preferably at least one of said first and second major surface of said panel is provided with a patterned non planar surface.
[0018] Preferably at least one of said first and second major surface consists of a plurality of upstands.
[0019] Preferably each said upstand is prismatic in shape.
[0020] Preferably at least one of said first and second major surface of said panel is a cobbled surface.
[0021] Preferably said first and third layer is substantially of gypsum.
[0022] Preferably said third and first layers include EVA additive.
[0023] Preferably said first and third layers include a fibre re-enforcing material.
[0024] Preferably said anhydrate material is a polyacrylate.
[0025] Preferably said anhydrate material is a potassium polyacylate.
[0026] In a further aspect the present invention consist in a method of providing a unitary wall or ceiling panel which comprises the steps of
a) providing a layer of wet pre-solidified phase gypsum based material and anhydrate material homogenous mixture, onto a layer of wet pre-solidified phase gypsum based material without said anhydrate, b) allowing curing to a solidified phase of said gypsum to occur.
[0029] Preferably the method further includes the provision of a layer of wet pre-solidified phase gypsum based material onto to the exposed surface of the layer of pre-solidified phase based gypsum and anhydrate material homogenous mixture.
[0030] Preferably the method further includes the provision of a layer of gypsum based material onto the exposed surface of wet pre-solidified phase gypsum and anhydrate material homogenous mixture by the dispersing of a gypsum based power form material onto the the exposed surface of wet pre-solidified phase gypsum and anhydrate material homogenous mixture.
[0031] Preferably said third mentioned layer is absent of anhydrate material.
[0032] Preferably said anhydrate is a polyacrylate.
[0033] Preferably said polyacrylate is potassium acrylate.
[0034] Preferably said third mentioned layer prior to it setting is screeded to provide a planar surface finish.
[0035] Preferably a fibrous material is provided in at least one of the first and third mentioned layers.
[0036] Preferably said fibrous material is fibreglass.
[0037] Preferably said second mentioned layer is applied onto a horizontal moulding surface which during the curing of said layers provides upward support to said layers.
[0038] Preferably said moulding surface has an patterned relief moulding surface to impart a non planar surface to said second mentioned layer.
[0039] In a further aspect the present invention consist in a wall structure of a building comprising
a vertically extending frame work spanning between a floor and ceiling of said building a wall panel subassembly comprising a first panel and at least one other panel said second panel engaged to said first panel in a substantially parallel manner and separated therefrom to define a space there between, said first and second panels engaged to each other in a separated manner by a compressible material spacer element, wherein said subassembly is mounted from and affixed to said frame work by mechanical fastening means in a manner wherein said first panel is positioned facing said frame work and wherein a compressible material spacer element in provided intermediate of said first panel and said framework.
[0044] Preferably said first and second panels are coextensively engaged with each other.
[0045] Preferably said first panel comprises
a first layer predominantly of a solidified gypsum based material and being of a non cavity structure, said first layer defining a first exterior major surface of the panel and a second layer of a solidified gypsum material having a plurality of substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface, said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor.
[0049] Preferably said second panel is of a homogenous gypsum based structure.
[0050] Preferably the surface of said first panel facing said frame structure side is non planar.
[0051] Preferably said surface of said first panel facing said frame structure is of a cobbled or prismatic texture.
[0052] Preferably said compressible material spacer is a strip material and extends at least proximate to the perimeter of and between the first and second panels.
[0053] Preferably a second wall panel sub assembly is provided and disposed from the other side of said frame work, said second wall panel sub assembly comprising a first panel and at least one other panel
said second panel engaged to said first panel in a substantially parallel manner and separated therefrom to define a space there between, said first and second panels engaged to each other in a separated manner by a compressible material spacer element, wherein said second subassembly is mounted from and affixed to said frame work by mechanical fastening means in a manner wherein said first panel is positioned facing said frame work and wherein a compressible material spacer element is provided intermediate of said first panel and said framework.
[0056] Preferably the distance between the first panel of said first wall panel subassembly and the first panel of the second wall panel sub assembly is approximately 170 mm.
[0057] Preferably said frame work comprises of vertically extending timber studs.
[0058] Preferably said frame work comprises two parallel and separated rows of studs a first row with which the first sub assembly is engaged and a second row with which said second sub assembly is engaged.
[0059] Preferably said first panel of said first sub assembly and said first panel of said second sub assembly each included a cobbled or prismatic surface detail.
[0060] In still a further aspect the present invention consists in a wall or ceiling panel assembly comprising
a first planar panel of a rigid sheet material a second planar panel of a rigid sheet material affixed to said first wall panel in a spaced apart disposition from said first wall panel, wherein the major surfaces of said first and second planar panels are parallel and in at least a significant overlapping relationship with each other at least one resiliently flexible element disposed between the facing major surfaces the first and second panels and sealing engaged to the facing surfaces of each panel, wherein at least one of said first and second panels (hereinafter the “cavity panel”) comprises a first layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said first layer defining a first exterior major surface of the panel and a second layer of a solidified gypsum based material having a plurality of preferably substantially homogenously provided cavities, said second layer engaged with the first layer and disposed from the side of said first layer opposite to said first exterior major surface, said cavities each including anhydrate material of a kind having a water content dependent volumetric displacement, said cavities having been formed by the volumetric shrinking of said anhydrate material resultant from the dissipation of water from said unitary panel gypsum wet phase precursor a third layer predominantly of a solidified gypsum based material and of a non cavity defining structure, said third layer defining a second exterior major surface of the panel.
[0069] Preferably at least one of the first or second exterior major surfaces of said cavity panel(s) is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.
[0070] Preferably one of the first or second exterior major surfaces of said cavity panel(s) is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.
[0071] Preferably only one of said first and second panels is a cavity panel.
[0072] Preferably the exterior (to said assembly) facing major surface of said cavity panel is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.
[0073] Preferably the major surface of said cavity panel facing the other of said first and second panels is of a non planar surface consisting of plurality closely or abuttingly spaced upstands.
[0074] Preferably said resiliently flexible element is a strip material and is provided between the first and second panels at or immediately inwardly of the overlying perimeter regions of said first and second panels.
[0075] Preferably said first and second panels are affixed to each other in a substantially coextensive relationship.
BREIF DESCRIPTION OF THE DRAWINGS
[0076] This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.
[0077] FIG. 1 is a sectional view through a preferred form of the panel of the present invention,
[0078] FIG. 2 is a side view of a panel of the present invention,
[0079] FIG. 3 is a sectional view through an installation which includes the panel of the present invention to define a sound absorbing wall structure,
[0080] FIG. 4 illustrates a means of joining adjacent panels,
[0081] FIG. 5 illustrates an arrangement for supporting a panel from a vertical or horizontal surface,
[0082] FIG. 6 illustrates a method of fixing a series of panels to a wall structure wherein the assembly provides enhanced soundproofing,
[0083] FIG. 7 illustrates an example of an assembly of a wall utilising the panel of the present invention in conjunction with additional panels and framing,
[0084] FIG. 8 illustrates a prismatic surface texture provided on the panel of the present invention,
[0085] FIG. 9 is a view of the core of the panel of the present invention,
[0086] FIG. 10 is an illustration of the setup of the acoustic testing room,
[0087] FIG. 11 is a graph of results of the testing as hereinafter described,
[0088] FIG. 12 shows a test data sheet of the wall construction incorporating the cavity panel, and
[0089] FIG. 13 shows a test data sheet of the wall construction incorporating the cavity panel.
DETAILED DESCRIPTION OF THE INVENTION
[heading-0090] The Wall or Ceiling Panel
[0091] The proposed panel of a first aspect of the inventions described provides a convenient way of absorbing noise transmission and is maintained within a standard panel thickness (e.g. 12.5 nm) commonly used in building trades. With reference to FIG. 1 , the face gauge (exterior layers 4 and 1 ) consists of a gypsum based material and provides a high density thin layer. The exterior layers 1 and 4 are of a non-cavity structure and may hence be considered of a solid non porous structure. The face gauges 1 and 4 consists of a gypsum based material and provides a substantially solid thin section to the panel of the present invention. One face gauge provides its exposed surface 2 to be provided in a condition in use to be exposed into the room but which can later be subjected to further treatment such as priming and painting or for the application by adhesion of a paper layer or similar cellulosic material.
[0092] Each face gauge 1 is preferably of a high density consistency. Each face gauge is preferably in a form to provide a high density thin section to the panel and may be for example be provided by a reasonably low water content wet mix of solidified gypsum pre-cursor.
[0093] The body gauge (the interior layer 3 ) consists of a gypsum material mixed with anhydrite gelling material.
[0094] The gelling material is a product, which upon contact with water, results in rapid swelling as a result of electrical forces pushing the inward structure of the particle away from the centre. When water is drawn away from the polymer the particle shrinks in volume.
[0095] Post curing, cavities are formed within the body gauge. These cavities provide sound wave dissipation. Noise that flanks past the body gauge is in part reverberated back to the cavities from the backward high-density exterior surface face of the panel. As a result of the cavities within the body gauge, many entering sound waves are internally reflected and dissipated.
[0096] A first face gauge 1 is provided in a mould or onto a mould in its wet form gypsum based pre-cursor and is spread to a thickness of for example 2 mm. Provided on top of the face gauge (i.e. against the surface of the face gauge away from the to be exposed surface 2 of the face gauge is the body gauge 3 . The body gauge consists of a gypsum material which has been mixed with a hydrated gelling material such as an anhydrate as potassium polyacrylate. An example of a potassium polyacrylate is that known by the trade mark TERAWET™ which is a crosslinked potassium polyacrylate/polyacrylamide copolymer which comes in the form of white granules and has a bulk density of 540±40 grams per cubic meter. Its Ph value is somewhere between 6-6.8. Terawet™ is a product which upon contact with water results in rapid swelling as a result of electrical forces pushing the inward structure of the particle away from the centre. Small spaces are created inside the particle which attract water. When water is drawn away from the polymer the particle shrinks in volume. With the provision of hydrated potassium polyacrylate with the gypsum to define the body gauge, a substantially solid, in its wet form, layer of material is applied to the (preferably still procured form) inwardly facing surface 10 of the face gauge 1 .
[0097] The body gauge may be allowed to cure along with curing of the face gauge. However preferably a third layer, a backing face gauge 4 is provided to the then upwardly facing exposed surface of the body gauge 3 . The backing face gauge 4 is preferably made of a substantially similar material to the face gauge 1 . The body gauge 3 may be provided in the form of 8.5 mm layer intermediate of the backing face gauge 4 and face gauge. Further intermediate layers may be provided of a different kind however the most preferred form of the panel is as shown, in cross section in FIG. 1 .
[0098] Preferably said third layer 4 has a normal to the plane of its exterior surface projecting in the opposite direction away from said panel to the normal of the plane of the exterior surface of said first layer 1 so the panel is of a uniform thickness . . . .
[0099] Upon the curing of the gypsum material moisture is drawn out from the wet phase of the face, backing and body gauges. As the potassium polyacrylate also contains water, upon the curing of the panel, that water is removed from the potassium polyacrylate. The potassium polyacrylate becomes dehydrated and reduces in volume. As it reduces in volume, cavities are formed within the body gauge such cavities being substantially of a size of the wet or hydrated phase of the potassium polyacrylate.
[0100] Once dehydrated, the swelled anhydrites at the core of the sheet shrinks to form small beads. The result is aerated cavities 30-40 times larger than the remaining bead of anhydrate. The dried anhydrites can re-swell to its original cavity mass when atmospheric moisture conditions are present. This phenomenon can occur repeatedly in a consistent manner.
[0101] The anhydrites within the panel will absorb and contain water ingress and release it when appropriate warm and dryer atmospheric conditions are present.
[0102] At the casting stage an anti-mould and fugal agent is added to at least the body gauge to combat the problems associated with water ingress such as product breakdown, rot, mildew and mould growth.
[0103] The application of the backing gauge to form part of the panel of the present invention, is achieved during the curing of the face and body gauge. As the curing of the face and body gauge takes place, moisture is floated to the surface of the body gauge. This moisture can be removed by the application of gypsum powder to the upper surface of the body gauge as the moisture is transferred therefrom. The application of gypsum powder to the upper surface of the body gauge provides the backing face gauge to the panel of the present invention. In order to achieve a smooth surface to the backing gauge the powdered gypsum that is applied to the surface of the body gauge is smoothed by for example a screed. The thickness of the backing gauge can be built up appropriately to cover the upper surface of the body gauge and to thereby define a panel which is of a desired thickness. By way of example, the thickness of the panel may be provided to approximately 12.5 mm.
[0104] Cavities in the body gauge, provide a disruption of reverberation of sound through the panel. The panel allows for mild reverberation of the face gauge allowing for a reasonably high percentage of noise to pass through to the body gauge. The reverberation of sound in the body gauge can be captured in the cavities in providing a dissipating effect of the noise. Noise that flanks past the body gauge is in part reverberated back to the cavities from the exterior layers. As a result of the cavities within the body gauge of the panel of the present invention, much sound that enters therein is internally reflected and eventually some if not most is absorbed.
[0105] To provide strength to the panel, fibre rovings may be provided throughout the panel or provided within at least one of the gauges and preferably within the body gauge 3 .
[0106] The panel of the present invention with the inclusions of a dehydrated anhydrate will also provide some degree of humidity or moisture absorption.
[0107] Further additives may be provided to the gypsum material for the purposes of hardening and such materials may include EPA and EP hardener and indeed anti-mould or antifungal agents may be added particularly considering the possibility of moisture absorption being provided by the anhydrates.
[0108] In designing the wallboard several factors were taken into account. These include the right weight for swelled anhydrites, the right amount of a typical hardener (EP hardener) which is added to both the face and body gauges, the fibre-glass strands. Table 1 shows one example of material detail. Table 2 shows an alternative. Table 2 gives weight values of components for the improved mix at a mass quantity gauge ratio of 100:60.
[0109] The panel of the present invention may further be provided with a surface modification to at least one of the outwardly facing surfaces of the face gauge or backing face gauge 1 , 4 . Such a surface modification is by way of a pattern of upstands or substantially the entire of the surface and provides a disruption to the otherwise flat exterior surface of the panel.
[0110] The panel of the present invention provides a convenient way of absorbing some noise transmission through the panel while still allowing it to be maintained within a standard thickness wall panel which are commonly used in the building trade.
[0111] With the provision of surface modifications to at least one and alternatively to both of the outwardly facing surfaces of the panel of the present invention, further sound reducing characteristics may be catered for. Surface upstands which may be provided as a pattern to the surface of the panel can provide further sound deflection. With reference to FIG. 3 , the panel is provided as part of a sound absorbing structure and the surface modifications 12 may be provided exposed into a cavity which is defined between the panel of the invention and an other like or other type of panel 13 .
[heading-0112] Wall Structure
[0113] The overall function of a wall, in conjunction with floors, and roofs, is to provide a barrier between two environments, so that one environment can be adjusted and maintained within acceptable limits.
[0114] A wall is a selective separator between two spaces where between an actual or potential flow of energy is involved. The greater the difference between the two spaces the greater is the stress of duty imposed on the wall. Thus, the elements of the wall must be selected so that in the first instance they impart the necessary resistance to keep noise levels within acceptable limits. The way they are arranged, however, is also important. This will determine the variation in conditions throughout the wall. Interaction between various factors involved may produce conditions within the wall structure that require special attention.
[0115] The panel 13 may be a standard plaster board sheet which is provided in association with the panel 14 of the present invention. The surface modifications 12 may be provided preferably within the cavities provided between two panels 14 , 13 . Alternatively the panel 14 may present the surface modifications outwardly for positioning facing a frame structure. The surface modifications will provide a disruption to the sound waves endeavouring to travel into the panel 14 from any sound transmitted from the inwardly facing surface of the panel 13 . To prevent direct vibrational transmissions between the two panels a spacer 15 of a low hardness material such as a foam or rubber is provided to create a space lamination such may be provided at appropriate locations between the panels 13 and 14 . This spacer will reduce the incidence of material vibrational transmission of sound.
[0116] The panel 14 is preferably mounted to a frame work structure 16 of a building such as timber framing directly, or with rubber or foam spaces in between or by way of mounts 17 . Such mounts may be rails of an extruded or roll formed kind to which the panel structure of the panels 13 , 14 are mounted. Rubber grommets 21 or strip material may be further provided intermediate of the structure 16 and the mounts 17 and/or between the mounts 17 and the panel 14 . With reference to FIG. 5 , there is shown a detailed view of the arrangement wherein the panel is provided to a timber framing structure as for example shown in FIG. 16 .
[0117] A putty like material may be provided to overlay the positions where the fastening means 22 may be provided to secure the panel 14 to the rails 17 . The application of such a putty 23 provides a sound seal to the migration of sound via the fastening means 22 to or from the other side of the panel 14 to which it is provided.
[0118] With reference to FIG. 6 , a wall utilising the panel construction of the present invention may be provided wherein a plurality of panels are provided adjacent to each other. Such a plurality of panels 20 are preferably engaged to adjacent like panels as for example shown in FIG. 4 . A sound sealing material 25 may be provided intermediate of the panels to thereby reduce transmission of vibration between adjacent abutting panels.
[0119] The spacer seal 15 may extend around or approximate to the formed perimeter of the plurality of panels. Intermediate of the spacer there may be provided a sound absorbing putty 26 . Such a sound absorbing may also be provided external of the seal 15 .
[0120] The exterior panel 13 may preferably be adhered to the panel 14 by adhesive regions 27 such as adhesive daubs. The adhesive is that which holds the facing panel 13 to the inner panel 14 .
[0121] With reference to FIG. 7 there is shown a double sided wall structure which includes a frame structure of a first row of studs 102 and a second row of studs 106 . The studs preferably extend from floor to ceiling of a building structure and nogs or dwangs may extend between adjacent studs in each row. However most preferably each row remains separated from the other row and accordingly a gap 107 is provided between the rows of studs. The gaps will reduce the possibility of solid mass sound transmission, between studs and hence each side of the wall.
[0122] On each side of the studs are provided a wall panel sub assembly. Each wall panel sub assembly preferably consists of a first panel 101 and a second panel 100 . In a most preferred form the panel 101 is of a kind as hereinbefore described which utilises the cavity structure defined by the anhydrate material therein. The first and second panels are engaged to each other but are separated by a space therebetween which is preferably defined by a spacer element 104 which is of a flexible material such as a foam or rubber strip or strips. The foam may for example be a high density foam seal. As mentioned above, additional adhesive daubs may be provided intermediate of the two panels of each sub assembly to fix these together. As a sub assembly, the two panels are then fixed to the appropriate side of the frame structure to a respective row of studs.
[0123] Preferably a high density foam seal is provided intermediate of the stud and the facing side of the first panel 102 to act as a vibration absorption spacer between the studs and the subassemblies. Fixing screws can then extend through the subassemblies (through both panels 101 and 100 to further fix the sub assemblies to the frame work). Screws of a sufficient length and of a kind often used in a plaster board panels can be used.
[0124] Intermediate of the two sub-assemblies of panels a thermal insulation material such as a fibre insulation mat can be positioned to further enhance sound absorption and to provide thermal insulation.
[0125] In the most preferred form the sub assemblies are positioned such that the non planar (e.g. the surface with the cobbled or prismatic upstands) panel of the sub assemblies are positioned engaged to the frame structure, facing the studs or facing the cavity between the studs. The non planar surface 108 positioned in this manner will encourage the sound dissipation within the cavity between the two facing sub assemblies, provided on each side of the frame structure.
[0126] It is perceived by the inventor that these wall structure as shown in FIG. 7 may utilise one only subassembly on one side only and the other side may be of a different kind. A single stud arrangement against which a single sub assembly is provided may also be utilised. However it has been recognised in testing that a double wall structure as shown in FIG. 7 and wherein the spacing between the interior facing surfaces of the wall sub assemblies provided at approximately 170 mm apart, provides a very attractive absorption characteristic of which reference will hereinafter be made.
[heading-0127] Tests
[0128] In order to achieve high STC valves it has been recognised by the inventor that, important factors, in addition to masses of the component layers, are the depth of air space, the use of sound absorbing materials within the air space and the rigidity of the mechanical coupling between the layers. This may be achieved by a wall assembly with no significant rigid mechanical connection between the two wall panel subassemblies on each side of the frame structure. The mechanical connection between the subassemblies of two panels is reduced by the use of separate rows of studs to support the subassemblies independently of each other.
[0129] With reference to FIGS. 11, 12 and 13 test results indicate that the cavity panel incorporating sub-assembly of this invention reached an STC of 63 dB. This value is higher than those reached with locally and internationally (Canada and USA) produced acoustic panels of solid (non cavity) configuration. The STC of Standard Commercial Wall Boards is 54 dB.
[0130] For the wall assembly of FIG. 7 the results also showed a significant improvement to the lower ranges of frequency (between 50-160 Hz). This effect can be avoided by increasing the air space between the non-continuous wooden frames to displace the facing surfaces of the two subassemblies. Tests were conducted to find the optimum airspace between the facing surfaces of the panel subassemblies on each side of the frame structure to suppress resonance. This was found to be optimum at 170 mm.
[0131] It was shown by analysis that the core shear parameter has a significant effect on the noise transmission characteristics of the proposed panel, which has better sound transmission characteristics than a homogenous panel, for two reasons: first, the coincidence frequencies are shifted to higher frequency ranges, and second, the coincidence transmission loss is considerably increased due to the presence of the cavities on the layer surface.
[0132] Tests were conducted on the new panel at the University of Auckland Acoustic Laboratories. Sound transmission loss was measured by testing in two separate rooms highly reverberant not in solid contact with either of them. A loud speaker and amplifier are used to generate random sound in one of the rooms and sound energy passes through the partition into the second receiving room ( FIG. 10 ):
[0133] The level in the receiving room is partly determined by the area of the partition and the total absorption of the receiving room. The larger the sound transmission class (STC) value, the better the partition (less sound energy passes through it).
[0134] The reverberation time in the echoic chambers was optimised. The reverberation time is directly related to the room volume and inversely related to total absorption in the room. The reverberation time is calculated using Sabine reverberation time equation:
RT= 0.161 V /(α S+ 4 mV )
where: V is the room volume in cubic meters, α is the mean absorption coefficient, S is the total surface area of the room, in square meters, m is the energy attenuation constant per meter due to air absorption.
[0140] An important improvement is achieved on the low frequency range (between 50-160 Hz). On curve of FIG. 11 , the variation of the transmission loss is shown with frequency:
For low values of frequency (between 50-160 Hz) the transmission loss curve follow the mass law. It shows significant improvement. At mid-ranged frequencies (between 200-630 Hz) a deviation from the mass law takes place. This is attributed to the fact that at this range the wave resonance acts to increase the frequency values. The larger the air space between the double layers or the heavier the materials, the lower the frequency at which resonance occurs. For higher frequency ranges, the transmission loss curve follows the mass law again.
[0144] The curve shows that the TL is significantly higher at intermediate frequency range (1000-2000 Hz). This is mainly due to the fact that the coincidence frequencies are much higher than for the larger values of frequency. A sharp drop in LT is noticed between (2000-2500 Hz) to then increase rapidly with increase in frequency (2500-4000 Hz).
[0145] To maximize the improvement due to airspace, frames should be designed so that the mass-air-mass resonance is at the lowest frequency as possible. Many common frame designs do not meet this criterion. The air trapped in the space between the layers acts as a spring transferring vibration energy from one frame to the other.
[0146] The concept of sound transmission of prismatic surface cavitated core of a wall barrier is of a significant importance in the research for more cost effective methods related to development of acoustic wallboards.
[0147] The sound transmission losses of a single or double layer walls are determined by the physical properties of the component materials and the method of assembly.
[0148] We believe that noise management of the whole system will dictate whether the subsystems will perform satisfactorily. Furthermore, it is estimated that the major failures can be avoided by proper design and suitably implemented wall barriers. The rate of noise failures can be reduced effectively if corrective measures are taken by the whole industry.
[heading-0149] Summary of the Measurement of Airborne Sound Insulation of Building Elements Regarding the Results of FIGS. 11-13 .
[heading-0150] Installation of Test Sample:
[0151] The wall under test is installed in the opening between two reverberation chambers chambers C and A for a wall, chambers A and B for a floor. These chambers are vibration isolated from each other which results in a structural discontinuity at the middle of the test opening. This gap is covered over by a collar, which seals the gap and provides for each of fixing of samples. The wall sample is constructed by the client following the techniques normally used in practice for that type of wall or floor/ceiling, and is sealed into the test opening with perimeter seals of acoustic sealant. For each of removal, the surfaces of the test opening are covered with an adhesive, heavy fabric tape prior to the construction of the building element.
[heading-0152] Method:
[0153] The measured transmission loss values are obtained in accordance with the recommendations of ISO standard 140-3:1995(E) “Laboratory Measurement of Airborne Sound Insulation of Building Elements” using a B&K 2133 analyser. The measurements were repeated and checked by an independent measuring system, the B&K 2260 sound level meter.
[0154] Essentially the transmission loss of a building element is measured by generating sound on one side of the building element (the source chamber) and measuring how much sound is transmitted into the receiving chamber. In the source chamber pink noise is radiated from a loudspeaker. Time and space averaged sound pressure levels in both the source and receiving chambers are measured by using a rotating boom microphone, and the average sound pressure levels are obtained by sampling the sound pressure levels as the boom rotates through one cycle (taking 32 seconds). This is repeated for a different loudspeaker position in the source chamber.
[0155] Measurements of the background noise levels in the receiving chamber are also made. Then, should it prove necessary, the transmitted noise levels are corrected for the influence of background noise as prescribed in the standard.
[0156] The sound absorption of the receiving chamber is also determined by measuring the reverberation times (ISO-354:1985(E) “Measurement of Sound Absorption in a Reverberation Room”).
[heading-0157] Results:
[0158] The third octave band sound reduction indices R are presented in both table and graph formats. Sometimes a highly reflective test sample means that the lower frequency sound pressure levels cannot be reliably measured; this is indicated by #N/A in the table of results. Additionally, if the specimen is highly insulating, sometimes the background noise affects the measurements, resulting in only an upper threshold being found; this is indicated by a > sign preceding the tabulated results.
[0159] Single figure ratings are also presented. The weighted sound reduction index R w , determined according to ISO 717-1, is presented along with spectrum adaptation terms C tr and C. R w is determined by fitting a reference curve to the third octave band sound reduction indices R from 100 Hz to 3150 Hz, and gives a single figure rating of the sound reduction through the building element (higher is better). The spectrum adaptation terms are added to R w and are used to take into account the characteristics of particular sound spectra. C is used for living activity noise, children playing, railway traffic at medium and high speed, highway (>80 km/h) road traffic, and jet aircraft at short distances. C tr is used for lower frequency noise such as urban road traffic, low speed railway traffic, aircraft at large distances, pop music, and factories which emit low to medium frequency noise. C and C tr without further subscripts are applied to a frequency range of 100 Hz to 3150 Hz. Other spectrum adaptation terms are provided with enlarged frequency ranges (if measured), e.g. C tr,50-5000 is applied to urban traffic noise with a frequency range of 50 Hz to 5000 Hz. For light timber constructions C tr will be negative, indicating the poor sound insulation abilities of such constructions at low frequencies.
[0160] The sound transmission class (STC) determined according ASTM E413 is also presented. This is determined by fitting a reference curve to the third octave band sound reduction indices R from 125 Hz to 4000 Hz, but in a slightly different way to ISO 717-2. The sound transmission class gives a single figure rating of the sound reduction through the building element so that higher is better.
TABLE 1 Gauge Type Weight Per Thickness Body (8.5 mm) Swelled anhydrates 1.42 kg/m 2 (i) Face (2 mm) Hardened (EPA) 19 mlt/m 2 (ii) Backing Face (2 mm) 76 mtl/m 2 (iii) Body (8.5 mm) Nil Body gauge surface Fibre-glass strands 220 gms/m 2
[0161]
TABLE 2
Gauge
Type
Weight Per Thickness
Body (8.5 mm)
Swelled anhydrites
1.54 kg/m 2
(i) Face ((2 mm)
Hardener (EPH)
61.7 mlt/m 2
(ii) Body (0.5 mm)
185.2 mlt/m 2
(iii) Backing Face (2 mm)
61.7 mlt/m 2
(i) Face layer
Fiber-glass strands
24 gms/m 2
(ii) Body layer
208 gms/m 2
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A unitary wall or ceiling panel comprising of a first solid layer solidified gypsum and a second layer of a solidified gypsum having a plurality cavities. The second layer is engaged with the first layer and disposed from one side thereof. The cavities each including anhydrate material of a kind having a water content dependent volumetric displacement. The cavities have been formed by the volumetric shrinking of the anhydrate material resultant from the dissipation of water from the unitary panel gypsum wet phase precursor during its curing to a solidified state.
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BACKGROUND OF THE INVENTION
Much research has been conducted in the area of cellulose hydrolysis to produce fermentable sugars, such as glucose therefrom. Cellulose is the most abundant polymer on earth, and is characterized as a straight chain polymer composed of glucose with beta 1,4-linkages. Cellulose may exist in crystalline or amorphous forms. Generally speaking, one can easily hydrolyze amorphous cellulose with dilute acid or enzymes. Crystalline cellulose, on the other hand, is difficult to hydrolize presumably due to a tight physical packing of the cellulose molecules. As a result, degradation of the hydrolysis products is significant as represented by the following scheme: ##STR1##
Various methods have been touted for decrystallizing cellulose through the use of solvents to precipitate it in an amorphous form. However, there methods all utilize cellulose which is solid, albeit amorphous.
Penque U.S. Pat. No. 4,018,620 describes a method of hydrolyzing cellulose using calcium chloride and dilute acid at a temperature of 100° C. to form a colloid suspension of the cellulose which is the hydrolyzed at a temperature of 120° C. for a period of 30 minutes. Contrary to Penque's findings, and due apparently to an error in the unit and chemistry of Penque's analysis, we have found that the claimed method does provide a complete conversion of cellulose to glucose. According to Penque, 10% (w/v) of newsprint (which contains cellulose and hemicellulose) was hydrolyzed, thereby obtaining a 10% (w/v) reducing sugar solution which is equivalent to 50% of the total reducing sugar.
Because the hemicellulose fraction is very easy to hydrolyze, and since newsprint generally contains at least 15% hemicellulose, one must subtract this value from the yield of glucose from cellulose fraction thereby getting a yield of only 20%. In addition, Penque used Clinitest tablets to quantitate the sugar. These tablets are also reactive to the degraded glucose, (Hydroxymethyl furfural) and do not provide a true reading of reducing sugars. On the other hand, analyzing with "Tes-tape" or glucose analyzer, which is specifically reactive to glucose, would provide a different and more accurate result.
It is thus, desirable to hydrolyze cellulose in a liquid state. Unfortunately, conventional cellulose swelling reagents and cellulose solvents are either too severe for glucose or unable to catalyze the cellulose hydrolysis.
Zinc chloride is known as a cellulose swelling reagent, and swells the cellulose at a concentration range from 60 to 80%, with maximum effect at 75% and 65%. The pH of ZnCl 2 at this range on concentration is 0 to -2, and thus is able to provide a catalytic function of cellulose hydrolysis. However, under such conditions glucose is also degraded at a faster rate.
In our concurrently filed application Ser. No. 377,077, titled "Quantitative Hydrolysis of Cellulose to Glucose Using Zinc Chloride", we describe a method for hydrolyzing cellulose to pretreating same with concentrated zinc chloride to liquify the cellulose, thereafter reducing the zinc chloride concentration (e.g. by dilution) and completing acid hydrolysis to form glucose. While that process provides hydrolyzed yields of over 90%, the separation of zinc chloride and glucose is costly.
Accordingly, it is the primary object of the present invention to provide a means for effectively pretreating cellulose with zinc chloride and thereafter separating the zinc chloride from the glucose produced.
This and other objects of the present invention will be more apparent from the discussion which follows.
SUMMARY OF THE INVENTION
Cellulose is selectively hydrolyzed to glucose without the formation of degradation by-products by pretreating the cellulose to form soluble cellodextrins through treatment with concentrated (60-80%) solutions of zinc chloride. Zinc chloride is then separated from the mixture by extraction with attendant precipitation of the cellodextrin material, which is then hydrolyzed, chemically or enzymatically to glucose.
The process according to the present invention generally comprises the steps of:
(a) forming a mixture of cellulose together with zinc chloride, said zinc chloride being in the form of an aqueous solution containing from about 60 to about 80% (preferably about 65 to 76%) by weight of zinc chloride;
(b) heating the mixture formed in step (a) at a temperature of from about 70° to about 180° C. (preferably from about 100° to about 145° C.) for a period of time sufficient to convert the cellulose to a liquid form;
(c) removing the zinc chloride from the mixture by solvent extraction thereby precipitating the partially hydrolyzed cellulose in the form of cellodextrins; and
(d) separating the precipitated cellodextrins from the extraction media;
(e) hydrolyzing the precipitated cellodextrin to glucose.
It is important that the zinc chloride be removed as soon as the cellulose has been liquified--i.e. as soon as the cellulose has been partially hydrolyzed to form soluble cellodextrins to avoid glucose degradation and formation of such undesirable by-products as hydroxymethylfurfural.
We have found that if cellulose is only partially hydrolyzed to soluble cellodextrins, the ZnCl 2 may be recovered by the addition of H 2 O, acetone, ethanol, ether, or other organic solvents. In the presence of such solvents, the cellodextrin precipitates and ZnCl 2 remains in the solvents. Summarizing the present process provides an improved means for producing glucose with removal of zinc chloride prior to glucose formation by:
1. Liquifying cellulose with ZnCl 2 /H+ or ZnCl 2 and partial hydrolyzing cellulose to a water soluble cellodextrin.
2. Recovering ZnCl 2 by extraction with H 2 O, acetone, methanol ethanol, ether or other suitable solvents.
3. Hydrolyzing water soluble dextrins to glucose by dilute acid or enzyme action.
DETAILED DESCRIPTION OF THE INVENTION
We have found that glucose can be dissolved in ethanol, acetone and other organic solvents in the presence of a high concentration of zinc chloride, but cellodextrin or higher glucose polymers do not dissolve in acetone, ethanol and other organic solvents. Thus, zinc chloride can readily be separated from the partially hydrolyzed cellulose, and the partially hydrolyzed cellulose (i.e. cellodextrins) can be further hydrolyzed to glucose in the absence of zinc chloride. Tests indicate that only water soluble cellodextrin can be readily hydrolyzed to glucose after the separation of zinc chloride. The present process therefor provides a means for the recycling of zinc chloride.
The hydrolysis of cellulose to form the cellodextrin can be carried out with and without the presence of acid, since the cellulose is a solution it can be hydrolyzed randomly. The distribution of molecular weight at certain reaction times is governed by the hydrolysis rate of cellulose and degradation rate of glucose. The hydrolysis rate and degradation rate is a function of temperature and the concentrations of acid and zinc chloride as discussed below.
For the convenience of recycling zinc chloride, the reaction may be stopped at a point where the fraction of soluble cellodextrin is at the maximum. These points depend on the temperature and concentration of zinc chloride and acids, and are easily determined by the chemist.
The solution of partially hydrolyzed cellulose is then added to acetone or ethanol (or other organic solvents). All of the cellodextrins will precipitated out with the exception of glucose.
Zinc chloride is soluble in acetone, ethanol, ether, and some other organic solvents. These organic solvents can then evaporated and recycled if desired. Zinc chloride and glucose may be further heated. Upon heating, glucose forms active charcoal with the evolution of gas, and zinc chloride can be separated easily and then recycled. Alternatively chloride may be recycled in the presence of glucose.
The cellodextrin precipitate may then be subjected to a stripping of solvent by either steam or air. Acid solution can then be added to the cellulose for further hydrolysis.
In forming the initial mixture of cellulose and zinc chloride solution, we have found that the maximum amount of cellulose which may be added to the concentrated zinc chloride solution is about 1 gram of cellulose for each 2 ml of zinc chloride solution.
As noted above, we have also found that the degradation rate of glucose is affected by temperature, the concentration of ZnCl 2 , and acid. The rate of glucose degradation can be expressed as:
K.sub.DEG =2.23×10.sup.2 ([ZnCl.sub.2 ]4.53+4.62[H.sup.+ ].sup.0.544)×e.sup.-2.185×10.spsp.4.sup./RT-20.85[H.spsp.+.sup.].spsp.0.551
This means that lower acid, ZnCl 2 concentration, and low temperature stabilizes glucose. However the concentration of ZnCl 2 that can dissolve cellulose is detrimental to the glucose. Fortunately, the data indicates that the dissolved and partially hydrolyzed cellulose can remain in solution at a lower concentration of ZnCl 2 achieved in accordance with the present invention.
The following examples are offered to more fully illustrate the invention, but are not to be construed as limiting the scope thereof.
EXAMPLE 1
Material and Methods
Avicel was used as noted as a source of cellulose. Cellulase from Trichoderma verdi was used for enzymatic hydrolysis. This enzyme was fractionated by 50% saturated ammonium sulfate to remove glucan. The protein content of the purified enzyme is 20% determined by Lowry's method with hovine serium albumia as standard.
Pretreatment of Cellulose
Avicel 10 gm was wetted with 12 ml of water. 50 ml of 74% ZnCl 2 solution containing 0.5% (w/v) HCl was added to the wetted avicel. The cellulose solution were then subjected to heating with the temperature ranging from 100° C. to 145° C. The heating time ranging from 6 minutes to 20 minutes. The heated cellulose now reduced to cellodextrin is then cooled by setting at room temperature or cooled by plunging the reactor cell in the ice slurry. The cellodextrin is precipitated by adding 25 ml of acetone per gram of cellodextrin to the cellulose solution. The precipitated cellodextrin was washed with 25 ml of acetone per gram of avicel for 4 times. The cellodextrin was then vacuum dried to remove acetone. The cellodextrin thus obtained was in lumps which were then resuspended in water and freeze dried. The freeze dried samples are powdery particles. 0.8 gm cellodextrin was suspended in 2 ml of sodium acetate buffer (pH 4.8, 0.05M) and 2 ml of enzyme in buffer solution was then added to this suspension with the final enzyme concentration of 0.01%, 0.1%, 0.5%, 2.5% and 5% (w/v). The samples were incubated at 48° C. in a shaker bath. 8 tiny glass beads were added to assist the agitation with and form glucose.
EXAMPLE 2
One gram of Avicel is swollen and hydrolyzed in 65% ZnCl 2 aqueous solution. After 4 hours of heating to 100° C., 80% of cellulose becomes water soluable dextrin. Fifteen percent of the cellulose is hydrolyzed after acetone extraction to glucose using dilute hydrochloric acid.
The invention having been thus described, it will be appreciated that various departures may be therefrom within the scope of the claims which follow.
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Cellulose is selectively hydrolyzed to glucose without the formation of degradation by-products by pretreating the cellulose to form soluble cellodextrins through treatment with concentrated (60-80%) solutions of zinc chloride. Zinc chloride is then separated from the mixture by extraction with attendant precipitation of the cellodextrin material which is the hydrolyzed, chemically or enzymatically to glucose.
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This application is a continuation of U.S. patent application Ser. No. 10/676,338, filed Sep. 30, 2003, now U.S. Pat No. 7,045,452 issued May 16, 2006, entitled “Circuit Structures and Methods of Forming Circuit Structures with Minimal Dielectric Constant Layers.”
BACKGROUND
1. Field
Integrated circuit processing.
2. Background
Modern integrated circuits use conductive interconnections to connect the individual devices on a chip or to send or receive signals external to the chip. Popular types of interconnections include aluminum alloy interconnections and copper or copper alloy interconnections.
One process used to form interconnections, particularly copper or copper alloy interconnections, is a damascene process. In a damascene process, a trench is cut in a dielectric and filled with copper to form the interconnection. A via may be in the dielectric beneath the trench with a conductive material in the via to couple the interconnection to underlying integrated circuit devices or underlying interconnections. In one damascene process (a “dual damascene process”), the trench and via are each filled with copper material by, for example, a single deposition.
A photoresist is typically used over the dielectric to pattern a via or a trench or both in the dielectric for the interconnection. After patterning, the photoresist is removed. The photoresist is typically removed by an oxygen plasma (oxygen ashing). The oxygen used in the oxygen ashing can react with an underlying copper interconnection and oxidize the interconnection. Accordingly, damascene processes typically employ an etch stop layer of silicon nitride (Si 3 N 4 ) directly over the copper interconnection to protect the copper from oxidation during oxygen ashing in the formation of a subsequent level interconnection. In intelayer interconnection levels (e.g., beyond a first level over a device substrate), the etch stop layer also protects against misguided or unlanded vias extending to an underlying layer or level.
In general, the Si 3 N 4 etch stop layer is very thin, for example, roughly 10 percent of the thickness of the pre-metal dielectric (PMD) layer or interlayer dielectric (ILD) layer. A thin etch stop layer is preferred primarily because Si 3 N 4 has a relatively high dielectric constant (k) on the order of 6 to 7. The dielectric constant of a dielectric material, such as an interlayer dielectric, generally describes the parasitic capacitance of the material. As the parasitic capacitance is reduced, the cross-talk (e.g., a characterization of the electric field between adjacent interconnections) is reduced, as is the resistance-capacitance (RC) time delay and power consumption. Thus, the effective dielectric constant (k eff ) of a PMD layer or ILD layer is defined by the thin etch stop layer and another dielectric material having a lower dielectric constant so that the effect of the high dielectric material typically used for the etch stop layer (e.g., Si 3 N 4 ) is minimized.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side view of a portion of a circuit substrate or interconnect layer on a substrate including a contact point and a first etch stop layer formed over the contact point.
FIG. 2 shows the structure of FIG. 1 following the formation of a dielectric layer on the first etch stop layer.
FIG. 3 shows the structure of FIG. 2 following the formation of an interconnection to the contact point.
FIG. 4 shows the structure of FIG. 2 following the formation of a second etch stop layer on the dielectric layer and interconnection.
FIG. 5 shows the structure of FIG. 4 following the optional formation of a subsequent dielectric layer on the second etch stop layer and an optional interconnection, and also shows the structure after a thermal decomposition of the dielectric layer.
FIG. 6 shows a representation of cyanate ester monomers and the formation of a polycyanurate.
DETAILED DESCRIPTION
FIGS. 1 to 3 illustrate a dual damascene process for forming an interconnection over a contact point. A contact point is, for example, a device on a substrate (e.g., gate, junction, etc.). Alternatively, in a multi-level interconnection device configuration, the contact point also includes an underlying interconnection (e.g., an interconnection line). A typical integrated circuit of a microprocessor may have, for example, five or more interconnection layers or lines stacked on one another, each insulated from one another by dielectric material.
FIG. 1 illustrates a cross-sectional, schematic side view of a portion of a circuit substrate structure. Structure 100 includes substrate 110 of, for example, a semiconductor material such as silicon or a semiconductor layer on an insulator such as glass. Substrate 110 , as viewed, may also include a device layer and one or more dielectric layers formed thereon with interconnections disposed therethrough. Substrate 110 includes contact point 120 on a surface thereof. In one embodiment, contact point 120 is a portion of an underlying interconnect line (e.g., a metal trench). A representative interconnect line is shown in dashed lines. Overlying contact point 120 and substrate 110 , in one embodiment, is etch stop layer 130 . Etch stop layer 130 is selected, in one embodiment, to be a material having a dielectric constant (k) less than on the order of about five. In the context of a contact point that is a copper interconnection (e.g., interconnection line), etch stop layer 130 is selected to have relatively good copper diffusion characteristics (i.e., to inhibit copper diffusion). Etch stop layer 130 is also selected such that it is a material that has an etch characteristic such that it may be selectively etched or retained during an etch operation involving a subsequently introduced dielectric material, such as a dielectric material that, together with barrier material 130 , will serve as a pre-metal dielectric (PMD) or interlayer dielectric (ILD) layer dielectric material.
A suitable material for etch stop layer 130 is a material that will be sufficiently strong or sturdy to remain in the absence of a supporting material. A suitable material should also have a relatively low dielectric constant so that its contribution to an overall dielectric constant (k eff ) is minimized. Further, the material for etch stop layer 130 should be selectively etchable in the presence of another dielectric material. Suitable materials include silicon dioxide (SiO 2 ) or silicon nitride (Si 3 N 4 ). Each of these materials may be introduced by chemical vapor deposition (CVD) and tend to serve as an inhibitor of copper diffusion when used as the barrier material in the context of copper.
In one embodiment, etch stop layer 130 of either SiO 2 or Si 3 N 4 is introduced, according to current technologies, to a thickness on the order of 40 nanometers (nm) to 100 nm. The thickness is selected, in one example, to be sufficient to protect an underlying contact point (e.g., contact point 120 (e.g., device or copper interconnection line)), but not to unacceptably increase the capacitance between contact point 120 and, for example, an overlying or adjacent interconnection (e.g., thickness selected to minimize the contribution of etch stop layer 130 to k eff ).
Overlying etch stop layer 130 in the illustration shown in FIG. 2 is dielectric layer 140 deposited to a thickness on the order of approximately 700 nanometers according to current technologies. The thickness of dielectric layer 140 will depend, in part, on size characteristics and scaling considerations for the structure. Dielectric layer 140 is, in one embodiment, selected of a material that may decompose, for example, in response to a thermal treatment acceptable to substrate 110 and any device layers and/or interconnect layers formed thereon. Thus, in one embodiment, dielectric material 140 is a sacrificial material that may be substantially removed in characterizing the final circuit structure. In one embodiment, a material for dielectric layer 140 has a glass transition temperature of at least 250° C. and a thermal decomposition temperature of at least 400° C. Representatively, a suitable material for dielectric layer 140 has a thermal decomposition temperature between 400° C. and 500° C. In one embodiment, a material for dielectric layer is polymerizable such that it may be deposited in a monomeric state, or partially polymerized state, and then substantially or completely polymerize, for example, upon exposure to heat or radiation, on substrate 110 to form dielectric layer 140 . In one embodiment, a material for dielectric layer 140 , after polymerization, has an elastic modulus greater than 3 gigaPascal (GPa) and a hardness greater than 0.3 GPa. A suitable material for dielectric layer 140 is a polycyanurate material.
Collectively, etch stop layer 130 and dielectric layer 140 define a composite dielectric layer. Once dielectric layer 140 is deposited and formed (e.g., polymerized), the material may be planarized, for example, with a polish (e.g., chemical-mechanical polish).
Referring to FIG. 3 , following the introduction of dielectric layer 140 , an opening is made to contact point 120 . In one embodiment, the opening includes via 160 and trench 170 formed, for example, by sequential photolithographic patterning and etching operations. Representatively, what is shown is a dual damescene process where via 160 and trench 170 are formed as the opening and are filled with conductive material 150 such as a copper material and the conductive material in trench 170 serves as an interconnection line. Thus, although not shown in the cross sectional view of FIG. 3 , trench 170 may extend into the page as viewed to act as a trench for a conductive material interconnection line to reside therein. In addition to conductive material of, for example, a copper material in via 160 and trench 170 , one or more layers may be deposited along the sidewalls of via 160 and trench 170 to, for example, inhibit diffusion of the conductive material and/or improve adhesion of the conductive material.
Via 160 and trench openings are made through dielectric layer 140 and etch stop layer 130 . To form an opening through dielectric layer 140 , a suitable etch process is selected that does not substantially react or disrupt underlying etch stop layer 130 . In the case of dielectric layer 140 of a polycyanurate and etch stop layer 130 of Si 3 N 4 , a suitable etching process to etch polycyanurate is, for example, a O 2 or SF 6 /O 2 plasma etching. With such an etching process, an etch of dielectric layer 140 will proceed through the material and substantially stop when etch stop layer 130 is exposed. A subsequent etch chemistry, such as a fluorine-carbon (e.g., CF 4 /O 2 /H 2 , C 2 F 6 , C 3 F 8 , or CHF 3 ) plasma can then be used to form an opening through etch stop layer 130 and expose contact point 120 .
FIG. 4 shows the structure of FIG. 3 following the deposition and formation of etch stop layer 180 . In one embodiment, etch stop layer 180 is similar to etch stop layer 130 (e.g., SiO 2 , Si 3 N 4 ) deposited to a similar thickness (e.g., on the order of 40 nm). Etch stop layer 180 overlies dielectric layer 140 and trench 170 (as viewed). In this manner, dielectric layer 140 is disposed between etch stop layer 130 and etch stop layer 180 .
FIG. 5 shows the structure of FIG. 4 and illustrates the optional formation of subsequent interconnection layer or line, illustrated by conductive material 190 (shown in ghost lines) overlying conductive material 150 . It is appreciated that conductive material 190 of, for example, a via and trench, may be encapsulated in dielectric material, such as dielectric material similar to a dielectric material of dielectric layer 140 , at least initially (see FIG. 4 ). Conductive material 190 may be connected to an underlying (as viewed) interconnection, such as conductive material in trench 170 .
FIG. 5 also shows a transformation of dielectric layer 140 . In one embodiment, structure 100 is disposed to a thermal treatment whereby the structure is heated to a temperature greater than the thermal decomposition temperature of a material for dielectric layer 140 and any subsequent similar dielectric layer. Referring to FIG. 5 , the thermal treatment decomposes a material serving as a dielectric layer, such as dielectric layer 140 leaving a void or an air gap between etch stop layer 130 and etch stop layer 180 . In one embodiment, any volatiles generated from the decomposition tend to defuse through the etch stop layer, such as etch stop layer 180 . FIG. 5 shows air gap or void 185 . By leaving an air gap or void substantially in the volume previously occupied by dielectric layer 140 , the composite dielectric constant (k eff ) may be substantially reduced (e.g., air providing a near zero contribution to k eff ). Certain materials for dielectric layer 140 , such as polycyanurate tend to leave a char on decomposition. FIG. 5 shows char 145 on etch stop layer 130 . In one embodiment, a material for dielectric layer 140 is selected such that any char 145 is not electrically conductive.
FIG. 6 illustrates the formation of a polycyanurate moiety suitable as a material for a dielectric layer, such as dielectric layer 140 illustrated above in FIGS. 1–4 . A polycyanurate material is formed, in this embodiment, from cyanate ester monomers. Cyanate ester monomers may be dissolved in a solvent such as a methyl ethyl keytone (MEK) solvent. The solution may be applied to a substrate, such as by spinning. Once deposited on the substrate, any solvent may be thermally removed and the material cured to form cross-link polycyanurate moiety materials (polymers).
Table I shows properties of some suitable polycynaurate materials:
Peak weight loss
Cyanate Ester Monomers
Tg (° C.)
rate temp (° C.)
Bisphenol A cyanate ester
257
468
Bisphenol E cyanate ester
258
467
Hexafluorobisphenol A cyanate ester
275
461
Phenol novolac cyanate ester
>350
462
To study the electrical conductivity of a char formed after decomposition of a polycyanurate material, an experiment was conducted to determine an electrical resistance of the char.
A novolac cyanate ester generally forms a char after decomposition. A novolac cyanate ester resin (Arocy XU-371, from Vantico Inc.) was coated on an aluminum foil, cured and thermally decomposed at about 475° C. The aluminum foil was then peeled off and a thin layer of char was used for electrical measurement. The electrical resistance of the char was measured using a Keithley 580 ohm micrometer with a four-point probe which has a measurement range of 10 μohm to 200 kohm.
Results: The electrical resistance of the char exceeds the upper limit of the meter, which means the resistance is higher than 200 kohm and the char is not conductive.
In the preceding detailed description, specific embodiments are described. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.
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An apparatus including a contact point formed on a device layer of a circuit substrate or an interconnect layer on the substrate; a first dielectric material; and a different second polymerizable dielectric material on the substrate and separated from the device layer or the interconnect layer by the first dielectric material following polymerization, the second dielectric material comprising a glass transition temperature of at least 250° C. and a thermal decomposition temperature of at least 400° C. A method including depositing a dielectric material and thermally treating the dielectric material at a temperature greater than the thermal decomposition temperature.
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The inventions described herein were made in the course of work under a grant or award from the Department of Health, Education and Welfare.
This invention relates to new and useful Phosphorus compounds which are particularly useful in the production of oligonucleotides.
CROSS REFERENCE
M. H. Caruthers et al. copending and commonly assigned patent application Ser. No. 247,144 filed Mar. 24, 1981.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to new and useful phosphoramidites which are intermediates for polynucleotides synthesis, as well as the improved process for production of oligonucleotides from which polynucleotides are prepared.
2. Description of the Prior Art
Numerous attempts have been made to develop a successful methodology for synthesizing sequence defined oligonucleotides. However, the stepwise synthesis of polynucleotides, and specifically oligonucleotides still remains a difficult and time consuming task, often with low yields. One prior art technique has included the use of organic polymers as supports during polynucleotide synthesis. Classically the major problems with polymer supported synthesis strategies has been inherent in the nature of the polymer support. Various prior art polymers used in such synthesis have proven inadequate for reasons such as: (1) slow diffusion rates of activated nucleotides into the support; (2) excessive swelling of various macroporous, low cross-linked support polymers; and (3) irreversible absorption of reagent onto the polymer. See for example, V. Amarnath and A. D. Broom, Chemical Reviews 77, 183-217 (1977).
Modified inorganic polymers are known in the prior art, primarily for use as absorption materials, for example, in liquid chromatography. The attachment of nucleosidephosphates to silica gel using a trityl linking group is described in the prior art (H. Koster, Tetrahedron Letters, 1527-1530, 1972) but the method is apparently applicable only to pyrimidine nucleosides. The cleavage of the nucleoside from the silica support can only be accomplished with acid to which the purine nucleosides are sensitive.
The production of phosphotriester derivatives of oligothymidylates is described in literature (R. L. Letsinger and W. B. Lunsford, Journal of the American Chemical Society, 98:12, 3655-3661) by reaction of a phosphorodichloridite with a 5'-O blocked thymidine and subsequent reaction of the product with a 3'-O blocked thymidine followed by oxidation of the resulting phosphite to a phosphate and removal of blocking groups to obtain the phosphotriesters; using this procedure, the tetramer and pentamer products, dTpTpTpT and TpTpTpTpT in which T is thymidine were prepared. Unfortunately, the process requires separation and purification of products at each stage to ensure proper sequencing of the added nucleosides. Separation techniques including precipitation and washing of precipitates are necessary to implement each successive stage reaction.
In the aforementioned commonly assigned patent application are described methods for forming internucleotide bonds, i.e. bonds linking nucleosides in an oligonucleotide or polynucleotide, by reaction of halophosphoridites with suitably blocked nucleoside or oligonucleotide molecules.
The deoxynucleoside-modified silica gel is condensed with a selected nucleoside through formation of a triester phosphite linkage between the 5'-OH of the deoxynucleoside. The phosphite linkage can be produced by first incorporating the phosphite group onto the 5'-OH of the nucleoside on the silica gel followed by condensation with the added nucleoside through the 3'-OH. Alternatively, and preferably, the phosphite group is incorporated into the added nucleoside at the 3'-OH (the 5'-OH being blocked as by tritylating) and the resulting nucleoside phosphite then reacted with the 5'-OH of the nucleoside of the silica gel.
The deoxynucleoside-modified silica gel can also be condensed with a selected nucleoside through formation of a triester phosphite linkage between the 3'-OH of the deoxynucleoside of the silica gel and the 5'-OH of the selected deoxynucleoside. The phosphite linkage can be produced by first incorporating the phosphite group onto the 3'-OH of the nucleoside on the silica gel followed by condensation with the added nucleoside through the 5'-OH. Alternatively and preferably by this approach, the phosphite group is incorporated into the added nucleoside at the 5'-OH (3'-OH being blocked as by tritylating using art form procedures) and the resulting nucleoside phosphite then reacted with the 3'-OH of the nucleoside on the silica gel.
The general reaction can be represented by the following: ##STR1##
The preferred reaction is represented as follows: ##STR2## wherein P is an inorganic polymer linked to the 3' or 5'-O- of the nucleoside through a base hydrolyzable covalent bond; R is H or a blocking group; R 1 is a hydrocarbyl radical containing up to 10 carbons; each B is a nucleoside or deoxynucleoside base; and each A is H, OH or OR 2 in which R 2 is a blocking group; and X is halogen, preferably Cl or Br or a secondary amino group.
The compounds of structure II and IIa wherein X is a 2° amino group include those in which the amino group is an unsaturated nitrogen heterocycle such as tetrazole, indole, imidazole, benzimidazole and similar nitrogen heterocycles characterized by at least two ethylenic double bonds, normally conjugated, and which may also include other heteroatoms such as N, S or O. These compounds of structure II and IIa wherein X is such a heterocyclic amine, i.e., one in which the amino nitrogen is a ring heteroatom, are characterized by an extremely high reactivity, and consequently relatively low stability, particularly in the indicated preparation of compounds of structure III and IIIa. These phosphoramidites and the corresponding chloridites from which they are prepared are unstable to water (hydrolysis) and air (oxidation). As a consequence, such compounds can only be maintained under inert atmosphere, usually in sealed containers, at extremely low temperatures generally well below 0° C. Thus, the use of these compounds in the preparation of compounds of structure III and IIIa requires extreme precautions and careful handling due to the aforesaid high reactivity and low stability.
The present new compounds are of structure II and IIa wherein X is a certain type of secondary amino group. Specifically, the present new compounds are those in which X is a saturated secondary amino group, i.e. one in which no double bond is present in the secondary amino radical. More particularly, X is NR 2 R 3 , wherein R 2 and R 3 taken separately each represents alkyl, aralkyl, cycloalkyl and cycloalkylalkyl containing up to 10 carbon atoms, R 2 and R 3 when taken together form an alkylene chain containing up to 5 carbon atoms in the principal chain and a total of up to 10 carbon atoms with both terminal valence bonds of said chain being attached to the nitrogen atom to which R 2 and R 3 are attached; and R 2 and R 3 when taken together with the nitrogen atom to which they are attached form a saturated nitrogen heterocycle including at least one additional heteroatom from the group consisting of nitrogen, oxygen and sulfur.
The present new compounds are not as reactive as those of the aforesaid copending application and not as unstable. However, the present new compounds do react readily with unblocked 3'-OH or 5'-OH of nucleosides under normal conditions. The present new phosphoramidites are stable under normal laboratory conditions to hydrolysis and air oxidation, and are stored as dry, stable powders. Therefore, the present new phosphoramidites are more efficiently employed in the process of forming internucleotide bonds, particularly in automated processing for formation of oligonucleotides and polynucleotides as described in the aforesaid copending application.
Amines from which the group NR 2 R 3 can be derived include a wide variety of saturated secondary amines such as dimethylamine, diethylamine, diisopropylamine, dibutylamine, methylpropylamine, methylhexylamine, methylcyclopropylamine, ethylcyclohexylamine, methylbenzylamine, methylcyclohexylmethylamine, butylcyclohexylamine, morpholine, thiomorpholine, pyrrolidine, piperidine, 2,6-dimethylpiperidine, piperazine and similar saturated monocyclic nitrogen heterocycles.
The nucleoside and deoxynucleoside bases represented by B in the above formulae are well-known and include purine derivatives, e.g. adenine, hypoxanthine and guanine, and pyrimidine derivatives, e.g. cytosine, uracil and thymine.
The blocking groups represented by R in the above formulae include trityl, methoxytrityl, dimethoxytrityl, dialkylphosphite, pivalyl, isobutyloxycarbonyl, t-butyl dimethylsilyl, and similar such blocking groups.
The hydrocarbyl radicals represented by R 1 include a wide variety including alkyl, alkenyl, aryl, aralkyl and cycloalkyl containing up to about 10 carbon atoms. Representative radicals are methyl, butyl, hexyl, phenethyl, benzyl, cyclohexyl, phenyl, naphthyl, allyl and cyclobutyl. Of these the preferred are lower alkyl, especially methyl and ethyl.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred new compounds are those of structure IIa wherein X is di-lower alkyl amino, pyrrolidino, morpholino or piperidino, particularly preferred being the lower alkyl amino, especially dimethylamino and diethylamino; A is H; R 1 is lower alkyl; R is a trityl group; B is a nuceloside or deoxynucleotide base; and P is silica gel.
The new compounds of the present invention can be prepared according to art-recognized procedures such as by reaction of the selected secondary amine with the corresponding nucleoside phosphomonochloridite. This reaction is accomplished by dissolving the said nucleoside in an organic solvent, such as tetrahydrofuran or acetonitrile, and adding the selected secondary amine. After removing unwanted hydrochloride salt, the organic solvent solution of the phosphoramidite may be used as such for polynucleotide synthesis or the product can be isolated from the organic solvent solution and purified before further reaction.
As a further embodiment of the invention, the phosphoramidites are preferably prepared by forming the desired chloro-(2° amino)alkoxyphosphine and thereafter condensing this product with the selected nucleoside. This procedure obviates the difficulties of handling inherent in the case of the nucleoside phosphomonochlorodite which is susceptible to moisture hydrolysis and air degradation.
The reaction of the chloro-(2° amino)alkyoxyphosphine is effected in an organic solvent solution of the selected nucleoside, preferably in the presence of a tertiary amine to take up the hydrogen chloride formed in the condensation reaction. The reaction proceeds smoothly at room temperature in a dry atmosphere and under an inert gas such as N 2 or helium. Organic solvents useful for this reaction include any solvent which will dissolve the reactants such as diethyl ether, chloroform, methylene chloride, ethylene chloride, ethyl acetate, and the like. The solution of product is separated from the precipitated hydrochloride salt of the added tertiary amine and can be used as such in forming polynucleotide or alternatively can be separated from the solvent and purified as by crystallization before further use. While the foregoing disclosure has mentioned the use of chloro compounds, it should be understood that bromo compounds can be used as desired with essentially the same results.
When the present new compounds are used in forming internucleotide bonds, they are preferably employed with proton donors. Thus, the phosphoramidites are activated by acidic compounds through protonation which facilitates the desired internucleotide bond formation. The acidic compounds to be employed for the purpose of the said activation are preferably mildly acidic and include, for example, amine hydrohalide salts and nitrogen heterocyclic compounds such as tetrazoles, imidazoles, nitroimidazoles, benzimidazoles and similar nitrogen heterocyclic proton donors. The amine hydrohalide salts to be used for the protonation activation are preferably tertiary amine salts, and, preferably, the hydrochloride salts, although hydrobromide, hydroiodide or hydrofluoride salts can also be used. The aforesaid tertiary amines include, for example, dimethylaniline, diisopropylaniline, methylethylaniline, methyldiphenylamine, pyridine and similar tertiary amines.
When the nucleoside is guanosine, i.e. where B is guanine, the use of amine hydrochlorides is not very effective for the purpose of activation, i.e. by protonation. With those compounds in which B is guanine, activation is preferably accomplished with the aforesaid nitrogen heterocyclic hydrogen donors.
Of course, as described in the aforesaid copending application, once the internucleotide bond is formed, the product is then further treated to remove blocking groups, e.g. blocking group R, which permits reaction with a further nucleoside of formula II herein and repeat reaction gives rise to the polynucleotide of determined sequence of nucleotides attached to the silica gel through the covalently-bonded linking groups, e.g. ester linking group.
After each nucleoside is added, the phosphite group preferably should be oxidized to phosphate, usually by reaction with iodine as oxidizing agent, although this can be accomplished by reaction with peroxides such as tertiary butyl peroxide and benzoyl peroxide, as well as hydroperoxides.
The oligonucleotide can then be obtained by hydrolytic cleavage to separate from the silica gel support, usually after removal of blocking groups such as R blocking groups and blocking groups on the nucleoside base moieties as described in the aforesaid copending application, generally by hydrolysis. with ammonia.
As used herein the symbols for nucleotides and polynucleotides are according to the IUPAC-IUB Commission of Biochemical Nomenclature Recommendations [(1970) Biochemistry 9, 4022].
The following examples further illustrate the invention.
EXAMPLE I
Preparation of phosphoramidites of the formula: ##STR3## represented as compounds I-IV, in which in compound
I, B=1-Thyminyl;
II, B=1-(N-4-benzoylcytosinyl);
III, B=9-(N-6-benzoyladeninyl);
IV, B=9-(N-2-isobutyrylguaninyl);
and DMT=di-p-anisylphenylmethyl.
The synthesis of compounds I-IV begins with the preparation of chloro-N, N-dimethylaminomethoxyphosphine [CH 3 O P(Cl) N(CH 3 ) 2 ] which is used a monofunctional phosphitylating agent. A 250 ml addition funnel was charged with 100 ml of precooled anhydrous ether (-78° C.) and pre-cooled (-78° C.) anhydrous dimethylamine (45.9 g, 1.02 mol). The addition funnel was wrapped with aluminum foil containing dry ice in order to avoid evaporation of dimethylamine. This solution was added dropwise at -15° C. (ice-acetone bath) over 2 h to a mechanically stirred solution of methoxydichlorophosphine (47.7 ml, 67.32 g, 0.51 mol) in 300 ml of anhydrous ether. The addition funnel was removed and the 1 l., three-necked round bottom flask was stoppered with serum caps tightened with copper wire. The suspension was mechanically stirred for 2 h at room temperature, then filtered and the amine hydrochloride salt washed with 500 ml anhydrous ether. The combined filtrate and washings were distilled at atmospheric pressure and the residue under reduced pressure. The product was distilled at 40°-42° C. 13 mm Hg and was isolated in 71% yield (51.1 g, 0.36 mol). d 25 =1.115 g/ml. 31 P-N.M.R., =-179.5 ppm (CDCl 3 ) with respect to internal 5% v/v aqueous H 3 PO 4 standard. 1 H-N.M.R. doublet at 3.8 and 3.6 ppm J P-H =14 Hz (3H, OCH 3 ) and two singlets at 2.8 and 2.6 ppm (6H, N(CH 3 ) 2 ). The mass spectrum showed a parent peak at m/e=141.
The 4'-O-di-p-anisylphenylmethyl nucleoside (1 mmol) was dissolved in 3 ml of dry, acid free chloroform and diisopropylethylamine (4 mmol) in a 10 ml reaction vessel preflushed with dry nitrogen. [CH 3 OP(Cl)N(CH 3 ) 2 ] (2 mmol) was added dropwise (30-60 sec) by syringe to the solution under nitrogen at room temperature. After 15 min the solution was transferred with 35 ml of ethyl acetate into a 125 ml separatory funnel. The solution was extracted four times with an aqueous, saturated solution of NaCl (80 ml). The organic phase was dried over anhydrous Na 2 SO 4 and evaporated to a foam under reduced pressure. The foam was dissolved with toluene (10 ml) (IV was dissolved with 10 ml of ethyl acetate) and the solution was added dropwise to 50 ml of cold hexanes (-78° C.) with vigorous stirring. The cold suspension was filtered and the white powder was washed with 75 ml of cold hexanes (-78° C.). The white powder was dried under reduced pressure and stored under nitrogen. Isolated yields of compounds I-IV were 90-94% (see Table I).
TABLE I______________________________________ ISOLATED δ-.sup.31 P (ppm) δ-.sup.31 P (ppm) YIELDCOMPOUND (Acetone-d.sub.6) (CDCl.sub.3) (%)______________________________________I -146.0, -145.4 -147.7, -146.8 93, 95*II -146.3, -145.5 -148.0, -147.0 92, 95*III -146.1, -145.8 -147.4, -147.3 90, 98*IV -145.9, -145.7 -147.7, -147.2 90, 98*Ia -139.6, -138.9 -140.8, -139.9 97**IIa -139.6, -139.0 -140.6, -140.0 94**IIIa -139.7, -138.9 -141.0, -139.9 97**IVa -140.3, -140.2 -143.6, -141.9 93**______________________________________ *Estimated purity from .sup.31 PN.M.R. **Estimated yield from .sup.31 PN.M.R.
The purity of the products was checked by 31 P-N.M.R. Additionally, when analyzed by 31 P-N.M.R., these compounds were stable for at least a month when stored at room temperature under nitrogen. Furthermore, no significant amount of (3'-3')dinucleoside phosphite was detected by 31 P-N.M.R. (less than 4%). The low content of the (3'-3') dinucleoside phosphite represents a significant improvement over the prior art phosphite coupling procedure where a considerable amount of unwanted (3'-3') dinucleoside phosphite was unavoidable.
The aminophosphoramidites I-IV were employed in condensation with 3'-O-blocked nucleosides to form internucleotide bonds. The phosphoramidites were activated by weak acids such as amine hydrochloride salts or tetrazoles.
A. In the following procedure, the process was monitored using 31 P-N.M.R. In a 10 mm. N.M.R. tube, 1.2 molar equivalents of 3'-O-levulinylthymidine and collidine were added to a mixture formed by adding N,N-dimethylaniline hydrochloride (1 mmol) in 0.5 ml dry CDCl 3 at room temperature under N 2 to amidite compound I (0.5 mmol, -147.7 and -146.8 ppm) in 2 ml of dry, acid free CDCl 3 and an essentially quantitative yield of dinucleoside phosphite Ia (-140.8 and -139.9 ppm) was obtained.
B. Amidite compound I (0.5 mmol) and 3'-O-levulinylthymidine (0.6 mmol) were placed in a 10 mm N.M.R. tube and sublimed 1H-tetrazole (1.5 mmol) in 2.5 ml of dry acetonitrile-d 3 was added under nitrogen atmosphere. The 31 P-N.M.R. spectrum was immediately recorded and displayed a quantitative yield of Ia. Similarly, dinucleosides were obtained when II, III and IV were reacted with 3'-levulinylthymidine as shown in Table I. The appropriate chemical shifts of compounds I-IV and Ia-IVa with respect to internal 5% v/v aqueous H 3 PO 4 standard are reported in Table I.
EXAMPLE II
Alternate procedure for Chloro-N,N-disubstituted Aminomethoxyphosphine
A 50 ml dropping funnel was charged with 31.59 g of N, N-Dimethylaminotrimethylsilane (42.1 ml, 0.27 mol) which wad added dropwise over 1 h under nitrogen atmosphere to 25 ml of cold (-15° C.) methoxydichlorophosphine (35.15 g, 0.27 mol) in a 250 ml round bottom flask. A white unidentified precipitate formed during the course of the addition. Once the addition was finished, the ice-acetone bath was removed and the suspension was stirred at room temperature for 1 h. The reaction mixture was then slowly vacuum distilled through a one foot long, vacuum jacketed glass helices (3/32") column. The product distilled at 40°-42° C. 13 mm Hg and was isolated in 81% yield (30.77 g, 0.22 mol). d 25 =1.115 g/ml. 31 P-N.M.R., =-179.5 ppm (CDCl 3 ) with respect to internal 5% aqueous H 3 PO 4 standard. 1 H-N.M.R. doublet at 3.8 and 3.6 ppm J P-4=14 Hz (3H, OCH 3 ) and two singlets at 2.8 and 2.6 ppm (6H, N(CH 3 ) 2 . The mass spectrum showed a parent peak at m/e=141.
(Anal. calcd. for C 3 H 9 ClNOP: C, 24.45; H, 6.42; N, 9.90; O, 11.30; P, 21.88. Found C, 24.53; H, 6.20; N, 10.04; O, 11.08; P, 21.44.
The procedure was successfully applied to the preparation of chloro-N, N-diethylaminomethoxyphosphine and chloropyrrolidino-methoxyphosphine.
EXAMPLE III
The applicability of phosphoramidites I-IV to the synthesis of deoxyoligonucleotides on polymer supports was accomplished by condensing compounds I-IV with N-2-isobutyryldeoxyguanosine attached covalently to silica gel. Thus, N-2-isobutyryldeoxyguanosine (1 μmole) covalently attached to silica gel (20 mg) at the 3'-position, I (10 μmole), and 1H-tetrazole (50 μmole in 0.1 ml dry acetonitrile) were shaken for 20 min and the reaction was then quenched with aqueous lutidine. The same reaction sequence was effected with II, III and IV. After the usual oxidation and deprotection procedures, d(TpG), d(CpG), d(ApG) and d(GpG) were obtained in 100%, 98%, 94%, and 93% yield respectively (measured spectrometrically from the dimethoxytrityl cation using an extinction of 7×10 4 at 498 nm). These dinucleotides were completely degraded by snake venom phosphodiesterase and the appropriate nucleosides and ncleotides were obtained in the proper ratios (monitored via high pressure liquid chromatography analysis of snake venom phosphodiesterase hydrolysates).
The following deoxynucleotides have been synthesized using this procedure:
__________________________________________________________________________d(C--T--C--A--A--A--T--G--G--G--T--C) d(C--C--A--C--A--A--A--C--C--C)d(A--A--A--T--G--C--G--A--C--C--C--A) d(A--G--C--T--A--T--G--G--G--T--T--T)d(T--T--T--G--A--G--C--C--A--A--C--A) d(T--T--A--G--C--T--C--A--C--T--C--A)d(T--C--A--T--C--C--T--G--T--T--G--G) d(T--T--A--G--G--C--A--C--C--C)d(G--G--G--C--C--G--A--A--T--T--G--T) d(C--A--G--G--C--T--T--T--A--C--A)d(C--G--G--C--C--C--C--T--T--A--C--T) d(C--T--T--T--A--T--G--C--T--T--C)d(T--C--C--T--C--A--A--G--T--A--A--G) d(C--G--G--C--T--C--G--T--A)d(T--G--A--G--G--A--T--A--A--A--T--T) d(T--G--T--A--C--T--A--A--G)d(A--T--G--T--G--T--G--A--T--T--T--A) d(G--A--G--G-- T--T--G--T--A--T--G)d(G--T--G--G--T--A--A--A--T--C--A) d(T--A--C--A--T--G--C--A--A)__________________________________________________________________________
The detailed procedure utilized is as follows:
5'-O-DMT-N-benzoyldeoxyadenosine [DMT rd (bzA)] (0.66 g., 1 mmole) in dry THF (3 ml) is added dropwise under an argon atmosphere to a stirred solution of the THF (3 ml) containing methyldichlorophosphite (0.113 ml, 1.2 mmole) and 2, 4, 6 trimethylpyridine (0.633 ml. 4.8 mmole) at -78° C. After 10 minutes at -78° C., the reaction solution is filtered through a sintered glass funnel and solvent is removed by concentration in vacuo. Excess methyl phosphodichloridite is removed by dissolving the resulting gum in toluene: THF (2 ml, 2:1) and re-evaporating in vacuo to a gum. This procedure is repeated several times to insured removal of the dichloridite. The nucleoside phosphomonochloridite is converted to the tetrazolide. The gum resulting from the final re-evaporation is dissolved in THF (2 ml). A solution of the selected secondary amine 0.9 mmole) in THF (2 ml) is then added dropwise with stirring at -78° C. to the nucleoside phosphomonochloridite. After 10 minutes at -78° C., the solution is transferred to a centrifuge tube, spun at low speed, and the supernatant is removed. This solution contains the activated nucleoside phosphoramidite. If not used immediately, this phosphoramidite can be placed in long term storage after precipitation by dropwise addition into dry pentane, followed by collection, drying in vacuo, and storing in sealed tubes under argon or other inert gas at room temperature, or lower temperatures, e.g. 0° C. All operations are performed under inert gas to avoid oxidation. At no time is the active agent exposed to air.
The foregoing procedure is applicable for the preparation of activated thymidine, deoxycytidine, and deoxyadenosine nucleotides. For the preparation of the activated deoxyguanosine nucleotide, the procedure is the same except for the stoichiometry. The molar ratio of 5'-O-DMT-N-isobutyryldeoxyguanosine [DMTrd(ibG)]; methyldichlorophosphite; 2, 4, 6 trimethylpyridine and tetrazole is 1:0.9:3.8:0.7. The steps necessary for addition of one nucleotide to the modified silica gel polymer support follow. The removal of the dimethoxytrityl group from the nucleotide is accomplished by exposing the modified silica gel support to 0.1 M ZnBr 2 in nitromethane for 15 to 30 minutes. The support is then washed initially with butanol:2,6 lutidine:THF (4:1:5 by volume) and finally with THF. The solvent ratio is not important since this step is used to remove potential zinc esters of nucleosides. This step could be eliminated but lower yields may result. Other Lewis acids could be substituted for ZnBr 2 , such as BF 3 , AlCl 3 and TiCl 4 . However ZnBr 2 is preferred. Protic acid can also be used. However approximately 3-5% depurination of each purine by protic acids is observed even when the amount of acid is reduced to the minimum amount needed to remove the dimethoxytrityl group. The next step in the process is condensation of the protected and activated nucleotide to the nucleoside or oligonucleotide covalently bound to the support. This is accomplished by using 10-15 equivalents of the activated phosphoramidite and a reaction time of about one hour. The solvent is anhydrous THF. The next step in the process is the blocking of unreacted 5'-hydroxyl groups. This is accomplished using a solution of acetic anhydride, dimethylaminopyridine, pyridine and THF. This may also be accomplished using a 0.33 M solution of diethylmonotriazolophosphite in 2,6-lutidine/THF (1:5 by volume). The reaction time is 5 min. and is followed by a THF wash. As a further alternative, a solution of phenylisocyanate/lutidine (45:55 by volume) and a 90 minute reaction time may be used for this step. This solution is then removed from the modified silica gel by washing the support with THF and with acetonitrile. The first procedure is preferred. This step can be eliminated or other reagents that react with 5'-hydroxyl groups and are compatible with the overall chemistry can be substituted therefore. However, by including this step, the final purification of the desirable oligonucleotide is rendered much easier. This is because the complexity of the total synthetic material bound to the support is reduced considerably. The final step in each cycle is oxidation of the phosphite to the phosphate. A composition of 0.1 M I 2 in water/2, 6 lutidine/THF (1:1:3) is preferred, although other ratios can be used. Furthermore, other oxidizing agents such as N-chlorosuccinimide or aryl or alkyl peroxides could also be used. T-butyl peroxide is presently preferred as oxidizing agent. After the addition of the appropriate activated nucleotides in any predetermined sequence, the deoxyoligonucleotide is removed from the support by base hydrolysis and blocking groups where present are also removed, either selectively i.e., stepwise, or in an overall hydrolysis treatment such as heating at 50° C. in ammonium hydroxide.
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A new class of nucleoside phosphoramidites which are relatively stable to permit isolation thereof and storage at room temperature. The phosphoramidites are derivatives of saturated secondary amines.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to downhole tools. More particularly, the invention relates to the control of downhole tools in a drill string from the surface of a well.
2. Description of the Related Art
Communication to and from downhole tools and components during drilling permits real time monitoring and controlling of variables associated with the tools. In some instances pulses are sent and received at the surface of a well and travel between the surface and downhole components. In other instances, the pulses are created by a component in a drill string, like measuring-while-drilling (“MWD”) equipment. MWD systems are typically housed in a drill collar at the lower end of the drill string. In addition to being used to detect formation data, such as resistivity, porosity, and gamma radiation, all of which are useful to the driller in determining the type of formation that surrounds the borehole, MWD tools are also useful in transmitting and receiving signals from the other downhole tools. Present MWD systems typically employ sensors or transducers which continuously or intermittently gather information during drilling and transmit the information to surface detectors by some form of telemetry, most typically a mud pulse system. The mud pulse system creates acoustic signals in drilling mud that is circulated through the drill string during drilling operations. The information acquired by the MWD sensors is transmitted by suitably timing the formation of pressure pulses in the mud stream. The pressure pulses are received at the surface by pressure transducers which convert the acoustic signals to electrical pulses which are then decoded by a computer.
There are problems associated with the use of MWD tools, primarily related to their capacity for transmitting information. For example, MWD tools typically require drilling fluid flow rates of up to 250 gallons per minute to generate pulses adequate to transmit data to the surface of the well. Additionally, surface the amount of data transferable in time using a MWD is limited. For example, about 8 bits of information per second is typical of a mud pulse device. Also, mud pulse systems used by an MWD device are ineffective in compressible fluids, like those used in underbalanced drilling.
Wireline control of downhole components provides adequate dada transmission of 1,200 bits per second but includes a separate conductor that can obstruct the wellbore and can be damaged by the insertion and removal of tools.
Other forms of communicating information in a drilling environment include wired assemblies wherein a conductor capable of transmitting information runs the length of the drill string and connects components in a drill string to the surface of the well and to each other. The advantage of these “wired pipe” arrangements is a higher capacity for passing information in a shorter time than what is available with a mud pulse system. For example, early prototype wired arrangements have carried 28,000 bits of information per second.
One problem arising with the use of wired pipe is transferring signals between sequential joints of drill string. This problem has been addressed with couplings having an inductive means to transmit data to an adjacent component. In one example, an electrical coil is positioned near each end of each component. When two components are brought together, the coil in one end of the first is brought into close proximity with the coil in one end of the second. Thereafter, a carrier signal in the form of an alternating current in either segment produces a changing electromagnetic field, thereby transmitting the signal to the second segment.
More recently, sealing arrangements between tubulars provide a metal to metal conductive contact between the joints. In one such system, for example, electrically conductive coils are positioned within ferrite troughs in each end of the drill pipes. The coils are connected by a sheathed coaxial cable. When a varying current is applied to one coil, a varying magnetic field is produced and captured in the ferrite trough and includes a similar field in an adjacent trough of a connected pipe. The coupling field thus produced has sufficient energy to deliver an electrical signal along the coaxial cable to the next coil, across the next joint, and so on along multiple lengths of drill pipe. Amplifying electronics are provided in subs that are positioned periodically along the string in order to restore and boost the signal and send it to the surface or to subsurface sensors and other equipment as required. Using this type of wired pipe, components can be powered from the surface of the well via the pipe.
Despite the variety of means for transmitting data up and down a string of components, there are some components that are especially challenging for use with wired pipe. These tools include those having relative motion between internal parts, especially axial and rotational motion resulting in a change in the overall length of the tool or a relative change in the position of the parts with respect to one another. For example, the relative motion between an inner mandrel and an outer housings of jars, slingers, and bumper subs can create a problem in signal transmission, especially when a conductor runs the length of the tool. This problem can apply to any type of tool that has inner and outer bodies that move relative to one another in an axial direction.
Drilling jars have long been known in the field of well drilling equipment. A drilling jar is a tool employed when either drilling or production equipment has become stuck to such a degree that it cannot be readily dislodged from the wellbore. The drilling jar is normally placed in the pipe string in the region of the stuck object and allows an operator at the surface to deliver a series of impact blows to the drill string by manipulation of the drill string. Hopefully, these impact blows to the drill string dislodging the stuck object and permit continued operation.
Drilling jars contain a sliding joint which allows relative axial movement between an inner mandrel and an outer housing without allowing rotational movement. The mandrel typically has a hammer formed thereon, while the housing includes a shoulder positioned adjacent to the mandrel hammer. By sliding the hammer and shoulder together at high velocity, a very substantial impact is transmitted to the stuck drill string, which is often sufficient to jar the drill string free.
Often, the drilling jar is employed as a part of a bottom hole assembly during the normal course of drilling. That is, the drilling jar is not added to the drill string once the tool has become stuck, but is used as a part of the string throughout the normal course of drilling the well. In the event that the tool becomes stuck in the wellbore, the drilling jar is present and ready for use to dislodge the tool. A typical drilling jar is described in U.S. Pat. No. 5,086,853 incorporated herein by reference in its entirety.
An example of a mechanically tripped hydraulic jar is shown in FIG. 1 . The jar 100 includes a housing 105 and a central mandrel 110 having an internal bore. The mandrel moves axially in relation to the housing and the mandrel is threadedly attached to the drill string above (not shown) at a threaded joint 115 . At a predetermined time measured by the flow of fluid through an orifice in the tool 100 , potential force applied to the mandrel from the surface is released and a hammer 120 formed on the mandrel 110 strikes a shoulder 125 creating a jarring effect on the housing and the drill string therebelow that is connected to the housing at a threaded connection 130 .
Methods to run a wire through a jar or tool of this type have not been addressed historically because the technology to send and receive high-speed data down a wellbore did not exist. Similarly, the option of using data and power in a drill string to change operational aspects of a jar have not been considered.
With recent advances in technology like wired pipe, there is a need to wire a jar in a drill string to permit data to continue down the wellbore. There is an additional need for a jar that can be remotely operated using data transmitted by wired pipe, whereby performance of the jar can be improved. There is a further need therefore, for a simple and efficient way to transmit data from an upper to a lower end of a wellbore component like a jar. There is a further need to transmit data through a jar where no wire actually passes through the jar. There is yet a further need for methods and apparatus to control the operational aspects of a jar in order to compensate and take advantage of dynamic conditions of a wellbore.
Jars are only one type of tool found in a drill string. There are other tools that could benefit from real time adjustment and control but that have not been automated due to the lack of effective and usable technology for transmitting signals and power downhole. Still other tools are currently controlled from the surface but that control can be much improved with the use of the forgoing technology that does not rely upon pulse generated signals. Additionally, most of the drill string tools today that are automated must have their own source of power, like a battery. With wired pipe, the power for these components can also be provided from the surface of the well.
SUMMARY OF THE INVENTION
The present invention generally provides a downhole tool with an improved means of transmitting data to and from the tool through the use of wired pipe capable of transmitting a signal and/or power between the surface of the well and any components in a tubular string. In one aspect, a downhole tool includes a body, and a mandrel disposed in the body and movable in relation to the body. A conducive wire runs the length of the body and permits signals and/or power to be transmitted though the body as the tool changes its length.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a section view of a jar for use in a drilling string.
FIGS. 2A and 2B illustrate the jar in a retracted and extended position with a data wire disposed in an interior thereof.
FIGS. 3A and 3B are section views of a jar having an inductive connection means between the jar housing and a central mandrel;
FIG. 4 is a section view of a jar having electromagnetic subs disposed at each end thereof.
FIGS. 5A and 5B are section views showing a jar with a hammer that is adjustable along the length of a central mandrel.
FIGS. 6A and 6B are section views of a jar having a mechanism to cause the jar to be non-functional.
FIGS. 7A and 7B are section views of a portion of a jar having an adjustable orifice therein.
FIGS. 8A and 8B are section views of a portion of a jar having a mechanism therein for permitting the jar to operate as a bumper sub.
FIG. 9 is a section view of a jar that operates electronically without the use of metered fluid through an orifice.
FIG. 10 is a section view showing a number of jars disposed in a drill string and operable in a sequential manner.
FIGS. 11A and 11B are section views of a wellbore showing a rotatable steering apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides apparatus and methods for controlling and powering downhole tools through the use of wired pipe.
Using high-speed data communication through a drill string and running a wire through a drilling jar, a jar can be controlled from the surface of a well after data from the jar is received and additional data is transmitted back to the jar to affect its performance. Alternately, the jar can have a programmed computer on board or in a nearby member that can manipulate physical aspects of the jar based upon operational data gathered at the jar.
FIG. 2A illustrates a jar 100 in a retracted position and FIG. 2B shows the jar in an extended position. The jar 100 includes a coiled spring 135 having a data wire disposed in an interior thereof, running from a first 140 to a second end 145 of the tool 100 . The coiled spring and data wire is of a length to compensate for relative axial motion as the tool 100 is operated in a wellbore. In the embodiment of FIGS. 2A and 2B, the coil spring and data wire 135 are disposed around an outer diameter of the mandrel 110 to minimize interference with the bore of the tool 100 . In order to install the jar in a drill string, each end of the jar includes an inductive coupling ensuring that a signal reaching the jar from above will be carried through the tool to the drill string and any component therebelow. The induction couplings, because of their design, permit rotation during installation of the tool.
In another embodiment, a series of coils at the end of one of the jar components communicates with a coil in another jar component as the two move axially in relation to each other. FIG. 3A show a jar 100 with a housing 105 having a number of radial coils 150 disposed on an inside surface thereof. Each of the coils is powered with a conductor running to one end of the tool 100 where it is attached to drill string. A single coil 155 is formed on an outer surface of a mandrel 110 and is wired to an opposing end of the tool. The coils 150 , 155 are constructed and arranged to remain in close proximity to each other as the tool operates and as the mandrel moves axially in relation to the housing.
In FIG. 3A, a single coil 150 is opposite mandrel coil 155 . In FIG. 3B, a view of the tool 100 after the mandrel has moved, the coil 155 is partly adjacent two of the coils 150 , but close enough for a signal to pass between the housing and the mandrel. In an alternative embodiment, the multiple coils 150 cold be formed on the mandrel and the single coil could be placed on the housing.
In another embodiment, a signal is transmitted from a first to a second end of the tool through the use of short distance, electromagnetic (EM) technology. FIG. 4 is a section view of a jar 100 with E.M. subs 160 placed above and below the jar 100 . The EM subs can be connected to wired drill pipe by induction couplings (not shown) or any other means. The subs can be battery powered and contain all means for wireless transmission, including a microprocessor. Using the E.M. subs 160 , data can be transferred around the jar without the need for a wire running through the jar. By using this arrangement, a standard jar can be used without any modification and the relative axial motion between the mandrel and the housing is not a factor. This arrangement could be used for any type of downhole tool to avoid a wire member in a component relying upon relative axial or rotational motion. Also, because of the short transmission distance, the power requirements for the transmitter in the subs 160 is minimal.
In other embodiments, various operational aspects of a jar in a drill string of wired pipe can be monitored and/or manipulated. For example, FIGS. 5A and 5B are section views of a jar 100 illustrating a means of adjusting the magnitude of jarring impact. A pressure sensor (not shown) in a high pressure chamber of the jar 100 can be used to determine the exact amount of overpull placed upon the jar from the surface of the well. An accelerometer (not shown) can be used to measure the actual impact of the hammer 120 against the shoulder 125 after each blow is delivered. This information can then be used by an operator along with a jar placement program to optimize the amount of overpull and adjust the free stroke length 165 of the jar to maximize the impact. The stroke length is adjustable by rotating the hammer 120 around a threaded portion 175 of the mandrel 110 , thus moving the hammer closer or further from the shoulder 125 . By changing the free stroke length 165 between the hammer 120 and the shoulder 125 , the distance the hammer travels can be optimized to deliver the greatest impact force. For example, adjusting the stroke length would allow the impact to occur when the hammer has reached its maximum velocity. The free stroke length may need to be longer or shorter depending on the amount of pipe stretch, hole drag, etc. In conventional jars, the amount of free stroke can only be set at one distance and therefore the hammer can lose velocity or not reach its full velocity before impact. An actuator, like a battery operated motor might be used in the tool 100 to cause the movement of the hammer 120 along the threaded portion 175 of the mandrel 110 .
In another embodiment, the operation of a jar can be controlled in a manner that can render the tool inoperable during certain times of operation. FIGS. 6A and 6B are section views of a tool 100 showing a solenoid 180 located in the bore of the mandrel 110 . The purpose of the solenoid is to stop metering flow in the jar until a signal is received to allow the jar to meter fluid as normal. In FIG. 6A the solenoid 180 is in an open position permitting fluid communication between a low pressure chamber 185 and a high pressure chamber 190 , through a metering orifice 195 and a fluid path 197 blocks the flow of internal fluid between the chambers 185 , 190 and does not allow the mandrel 110 to move to fire the jar 100 . When in the position of FIG. 6B, the jar 100 can operate like a stiff drill string member when not needed. This makes running in much easier and safer by not having to contend with accidental jarring. This also overcomes problems associated with other jars that have a threshold overpull that must be overcome to jar. Using this arrangement, the jar works through a full range of overpulls without any minimum overpull requirements. Also, by making the solenoid 180 assume the “closed” position when not connected to a power line, the requirement for a safety clamp can be eliminated. This feature is especially useful in horizontal drilling applications where external forces can cause a jar to operate accidentally. As shown in the Figures, the solenoid is typically powered by a battery 198 which is controlled by a line 199 .
In another embodiment, the timing of operation of a jar can be adjusted by changing the size of an orifice in the jar through which fluid is metered. FIGS. 7A and 7B are section views of a jar 100 with an orifice 200 disposed therein. A solenoid 180 is placed in an internal piston 205 of the jar 100 and a battery 210 and microprocessor 215 are installed adjacent the solenoid 180 . By moving the solenoid 180 between a first and second positions, the relative size of the orifice can be changed, resulting in a change in the time needed for the jar to operate. For example, in FIG. 7A with the solenoid 180 holding a plug 217 in a retracted position, the orifice is a first size and in FIG. 7B with the solenoid holding the plug 217 in an extended position, the orifice is a second, smaller size. Alternatively, the orifice can be completely closed. With the ability to change the amount of time between the start of overpull and the actual firing of the jar, the number and magnitude of the blows can be affected. For example, by allowing more time before firing, the operator could be sure that the maximum overpull was being applied at the jar and that the overpull is not being diminished by hole drag or other hole problems. By changing the timing to a faster firing time, the operator can get more hits in a given amount of time.
In still another embodiment, a jar 100 can be converted to operate like a bumper sub during operation. A bumper sub is a shock absorber-like device in a drill string that compensates for jarring that takes place as a drill bit moves along and forms a borehole in the earth. In the embodiment of FIGS. 8A and 8B, a section view of a jar 100 , a solenoid 180 is actuated to open a relatively large spring-loaded valve 220 (FIG. 8B) that allows internal fluid to freely pass through the tool 100 . Since no internal pressure can build up, the tool opens and closes freely. This feature provides the usefulness of a bumper sub when needed during drilling.
FIG. 9 is a section view of an electronically actuated jar 100 . Because data can be quickly transmitted to the jar using the wired pipe means discussed herein, a jar can be provided and equipped with an electronically controlled release mechanism. The release mechanism could be mechanical or electromagnetic. This mechanism would hold the jar in the neutral position until a signal to fire is received. The electronic actuation means eliminates the use of fluid metering to time the firing of the jar. By using an electronically actuated jar, many of the problems associated with hydraulic jars could be eliminated. This would eliminate bleed-off from the metering of hydraulic fluid and would allow the jar to fire only when the operator is ready for it to actuate. Also, because the jar would be mechanically locked at all times, the need for safety clamps and running procedures would be eliminated.
In another embodiment, jars 100 arranged in a series on a drill string 250 can be selectively fired to affect a stress wave in the wellbore. FIG. 10 shows jars 100 connected in a drill string 250 with collars or drill pipe 101 therebetween. By using an electronically actuated jar, a series of jars could be set off at slightly different times to maximize the stress wave propagation and impulse. Stress wave theory could be used to calculate the precise actuation times, weight and length of collars, and drill string arrangement to generate the largest impulse to free the stuck string. Data measuring the effectiveness of each actuation could be sent to the surface for processing and adjustment before the next actuation of the jars. Using this arrangement with wired pipe, it is possible to maximize the impulse each time and therefore give a greater chance of freeing the drill string each time. This would result in fewer jarring actions and less damage to drill string components.
While the invention has been described with respect to jars run on drill pipe, the invention with its means for transmitting power and signals to and from a downhole component is equally useful with tubing strings or any string of tubulars in a wellbore. For example, jars are useful in fishing apparatus where tubing is run into a well to retrieve a stuck component or tubular. In these instances, the tubing can be wired and connections between subsequent pieces of tubular can include contact means having threads, a portion of which are conductive. In this manner, the mating threads of each tubular have a conductive portion and an electrical connection is made between each wired tubular.
FIGS. 11A and 11B are section views of a wellbore showing a rotatable steering apparatus 10 disposed on a drill string 75 . The apparatus includes a drill bit 78 or a component adjacent the drill bit in the drilling string that includes non-rotating, radially outwardly extending pads 85 which can be actuated to extend out against the borehole or in some cases, the casing 87 of a well and urge the rotating drill bit in an opposing direction. Using rotatable steering, wellbores can be formed and deviated in a particular direction to more fully and efficiently access formations in the earth. In FIG. 11A, the drill bit 78 is coaxially disposed in the wellbore. In FIG. 11B, the drill bit 78 has been urged out of a coaxial relationship with the wellbore by the pad 85 . Typically, a rotatable steering apparatus includes at least three extendable pads and technology exists today to control the pads by means of pulse signals which are transmitted typically from a MWD device 90 disposed in the drill string thereabove. By sending pulse signals similar to those described herein, the MWD can determine which of the various pads 85 of the rotatable steering apparatus 10 are extended and thereby determine the direction of the drill bit. As stated herein, only a limited amount of information can be transmitted using pulse signals and the rotatable steering device must necessarily has its own source of power to actuate the pads. Typically, an on-board battery supplies the power. Rotary steerable drilling is described in U.S. Pat. Nos. 5,553,679, 5,706,905 and 5,520,255 and those patents are incorporated herein by reference in their entirety.
Using emerging technology whereby signals and/or power is provided in the drill string, the rotatable drilling apparatus can be controlled much more closely and the need for an on-board battery pack can be eliminated altogether. Using signals travelling back and forth between the surface of the well and the rotary drilling unit 10 , the unit can be operated to maximize its flexibility. Additionally, because an ample amount of information can be easily transmitted back and forth in the wired pipe, various sensors can be disposed on the rotatable steering unit to measure the position and direction of the unit in the earth. For example, conditions such as temperature, pressure in the wellbore and formation characteristics around the drill bit can be measured. Additionally, the content and chemical characteristics of production fluid and/or drilling fluid used in the drilling operation can be measured.
In other instances a drill bit itself can be utilized more effectively with the use of wired pipe. For example, sensors can be placed on drill bits to monitor variables at the drilling location like vibration, temperature and pressure. By measuring the vibration and the amplitude associated with it, the information cold be transmitted to the surface and the drilling conditions adjusted or changed to reduce the risk of damage to the bit and other components due to resonate frequencies. In other examples, specialized drill bits with radially extending members for use in under-reaming could be controlled much more efficiently through the use of information transmitted through wired pipe.
Yet another drilling component that can benefit from real time signaling and power, is a thruster 95 . A thruster is typically disposed above a drill bit in a drilling string and is particularly useful in developing axial force in a downward direction when it becomes difficult to successfully apply force from the surface of the well. For example, in highly deviated wells, the trajectory of the wellbore can result in a reduction of axial force placed on the drill bit. Installing a thruster near the drill bit can solve the problem. A thruster is a telescopic tool which includes a fluid actuated piston sleeve. The piston sleeve can be extended outwards and in doing so can supply needed axial force to an adjacent drill bit. When the force has been utilized by the drill bit, the drill string is moved downwards in the wellbore and the sleeve is retracted. Thereafter, the sleeve can be re-extended to provide an additional amount of axial force. Various other devices operated by hydraulics or mechanical can also be utilized to generate supplemental force and can make use of the invention.
Conventional thrusters are simply fluid powered and have no means for operating in an automated fashion. However, with the ability to transmit high speed data back and forth along a drill string, the thrusters can be automated and can include sensors to provide information to an operator about the exact location of the extendable sleeve within the body of the thruster, the amount of resistance created by the drill bit as it is urged into the earth and even fluid pressure generated in the body of the thruster as it is actuated. Additionally, using valving in the thruster mechanism, the thruster can be operated in the most efficient manner depending upon the characteristics of the wellbore being formed. For instance, if a lessor amount of axial force is needed, the valving of the thruster can be adjusted in an automated fashion from the surface of the well to provide only that amount of force required. Also, an electric on-board motor powered from the surface of the well could operate the thruster thus, eliminating the need for fluid power. With an electrically controlled thruster, the entire component could be switched to an off position and taken out of use when not needed.
Yet another component used to facilitate drilling and automatable with the use of wired pipe is a drilling hammer 96 . Drilling hammers typically operate with a stroke of several feet and jar a pipe and drill bit into the earth. By automating the operation of the drilling hammer, its use could be tailored to particular wellbore and formation conditions.
Another component typically found in a drill string that can benefit from high-speed transfer of data is a stabilizer 97 . A stabilizer is typically disposed in a drill string and, like a centralizer, includes at least three outwardly extending fin members which serve to center the drill string in the borehole and provide a bearing surface to the string. Stabilizers are especially important in directional drilling because they retain the drill string in a coaxial position with respect to the borehole and assist in directing a drill bit therebelow at a desired angle. Furthermore, the gage relationship between the borehole and stabilizing elements can be monitored and controlled. Much like the rotary drilling unit discussed herein, the fin members of the stabilizer could be automated to extend or retract individually in order to more exactly position the drill string in the wellbore. By using a combination of sensors and actuation components, the stabilizer could become an interactive part of a drilling system and be operated in an automated fashion.
Another component often found in a drilling string is a vibrator. The vibrators are disposed near the drill bit and operate to change the mode of vibration created by the bit to a vibration that is not resonant. By removing the resonance from the bit, damage to other downhole components can be avoided. By automating the vibrator its operation can be controlled and its own vibratory characteristics can be changed as needed based upon the vibration characteristics of the drill bit. By monitoring vibration of the bit from the surface of the well, the vibration of the vibrator can be adjusted to take full advantage to its ability to affect the mode of vibration in the wellbore.
The foregoing description has included various tools, typically components found on a drill string that can benefit from the high speed exchange of information between the surface of the well and a drill bit. The description is not exhaustive and it will be understood that the same means of providing control, signaling, and power could be utilized in most any tool, including MWD and LWD (logging while drilling) tools that can transmit their collected information much faster through wired pipe.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
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The present invention generally provides a downhole tool with an improved means of transmitting data to and from the tool through the use of wired pipe capable of transmitting a signal and/or power between the surface of the well and any components in a drill string. In one aspect, a downhole tool includes a body, and a mandrel disposed in the body and movable in relation to the body. A conducive wire runs the length of the body and permits signals and/or power to be transmitted though the body as the tool changes its length.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the field of in circuit emulation (ICE). More specifically, the present invention relates to power sources used to activate a device under test (DUT) on a test pod used in an ICE system. An embodiment of the present invention relates to protection of a DUT on a test pod from the simultaneous application of more than one power source.
2. Related Art
In circuit emulation (ICE) has been used by software and hardware developers for a number of years as a development tool to emulate the operation of complex circuit building blocks. Such ICE is most commonly used currently to analyze and debug the behavior of complex devices such as microcontrollers and microprocessors that have internal structures that are far too complex to readily model using computer simulation software alone.
An exemplary conventional ICE arrangement used to model, analyze and debug the operation of a circuit such as a microcontroller consists of a host computer (e.g., a personal computer) connected to an ICE which is further connected to a pod providing coupling to a circuit or microcontroller to be tested.
Existing ICE systems have a number of disadvantages and limitations. Firstly, the power required to operate a DUT is typically supplied by the ICE power grid. In general, the ICE power grid may not be capable of supplying power at various voltage levels and at power ratings required for different circuit designs. In order to overcome such disadvantages, the pod on which a DUT is mounted may have provisions for connection to external power sources.
However, the ability to apply external power to the pod offers a second disadvantage. That is, the possibility of damage to the DUT as well as the ICE system may occur if external power is erroneously or inadvertently applied simultaneously with power from the ICE power grid.
Furthermore, existing in circuit emulation systems do not always provide the ability to determine if power is being correctly applied to a DUT.
SUMMARY OF THE INVENTION
Accordingly, what is needed is an ICE system that may be used to supply power to a DUT in accordance with the design requirements of the circuit. What is also needed is an ICE system that may be used to detect a condition whereby a power source external to the in circuit emulator is being used to supply power to a DUT. What is further needed is an ICE system that prevents the simultaneous application of power to a DUT from both the ICE and an external power source. Additionally what is needed is an ICE system that will sense a fault condition in a DUT and remove power being applied to the DUT. The present invention provides a novel solution to these needs.
One embodiment is described as a power management system and circuit comprising instructions stored in computer memory for the prevention of simultaneous coupling of more than one power source to a DUT. An unpowered DUT residing on a pod is coupled to an ICE having a power grid which may be used to apply power to the DUT. Power for the DUT may also be applied directly to the DUT from a power source external to the ICE. Instructions stored in memory prevent the simultaneous application of power to the DUT from both the ICE power grid and an external power source. In the initial phase of testing, the Debug Software performs an acquire of the DUT to determine whether external power has been applied. External power applied to the DUT results in at least one activity signal detected by the computer, a bit is stored in the instruction set to prevent the application of ICE power and testing of the DUT continues under control of the Debug Software. In the absence of an activity signal from the DUT, the DUT is powered from the ICE grid and detection of activity signals is continued. If no activity signal appears, the computer sets a bit in the instruction set that is interpreted as a fault condition in the DUT, and the Debug Software terminates testing. If an activity signal is detected by the computer, testing continues under control of the Debug Software.
More specifically, one embodiment of the present invention includes a processor and an ICE coupled to a bus, a DUT coupled to the ICE and a memory coupled to the bus comprising instructions that when executed implement a method of supervising the coupling of power to the DUT. The DUT is positioned on a pod such that power to activate the DUT can be supplied from the ICE power grid by means of a CAT5 cable or from an external power source. CAT5 cable is typically unshielded twisted pair, containing four twisted wire pairs. Fast Ethernet (100Base-T) and 10Base-T use only two of these pairs, leaving two pairs unused. Gigabit Ethernet (1000Base-T) uses all four pairs. Similar to full-duplex Fast Ethernet, 1000Base-T transmits and receives simultaneously. The difference is that 1000Base-T uses four transmit/receive pairs, each pair operating at 250M bit/sec. In one embodiment of the present invention, the DUT is a microcontroller.
Testing is initiated with the ICE power grid deactivated, and Debug Software performs an acquire of the DUT to determine if power is applied from an external source. The detection of an activity signal, such as a clock, indicates the application of power to the DUT from an external power source. In this instance, a bit is stored in the instruction set to prevent coupling of the ICE power grid to the DUT, and the Debug Software continues the test routine.
If the DUT is not powered from an external source, there will be no activity signal. Power from the ICE power grid is then applied to the DUT and the Debug Software will monitor for a resulting activity signal. Detection of an activity signal will indicate normal operation, and the Debug Software continues the test routine. If no activity signal is detected, a bit is stored in the instruction set that is interpreted as a fault condition in the DUT. Power from the ICE is decoupled from the test circuit and the testing operation is terminated. By these means, the simultaneous application of two different power sources to the DUT is avoided.
Another embodiment of the present invention includes a host computer comprising a memory coupled to an ICE having a power grid capable of activating a DUT positioned on a pod. The pod is coupled to the ICE with a CAT5 cable, and in addition is coupled to an external power supply capable of activating a DUT. The host computer memory comprises instructions that when executed implement a method of supervising the coupling of power to the DUT. More specifically, the simultaneous application of power to the DUT from both the ICE power grid and the external power source is prevented.
The Debug Software initiates testing by withholding the application of ICE power from the DUT and performing an acquire of the DUT. The presence of an activity indicator, such as a system clock, signifies the presence of DUT activation by means of an external power source, and Debug Software continues the test routine.
If the DUT is not powered from an external source, there will be no activity signal. Power from the ICE power grid is then applied to the DUT and the Debug Software will monitor for a resulting activity signal. Detection of an activity signal will indicate normal operation, and the Debug Software continues the test routine. If no activity signal is detected, a bit is stored in the instruction set that is interpreted as a fault condition in the DUT. Power from the ICE is decoupled from the DUT and the testing operation is terminated.
In one embodiment of the present invention, the ICE comprises a field programmable gate array (FPGA) that can be programmed to emulate a microcontroller located on the test pod such that the programmed FPGA and the microcontroller operate in lock step under the Debug Software test routine.
The present invention provides these advantages and others not specifically mentioned above but described in sections to follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general purpose computer system on which embodiments of the present invention may be implemented.
FIG. 2 illustrates an external power detect and supply algorithm in block diagram form according to one embodiment of the present invention.
FIG. 3 illustrates a high level block diagram of a computer controlled system for supervising the coupling of power to a test circuit according to one embodiment of the present invention.
FIG. 4 illustrates a flow diagram of computer implemented steps for supervising the coupling of power to a test circuit according to one embodiment of the present invention.
FIG. 5 illustrates a timing diagram of signals when external power is applied to the emulator pod according to one embodiment of the present invention.
FIG. 6 illustrates a timing diagram of signals when external power is not applied to the emulator pod according to one embodiment of the present invention.
FIG. 7 illustrates a timing diagram of signals showing a fault condition on the emulator pod according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, external power detect and supply, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one skilled in the art that the present invention may be practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
Notation and Nomenclature
Some portions of the detailed descriptions which follow are presented in terms of procedures, steps, logic blocks, processing, and other symbolic representations of operations on data bits that can be performed on computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, computer executed step, logic block, process, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those utilizing 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 in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, 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 convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing terms such as “checking,” “comparing,” “accessing,” “processing,” “computing,” “suspending,” “resuming,” “translating,” “calculating,” “determining,” “scrolling,” “displaying,” “recognizing,” “executing,” or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Computer System 112
Aspects of the present invention, external power detect and supply, are discussed in terms of steps executed on a computer system. Although a variety of different computer systems can be used with the present invention, an exemplary computer system 112 is shown in FIG. 1 .
Exemplary computer system 112 comprises an address/data bus 100 for communicating information, a central processor 101 coupled with the bus for processing information and instructions, a volatile memory 102 (e.g., random access memory) coupled with the bus 100 for storing information and instructions for the central processor 101 and a non-volatile memory 103 (e.g., read only memory) coupled with the bus 100 for storing static information and instructions for the processor 101 . Computer system 112 also includes a data storage device 104 (“disk subsystem”) such as a magnetic or optical disk and disk drive coupled with the bus 100 for storing information and instructions and a display device 105 coupled to the bus 100 for displaying information to the computer user.
The display device 105 of FIG. 1 utilized with the computer system 112 of the present invention may be a liquid crystal device, other flat panel display, cathode ray tube, or other display device suitable for creating graphic images and alphanumeric characters recognizable to the user.
Also included in computer system 112 is an alphanumeric input device 106 including alphanumeric and function keys coupled to the bus 100 for communicating information and command selections to the central processor 101 . Generally, alphanumeric input device 106 is called a keyboard or keypad. System 112 also includes a cursor control or directing device 107 coupled to the bus for communicating user input information and command selections to the central processor 101 . Within the context of the present invention, the cursor directing device 107 can include a number of implementations including a mouse device, for example, a trackball device, a joystick, a finger pad (track pad), an electronic stylus, an optical beam directing device with optical receiver pad, an optical tracking device able to track the movement of a user's finger, etc., or any other device having a primary purpose of moving a displayed cursor across a display screen based on user displacements.
Computer system 112 of FIG. 1 also includes an optional signal input/output communication device 108 coupled to the bus 100 . Communication device 108 may represent an external test device such as an ICE, or a field programmable gate array (FPGA). Communication between the optional signal input/output communication device 108 and the bus 100 may be accomplished using a standard PC interface such as a parallel printer port connection or a universal serial port (USB) connection.
External Power Detect and Supply
An algorithm 200 for applying power to a device under test (DUT) is illustrated in block diagram form in FIG. 2 . A device under test residing on a pod is coupled to an ICE under the control of a computer. In one embodiment, the ICE is coupled to the pod using a CAT5 cable. The ICE has a power grid capable of supplying the necessary power to activate the DUT, and software referred to as the Debug Software stored in the computer contains instructions for applying power from the ICE. Provisions for coupling an external power source to the pod for the purpose of supplying power to the DUT are also present. The algorithm is devised such that the simultaneous application of power to the DUT from the ICE power grid and an external source is prevented.
Testing is initiated in step 205 with the ICE power grid active but not coupled to the DUT. The Debug Software performs an acquire of the DUT in step 210 and looks for an activity indicator. Detection of a signal such as a clock indicates activity of the DUT due to the application of power from an external source. In the presence of an activity indicator, a signal is generated to prevent application of power from the ICE power grid to the DUT and the algorithm proceeds to step 220 where testing under control of the Debug Software continues.
If an activity indicator such as a clock is not present in step 210 , external power is not being supplied to the DUT and the algorithm proceeds to step 230 . The ICE power grid is coupled to the DUT in step 230 , and after the application of power the Debug Software looks for an activity indicator in step 240 .
Detection of a signal such as a clock in step 240 indicates activity of the DUT due to the application of power from the ICE power grid in step 230 . The algorithm then proceeds to step 250 where testing under control of the Debug Software continues.
The absence of an activity signal from the DUT in step 240 after the application of power from the ICE power grid is an indication of a fault condition concerning the DUT. The algorithm then proceeds to step 260 wherein power from the ICE power grid is removed from the DUT. Also, in step 260 a signal is generated to indicate the existence of a fault condition and testing of the DUT is halted.
FIG. 3 illustrates a high level block diagram 300 of a computer controlled system for supervising the coupling of power to a test circuit 335 according to one embodiment of the present invention. A host computer 310 comprises instructions, Debug Software 312 , stored in memory that when executed implement a method of supervising the coupling of power to a test circuit 335 disposed accordingly on a pod 330 . The host computer 310 is coupled to an ICE 320 by cabling 315 .
The ICE 320 comprises a power grid 325 capable of supplying the power necessary for operation of the test circuit 335 . In the present embodiment, coupling between the ICE 320 and the pod 330 is a CAT5 cable 350 , at least one line of which 352 is for the application of ICE grid power to the test circuit 335 and at least one line of which 351 is for the communication of signals between the ICE 320 and the pod 330 . An external power supply 340 capable of supplying the power necessary for operation of the DUT 335 is coupled to the pod 330 by means of cabling 345 .
In one embodiment of the present invention, the DUT 335 is a microcontroller, and a field programmable gate array (FPGA) 326 disposed on the ICE 320 may be programmed to emulate the microcontroller. The emulated microcontroller on the FPGA 326 then operates in lock step with the DUT 335 microcontroller.
Debug Software 312 stored in the host computer 310 memory contains instructions for applying power to the DUT 335 from the ICE power grid 325 . Testing is initiated with the ICE power grid 325 active but not coupled to the DUT 335 . The Debug Software 312 performs an acquire of the DUT 335 and looks for an activity indicator. Detection of an activity indicator such as a clock indicates activation of the DUT 335 due to the application of power from an external source 340 .
In the presence of an activity indicator, a signal is generated to prevent application of power from the ICE power grid 325 to the DUT 335 and testing under control of the Debug Software 312 continues. In one embodiment of the present invention, the generated signal causes a bit to be stored in the host computer 310 memory to indicate activation of the DUT 335 by an external power source 340 . If an activity indicator such as a clock is not present, external power 340 is not being supplied to the DUT 335 . The ICE power grid 325 is then coupled to the DUT 335 , and after the application of power the Debug Software 312 looks for an activity indicator.
Detection of an activity indicator such as a clock indicates activation of the DUT 335 due to the application of power from the ICE power grid 325 , and testing under control of the Debug Software 312 continues. The absence of an activity signal from the DUT 335 after the application of power from the ICE power grid 325 is an indication of a fault condition concerning the DUT 335 . Power from the ICE power grid 325 is then removed from the DUT 335 . A signal is generated to indicate the existence of a fault condition and the Debug Software 312 halts testing of the DUT 335 . In one embodiment of the present invention, the generated signal causes a bit to be stored in the host computer 310 memory to indicate a fault condition relative to the DUT 335 .
In one embodiment of the present invention, the simultaneous application of power to the DUT 335 from the ICE power grid 325 and an external power source 340 is thereby prevented. Furthermore, the automatic removal of power applied to a faulty DUT 335 or a faulty DUT condition is realized.
FIG. 4 illustrates a flow diagram 400 of computer implemented steps for supervising the coupling of power to a DUT according to one embodiment of the present invention. A DUT residing on a pod is coupled to an ICE under the control of a computer. In one embodiment, the ICE is coupled to the pod using a CAT5 cable. The ICE has a power grid capable of supplying the necessary power to activate the DUT and software referred to as the Debug Software stored in the computer contains instructions for applying power from the ICE. Provisions for coupling an external power source to the pod for the purpose of supplying power to the DUT are also present. The flow diagram illustrates the steps taken to prevent the simultaneous application of power to the DUT from the ICE power grid and an external source.
Testing is initiated in step 420 with the ICE power grid active but not coupled to the DUT. The Debug Software performs an acquire of the DUT in step 430 and looks for an activity indicator in step 440 . Detection of a signal such as a clock indicates activity of the DUT due to the application of power from an external source and the system proceeds to step 450 . In step 450 a signal is generated to prevent application of power from the ICE power grid to the DUT. In one embodiment of the present invention the generated signal causes a bit to be stored in the host computer memory to indicate activation of the DUT by an external power source. The system then proceeds to step 460 where testing under control of the Debug Software continues.
If an activity indicator such as a clock is not present in step 440 , external power is not being supplied to the DUT and the algorithm proceeds to step 470 . The ICE power grid is coupled to the DUT in step 470 , and after the application of power the Debug Software looks for an activity indicator in step 480 .
The detection of a signal such as a clock in step 480 indicates activity of the DUT due to the application of power from the ICE power grid in step 470 . The system then proceeds to step 460 where testing under control of the Debug Software continues.
The absence of an activity signal from the DUT in step 480 after the application of power from the ICE power grid is an indication of a fault condition concerning the DUT. The system then proceeds to step 490 wherein power from the ICE power grid is removed from the DUT. Also, in step 490 a signal is generated to indicate the existence of a fault condition and testing of the DUT is halted. In one embodiment of the present invention, the generated signal causes a bit to be stored in the host computer memory to indicate a fault condition relative to the DUT.
In one embodiment of the present invention, the simultaneous application of power to the DUT from the ICE power grid and an external power source is thereby prevented. Furthermore, the automatic removal of power applied to a faulty DUT or a faulty DUT condition is realized.
A timing diagram 500 showing externally applied power 540 coupled to a DUT in the absence of power from the ICE power grid 530 and a DUT activity signal 520 is illustrated in FIG. 5 . A time line 510 illustrates increasing time in a direction from left to right. Testing of the DUT begins at point 550 on the time line 510 when the Debug Software performs an acquire. The external power 540 has an off level 541 and an on level 542 illustrating the application of external power. The ICE power grid 530 has an off level 531 and an on level 532 illustrating the absence of power from the ICE power grid. In one embodiment, the DUT activity signal 520 is a clock with high-low activity levels 522 – 521 respectively illustrating DUT activity. In this instance, shortly after point 550 on the time line, the system detects the activity signal, causes a bit to be stored in system software indicating externally applied power and preventing the application of ICE grid power, and proceeds with testing.
In one embodiment of the present invention, the simultaneous application of power to the DUT from the ICE power grid 530 and an external power source 540 is thereby prevented. Furthermore, the automatic removal of power applied to a faulty DUT or a faulty DUT condition is realized.
A timing diagram 600 showing power from the ICE power grid 630 coupled to a DUT in the absence of externally applied power 640 and a DUT activity signal 620 is illustrated in FIG. 6 . A time line 610 illustrates increasing time in a direction from left to right. Testing of the DUT begins at point 650 on the time line 610 when the Debug Software performs an acquire.
Prior to point 650 on the time line, the external power 640 has an off level 641 and an on level 642 illustrating the absence of external power. The ICE power grid 630 has an off level 631 and an on level 632 illustrating the absence power from the ICE power grid. A DUT activity signal 620 illustrated as a clock with high-low activity levels 622 – 621 respectively shows a lack of DUT activity.
In this instance, shortly after point 650 on the time line, the system detects the absence of an activity signal 620 , which indicates the absence of external power 640 applied to the DUT. Power from the ICE power grid 630 is then applied to the DUT and the system looks for a DUT activity signal 620 . The activity signal 620 appears at point 660 on the time line 610 and the system proceeds with testing.
In one embodiment of the present invention, the simultaneous application of power to the DUT from the ICE power grid 630 and an external power source 640 is thereby prevented. Furthermore, the automatic removal of power applied to a faulty DUT or a faulty DUT condition is realized.
A timing diagram 700 showing power from the ICE power grid 730 coupled to a DUT in the absence of externally applied power 740 and a DUT activity signal 720 is illustrated in FIG. 7 . A time line 710 illustrates increasing time in a direction from left to right. Testing of the DUT begins at point 750 on the time line 710 when the Debug Software performs an acquire.
Prior to point 750 on the time line, the external power 740 has an off level 741 and an on level 742 illustrating the absence of external power. The ICE power grid 730 has an off level 731 and an on level 732 illustrating the absence power from the ICE power grid. A DUT activity signal 720 illustrated as a clock with high-low activity levels 722 – 721 respectively shows a lack of DUT activity.
In this instance, shortly after point 750 on the time line, the system detects the absence of an activity signal 720 , which indicates the absence of external power 740 applied to the DUT. Power from the ICE power grid 730 is then applied to the DUT at point 760 on the time line 710 , and the system looks for a DUT activity signal 720 . The activity signal 720 fails to appear, and at point 770 on the time line 710 the system removes ICE power 730 from the DUT and halts testing. The system also causes a bit to be stored in system software indicating a fault in the DUT or in the DUT configuration.
In one embodiment of the present invention, the simultaneous application of power to the DUT from the ICE power grid 730 and an external power source 740 is thereby prevented. Furthermore, the automatic removal of power applied to a faulty DUT or a faulty DUT condition is realized.
The preferred embodiment of the present invention, external power detect and supply, is thus described. While the present invention has been described in particular embodiments, it should be appreciated that the present invention should not be construed as limited by such embodiments, but rather construed according to the below claims.
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A power management system and circuit comprising instructions stored in computer memory for the prevention of simultaneous coupling of more than one power source to a device under test (DUT). Instructions stored in memory prevent the simultaneous application of power to the DUT from both the in circuit emulator power grid and an external power source. External power applied to the DUT results in at least one activity signal detected by the computer. If no activity signal appears, a fault condition in the DUT is interpreted. If an activity signal is detected, testing continues under control of Debug Software.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This Divisional application claims the benefit of U.S. Ser. No. 13/236,072 filed Sep. 19, 2011, now allowed, which in turn is a U.S. Non-Provisional application which claims the benefit of U.S. Provisional application Ser. No 61/392,183 filed Oct. 12, 2010, now expired.
BACKGROUND OF THE INVENTION
[0002] The disclosure generally relates to a synthetic process for preparing compounds of formula I including the preparation of chemical intermediates useful in this process.
[0003] CGRP inhibitors are postulated to be useful in pathophysiologic conditions where excessive CGRP receptor activation has occurred. Some of these include neurogenic vasodilation, neurogenic inflammation, migraine, cluster headache and other headaches, thermal injury, circulatory shock, menopausal flushing, and asthma. CGRP antagonists have shown efficacy in human clinical trials. See Davis C D, Xu C. Curr Top Med Chem. 2008 8(16):1468-79; Benemei S, Nicoletti P, Capone J G, Geppetti P. Curr Opin Pharmacol. 2009 9(1):9-14. Epub 2009 Jan. 20; Ho T W, Ferrari M D, Dodick D W, Galet V, Kost J, Fan X, Leibensperger H, Froman S, Assaid C, Lines C, Koppen H, Winner P K. Lancet. 2008 372:2115. Epub 2008 Nov. 25; Ho T W, Mannix L K, Fan X, Assaid C, Furtek C, Jones C J, Lines C R, Rapoport A M; Neurology 2008 70:1304. Epub 2007 Oct. 3.
[0004] CGRP receptor antagonists have been disclosed in PCT publications WO 2004/092166, WO 2004/092168, and WO 2007/120590. The compound (5S,6S,9R)-5-amino-6-(2,3-difluorophenyl)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-9-yl4-(2-oxo-2,3-dihydro-1H-imidazo [4,5-1)]pyridin-1-yl)piperidine-1-carboxylate is an inhibitor of the calcitonin gene-related peptide (CGRP) receptor.
[0000]
[0005] For purposes of large-scale production there is a need for a high-yielding synthesis of compound of formula I and related analogs that is both efficient and cost-effective.
DESCRIPTION OF THE INVENTION
[0006] One aspect of the invention is a process for the preparation of a compound of formula I, or a salt thereof, where Ar 1 is phenyl substituted with 0-3 substituents selected from the group consisting of cyano, halo, alkyl, haloalkyl, alkoxy, haloalkoxy, and alkylSO 2
[0000]
[0000] comprising the reductive amination and alcohol deprotection of a compound of formula IV where R 1 is selected from the group consisting of trialkylsilyl, alkoxy, alkylcarbonyl, benzyl, substituted benzyl, benzoyl, and pivaloyl to a compound of formula II where R 1 is hydrogen, and coupling the compound of formula II, or a salt thereof, with a compound of formula III where R 2 is selected from the group consisting of imidazolyl, pyrrolyl, N-hydroxysuccinimidyl, chloro, phenoxy, substituted phenoxy, phenylthio, and substituted phenylthio.
[0000]
[0007] Another aspect of the invention is a process for the preparation of a compound of formula I, or a salt thereof, where Ar 1 is phenyl substituted with 0-3 substituents selected from the group consisting of cyano, halo, alkyl, haloalkyl, alkoxy, haloalkoxy, and alkylSO 2
[0000]
[0000] comprising coupling a compound of formula II, or a salt thereof, where R 1 is hydrogen, or a salt thereof, with a compound of formula III, or a salt thereof, where R 2 selected from the group consisting of imidazolyl, pyrrolyl, N-hydroxysuccinimidyl, chloro, phenoxy, substituted phenoxy, phenylthio, and substituted phenylthio.
[0000]
[0008] Another aspect of the invention is where the compound of formula II is
[0000]
[0000] or a salt thereof, and the compound of formula III is
[0000]
[0000] or a salt thereof.
[0009] Another aspect of the invention is a process for the preparation of a compound of formula II, or a salt thereof, where Ar 1 is phenyl substituted with 0-3 substituents selected from the group consisting of cyano, halo, alkyl, haloalkyl, alkoxy, haloalkoxy, and alkylSO 2 and R 1 is hydrogen,
[0000]
[0000] comprising the reductive amination and deprotection of a compound of formula IV, or a salt thereof, where Ar 1 is phenyl substituted with 0-3 substituents selected from the group consisting of cyano, halo, alkyl, haloalkyl, alkoxy, haloalkoxy, and alkylSO 2 and R 1 is trialkylsilyl, alkoxy, alkylcarbonyl, benzyl, substituted benzyl, benzoyl, and pivaloyl.
[0010] Another aspect of the invention is a process where Ar 1 is 2,3-difluorophenyl and where R 1 is triisopropylsilyl for the compound of formula IV.
[0011] Another aspect of the invention is a process for the preparation of a compound of formula III, or a salt thereof, where R 2 is imidazolyl
[0000]
[0000] comprising coupling 3-N-piperidin-4-ylpyridine-2,3-diamine, or a salt thereof, or 1-(piperidin-4-yl)-1H-imidazo[4,5-b]pyridin-2(3H)-one, or a salt thereof, with carbonyl diimidazole or triphosgene and imidazole.
[0012] Another aspect of the invention is a compound of formula II, or a salt thereof, where Ar 1 is phenyl substituted with 0-3 substituents selected from the group consisting of cyano, halo, alkyl, haloalkyl, alkoxy, haloalkoxy, and alkylSO 2 and R 1 is hydrogen or trialkylsilyl, alkoxy, alkylcarbonyl, benzyl, substituted benzyl, benzoyl, and pivaloyl. Another aspect of the invention is a compound of formula II where Ar 1 is 2,3-difluorophenyl and R 1 is hydrogen or a salt thereof. Another aspect of the invention is a compound of formula II which is the dihydrochloride salt.
[0013] Another aspect of the invention is a compound of or formula II where Ar 1 is 2,3-difluorophenyl and R 1 is triisopropylsilyl or a salt thereof. Another aspect of the invention is a compound of formula II which is the dihydrochloride salt.
[0000]
[0014] Another aspect of the invention is a compound of formula III, or a salt thereof, where R 2 is selected from the group consisting of imidazolyl, pyrrolyl, N-hydroxysuccinimidyl, chloro, phenoxy, substituted phenoxy, phenylthio, and substituted phenylthio. Another aspect of the invention is a compound of claim 12 where R 2 is imidazolyl.
[0000]
[0015] Unless specified otherwise, these terms have the following meanings “Alkyl” means a straight or branched alkyl group composed of 1 to 6 carbons, preferably 1 to 3 carbons. “Alkenyl” means a straight or branched alkyl group composed of 2 to 6 carbons with at least one double bond. “Cycloalkyl” means a monocyclic ring system composed of 3 to 7 carbons. “Hydroxyalkyl,” “alkoxy” and other terms with a substituted alkyl moiety include straight and branched isomers composed of 1 to 6 carbon atoms for the alkyl moiety. “Haloalkyl” and “haloalkoxy” include all halogenated isomers from monohalo substituted alkyl to perhalo substituted alkyl. “Aryl” includes carbocyclic and heterocyclic aromatic ring systems.
[0016] Those skilled in the art understand that there are a variety of alternative reagents and solvents that can be interchanged. The following definitions are meant to serve as non-limiting examples to illustrate a term and are not meant to limit the definition to the examples listed.
[0017] Some suitable protecting groups at R 1 include trialkylsilyl, alkyl ether, benzyl ether, alkyl carbonate, benzyl carbonate, and ester. Trialkylsilyl includes TMS, TES, TIPS, TPS, TBDMS, and TBDPS. Alkyl ethers include methyl, MOM, BOM, PMBM, t-Butoxymethyl, SEM, THP, t-Bu, and allyl. Benzyl ether includes methoxybenzyl, dimethoxybenzyl, trifluoromethylbenzyl, nitrobenzyl, dinitrobenzyl, cyanobenzyl, and halobenzyl, diphenylmethyl and triphenylmethyl. Alkyl carbonate includes methyl, ethyl, isobutyl, vinyl, allyl and nitrophenyl. Substituted benzyl carbonate includes methoxybenzyl, dimethoxybenzyl and nitrobenzyl. Ester includes pivolate, adamantoate, benzoate, phenylbenzoate, and mesitoate.
[0018] Some suitable leaving groups at R 2 include imidazolyl, pyrrolyl, N-hydroxysuccinimidyl, chloro, substituted phenoxy, and substituted phenylthio. Substituted phenoxy includes nitrophenoxy, cyanophenoxy, and trifluoromethylphenoxy. Substituted phenylthio includes nitrophenylthio, cyanophenylthio, and trifluoromethylphenylthio.
[0019] Some suitable reductive amination conditions include using ammonia, hydroxyamine, protected hydroxyamine (for example, methoxyamine, benzyloxyamine, acetoxyamine), benzylamine, and the salts of these aminating reagents (for example, ammonium acetate, ammonium chloride). Benzyl includes methoxybenzyl, dimethoxybenzyl, trifluoromethylbenzyl, nitrobenzyl, dinitrobenzyl, cyanobenzyl, and halobenzyl, diphenylmethyl and triphenylmethyl.
[0020] Some suitable reagents for dehydrating agents in the reductive amination include titanium alkoxides, titanium chloride, mixed titanium alkoxides/chlorides, aluminum chloride, zirconium chloride, tin chloride, boron trifluoride, copper sulfate, magnesium sulfate, and molecular sieves. Titanium alkoxides include isopropoxide, propoxide, ethoxide, methoxide, butoxide, and t-butoxide.
[0021] Some suitable reduction conditions include transition metal catalyzed hydrogenations with for example, palladium, platinum, or iridium catalysts, metal hydrides of aluminum and boron, and zinc with acetic acid. Some catalysts include palladium on alumina, palladium on calcium carbonate, palladium-lead on calcium carbonate, palladium on carbon and Perlman's catalyst.
[0022] Some suitable acids for deprotecting the alcohol include any acid or fluoride containing reagent. For example, hydrogen chloride, hydrogen bromide, sulfuric acid, methanesulfonic acid, p-toluenesulfonic acid, trifluoroacetic acid, hydrogen fluoride, hydrogen fluoride-pyridine, and tetrabutylammonium fluoride.
[0023] Some suitable bases for the coupling include group I and II metal alkoxides (for example, sodium methoxide, potassium t-butoxide and sodium t-butoxide), group I metal disilazides (for example potassium disilazide), group I and II hydrides (for example, sodium hydride), group I amides (for example, lithium diisopropylamide), and group I metal alkydes (for example, butyl lithium).
Synthetic Methods
[0024] The following methods are for illustrative purposes and are not intended to limit the scope of the invention. Those skilled in the art understand that there will be a number of equivalent methods for the preparation of these compounds and that the synthesis is not limited to the methods provided in the following examples. For example, some reagents and solvents may have equivalent alternatives known to those in the art. The variables describing general structural formulas and features in the synthetic schemes are distinct from and should not be confused with the variables in the claims or the rest of the specification. These variables are meant only to illustrate how to make some of the compounds of the invention.
[0025] Abbreviations used in the description generally follow conventions used in the art. Some abbreviations are defined as follows: “1×” for once, “2×” for twice, “3×” for thrice, “° C.” for degrees Celsius, “eq” for equivalent or equivalents, “g” for gram or grams, “mg” for milligram or milligrams, “L” for liter or liters, “mL” for milliliter or milliliters, “μL” for microliter or microliters, “N” for normal, “M” for molar, “mmol” for millimole or millimoles, “min” for minute or minutes, “h” for hour or hours, “rt” for room temperature, “RT” for retention time, “atm” for atmosphere, “psi” for pounds per square inch, “conc.” for concentrate, “sat” or “sat'd “for saturated, “MW” for molecular weight, “mp” for melting point, “ee” for enantiomeric excess, “MS” or “Mass Spec” for mass spectrometry, “ESI” for electrospray ionization mass spectroscopy, “HR” for high resolution, “HRMS” for high resolution mass spectrometry , “LCMS” for liquid chromatography mass spectrometry, “HPLC” for high pressure liquid chromatography, “RP HPLC” for reverse phase HPLC, “TLC” or “tic” for thin layer chromatography, “NMR” for nuclear magnetic resonance spectroscopy, “ 1 H” for proton, “δ” for delta, “s” for singlet, “d” for doublet, “t” for triplet, “q” for quartet, “m” for multiplet, “br” for broad, “Hz” for hertz, and “α”, “β”, “R”, “S”, “E”, and “Z” are stereochemical designations familiar to one skilled in the art.
[0026] Scheme 1 illustrates a synthesis of formula I compounds.
[0000]
DESCRIPTION OF SPECIFIC EMBODIMENTS
Example 1
[0027]
(6S,9R)-6-(2,3-difluorophenyl)-9-(triisopropylsilyloxy)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-5-amine
[0028] To a 100 mL hastelloy autoclave reactor was charged (65,9R)-6-(2,3-difluorophenyl)-9-(triisopropylsilyloxy)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-5-one (5.00 g, 11.22 mmol), 1,4-dioxane (50 mL) and titanium tetra(isopropoxide) (8.33 mL, 28.11 mmol). The reactor was purged three times with nitrogen and three times with ammonia. After the purge cycle was completed, the reactor was pressurized with ammonia to 100 psig. The reaction mixture was heated to 50° C. (jacket temperature) and stirred at a speed to ensure good mixing. The reaction mixture was aged at 100 psig ammonia and 50° C. for 20 h. The mixture was then cooled to 20° C. then 5% Pd/Alumina (1.0 g, 20 wt %) was charged to the autoclave reactor. The reactor was purged three times with nitrogen and three times with hydrogen. After the purged cycle completed, the reactor was pressurized with hydrogen to 100 psig and mixture was heated to 50° C. (jacket temperature) and stirred at a speed to ensure good mixing. The reaction mixture was aged at 100 psig H 2 and 50° C. for 23 h (reactor pressure jumped to ˜200 psig due to soluble ammonia in the mixture). The mixture was then cooled to 20° C. then filtered then transferred to a 100 ml 3-necked flask. To the mixture water (0.55 mL) was added drop wise, which resulted in yellow slurry. The resulting slurry was stirred for 30 min then filtered, then the titanium dioxide cake was washed with 1,4-dioxane (30 mL). The filtrate was collected and the solvent was removed. The resulting oil was dissolved in isopropanol (40 mL). To the solution ˜5N HCl in isopropanol (9.0 ml) was added drop wise resulting in a thick slurry. To the slurry isopropyl acetate (60 ml) was added and heated to 45° C. for 10 min and then cooled to 22° C. over approximately 3 h to afford a white solid (3.0 g, 51.5%). 1 H NMR (500 MHz, CD 3 OD) δ ppm 8.89 (d, J=5.3, 1H), 8.42 (bs, 1H), 8.05 (bs, 1H), 7.35 (dd, J=8.19, 16.71), 7.2 (bs, 2H), 7.22 (m, 1H) 7.15 (m, 1H), 5.7 (dd, J =1.89, J=8.51), 5.4 (m, 1H), 3.5 (m, 1H), 1.9-2.5 (B, 4h) 1.4 (sept, J=15.13, 3H), 1.2 (t, J=7.57 18H); 13 C NMR (125 MHz, CD 3 OD) δ 153.5, 151.6, 151.5, 151.3, 149.4, 143.4, 135.03, 129.8, 129.8, 127.8, 126.8, 126.4, 118.6, 72.4, 54.1, 41.4, 34.3, 32.3, 25.4, 18.6, 18.5, 13.7, 13.6, 13.5, 13.3.
Example 2
[0029]
(6S,9R)-5-amino-6-(2,3-difluorophenyl)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-9-ol
[0030] To a 250 ml flask was charged (65,9R)-6-(2,3-difluorophenyl)-9-(triisopropylsilyloxy)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-5-amine di HCl salt (15 g, 25.88 mmol) and a solution of isopropanol:water (45 mL : 15 mL). The mixture was heated to 82° C. for 6 h then dried via azeotropic distillation at atmospheric pressure using isopropanol until the KF was less than <3%. After fresh isopropanol (25 ml) was added, the mixture was heated to 70° C. and then isopropyl acetate (45 ml) was added that resulting in a white slurry. The slurry cooled to 22° C. for 15 min to afford a white solid (9.33 g, 99%). 1 H NMR (500 MHz CD 3 OD) δ 8.77 (d, J=5.7 Hz, 1H), 8.47 (d, J=7.9 Hz, 1H), 8.11 (dd, J=6.0, 8.2 Hz, 1H), 7.21-7.32 (m, 3H), 5.53 (dd, J=3.8, 9.8 Hz, 1H) 5.33 (d, J=9.8 Hz, 1H), 3.5 (bm, 1H), 2.25-2.40 (m, 2H), 2.15 (bm, 1H), 1.90 (bm, 1H); 13 C NMR (125 MHz, MeOD) δ 159.4, 153.9, 151.9 and 151.8, 149.7, 143.6, 141.8, 135.7, 130.6, 127.7, 126.8, 118.9, 70.0, 54.9, 42.2, 34.5, 33.4.
Example 3
[0031]
(5S,6S,9R)-5-amino-6-(2,3-difluorophenyl)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-9-yl-4-(2-oxo-2,3-dihydro-1H-imidazo[4,5-b]pyridin-1-yl)piperidine-1-carboxylate
[0032] To a round bottom flask was charged (5S,65,9R)-5-amino-6-(2,3-difluorophenyl)-6,7,8,9-tetrahydro-5H-cyclohepta[b]pyridin-9-ol dihydrochloride (1.00 g, 2.73 mmol) and dichloromethane (15 mL). A solution of sodium carbonate (0.58 g, 5.47 mmol), 20 wt % aqueous sodium chloride (5 mL), and water (10 mL) was added and the biphasic mixture was aged for 30 min. The phases were allowed to separate and the organic stream was retained. The dichloromethane solvent was then switched with azeotropic drying to tetrahydrofuran, with a final volume of (15 mL). At 20° C. was added, 1-(1-(1H-imidazole-1-carbonyl)piperidin-4-yl)-1H-imidazo[4,5-b]pyridin-2(3H)-one (0.95 g, 3.01 mmol), followed by a 20 Wt % potassium tert-butoxide solution in THF (4 mL, 6.20 mmol). The thin slurry was aged for 1 h, and then the reaction was quenched with the addition of 20 wt % aqueous sodium chloride (5 mL) and 20 wt % aqueous citric acid (2.5 mL). The layers were allowed to separate and the organic rich layer was retained. The organic layer was washed with 20 wt % aqueous sodium chloride (15 mL). The organic tetrahydrofuran stream was then concentrated in vacuo to afford an oil which was resuspended in dichloromethane (20 mL) and dried with MgSO 4 . The dichloromethane stream was concentrated in vacuo to afford an oil, which was crystallized from ethanol:heptane to afford a white solid (1.14 g, 78.3%). LCMS: [M+H]=535: 1 H NMR (600 MHz, d 6 -DMSO) δ 11.58 (1H, bs), 8.45 (1H, bd), 8.03 (1H, d, J=7.3 Hz), 7.91 (1H, bs), 7.54 (1H, bd), 7.36 (1H, bm), 7.34 (1H, bm), 7.28 (1H, m), 7.21 (1H, m), 7.01 (1H, bs), 6.01 (1H, dd, J=3.2, 9.8 Hz), 4.48 (1H, d, J=9.5 Hz), 4.43 (1H, bm), 4.38 (1H, bm), 4.11 (1H, bm), 3.08 (1H, bm), 2.93 (1H, bm), 2.84 (1H, m), 2.62 (1H, bm), 2.20 (2H, bm), 2.13 (1H, bm), 2.12 (1H, bm), 1.75 (1H, bm), 1.72 (1H, bm), 1.66 (1H, bm); 13 C NMR (125 MHz, d 6 -DMSO) δ 156.6, 154.2, 153.0, 149.8, 148.1, 146.4, 143.5, 139.6, 137.4, 134.0, 132.8, 124.7, 124.5, 123.3, 122.2, 116.3, 115.0, 114.3, 73.7, 52.8, 50.0, 43.8, 43.3, 32.0, 30.3, 28.6; mp 255° C.
Example 4
[0033]
1-(1-(1H-imidazole-1-carbonyl)piperidin-4-yl)-1H-imidazo[4,5-b]pyridin-2(3H)-one
[0034] To a round bottom flask was added, 1,1′-carbonyldiimidazole (8.59 g, 51.4 mmol), diisopropylethylamine (12.6 mL, 72.2 mmol) and tetrahydrofuran (100 mL). This mixture was warmed to 40° C. and aged for 10 min, after which 1-(piperidin-4-yl)-1H-imidazo[4,5-b]pyridin-2(3H)-one dihydrochloride (10 g, 34.3 mmol) was added. The slurry was aged at 40° C. for 3 h, and then upon reaction completion, the solvent was swapped to acetonitrile which afforded an off white solid (9.19 g, 85.9%). LCMS: [M+H]=313; 1 H NMR (400 MHz, d 6 -DMSO) δ 11.58 (1H, s), 8.09 (1H, s), 7.97 (1H, d, J=8.0 Hz), 7.73 (1H, d, J=4.0 Hz), 7.53 (1H, s), 7.05 (1H, s), 7.00 (1H, dd, J=4.0, 8.0 Hz), 4.52, (1H, dd, J=8.0, 12.0 Hz), 4.05 (2H, bd, J=8.0 Hz), 3.31 (2H, m), 2.34 (2H, m), 1.82 (2H, bd, J=12.0 Hz); 13 C NMR (100 MHz, d 6 -DMSO) δ 153.0, 150.4, 143.4, 139.8, 137.2, 128.9, 123.0, 118.7, 116.4, 115.2, 49.3, 45.1, 28.5; mp 226° C.
Example 5
[0035]
1-(1-(1H-imidazole-1-carbonyl)piperidin-4-yl)-1H-imidazo[4,5-b]pyridin-2(3H)-one
[0036] To a 250 ml round bottom flask was added 3-N-piperidin-4-ylpyridine-2,3-diamine dihydrochloride (10 g, 52 mmol) and acetonitrile (100 mL). Triethyl amine (11.44 g, 113 mmol) and 1,1′-Carbonyldiimidazole (18.34 g, 113 mmol) were added at ambient temperature and the mixture was stirred for 2 h. The solvent was evaporated under vacuum to ˜30 ml reaction volume and isopropyl acetate (50 mL) was added into the resulting slurry at 40° C. The slurry was cooled to 10-15° C. and then stirred for 1 h to afford an off white solid (10 g, 85%).
[0037] It will be evident to one skilled in the art that the present disclosure is not limited to the foregoing illustrative examples, and that it can be embodied in other specific forms without departing from the essential attributes thereof. It is therefore desired that the examples be considered in all respects as illustrative and not restrictive, reference being made to the appended claims, rather than to the foregoing examples, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
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The disclosure generally relates to a process for the preparation of compounds of formula I, including synthetic intermediates which are useful in the process.
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[0001] This invention is based upon provisional patent application No. 60/330,048, entitled Refrigerator Air Sterilization Device, filed Oct. 17, 2001; and provisional patent application No. 60/330,050, entitled Room Air Sterilization Device, filed Oct. 17, 2001. The priority date for these provisional patent applications is claimed herein.
BACKGROUND OF THE INVENTION
[0002] Since the beginning of the refrigeration industry there have been improvements in the preservation of food products and other heat sensitive products. However, the refrigeration systems utilized do not inhibit the formation of fungi and bacteria inside the refrigerators and other cooling chambers. More recently, some refrigerators have presented new interior air circulation systems that improve the refrigeration of food products by maintaining a constant flow of cold air of essentially constant temperature which keeps foods at a desired constant temperature. These systems, however, have the drawback of increasing the incidence of cross contamination between food items when bacteria and spores are transported by air from one food item to another throughout the entire refrigeration chamber.
[0003] Accordingly, there is a need for an improved air sterilization system which can be utilized with existing and new refrigerators with enhanced airflow and temperature technologies so that bacteria, spores, fungi and smells are reduced without negatively impacting the temperature control quality of the refrigeration or other cooling systems.
SUMMARY OF THE INVENTION
[0004] The invention is generally directed to an improved air sterilization system for refrigerators, multipurpose chambers, and compartments where it is desired that the sterilization system will not significantly affect the air temperature where the air within the chamber is substantially confined. The system may include an air sterilization assembly that is located wholly within the interior of a chamber, or may be attached to the exterior or may have some components located in the interior while others are located outside of the chamber. The system has at least one air sterilization assembly, at least one air entrance and at least one air exhaust. The air entrance and exhaust are located within the interior of the chamber such that interior air will freely enter and exhaust the air sterilization assembly by means of air convection. The unsterilized air enters the assembly, is cleaned, and the sterilized air is returned to the chamber without significantly altering the inside temperature of the chamber.
[0005] The invention uses intense heat contained within capillaries to effectively kill micro-organisms such as mold, bacteria, and virus. Because the device operates without the release of large quantities of heat into the environment, it is particularly suited for use as part of an air sterilization system for a refrigerator, room, multi purpose chamber or compartment requiring air purification. When used inside a refrigeration chamber, the air sterilization system will reduce the development of smells, bacteria, spores and fungi inside the chamber to preserve and extend the shelf life of food products and stored materials.
[0006] The air sterilisation device consists of a ceramic core having at least one tube, with at least 2 longitudinal capillaries extending the length of the tube. The capillaries have a diameter between 1 mm and 8 mm and the tube may extend between about 120 mm and 2400 mm in length. In the preferred embodiment, the capillaries are heated with an electrically resistant wire that runs the length of the capillaries. The wire is connected to a power supply. When power runs through the wire, the resistance of the wire generates heat, which is radiated into the air surrounding the wire inside the capillary. The resistant wire is designed to produce heat inside each capillary in excess of 160° Celsius. The heat inside the capillaries generates an upward air stream by heating the air when the ceramic pipe is in a vertical position. The heated air exiting from the upper ends of the capillaries creates a negative pressure at the lower ends of the capillaries which sucks exterior air into the ceramic capillaries and sustains a continuous air circulation through the capillaries. Airborne micro-organisms are exterminated by heat as they pass through the heated capillaries. The continuous airflow generated by air convection assures substantial air sterilisation in a quiet and efficient way and with low power consumption. In the preferred embodiment, the tubes are made of a good quality ceramic or equivalent material that can withstand heat greater then 200° C., and that allows the capillaries to be situated closely together where heat may be exchanged between them. The ceramic core is located within an exterior casing having an air access opening at the bottom. An optional heat exchanger can be used at some distance above the ceramic capillaries, and may have a casing top that is resistant to impact and heat, and that has at least one air outlet that will boost airflow out of the device. In the preferred embodiment, the casing will incorporate the ceramic core and be attached to a wall.
[0007] Accordingly, it is an object of the invention to reduce airborne micro-organisms and of avoid the formation of smells, fungi, mold and bacteria in food-containing air chambers.
[0008] It is a second object of the invention to provide an improved sterilization system for refrigerators, incorporating air sterilization assemblies.
[0009] Another object of the invention is to provide an improved air sterilization system for refrigerators in which air sterilization assemblies including intake and outlet connections pass air in the refrigerator through the air sterilization assembly which kills fungus, bacteria and other airborne micro-organisms through heat.
[0010] Still a further object of the invention is to provide an improved air sterilization system for refrigerators which utilizes a fan to enhance the air flow through the air sterilizing assembly.
[0011] Yet still a further object of the invention is to provide an improved air sterilization system in which the air sterilization assembly is coupled to a cooling chamber so that the air from the cooling chamber passes through the sterilization system where the heat inside is used to kill the micro-organisms and the heat does not adversely affect the internal temperature of the cooling chamber.
[0012] Still another object of the invention is to provide an improved air sterilization system in which the air assembly is coupled to a multi purpose chamber or room for sterilizing the air.
[0013] Yet another object of the invention is to provide an improved air sterilization system to be attached to automobiles, trains, subway cars, submarines, aircraft, cruise ships, war vessels and other types of vehicles in which the air in a restricted volume is to be purified.
[0014] Still other objects and advantages of the invention will be apparent from the following description of the preferred embodiments.
[0015] The invention accordingly comprises the features of construction, combination of elements, arrangement of parts, combination of steps and procedures, all of which will be exemplified in the constructions and processes hereinafter set forth and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawings, in which:
[0017] [0017]FIG. 1 is a cutaway perspective view of an air sterilization assembly constructed in accordance with a preferred embodiment of the invention;
[0018] [0018]FIG. 2 is a side elevation view of a air sterilizing assembly as in FIG. 1, attached through the wall of a refrigerator;
[0019] [0019]FIG. 3 is a cutaway perspective view of an air sterilization assembly constructed in accordance with a preferred embodiment of the invention in which the air sterilization assembly is inside the refrigerator wall;
[0020] [0020]FIG. 4 is a partially cutaway perspective view of an air sterilizing assembly inserted in a wall constructed in accordance with a preferred embodiment of the invention; and
[0021] [0021]FIG. 5 is a cutaway perspective view of an air sterilization assembly attached to the outside surface of a chamber wall, constructed in accordance with another preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Reference is first made to FIG. 1 in which an air sterilizing assembly, generally indicated as 100 , constructed in accordance with a preferred embodiment of the invention, is depicted. Air sterilizer assembly 100 has contaminated air entering by air convection at inlet 12 . The air in sequence enters the sterilizing ceramic element 1 of the type shown and described in Applicant's prior U.S. Pat. No. 5,874,050, which is inserted in an optional insulated element 2 . The hot sterilized air exhausts at the sterilizing element top end 3 . The hot sterilized air is then cooled at optional heat exchanger 8 . Finally the cooled, sterilized air exhausts air sterilizer chamber 10 through outlet 11 back to the refrigerator or chamber.
[0023] As shown in FIG. 2, like referenced elements being represented by like referenced numerals, air sterilization assembly 100 is affixed outside of the wall 20 of the chamber. As shown in FIG. 2, the left side of wall 20 is the interior of the chamber compartment. Air inlet 12 is shown open on the inside of the chamber compartment with the flow of air through air sterilization assembly 10 and then back out through exhaust outlet 11 through wall 20 of the chamber. In this way, the heat associated with the sterilization process is applied outside of the chamber wall causing less impact on the interior temperature of the refrigerator.
[0024] Reference is next made to FIG. 3 where air sterilization system 200 with air sterilization assembly 10 (not shown) including ceramic element 1 inserted in optional insulated element 2 and optional heat exchanger 8 , all at the inside of the refrigerator corner next to wall 20 is shown. In this case, the air sterilization assembly 10 is placed in an insulated chamber 14 and the air sterilization assembly 10 includes optional contaminated air inputs 12 and 12 A and one exhaust 11 .
[0025] Reference is next made to FIG. 4 wherein an air sterilization assembly 300 constructed in accordance with another preferred embodiment of the invention is depicted, like elements being depicted by like referenced numerals. In this case, the air sterilization assembly 300 is placed in a tube 30 in refrigerator wall 20 . One portion of channel 30 serves as air inlet 12 A and another portion as exhaust outlet 11 A. An optional circulation fan 5 is shown in the air channel to assist in improving airflow through the assembly. Although the fan is located above the assembly, its positioning is not critical, and it may be mounted below the sterilization assembly, if desired. The air sterilization assembly 300 again includes an air sterilizing element 1 , an insulating element 2 and a heat exchanger 8 . Though only a single such sterilizing element 1 is shown, it is possible to have multiple elements of this sort in the same refrigerator.
[0026] In each of these embodiments the electrical connections to the air sterilizing units are not shown. These are conventional connections, such as those of the type already shown in Applicant's prior U.S. Pat. No. 5,874,050.
[0027] Reference is next made to FIG. 5 wherein an air sterilization assembly 400 , constructed in accordance with another preferred embodiment of the invention, is depicted. Air sterilization assembly 400 is one in which contaminated air from the inside of a room wall 20 enters inlet 12 , passes through sterilization assembly main body 10 and exhausts via outlet 11 back to the room. A cooling chamber 17 , receiving cold air from inlet 18 and exhausting via outlet 19 is used to cool the sterilization assembly 400 which in turn will reduce the temperature of the air returning to the inside of the room of side wall 20 so as to minimize the increase in temperature inside the room as a result of the sterilization process. Air sterilization assembly main body 10 is held in place within cooling chamber 17 via attachment means 16 which may be of a conventional nature. The air sterilization assembly 400 may also be held in place by other means.
[0028] With the use of the new air sterilization system as shown in the various figures, air circulation through the air sterilization assemblies is created by air convection through the use of air sterilizers similar to those used in room air sterilizer devices invented by Applicant in U.S. Pat. No. 5,874,050. The air sterilization technology utilized offers excellent results with exceptional reduction in micro-organisms and improvement in indoor air quality as proven by international laboratories, including INETI—Laboratory of Microbiology in Lisbon, SGS Natec in Hamburg, Universidad Complutense of Madrid, TMC—Technical Micronics Corporation in the United States of America and other tests. These tests show that the sterilization assembly system operates in a highly improved fashion when compared to systems relying on filters, and chemical agents. No air sterilizing or air purifying systems are available up to today for refrigerators and cooling chambers.
[0029] In other preferred embodiments of the invention the refrigerator or chamber or room would be outfitted with one or more sterilization assemblies. Generally, each of the air sterilization assemblies includes at least one air input and at least one air exhaust outlet connected to the interior of the contained volume so that the air inside said contained volume will freely enter and exhaust each air sterilization assembly. The system can operate either with the natural air convection occurrence caused by air heating at the capillaries of the air sterilizing assembly ceramic element or by a dedicated air flow system associated with the air sterilization assembly. The dedicated air flow system may include a fan to blow air into the air sterilization assembly input port or a fan to pull air from the output port.
[0030] To minimize the effect of the heat utilized in the air sterilization assembly, the system may include an additional cooling chamber inside or outside of the air sterilization assembly which cools the flow of air coming out of the ceramic core exhaust outlet prior to re-entry into the enclosed air volume such as a chamber, room or refrigerator.
[0031] In addition to being utilized in refrigerators, cooling and multipurpose chambers and rooms, the air sterilization assembly can be utilized in enclosed volumes and also in connection with cooling or heating systems such as vehicles as automobiles, trains, subway cars, submarines, aircraft, cruise ships, war vessels and other types of vehicles in which there are enclosed volumes which are either cooled, heated or merely include airflow. In these cases, the size and number and location of the air sterilization assemblies incorporated into the system are adaptable based upon the needs of the system, including its volume, airflow, temperature, humidity and other physical characteristics.
[0032] Accordingly, an improved air sterilization assembly capable of sterilizing a refrigerator or other air contained volume is provided. The air sterilization assembly includes input and exhaust outlets with air flowing through a sterilization chamber where the air is heated to a sufficiently high temperature so as to kill micro-organisms and the output air is cooled either through the use of a heat exchanger and/or a cooling chamber. The air sterilization assembly can be placed either fully inside the room, chamber, compartment, refrigerator or inside or outside its side walls and or a partial or total mixture of said options with direct inlet and outlet connections to the room, chamber, compartment, refrigerator or into channels built into their side walls.
[0033] It will thus be seen that the objects set forth above, among those made apparent in the proceeding description, are efficiently obtained and, since certain changes may be made in the above constructions and processes without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanied drawings shall be interpreted as illustrative, and not in the limiting sense.
[0034] It will also be understood that the following Claims are intended to cover all of the generic and specific features of the invention herein described and that all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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An improved air sterilization system has unobstructed air passageways from a chamber substantially enclosing a volume of air to the air sterilization assembly unit in which the air sterilization assembly unit has heating elements located within air passageways in the unit to exterminate airborne micro-organisms by applying heat to the continuously flowing airstream, and in which the temperature of air leaving the system is insignificantly higher than the temperature of air entering the system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of two-flow jet engines comprising an elongate secondary flow duct. It relates to the engines of this type which are secured to the fuselage of the aircraft or to military engines.
2. Description of the Related Art
A two-flow jet engine comprises a fan which, when it is at the front of the engine, provides a flow of compressed air which is separated into two concentric annular flows, i.e. a primary flow and a secondary flow which surrounds the primary flow. The latter is guided towards the gas generator part of the engine, which comprises compression stages, a combustion chamber, and a turbine section by means of which the fan is driven. The primary flow containing the combustion gases is then ejected into an exhaust pipe. The secondary flow is rectified downstream from the fan, and is itself ejected. In civilian engines it provides the substantial part of the thrust.
According to one configuration, the secondary flow is guided in a by-pass duct which extends around the engine between the fan and the exhaust pipe of the primary flow, and comprises two coaxial, substantially cylindrical walls which delimit an annular space between one another. The inner wall of the by-pass duct forms the envelope of the gas generator. The outer wall of the by-pass duct forms a duct which extends from the plane of the rectifier fins as far as the level of the exhaust pipe. The outer duct of the by-pass duct is designated in the field by the acronym OFD (outer fan duct).
The engine can be fitted under the wing of the aircraft or along its fuselage, and in particular towards the rear. In this case, the engine comprises a by-pass duct as previously described. The attachments of the engine to the aircraft are situated at the level of two transverse planes, i.e. an upstream plane which passes via the upstream structural casing, designated as the intermediate casing, and a downstream plane which passes via the downstream structural casing, designated as the exhaust casing.
In the case of fitting onto the fuselage, in order to assure the downstream securing, a structural ring is provided on the outer duct of the by-pass duct, i.e. the OFD, this ring being connected by arms or connecting rods to the ferrule or outer ring of the exhaust casing. Patent application EP 2022973 in the name of the applicant describes an example of the structure of the by-pass duct outer duct.
The link between the two above-described rings can be in the form of radial arms which are distributed all around the axis of the engine, and are secured rigidly to the two rings. The link can also be in the form of connecting rods which are inclined relative to the axis of the engine. The connecting rods are secured to the two rings by attachments of the clevis and pin type. An attachment of this type is formed by two, single or double clevises, which are integral, one of them with the end of the connecting rod, and the other with the wall of the ring, and a common pin passes through them.
More particularly, the connecting rods are arranged in pairs, the connecting rods of each pair being tangent to the ring of the exhaust casing, whilst being convergent on an attachment of the ring of the outer duct of the by-pass duct.
Whether the link is formed by radial arms or connecting rods, it is hyperstatic; the forces thus pass via all the arms or connecting rods. In the solutions according to the prior art, all the elements of the link, i.e. pins, clevises, connecting rods or arms, have dimensions such as to withstand mechanically the forces which would be derived from the imbalance generated by the loss of a vane in the engine. The objective is to avoid the risk of the engine stalling if such a critical situation were to arise. The weight of the assembly which forms the link is consequently heavy. In addition, since the forces which can result from breakage of a vane are potentially transmitted to all the arms or connecting rods, the ring of the outer duct of the by-pass duct must also be able to withstand these loads around its entire circumference. Its size is therefore designed accordingly.
BRIEF SUMMARY OF THE INVENTION
The objective of the present invention is to provide a link between the two above-described rings which, whilst assuring absorption of the forces of the type generated by breakage of a fan blade, make it possible to reduce the weight of the assembly relative to solutions according to the prior art.
The object of the invention is also to provide a link which does not modify the structure of the assembly.
The object of the invention is also a solution which can be applied to any form of link between the two rings, consisting of arms with rigid mountings or connecting rods which are secured by means of pins which pass through clevises.
The objective of the invention is achieved by means of an assembly comprising an exhaust casing ring, a structural ring of an outer duct of the by-pass duct of a two-flow jet engine which is concentric relative to the ring of the exhaust casing, and at least one first and one second arm or connecting rod which form(s) a hyperstatic link, whilst being secured at one end to the ring of the exhaust casing, and at the other end to the structural ring of the outer duct, characterized in that the link which is formed by the first arm or connecting rod is designed to be broken when it is subjected to a load in excess of a predetermined load, and the second arm or connecting rod is designed to form a path for transmission of the forces between said rings when said link is broken.
The predetermined load is advantageously greater than the limit load, and smaller than the load which would be generated by the breakage of a blade, of the fan in particular. By means of the invention, since there is definition of the elements of the link which must assure the transmission of the forces in the case when this critical situation occurs, it is possible to lighten the other elements and save weight.
According to another characteristic, the structural ring of the outer duct of the by-pass duct comprises a means for suspension of the jet engine on the structure of an aircraft, and the second arm or connecting rod is then closer to said suspension than the first arm or connecting rod. In the same manner as for the arms or connecting rods, by determining the paths of the forces in the situation of breakage of a blade, dimensioning with a reduced weight is made possible.
The invention can be implemented in different manners. The following embodiments are non-exhaustive:
The first arm or connecting rod has dimensions such as to buckle when it is subjected to said predetermined load.
The assembly comprises at least a first and a second one of said arms, and said arms are arranged radially relative to the axis of the rings.
The assembly comprises a first and a second one of said connecting rods, the attachments of which are of the type with pins and clevises, and the first connecting rod comprises at least one attachment which breaks when it is subjected to said predetermined load.
More particularly, according to this last embodiment, the assembly comprises at least two pairs of connecting rods which are inclined relative to the radial direction, and in particular tangentially relative to the exhaust casing ring, with at least one pair of said first connecting rods and at least one pair of said second connecting rods.
When the link comprises three pairs of connecting rods, two pairs of connecting rods advantageously form said first connecting rods, and one pair forms said second connecting rods.
For example, one pair of said first connecting rods comprises a fusible pin of the attachment to the ring, which pin can break when it is subjected to the predetermined load, the pin of the second pair of connecting rods being fitted with a polarizing means. In particular, the polarizing means is formed by the difference in the diameters of the heads of said fusible pin and pin of the attachment of the second pair of connecting rods, and by the diameter of the passage of the head of the pin of the attachment of the second pair of connecting rods.
The invention also relates to the two-flow jet engine with a front fan and a secondary flow duct which extends downstream from the fan at least as far as the plane of the exhaust casing comprising an assembly such as previously described.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other characteristics and advantages will become apparent from the following description of different embodiments, the description being accompanied by attached drawings in which:
FIG. 1 is a schematic view in perspective of a two-flow jet engine;
FIG. 2 represents schematically a transverse cross section of the engine in FIG. 1 , passing via the two structural rings of the outer duct of the by-pass duct and the outer duct of the exhaust casing;
FIG. 3 represents a variant of the link in FIG. 2 ;
FIG. 4 represents a fusible pin with a hollow rod;
FIG. 5 represents a non-fusible pin;
FIG. 6 shows a fitting with a polarizing unit; and
FIG. 7 shows a variant link with radial arms.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents a two-flow jet engine 10 with a front fan inside a pod 12 , and comprising, going from upstream towards downstream, a fan casing 14 , an intermediate casing 16 and an annular by-pass duct which is provided between two substantially cylindrical ducts, with an inner duct 18 forming the envelope of the part of the engine through which the primary flow travels, forming a gas generator, and an outer duct 20 . The outer duct 20 of the by-pass duct extends in this case as far as downstream of the area of confluence between the primary flow 26 and the secondary flow 28 , where the two flows are mixed by the mixer 22 . The outer duct 20 of the by-pass duct has a structural function, whilst assuring absorption of the forces between the engine and the aircraft on which it is fitted. It thus comprises a structural ring 21 , which in this case is connected by connecting rods 40 to the outer ring 23 of the exhaust casing of the gas generator. The engine is secured upstream to the aircraft by means of an attachment 17 which is integral with the intermediate casing, and downstream by means of an attachment 27 which is integral with the structural ring 21 of the outer duct 20 of the by-pass duct.
In the example represented, the link between the structural ring 21 of the outer duct of the by-pass duct and the ring 23 of the exhaust casing is formed by connecting rods 40 which are secured by their ends to the two rings. As is known, and is not represented, each mounting comprises a clevis which is integral respectively with the ring and the end of the connecting rod, the two clevises having a common pin which passes through them. As can be seen in the figure, the link is formed more specifically by three pairs of connecting rods 40 , which are tangent to the ring 23 of the exhaust casing, and converge in pairs on the outer structural ring 21 .
Whereas, according to the prior art, the elements which constitute the link between the rings have dimensions such that each of them can transmit the forces if a fan blade were to break, according to the invention the elements of the link are sized differently. The link comprises fusible elements, i.e. which give way when they are subjected to a load which is greater than a predetermined load. This predetermined load is advantageously smaller than the blade loss load, which corresponds to the ultimate load, whilst remaining greater than the limit load. Said limit load is defined as being the load beyond which no deterioration of said fusible elements is acceptable. The link also comprises non-fusible elements which have dimensions such as to withstand the load which arises if a blade breaks, in particular a fan blade. These elements assure the transmission of the forces between the engine and the attachment to the aircraft, after the fusible elements have broken.
FIG. 2 illustrates a first embodiment of the invention. It represents a schematic view in transverse cross-section perpendicular to the axis 44 of the engine which passes via the link between the two rings 21 and 23 . As in the example in FIG. 1 , the link comprises three pairs of connecting rods 40 , respectively 40 A and 40 B; 40 C and 40 D, 40 E and 40 F. The connecting rods are secured to each of the rings 21 and 23 respectively by attachments of the clevis and pin type, in a known manner which is not represented. The connecting rods are positioned relative to the attachment 27 of the structural ring 21 of the outer duct of the by-pass duct 20 . The attachment to the fuselage of an aircraft is lateral, i.e. to the right, defined looking towards upstream, or to the left, according to whether the engine is fitted on one side or the other of the fuselage.
Two pairs of first connecting rods 40 A, 40 B, and 40 C, 40 D have dimensions such as to buckle when they are subjected to said predetermined loads. In practice their buckling dimensions are such as to withstand 1.1 times said limit loads. For their part, the pins and clevises of the attachments of the fusible connecting rods have dimensions such as not to break until the connecting rods have buckled.
The second connecting rods 40 E and 40 F have dimensions such as to resist and not break when they are subjected to said predetermined loads and to the loads corresponding to the loss of a blade. It should be noted that the second connecting rods are amongst the connecting rods which form the link amongst those which are closest to the attachment 27 . The path of forces which separates the point of convergence of the two second connecting rods 40 E and 40 F from the attachment is shorter than the path which the forces may travel between the points of convergence of the first attachments and the attachment 27 . Thus, firstly the lever arm between the point of convergence and the attachment is minimal, and secondly it is sufficient to reinforce this portion of the structural ring 21 , which constitutes a possibility of global lightening of the structure.
When a fan blade breaks, substantial imbalance is generated by the resulting lack of balance of the rotor; this imbalance is transmitted downstream to the downstream securing plane. According to the invention, the first connecting rods buckle, and the load is transmitted to the attachment by the second connecting rods 40 E and 40 F, and the path along the outer structural ring 21 .
FIG. 3 represents a variant embodiment in which the fusible elements are arranged in the attachments. The link 140 between the two same rings 21 and 23 comprises three pairs of connecting rods. The first connecting rods 140 A and 140 B are connected to the rings by the attachments 140 A 1 , 140 B 1 and 140 AB, respectively to the outer ring of the exhaust casing 23 and to the structural ring 21 . These first connecting rods are fusible, either by being able to buckle, or by means of their attachments, in particular the pins which pass through the clevises.
Another pair of first connecting rods is formed by the connecting rods 140 C and 140 D; these first connecting rods in this case have dimensions such as to withstand the blade breakage loads. Only the attachment 140 CD of the connecting rods to the structural ring 21 is fusible; the other attachments 140 C 1 and 140 D 1 are not fusible. The pins of the attachments 140 A 1 , 140 B 1 , 140 AB and 140 CD advantageously have dimensions such as to withstand 1.1 times the limit loads determined for transverse buckling.
The second connecting rods 140 E and 140 F are not fusible, either in the case of the connecting rods themselves or their attachments 140 E 1 , 140 F 1 and 140 EF.
The operating principle is the same as previously in the case of breakage of a fan blade. The link formed by the first connecting rods 140 A, 140 B, 140 C and 140 D gives way, and the one formed by the second connecting rods is resistant and assures transmission of the forces. As in the preceding solution, the second connecting rods are arranged as close as possible to the attachment 27 , so that the lever arm is as weak as possible.
The variant in FIG. 3 has the advantage, in the case when the fitting on the fuselage of the aircraft has to be changed from right to left, of needing to change only the pins 140 CD and 140 EF, and inverting them because of the symmetry relative to the vertical plane which passes via the axis of the engine. In the case when this variant is adopted, it is necessary to associate with it a polarizing unit which prevents the risk of inverting the fusible pins of the attachments 140 CD and 140 EF during fitting.
An example of a polarizing unit is illustrated in FIGS. 4 to 6 . The fusible pin 50 which is represented in FIG. 4 is hollow, and has lower strength than the non-fusible pin 51 . In order to distinguish them, the diameter D 1 of the head 50 A of the pin 50 is larger than the diameter of the pin D 2 of the head 51 A of the pin 51 . FIG. 6 shows a polarizing means. The structural ring 21 of the outer duct of the by-pass duct comprises with the attachment 27 a plate 28 which is fitted on one side on the attachment 27 , and on the other side on the plane where the head 51 A of the non-fusible pin 51 is supported. This plate 28 has a notch 28 A with a width D 3 which is wide enough to allow the head 51 A with a diameter D 2 to be accommodated in it, but not the head 50 A with a diameter D 1 , since D 1 >D 2 . Thus, during the fitting, the fitter will not be able to introduce the fusible pin into the receptacle for securing of the second connecting rods.
The invention has been described with a link formed by three pairs of connecting rods. The scope of the invention also includes application of the solution to a link with eight connecting rods, or also a different number of connecting rods.
FIG. 7 shows a schematic example of a link 240 with arms arranged radially between the outer ring 23 of the exhaust casing and the structural ring of the outer duct of the by-pass duct. The solution is applied mutatis mutandis.
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An assembly including an outer ring of an exhaust casing, a structural ring of an external duct of a fan channel and of a two-flow jet engine that is concentric relative to the outer ring of the exhaust casing, and at least one first and second linking arm or rod forming a hyperstatic link by being attached by one end to the outer ring of the exhaust casing and, by the other end, to the structural ring. The link formed by the first linking arm or rod is configured to break when a predetermined load is exceeded, and the second linking arm or rod is configured to form a force-transmission path between the rings when the link is broken.
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BACKGROUND OF THE INVENTION
The conventional home sewing machine has either one or two needles and in combination with a bobbin forms a seam which, when executed properly, generally unites two or more pieces of material.
Another type of sewing machine, initially called an overlock machine, now more commonly referred to as a serger, has been made available to the home sewer. The serger cuts the fabric being fed into the machine and the loopers and needles encase the cut edge of the material with a chain-like edge of thread or other flexible filament to prevent the cut edge from fraying. In the case of only one layer of fabric introduced into the machine, the serger cuts and encapsulates. In the case of more than one layer of fabric being introduced into the machine, the serger cuts, encapsulates and unites, all in one operation. The stitch fingers, i.e., small projections or prongs on the needle plate or presser Foot then feed the stitches encasing the fabric off the machine.
Like most conventional sewing machines, the serger uses one or two needles. Unlike most conventional sewing machines, the serger has no bobbin; therefore in some respects the loopers replace the work of the bobbin. Thus a series of loopers along with the needles perform the sewing operation.
Different models of sergers utilizing from two to five spools of thread are available with each machine offering various types of stitches; however for the purpose of describing the invention herein, a machine utilizing four spools of thread with two needles and two sets of loopers will be described. The present invention functions satisfactorily with any serger sewing machine.
In addition to other mechanisms found on the machine not strictly relative to the invention, sergers have thread guide bars, tension discs and guides which create a thread path. A four-spool serger would have four bar guides, four tension discs and approximately 12 thread guides. Thread path information is posted on each machine and if followed correctly, makes threading of the guides, discs and thread guides relatively easy as the guides, discs and thread guides are positioned both on top and on front of the serger. The front of the machine faces the operator thereby placing bars, discs and guides in plain view.
Threading the loopers is another matter as they are located in an almost-impossible-to-reach cavity beneath the working surface of the machine.
All threading is done sequentially: bar guides, tension discs, thread guides, upper looper, lower looper and finally the needle or needles. Flexible filaments are withdrawn from spools placed on spindles to the rear and/or side of the machine. The filament or, in case of more than one, filaments are drawn from each spool one at a time by hand and placed through each relative bar guide, tension disc and thread guide until thread and/or threads have been drawn from all the corresponding spools and all bar guides, tension discs and thread guides have been threaded and the filaments are now ready to be passed through the eyes of the upper looper, lower looper and needle or, in case of two needles, needles.
Each looper contains two eyes and because they are in the heretofore mentioned difficult-to-reach undercarriage of the serger, threading the looper eyes is virtually impossible without the aid of some type of threading device.
In some cases tweezers are used to thread the eyes of loopers. For purposes of clarity let us assume that one length of thread is being used in each needle, therefore it is herein assumed the operator has drawn the thread through the bars, discs and guides and is prepared to thread the loopers. The operator must pinch the cut end of the thread between the opposed, pointed end of the tweezers and carefully insert the cut end through the looper eyes. The application herein described is difficult to manage because of the confined area wherein the loopers are placed therefore this threading technique is generally not within the scope of manual dexterity of many operators.
Another method of threading is to use a fine wire loop which has been encased within one end of a relatively long metal tube holder having a tab handle at the opposite end of the wire loop. After drawing the thread by hand through bars, discs and guides, the operator need pierce each looper eye with the fine wire loop, thereinafter pass the wire loop through the eye, thread the leading cut end of the flexible filament through the already inserted wire loop then withdraw the loop from the eye, leaving the flexible filament passed through that particular looper eye. This procedure must be practiced for each eye in each looper. The wire in the wire threader, by necessity, is so fine that it bends and ultimately breaks after being used only a few times. As heretofore mentioned, the space herein described is extremely limited and the length and rigidity of this wire loop threader precludes a swift threading procedure.
Specific instructions as to correct threading procedure are provided with each individual serger machine and must be followed exactly if the serger is to operate properly. If the serger is threaded incorrectly or if the sewing threads become tangled or if the sewing threads become broken, the machine will not stitch properly and the threading procedure must be repeated from the beginning and if the color of the thread needs to be changed, the threading process must be repeated from the beginning.
The needles are threaded thereafter.
U.S. Pat. No. 4,667,860 discloses a needle having a trailing deformable loop made of thin spring steel wire, flexible plastic or other deformable material while the body of the needle is formed of a rigid material such as steel hypodermic tubing. The rigid body of this device would not allow the device to negotiate the constrictive cavity of the undercarriage of a serger. Therefore the inadequacies of this invention for threading a serger sewing machine are evident.
U.S. Pat. Nos. 3,929,144 and 4,133,339 disclose a looped filament for guiding dental floss between a person's teeth. The looped filament is not formed in a manner that would permit it to be used to thread the intricacies of the serger because the thread could be easily separated from the device.
SUMMARY OF THE INVENTION
The present invention closely resembles a needle, however the thread guide has a blunt end, not a pointed one. The invention has a leading guide portion which can be curved by hand to conform to the confined under-carriage of the serger and yet the leading guide portion is rigid enough to reach and penetrate the almost inaccessible first eyes of both upper and lower loopers.
The thread guide according to the present invention has a relatively small deformable loop on the opposite end of the leading guide portion. The loop is small enough to retain a fine sewing thread therein during the threading process. The small loop is preferably crimped at the trailing end to facilitate fine sewing thread retention.
The present invention in one form embodies a looped length of a relatively flexible strand-like material with the ends thereof bonded together to form an elongated portion with a blunt tip; the leading guide portion having sufficient rigidity so that it can be inserted through the eyes of loopers found in a serger sewing machine, the looped segment having been crimped to retain fine sewing threads. The cut end of a length of flexible filament, such as but not limited to thread coming from a cone or spool already placed on a spindle of the serger, is drawn through the bar guides, tension discs, and guides of the machine. The cut end of the flexible filament is passed through the crimped loop and the elongated leading end of the thread guide with the filament passed through the loop is threaded through the eyes of the loopers until the flexible filament is threaded through all the eyes of all the loopers wherein the flexible filament is withdrawn from the thread guide leaving the flexible filament passed through all the bar guides, tension discs and loopers. At this point, the thread guide is set aside for further use.
Therefore, it is an object of this invention to provide an implement for threading flexible filament through several orifices in a swift and efficient manner. It is another object to provide an economical threading guide for threading these hard-to-reach areas.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a serger sewing machine showing both upper and lower loopers already having been threaded and showing the relative relationship of both upper and lower looper and the close proximity in which they are necessarily positioned to perform the function of the serger sewing machine.
FIG. 2 illustrates the upper looper of a serger sewing machine and a thread guide according to this invention being used to insert a length of flexible filament into the first eye of a set of two eyes of the upper looper.
FIG. 3 illustrates the lower looper of a serger sewing machine and a thread guide according to this invention being used to insert a length of flexible filament into the first eye of a set of two eyes of the lower looper.
FIG. 4 illustrates the thread guide of FIGS. 2 and 3 being used to guide a relatively large diameter sewing thread through a passage.
FIG. 5 illustrates the thread guide of FIGS. 2 and 3 being used to guide a relatively small diameter thread through a passage.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 shows an illustration of an upper looper 27 and a lower looper 37 of a serger sewing machine threaded with flexible filament and juxtaposed in one of many positions necessary to achieve the sewing process and the partial thread path of the machine. The looper arms, being at the uppermost end of each looper, rotate on a stationary base and the looper arms pass each other on a vertical plane within a fixed arc. Flexible filament such as sewing thread 20 coming from a source such as but not limited to a spool (not illustrated) is shown threaded through guides 23, 24 and 25 then threaded through the first eye 26 of looper 27 wherein the filament is shown exiting through second eye 28 of the looper 27. FIG. 1 also shows an illustration of flexible filament such as sewing thread 30 coming from a spool (not illustrated) threaded through guides 33, 34 and 35 then threaded through the first eye 36 of looper 37 wherein the filament is shown exiting through second eye 38 of the looper 37.
FIG. 2 shows an illustration of upper looper 27 of a serger sewing machine and a partial thread path of the machine. Flexible filament such as sewing thread 20 coming from a source such as, but not limited to a spool (not illustrated) is threaded through guides 22, 23, 24 and 25. A thread guide 10 according to the present invention is employed by threading leading cut end 16 of thread 20 through a crimped loop 12.
Preferably 6 to 7 inches of thread 20 are drawn through loop 12 leaving already threaded guides 22 through 25 intact. The threading device 10 includes an elongated portion 14 that extends from the loop 12. Elongated guide portion 14 with connected thread 20 is introduced through eye 26 of upper looper 27 wherein thread guide 10 is passed therethrough until thread guide 10 and thread 20 are passed through eye 26 of upper looper 27. Elongated guide portion 14 with connected thread 20 is introduced through eye 28 of upper looper 26 wherein thread guide 10 is passed therethrough until thread guide 10 and thread 20 are passed through eye 28 of upper looper 26. Broken line 21 shows the finished thread path of successfully threaded upper looper 27. Thread 20 is thereafter removed from thread guide 10 and is positioned for further use in the sewing process.
FIG. 3 shows an illustration of lower looper 37 of a serger sewing machine and a partial thread path of the machine. Flexible filament such as sewing thread 30 coming from a source such as but not limited to a spool (not illustrated) is threaded through guides 32, 33, 34 and 35. Thread guide 10 is employed by threading leading cut end 16 of thread 30 through crimped loop 12.
Preferably 6 to 7 inches of thread 30 are drawn through loop 12 leaving already threaded guides 32 through 35 intact. The threading device 10 includes an elongated portion 14 that extends from the loop 12. Elongated guide portion 14 with connected thread 30 is introduced through eye 36 of lower looper 37 wherein thread guide 10 is passed therethrough until thread guide 10 and thread 30 are passed through eye 36 of lower looper 37. Elongated guide portion 14 with connected thread 30 is introduced through eye 38 of lower looper 36 wherein thread guide 10 is passed therethrough until thread guide 10 and thread 30 are passed through eye 38 of lower looper 36. Broken line 31 shows the finished thread path of successfully threaded lower looper 37. Thread 30 is thereafter removed from thread guide 10 and is positioned for further use in the sewing process.
FIG. 5 shows a relatively small diameter thread 58 being retained in the deformable loop 12 while it is being drawin through a narrow passage 52. The deformable loop 12 folds at the crimp 18 so that the thread 58 is pinched between flattened portions 60 and 62 of the loop 12 which is on opposite side of the leading guide 14. The thread guide 10 is formed of a semi-rigid material and deformation of the small loop 12 would be difficult without crimp 18. The crimp 18 makes it possible for the loop to flatten thereby allowing it to pass through all the passages in the thread path yet still retain its capability of thread 58 retention.
The guide portion 14 has a leading end 15 formed by cutting across the length of the guide portion at a 90° angle. The thread guide 10 is preferably formed of a flexible nylon strand-like filament. The guide portion 14 preferably has a diameter that is twice the diameter of the filament that forms the deformable loop 12. The diameter of the guide portion 14 of the filament preferably is approximately 0.0030 inch. The loop 12 preferably has a length of approximately 0.75 inch.
With the use of the thread guide, sewing thread can be readily and easily positioned through the eyes of both upper and lower loopers. Since the material from which the thread guide is fashioned is relatively durable, the thread guide can be used repeatedly with all types of sewing machine filaments.
While particular embodiments of the invention have been described in connection with the threading process of a serger sewing machine, the easy threading features of the present invention are equally advantageous in other threading applications such as that used in darning, or for the application of yarn. The crimped end of the filament loop provides secure retention of small diameter threads as well as bulky yarns. The monofilament material of which the thread guide preferably can be made ranges in diameter from 0.0010 inches to 0.60 inches. Because the material is flexible and deformable, the thread guide can be used over and over again. The loop of the thread guide is flexible and deformable thereby retaining its original shape and dimension over the life of the device.
The present invention also provides a threading device and method for threading the eye or, in case of multiple needles, the eyes of conventional sewing machines. A flexible filament is passed through the loop which is then, with the flexible filament passed therethrough, guided through the eye of the needle or eyes of the needles of a conventional sewing machine.
The present invention may also be used to close a seam, to add decorative threads or yarns in a pleasing pattern or to put up a hem in an already knitted garment. Flexible filaments such as yarn are passed through the loop of the thread guide then the thread guide with decorative threads or yarns having been passed therethrough, is threaded through the loops of knitted material to complete the task required.
While the invention has been disclosed herein in connection with certain specific embodiments of the same, it will be understood that this is intended by way of illustration only, and that modifications may be made in the configuration of the threader as well as in the steps of the method by which it is formed without departing from the spirit of the invention and it is intended the invention and these modifications be covered by the appended claims.
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A length of a flexible material such as a monofilament nylon is folded back on itself to form a loop and an elongated guide portion. The ends and portions of the flexible material adjacent the ends are fastened together. The trailing end portion of the loop is crimped so that when the loop is flattened, it folds at the crimp. A sewing thread that has been introduced into the loop is retained as it is drawn through the narrow passages of a serger sewing machine.
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BACKGROUND OF THE INVENTION
The present invention relates to a semiconductor laser structure and, more particularly, to a semiconductor laser array which includes a plurality of active wave guides.
A semiconductor laser has been widely used as a light source in optical information processing systems such as an optical disc system a laser printer, and a medical apparatus.
However, the conventional semiconductor laser has merely a single active wave guide structure. Therefore, the maximum output of the laser in practice is about 60 to 70 mW.
Recently, to enhance the output level, a semiconductor laser having a plurality of active wave guides has been developed. The active wave guides are optically phase coupled to each other so as to emit the laser beam in a single phase. In other words, the laser beam from the adjacent two laser emitting regions is coupled so as to synchronize optical phases. This is referred to as the phase coupled laser array.
For example, W. Streifer et al of XEROX Corporation proposed a semiconductor laser array having ten active wave guides. (Appl. Phys. Letters, 42495 (1983)) The proposed laser array has, it has been reported, up to an output power of 200 mW, the device having a half value and full width less than 2 degrees in a far field pattern. In this laser structure, the beam output in the vertical mode from each of active wave guides are different from one another. Therefore, the beam phase from the active wave guides can not be synchronized with the other beam phases.
Another laser structure has a plurality of active wave guides in parallel in which the laser beams from the active wave guides are coupled by using a leak beam from each of the active wave guides. But, the above problem described in the first example still occurs. At the same time, in the above structure, the adjacent two active wave guides are coupled with polarizing action in crystallization like a wave guide type directional coupler. Therefore, the electric field has a phase difference of 180 degrees at the adjacent two active guides. The far field pattern has two peaks as shown in FIG. 4. In this situation, the optical system is not used to concentrate rays of light into a focus.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a semiconductor laser array which exhibits stable operation and a high power output in a single narrow beam.
Another object of the present invention is to provide a semiconductor laser array having a plurality of active wave guides in which each of the active wave guides has a curved portion, wherein the vertical modes of all of the active wave guides are identical to each other with a phase difference of zero degrees.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description of and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
To achieve the above objects, according to an embodiment of the present invention, a semiconductor laser array is provided which includes a plurality of active wave guides having an index guide structure. Each of the active wave guides has a curved portion for connecting two adjacent active wave guides. The adjacent two active wave guides on one laser facet, are led to a single active wave guide on the opposing facet.
Further, the preferred embodiment of the present invention will be briefly described. A semiconductor layer array comprises a first wave guide disposed on a first laser facet, a second wave guide disposed parallel to the first wave guide on the first laser facet, a second third wave guide disposed on a laser facet opposed to the first laser facet, wherein the first and second wave guides converge into the third wave guide. The first and the second wave guides curve so as to converse into the third wave guide. A plurality of sets of first, second and third wave guides also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention and wherein:
FIG. 1 shows a plan view of a semiconductor laser array according to an embodiment of the present invention;
FIG. 2 shows a vertical view of a semiconductor laser array taken along a line A--A;
FIG. 3 shows the far field pattern of the semiconductor laser array of FIGS. 1 and 2; and
FIG. 4 shows the far field pattern of the conventional semiconductor laser array.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a plan view of a semiconductor laser array according to a preferred embodiment of the present invention. FIG. 2 shows a sectional view of the semiconductor laser array of FIG. 1 taken along a line A--A. FIG. 3 shows the far field pattern of the semiconductor laser array of the present invention.
A semiconductor laser array of the present invention comprises a p-type GaAs substrate 1, a n-type GaAs layer 2, a p-type AlxGa(1-x)As cladding layer 3, a p- or n-type AlyGa(1-y)As active layer 4, a n-type AlxGa(1-x)As cladding layer 5 and a n + -type GaAs cap layer 6. The semiconductor laser array further includes a p-type ohmic electrode 7 and a n-type ohmic electrode 8.
The semiconductor laser array of a preferred embodiment of the present invention is provided as follows:
The n-type GaAs layer 2 is formed on the p-type GaAs substrate 1 by a crystal growth technique such as a liquid-phase epitaxial (LPE) growth method. A plurality of V-shaped channels 20 (20-1, 20-2, 20-3, . . . ) and 20' (20'-1, 20'-2. 20'-3, . . . ) are formed through the n-type GaAs layer 2 to the p-type GaAs substrate 1 by a photolithography method and an etching technique. On the p-type GaAs substrate 1 covered by the n-type GaAs layer 2 having the plurality of V-shaped channels 20 and 20', the p-type AlxGa(1-x)As cladding layer 3, the p- or n-type AlyGa(1-y)As active layer 4, the n-type AlxGa(1-x)As cladding layer 5 and the n + -type GaAs cap layer 6 are successively and sequentially grown by the liquid-phase epitaxial (LPE) growth method to form a multi-layered crystal of the double-hetero junction for laser diodes. (The AlAs molar fractions of the layers 3, 4 and 5 must satisfy x>y.) The p-type ohmic electrode 7 is formed on the rear surface of the p-type GaAs substrate 1. The n-type ohmic electrode 8 is formed on the surface of the grown crystal, which creates the ohmic contact to the n + -type GaAs cup layer 6.
Finally, mirror facets 9 and 10 as the laser cavity facet are provided so as to form a cleavage plane.
The plurality of V-shaped channels 20 (20-1, 20-2, 20-3, . . . ) and 20' (20'-1, 20'-2, 20'-3, . . . ) function as active wave guides, respectively. On one laser facet (for example, on the mirror facet 9), two V-shaped channels 20-1 and 20-2 are adjacently provided in parallel, while on the opposing laser facet (for example, on the mirror facet 10), these two channels 20-1 and 20-2 are led to a single wave guide 20'-1.
On the contrary, while two adjacent V-shaped channels 20'-1 and 20'-2 are provided on the mirror facet 10, a common single V-shaped channel 20-1 as the active wave guide is provided on the mirror facet 9 for these two V-shaped channels 20'-1 and 20'-2. Thus, the V-shaped channels 20 (20-1, 20-2, 20-3, . . . ) on the mirror facet 9 and the V-shaped channels 20' (20'-1, 20'-2, 20'-3, . . . ) on the mirror facet 10 are alternatively shifted with a half pitch, respectively.
The V-shaped channels 20 on the mirror facet 9 and the V-shaped channels 20' on the mirror facet 10, which are shifted with a half pitch, are connected to each other by using a curved channel in the middle of the laser cavity.
The curved active guide area 111 is provided between the areas 110 and 112. In the areas 110 and 112, the plurality of V-shaped straight channels 20 and 20' are formed in parallel, and the adjacent two V-shaped channels are symmetrically provided. A radius of curvature of the curved active wave guide at the curved active wave guide area 111 is equal to or more than about 200 μm. This value is the minimum radius of curvature necessary to confine the beams well within the curved active wave guide. If the radius of curvature is less than about 200 μm, the beam is not reflected perfectly at the interface between the wave guides, and further, the beam may be radiated to the outside of the wave guides.
The V-shaped channels 20 and 20' on the mirror facets 9 and 10, which are deviated with the half pitch, are connected to each other to form a curved wave guide structure in the middle of the mirror facets 9 and 10.
Since the V-shaped channels 20 and 20' have curved channel portions, respectively, the adjacent two active wave guides at the areas 110 and 112 in FIG. 2 are connected to form the single active guide on the opposing laser facet.
In the embodiment of the present invention, when a first set of the wave guides includes the first, the second and the third wave guides 20-1, 20-2 and 20'-1, the substantial portion of the second wave guide 20-2 of the first set of the three wave guides is also a substantial portion of the first wave guide 20-2 of the adjacent set of the three wave guides 20-2, 20-3, 20'-2. The first and second wave guides 20-1 and 20-2 are symmetrically provided across the center line between the first and second active wave guides 20-1 and 20-2. The third wave guide 20'-1 on the opposing laser face commonly connected to the first and second wave guides 20-1 and 20-2 is symmetrically provided across the center line between the first and second wave guides 20-1 and 20-2. Substantial portions these first and the second wave guides 20-1 and 20-2 are formed straight in parallel for optically coupling of the two wave guides.
One example of the semiconductor laser array of the present invention is as follows:
The width W of the channel 20 and 20' is about 4 μm. The pitch P of the active wave guides is about 8 μm. If desired, the width W may be less than 4 μm, and the pitch P may be less than about 8 μm. This reason is that the adjacent two active wave guides are optically coupling to each other on the areas 110 and 112. The length of the areas 110 and 112 is about 110 μm. The length of the curved wave guide area 111 is about 70 μm. The radius R of curvature of the curved wave guide at the curved wave guide area 111 is about 300 μm. The radius of curvature should be determined to ensure that the beam is well-confined in the curved active wave guide.
As described above, in the present invention, the adjacent two active wave guides such as the adjacent two V-shaped channels are connected to each other to form the single wave guide at a suitable portion, so that the 180 degrees phase shift modes are cancelled to each other. On the contrary, the zero degree phase shift modes are strengthened even at the connection area. In the embodiment of the present invention, the threshold gain of the zero degree phase shift mode is minimum, and the 180 degrees phase shift mode is actually suppressed. In this case, a single zero degree phase shift mode oscillation can be obtained. A single lobed far field pattern having a smaller half value width is shown in FIG. 3.
The main characteristices of the embodiment of the present invention is as follows:
Threshold current: about 200 mA.
Maximum zero degree phase mode output: 350 mW.
As described above, the semiconductor laser array has the plurality of active wave guides. The adjacent two active wave guides on one laser facet are connected to each other and lead to a single active guide on the opposing laser facet by using a curved wave guide portion. On one laser facet, the adjacent active wave guides are provided, but on the opposing laser facet, the adjacent two wave guides on one laser facet are connected to each other and lead to a single active wave guide. The adjacent two active wave guides are symmetrially provided on one laser facet. Therefore, the vertical modes of the all active wave guides becomes single. The phase of each of all of the active wave guides is synchronized.
The adjacent active wave guides which are symmetrically provided, are connected to each other so that a single wave guide is provided on the opposing laser facet. The single wave guide is symmetrically provided. Across the line at the center of the single wave guide on the opposing laser facet, the two adjacent active wave guides on one laser facet are symmetrically disposed. Therefore, the transverse modes of the all active wave guides are identically single and the phase of the all active wave guides are synchronized with each other. Therefore, the stabilized zero degree phase shift mode can be obtained even in the high output power region.
In the present invention, the cladding layer 3 may completely fill the V-shaped channels 20 and 20' to a flat top and the active layer 4 may be flat without the curviture. The semiconductor layer used to form the active wave guide so as to confine the laser beam may be substantially flat over the light emitting area of the laser array.
The active wave guides may be formed in an index guide structure.
In the connections of the active wave guides, the wave guides are formed in the shape of "Y".
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.
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A semiconductor laser array which includes a plurality of active wave guide in a substantially parallel manner disposed on first and second laser opposing laser facets so as to be optically coupled and so that adjacent wave guides converse into one or more active wave guides on an opposing laser facet. The laser array exhibits stable operations and a high output power in a single narrow beam. The active wave guides have identical vertical modes and a phase difference of zero degrees.
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FIELD OF INVENTION
This invention relates to a factory manager WEB enabled wafer fabrication operations equipment operator certification, production monitoring and authorization system.
BACKGROUND OF INVENTION
A manufacturing semiconductor fabrication facility can use many tools and materials. At a Texas Instruments Incorporated there are as many as 900 tools and associated software at a single fabrication facility. The tools and materials change from time to time. A source of bad processing or scrapping customer production materials in semiconductor processing is unqualified or unauthorized individuals loading or running production/customer materials. It is highly desirable to have a system that tracks employee operations and employee certification of fabrication equipment and processes in real time format to ensure that only qualified personnel are allowed to process customer materials.
SUMMARY OF INVENTION
In accordance with one embodiment of the present invention an integrated system is provided that tracks user operation certification of fabrication equipment and processes in real time format to ensure only qualified personnel are allowed to process customer materials.
DESCRIPTION OF DRAWING
FIG. 1 illustrates the system components for tracking employee operations and certification of according to one embodiment of the present invention.
FIG. 2 is a flow diagram of the system of FIG. 1 .
FIG. 3 illustrates a certification record.
FIG. 4 illustrates a screen access for user number.
FIG. 5 illustrates a screen access to select a module or tool, a process and a cadre or trainer if being trained.
FIG. 6 illustrates the initial step steps of an audit to determine if the audit is a subform or a primary form.
FIG. 7 illustrates the steps where the audit is a subform initial certification.
FIG. 8 illustrates the steps if a subform re-certification is to be performed.
FIG. 9 illustrates the steps if the audit is a nonsubform/initial certification.
FIG. 10 illustrates the steps if the audit is a nonsubform re-certification.
FIG. 11 illustrates the steps for final signoff entry process for re-certification.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to FIG. 1 there is illustrated the system components according to one embodiment of the present invention that tracks employee operations and employee and other user certification of fabrication equipment and processes in real time format to ensure that only qualified personnel are allowed to process customer materials.
Each of Automation Systems 1 thru N in FIG. 1 represents a fabrication equipment tool control system. Each automation system includes a Super Service Bundle (SSB) that identifies which tool is working on which material, which type of device and which material it can run. It also contains the log point operations or steps to build the device. Each automation control systems 1 thru N is coupled to the equipment and will lock the system from use unless the user is certified. The object is to have a system that tracks employee or contractor operations/certification of fabrication equipment and processes in real time format to ensure that only qualified personnel are allowed to process customer materials.
In accordance with an embodiment of the present invention each of the automation systems 1 through N check to determine if the requesting user of the tool or other equipment is an employee or certified contractor, if the user is qualified to run the type of tool or other equipment, to work on the device being fabricated and the material being used. The user of the tool for the process accesses the tool by, for example, passing a bar code such as on the users badge or other access card across a reader at the tool access point. The automation system (system 1 through N) with knowledge of the tool or other equipment requirements inquires at a certification server 11 to determine if the requester is certified to access the equipment. The certification server 11 checks an auto-certification database 13 to determine a match for the employee or contractor to determine if access is permitted. The database 13 contains the record of the employee or contractor and the equipment and materials and products the employee is certified to use.
Semiconductor Manufacturing System (SMS) 15 keeps tracks of a product. It contains a record of the product. It has the customer identification, device name, lot number and wafer identification. It records the log points and operations. It provides updates to a qualification database 17 which, in turn, provides daily SMS updates and qualification records to the auto-certification database 13 . The updates include tool updates, material updates and user updates and certification updates and records.
Referring to FIG. 2 is illustrated the process. In Step 1 the operator scans the operators badge and lot data information for the device being made at the tool or equipment location. The Super Service Bundle (SSB) associated with each automated system or tool defines the tool the user is working on and which material. The next Step 2 is the automation system such as System 1 inquires at the certification server 11 for qualification of the user for this type of system. In Step 3 the certification server 11 checks certification for the requested operator for which tools and log point operation which is the device type, log point to build the device and the operations which is the subsets of the step to build the device. In Step 4 the certification server replies to the automation. In Step 5 the server decides if there is certification to use the tool. If the answer is “yes”, certification is given and automation continues as usual in Step 6 . If the answer is “no” the system shows an error screen and warning not to process lot at Steps 7 and 8 respectively and process with that user ends.
The auto-certification database 13 gets updated every four hours. The SMS updates are sent to the training database 17 and once every day this is sent to the auto-certification database 13 . Certification data is uploaded automatically to the production servers for systems 1 through N on a daily basis. However, a manual “push” of the data can be performed at any time using an IMS user/password controlled web page 19 . Because the certification server 11 is such a critical part of the process there is a backup secondary server 11 A.
The database 17 contains personnel management information. It contains a listing of employees and contractors and their certification status on the different tools or equipment and processes. FIG. 3 illustrates a record. It lists the employee and contractor and identifies which equipment or process and identified if employee or contractor is certified, if in-training or certification has expired. The certification server 11 with the database 13 stores the certification information. It also contains training information for those who intend to be certified.
The certification server 11 contains an “In Training” access to permit access to permit a potential user to be certified via a training manager and a small group of instructors or cadre who are certified. The access to the tool through the certification server 11 may be through a web page using a training manager program. This may be by connection at manual web page option 19 or by a connection to the training database 17 .
A training manager is provided that manages the training of users of the tools. The database and the certification server provide a list of cadre or peer trainers. It also has a listing of those who intend to be certified. When a user wants to be certified or to be re-certified he or she must access the system via a web page for example. A Graphical User Interface (GUI) screen access may be used. FIG. 4 illustrates a screen GUI access where an employee or contractor can enter his or her name by entering an employee or contractor number. The Screen 2 in FIG. 5 illustrates how the user may select a module or tool, a process and a cadre or trainer if being trained. The selection of the module may include a pull own menu of equipment. The selection of the process may include a pull down menu of processes. The selection of a cadre may include a pull down menu of cadres or trainers who are in the system and are certified to train before access is given to the tool.
The person being audited is first determined if the audit form is a subform or a primary form. See FIG. 6 . The subform address unique combinations/sequences. There are devices that use a different sequence of log points and operations on a tool. An example would be a thin film process tool that has six chambers on it, each with different chemical/process steps options available. Any combination of the six could be used, i.e. there can be 720 different combinations/devices that are unique. If a primary form, then it is determined if the audit is an initial certification or a re-certification. If a subform, then it is determined if this is a re-certification or in initial certification. The system determines when re-certification is deemed necessary. The system has a time limit for completing the certification or re-certification.
Referring to FIG. 7 there is illustrated the steps where the audit is a subform initial certification. It determines if the minimum training time limit passed on the primary form. If no, the audit is terminated. If passed (yes), it determines if there is a prerequisite certification for this audit. If not, the audit is performed. If there is a prerequisite certification, it determines if the specialist has the required prerequisite. If not the audit is terminated. If yes, the audit begins.
If a subform re-certification is to be performed, the flow follows FIG. 8 . It first determines if an audit is required for re-certification and, if not, the audit is terminated. If the audit for re-certification is required, it determines if the certification process is locked in an OpTraining table on a Primary Form. If yes, the audit is terminated. If no, the audit begins.
If the audit is a nonsubform/initial certification, as illustrated in FIG. 9 , it is determined if the minimum training time limit is passed. If not, the audit is terminated. If “yes”, then it is determined if there is a prerequisite certification for this audit. If “no”, the audit is terminated. If “yes”, then it is determined if there is a prerequisite certification for this audit. If “no”, the audit begins. If “yes”, then it is determined if the specialist has the required prerequisite. If “no”, it is terminated. If “yes”, the audit begins.
If the audit is a nonsubform re-certification, it is determined if an audit is required in FIG. 10 . If “no”, the audit is terminated and if required it determines if the certification process is locked in the OPTraining table. If so, it is terminated and if not the audit is started.
FIG. 11 illustrates the final signoff entry process for re-certification. It first determines if there is a test for this certification. If “yes”, a signoff ID is inserted into an active OpTraining record. It then sends email to specified parties saying that the test is needed for certification completion. If there is not a test, it determines if this is a subform of a primary form. If “no”, it updates re-certification date and signoff ID in the OpTraining table and sends email to specified parties saying the certification is complete. If this is a subform, it is determined if all the subforms for the primary form are completed. If “yes”, then update re-certification date of primary form in the OpTraining table. The system then updates re-certification date and signoff ID in the OpTraining table and sends email to specified parties saying the certification is complete.
The system also generates a report on attempts to process material by an unqualified person. Wherever a person tries to access a machine or process and that person is not certified, the certification server records the person or machine and the time and date and sends that to the database 13 and that record can be retrieved by an access point such as through the web. The system also keeps track of production from the automation systems.
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention.
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A software system is provided that tracks employee and contractor operation/certification of fabrication equipment and processes is provided to ensure that only qualified personnel are allowed to process the materials. The system is real time with an auto-update features, Web enabled, dynamic tool interface with automatic record checking and reporting.
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BACKGROUND OF THE INVENTION
Quantum well lasers have very favorable properties for use in optoelectronic integrated circuits and optical communication systems. In this regard, there has been extensive study of quantum well lasers, including single quantum well lasers, fabricated from heteroepitaxial structures comprising contiguous layers of AlGaAs and GaAs. The principles of operation of such devices are described, for example, in U.S. Pat. No. 3,982,207 issued on Sept. 21, 1976 to Raymond Dingle and Charles H. Henry, hereafter "Dingle." In such devices, the quantum well is a thin layer, here called an active layer, comprising material of relatively low bandgap, bounded on both sides by layers, here called confinement layers, comprising material of higher bandgap. The active layer is thin enough for the optical emission from the recombination of electrons and holes in the layer to exhibit a quantum mechanical size effect. The active layer is usually less than about 300 Å thick.
Typically, the low bandgap material of a quantum well laser is GaAs, and the higher bandgap material is AlGaAs. Electrons and holes created by optical or electrical pumping are captured in the quantum well, where they desirably recombine radiatively, thus emitting radiation. It is advantageous to confine the laser radiation in thin-film optical waveguides adjacent to the active layer. Thus, in a so-called "separate confinement heterostructure" laser, at least one confinement layer also functions as a waveguide. This is achieved by bounding the waveguiding confinement layer on the side opposite the active layer by a layer having a lower refractive index. Although the active layer has a higher refractive index than the confinement layers, it is too thin to confine radiation and act as a waveguide. Thus, the recombining carriers are confined in the active layer, and the radiation is "separately confined" in one or more waveguiding layers.
The (Al, Ga)(As) material system is advantageous for growing heteroepitaxial structures because the mole fraction of aluminum, relative to gallium, can be varied from 0 to 100% without substantially affecting the lattice constant. As a result, heteroepitaxial structures can be grown without appreciable lattice strain. However, the laser emission from this material system occurs at wavelengths that are too short to be useful for many applications in optical communications. That is, because of considerations pertaining to transmission loss in optical fibers, the most useful wavelengths for optical communication are 1.3 and 1.55 μm. However, the band gaps of (Al, Ga)(As) materials are too large for laser emission to take place at such wavelengths. A typical wavelength of laser emission from GaAs, for example, is about 0.87 μm.
As a consequence, there is great interest in alternative, lower bandgap III-V material systems in the (In, Ga)(As, P) system. Quantum well lasers of the (In, Ga)(As, P) material system are advantageous because they can be operated at the wavelengths most useful for optical communication; namely, at 1.3 and 1.55 μm. The quaternary material InGaAsP is advantageously used for the confinement regions, and the ternary material InGaAs is advantageously used for the active regions. The binary material InP has a smaller refractive index than the quaternary material, and therefore quaternary layers bounded by InP are readily used as waveguiding layers.
However, when the lasers are grown using conventional metalorganic vapor-phase epitaxy, it is found that the quaternary material does not grow well on the ternary material. In particularly, the top quaternary layer is found to exhibit an unacceptable amount of strain and an unacceptably high density of dislocations. Dislocations are undesirable because they enhance the rate of nonradiative recombination, and thus decrease the efficiency of the laser. In consequence, the threshold current of the laser is increased.
SUMMARY OF THE INVENTION
More generally, quaternary layers are inherently difficult to grow, and it is advantageous for improving the quality of such layers to provide a binary base having a high degree of crystalline perfection for a quaternary layer to grow on.
We have found that ternary/quaternary interfaces of improved quality can be grown by metalorganic vapor-phase epitaxy when one or several monolayers of binary material, for example InP, are grown between the ternary and quaternary layers. Additionally, we have found that in order to form a relatively sharp transition in material composition at each interface, it is desirable to flush the growth chamber with at least one Group V hydride gas, and preferably with two Group V hydride gases in succession, after each layer has been grown, but before the growth of the succeeding layer. We have found that the first flush gas should correspond in composition to the Group V element characteristic of the layer just deposited, and the second flush gas should likewise correspond to the succeeding layer. (If the composition of a layer comprises only one Group V element, then that element is "characteristic" of the layer. If the composition of the last-deposited layer comprises two Group V elements, then whichever of those elements is absent from the succeeding layer is "characteristic" of the last-deposited layer. Likewise, if the composition of the succeeding layer comprises two Group V elements, then whichever of those elements is absent from the last-deposited layer is "characteristic" of the succeeding layer.) We have found that as a result of the binary buffer layer, crystalline perfection near the interface is improved, and the threshold current of quantum well lasers made according to the invention is reduced. We have also found that as a result of the flush technique using pairs of Group V hydrides, interfaces of improved sharpness can be achieved. Such improved sharpness also contributes to lowering the threshold current of quantum well lasers.
In a preferred embodiment, the ternary material is InGaAs, and the quaternary material is InGaAsP. Between the ternary and quaternary layers, a thin layer of the binary material InP is grown. The InP layer should be at least one, but not more than about ten, atomic planes in thickness, and it is preferably about 10 Å thick, corresponding to the thickness of about two atomic planes. After depositing InGaAs or InGaAsP, but before depositing InP, the growth chamber is flushed first with arsine, and then with phosphine. The order of these gases is reversed when the growth chamber is flushed after depositing InP, but before depositing InGaAs or InGaAsP.
Thus, in a broad sense, our invention is a method for forming a heteroepitaxial structure comprising first and second layers of III-V semiconductor materials, where the first layer has at least three elemental components, and the second layer has at least four elemental components. For purposes of this invention, an epitaxial pair of semiconductor layers forms a heteroepitaxial structure if the respective bandgaps differ by at least 0.1 eV. This gives rise to a room-temperature energy barrier of about 4 kT and would thus impede carrier flow at room temperature. The method comprises the steps of: placing a substrate in a vapor-phase epitaxial growth chamber, forming the first and second layers, and between the first and second layers, and epitaxial with them, forming a binary layer of III-V semiconductor material. The binary material is preferably at least one, but not more than ten, monolayers thick. At least one component of the binary layer is common to the first and second layers.
BACKGROUND OF THE INVENTION
FIG. 1 is a schematic representation of a quantum well laser made according to the inventive method.
FIG. 2 is a schematic representation of the active region of a multiple quantum well laser made according to the inventive method.
FIG. 3 is a graph depicting the relationship between optical power and current for CW operation of a double quantum well laser according to the invention.
DETAILED DESCRIPTION
As a pedagogic aid to a more complete understanding of the invention, the steps involved in making, for example, a quantum well laser are described below.
Turning to FIG. 1, there is shown an illustrative quantum well laser made in accordance with the inventive method. First, a substrate 10 is placed in the growth chamber of a reactor for metalorganic vapor-phase epitaxy (MOVPE). The substrate material is preferably a binary III-V material, and still more preferably is InP. Typically, electrical contact of one polarity, e.g., negative polarity, is made through the substrate, and the substrate material is doped to produce a corresponding conductivity type, e.g., n-type.
Next, an optical buffer region 20 is advantageously grown directly on substrate 10. The purpose of region 20 is to initiate epitaxial growth on the substrate, which has been chemically and mechanically processed. The buffer region is preferably of the same composition and conductivity type as the substrate. Still more preferably, the optical buffer region comprises a highly doped layer 23 grown directly on the substrate to minimize contact resistance to the lasing region, and a more lightly doped layer 26 grown directly on layer 23 to minimize diffusion of the dopant into the active laser region, because such diffusion could adversely affect the recombination properties. For example, layer 23 is desirably n-type InP, with a thickness at least 0.1 μm in order to insure good growth nucleation on the substrate, but not more than 1.0 μm because this would not add to the desired result but would unnecessarily increase the process cost, and with a doping level in the range 3×10 17 to 5×10 18 cm -3 in order to provide good electrical conduction. Layer 26 is desirably n-type InP, with a thickness at least 0.1 μm in order to isolate the heavily doped layer 23 from the active laser area, but not more than 1.0 μm because this, again, would not add to the desired result, and with a (lower) doping level in the range 1×10 17 to 5×10 17 cm -3 in order to provide adequate electrical conduction for current flow through the device.
Following the growth of buffer region 20, laser heterostructure 100 is grown. Heterostructure 100 comprises confinement layer 30, active region 200, and waveguide layer 50. Active region 200 comprises at least one active layer 40.
Whenever the growth of one layer is followed by the growth of a second layer of a different elemental composition, the reactor may be flushed by a flow of gas to remove constituents of one composition before growth of a second composition. This aids in achieving sharp interfaces. Advantageously, the flush comprises a Group V hydride gas. Still more advantageously, each flushing step comprises two separate flows of gas. The first flush comprises a gas corresponding in composition to the layer last grown, and the second flush comprises a gas corresponding in composition to the layer next to be grown. Thus, for example, if buffer layer 26 is InP and confinement layer 30 is InGaAsP, then after the growth of layer 26, the reactor is flushed first with phosphine and then with arsine.
Heterostructure 100 includes a quantum well in the region of layer 40, created by the difference in bandgaps between layer 40, on the one hand, and layers 30 and 50, on the other. To this end, the material composition of layers 30 and 50 should be chosen such that layers 30 and 50 have a band gap greater than the band gap of active layer 40. The difference in the band gaps should be great enough to form a quantum well capable of confining electrons and holes within layer 40. The design of quantum well laser heterostructures is described, for example, in Dingle, incorporated herein by reference, and also in U.S. Pat. No. 4,599,728, issued on Jul. 8, 1986 to K. Alavi, et al., also incorporated herein by reference.
The thickness of confinement layer 30 should be at least 0.05 μm in order to confine the optical field, but not more than 0.5 μm because at about that thickness the confinement factor becomes essentially unity, and therefore additional thickness does not add to the desired result. The thickness of waveguide layer 50 should fall within the same limits, for the same reasons. The thicknesses of layers 30 and 50 are preferably about 0.05 μm.
The compositions of layers 30, 40, and 50 are III-V semiconductors, preferably of the (In, Ga)(As, P) material system. Layers 30 and 50 are advantageously of quaternary composition, and layer 40 is advantageously of ternary composition. Thus, for example, layers 30 and 50 are readily grown from undoped InGaAsP having a band-gap wavelength of, e.g., 1.25-1.46 μm, and layer 40 is readily grown from undoped InGaAs having a band-gap wavelength of, e.g., 1.66 μm.
After layer 30 is grown, but before layer 40 is grown, cladding layer 35 is grown on layer 30. Layer 35 must be thin enough that carriers readily tunnel through it, so that current flow is not impeded. Layer 35 must also be thin enough that it does not affect optical confinement in heterostructure 100. To those ends, the thickness of layer 35 is desirably at least one, but not more than ten, atomic planes. Layer 35 is composed of a binary III-V semiconductor material, preferably InP. Thus, for example, layer 35 is readily grown from InP in a layer 0.3-5 nm thick. Between the growth steps of layer 30 and layer 35, the reactor is flushed as described above. Thus in the present example, the reactor is preferably flushed first with arsine and then with phosphine. Similarly, the reactor may be flushed between the growth steps of layer 35 and layer 40. In the present example, the reactor is preferably flushed first with phosphine and then with arsine.
If the laser is to be a single quantum well laser, active region 200 simply consists of a thin active layer 40. In that case, the growth of active layer 40 is followed by a gas flush, as described above, the growth of cladding layer 45, similar to cladding layer 35, another gas flush, as described above, and then by the growth of waveguide layer 50. If, on the other hand, the laser is to be a multiple quantum well laser, then, with reference to FIG. 2, active region 200 comprises at least two active layers 40', similar in description to active layer 40. The active layers 40' are separated by barrier layers 50', preferably of the same composition as layers 30 and 50. The thickness of barrier layers 50' should be at least 100 Å in order to prevent carrier coupling between the wells, but should not exceed 300 Å because barrier layers substantially thicker than this may optically isolate the active layers, forming separate, optically decoupled lasers. Thus in the present example, the barrier layers are preferably about 0.015 μm thick. Each barrier layer 50' is clad on both sides with a cladding layer 35' similar to layer 35. After growth of the last active layer, cladding layer 45 is grown as described above, and then waveguide layer 50 is grown, as also described above. As described, the reactor is flushed between each pair of growth steps.
Referring back to FIG. 1, growth of waveguide layer 50 is followed by a gas flush, as described, and following this, a setback layer 60 is grown. The purpose of layer 60 is to prevent the diffusion of dopant impurities into the active layers 40 or 40'. The material of setback layer 60 should be chosen to have a lower refractive index than waveguide layer 50 in order to produce optical confinement in waveguide layer 50. The material of layer 60 is undoped, is advantageously a binary III-V material, and is preferably InP. The thickness of layer 60 should be at least 0.01 μm in order to isolate the active area from diffusion of impurities, but not more than 0.2 μm because this might displace the p-n junction away from the recombination region by a distance of the order of a diffusion length, thus reducing injection of carriers into the active layer. Thus, the thickness of layer 60 is preferably about 0.05 μm.
The growth of the setback layer is followed by the growth of an optically isolating cladding layer 70 and then a contact layer 80. For example, if the contact layer is p-type InGaAsP, the cladding layer is advantageously made of p-type InP. Cladding layer 70 should be at least 0.5 μm thick in order to isolate the optically absorbing contact from the lasing region, but not more than 2 μm thick because this would not add to the desired result, and is preferably about 1 μm thick. Contact layer 80 should be at least 0.05 μm thick in order to insure complete coverage of the surface with a low-resistance growth of easily contacted material, but not more than 0.5 μm thick because this would not add to the desired result, and is preferably about 0.2 μm thick. The reactor is flushed, as described, between the growth of layer 70 and layer 80.
EXAMPLE I
A separate confinement single quantum well laser was grown on a (100) n-type InP substrate by metalorganic vapor phase epitaxy. The growth took place in a conventional, atmospheric pressure, horizontal reactor operated at 625° C. The source materials were trimethylindium, trimethylgallium, phosphine diluted to 20% in hydrogen, and arsine diluted to 5% in hydrogen. N-type materials were doped with sulfur, and p-type materials were doped with zinc, using hydrogen sulfide and diethylzinc, respectively, as the dopant source materials.
The process steps are described with reference to FIG. 1. First, a highly doped n-InP buffer layer 23 was grown directly on the substrate 10. This layer was 0.5 μm thick, and doped at 1×10 18 cm -3 . Next, a lightly doped n-InP buffer layer 26 was grown. This layer was 0.5 μm thick, and doped at 3×10 17 cm -3 . Following this step, the reactor was flushed with phosphine for two seconds, and then with arsine for two seconds. (All subsequent gas flushes also used arsine and phophine and lasted for two seconds.) Next, a 50-nm-thick confinement layer 30 of undoped InGaAsP (having a band-gap wavelength of 1.25-1.46 μm) was deposited, followed by an arsine flush and then a phosphine flush. Following this, a monolayer 35 of InP (0.3-5 nm in thickness) was deposited, followed by a phosphine flush and then an arsine flush. Next, an active layer 40 of InGaAs 10-20 nm in thickness was deposited, followed by an arsine flush and then a phosphine flush. A second InP monolayer 45 was then deposited, followed by a phosphine flush and then an arsine flush. Next, a 50-nm-thick waveguide layer 50 of InGaAsP (having a bandgap wavelength of 1.25-1.46 μm) was deposited, followed by an arsine flush and then a phosphine flush. Following this, a 50-nm-thick setback layer 60 of undoped InP was deposited. Next, a 1-μm-thick cladding layer 70 of p-InP doped at 5×10 17 cm -3 was deposited, followed by a phosphine flush and an arsine flush. This was followed by growth of a 0.2-μm-thick p-InGaAsP contact layer 80 doped to 3×10 18 cm -3 .
The single quantum well structure was examined by bright-field cross sectional transmission electron microscopy (TEM) using a Philips 420 microscope operated at 120 keV. Samples were prepared by chemical thinning with brominated methanol using a grid masking technique after the removal of the cap layers. TEM micrographs were taken using a [400] reflection to reveal interfacial strain and defects. Although a weak strain contrast was observed at the interface, the structure was basically of high quality. By contrast, micrographs of a control sample, grown by the identical procedure but omitting the InP cladding of the quantum wells, revealed strong interfacial strain and a highly dislocated top layer (i.e., the layer farthest from the substrate). The dislocations were all observed to originate from the defective top interface.
Room-temperature photoluminescence measurements showed that the InP cladding improved both efficiency and uniformity of luminescence by at least a factor of ten over the control sample. Under high excitation, the photoluminescence intensity showed a dominant peak at 1.58-1.60 μm, with a negligible intensity from the quaternary cladding layers, indicating that carriers were effectively confined in the wells, and indicating very small optical absorption in the confinement layers. When quaternary layers were substituted having a bandgap wavelength of 1.25 instead of 1.46 μm, there was observed a negligible change in both the electroluminescence and the photoluminescence peak wavelengths, which remained at 1.58-1.60 μm. This clearly indicates that recombination occurred mainly within the quantum wells.
The threshold current for laser operation at 20° C. was found to be about 55 mA. The output optical power was found to depend linearly on current up to a power of 18 mW per facet. The external differential quantum efficiency was found to be 19% per facet. The laser operated continuously at temperatures above 50° C. The laser emission occurred close to the heavy hole exciton energy of about 1.55 μm.
EXAMPLE II
A quantum well laser having two wells was grown in accordance with the inventive method. Between the two wells, an additional layer of InGaAsP, 15 nm thick, was grown between the quantum well layers. That is, the sequence of growth was: the first quantum well layer, an InP cladding layer, the additional InGaAsP layer, an InP cladding layer, and the second quantum well layer. Before the additional InGaAsP layer was grown, the growth chamber was flushed with phosphine and then arsine. After the layer was grown, the growth chamber was flushed with arsine and then phosphine. In all other respects, the procedure followed was the same as in Example I.
FIG. 3 shows how the optical output power of this laser depended on current, for CW operation at 20° C. It is apparent from FIG. 3 that the threshold current at this temperature was 35 mA, and the output power was linearly dependent on current up to a power of 15 mW per facet. The external differential quantum efficiency was found to be 21% per facet. An investigation of the effect of temperature on the light output vs. current relationship showed that the threshold temperature T 0 was 76° K., with no break point above room temperature. The laser operated continuously at temperatures above 50° C. The laser emission occurred at about 1.55 μm, representing a high-energy shift from the room-temperature band-edge wavelength of 1.66 μm. This shift was clear evidence of a quantum size effect. The emission consisted of 2-3 longitudinal modes.
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Described is a method for forming epitaxial films comprising successive layers of at least ternary and at least quaternary III-V material grown by metalorganic vapor-phase epitaxy. Between the steps of growing successive layers, the growth chamber is first flushed, advantageously in successive steps using a pair of gaseous Group V hybrides, a few monolayers of binary III-V material are then deposited, and then the growth chamber is again flushed. As a result, interfaces are sharper and interfacial defects are reduced. Also described are quantum well lasers made according to the inventive method.
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This application is a 371 of PCT/SE05/00850 filed on 3 Jun. 2005.
FIELD OF THE INVENTION
The present invention relates to a frame for a twin-wire press and a method for exchange of wire in twin-wire press comprising said frame.
BACKGROUND OF THE INVENTION
Twin-wire presses for dewatering of a fiber suspension and forming of a continuous web thereof are previously known. Dewatering of the pulp is usually done from an inlet pulp concentration of 3 to 8 percent by weight to an outlet pulp concentration of 30 to 50 percent by weight. According to the state of the art, such twin-wire presses comprises lower rolls, an endless lower wire running in a path around the lower rolls, upper rolls, and an endless upper wire running in a path around the upper rolls. The two wires co-operate with each other along sections of said paths that run substantially in parallel with each other for dewatering of the fiber suspension between the wires during displacement thereof. An inlet box provides for supply of the fiber suspension to a wedge-shaped dewatering space between the wires. The twin-wire press further comprises two dewatering tables supporting the respective wire in said sections of the path and forming the wedge-shaped dewatering space between the wires for initially pressing and dewatering the fiber suspension, whereby a web is formed between the wires, and a roll arrangement situated after the dewatering tables in said sections of the paths, as seen in the direction of movement of the wires, for finally pressing and dewatering the web between the wires, so that the web will get a desired dryness.
It is often necessary in a simple way and as quickly as possible during maintenance, exchange of wire and cleaning of the twin-wire press, without prolonged stoppage of production, to be able to reach the space between the upper and lower rolls in the roll arrangement. The supporting structure of known twin-wire presses is formed of a framework of longitudinal, parallel arranged, I-beams in the longitudinal direction of the twin-wire press, respectively of transversely parallel arranged I-beams in the transverse direction of the twin-wire press. The transverse and longitudinal beams are firmly fixed, such as welded together, with each other whereby a rigid and stable framework structure is formed. The rolls in these presses are arranged in connection to the longitudinal beams between opposite long sides of the press. In order to be able to reach the space between the upper and lower rolls of the known presses, a hinge joint is arranged along a long side of the press between two longitudinal parallel arranged beams, hereinafter called first longitudinal side member. A space in the longitudinal direction of the press between upper and lower rolls on the opposite long side of the press may then if required be widened by disengaging fixations in the shape of distance elements between longitudinal parallel arranged beams on this opposite side, hereinafter called second longitudinal side member. With the aid of a jack, or the like, arranged to push apart two of the parallel arranged second longitudinal side members between which distance elements have been disengaged, a space between upper and lower rolls can be widen, whereby it is possible to reach the space in the roll arrangement for maintenance, cleaning and exchange of wire.
However, this known structure with a hinge joint is very expensive, complicated and not flexible. Even during production of the twin-wire press a decision has to be taken on which longitudinal side of the press the hinge joint shall be arranged, since that is a question of vital importance for the accessibility to said space between the rolls once the twin-wire press is arranged on the intended position in the paper plant.
One object of the present invention is to achieve an easier, more effective and improved twin-wire press where the space between the upper and lower rolls in the roll arrangement is easily accessible for maintenance, exchange of wire and cleaning if required, and where at least those drawbacks that are associated with previously known state of the art can be partially eliminated. It is another object of the present invention to achieve a twin-wire press that permits an option which long side of the press the space shall be widen between upper and lower rolls for accessibility for maintenance, exchange of wire and cleaning. Yet another object of the present invention is to provide a twin-wire press where maintenance, exchange of wire and cleaning of the press can be carried out cost efficiently and in a work saving way.
SUMMARY OF THE INVENTION
In accordance with the present invention, these and other objects have now been realized by the invention of a frame for a twin-wire press comprising first and second pairs of longitudinal side members, the respective pairs of longitudinal side members comprising an upper side member and a lower side member arranged along each opposite longitudinal side of the twin-wire press, between which first and second pairs of upper and lower rolls are intended to be attached in the twin-wire press, and a plurality of transverse beams arranged between the first and second pairs of longitudinal side members, the respective pairs of the upper and lower side members at least partially comprising sections of flat sheet metal elements, and distance elements for mutually releasably connecting the upper and lower side members, the sheet metal elements being formed such that they permit a predetermined degree of curving in the vertical plane transverse to the horizontal plane which facilitates access to the space between the upper and lower rolls for performing maintenance, exchange of wire or cleaning. In a preferred embodiment of the frame of the present invention, respective pairs of the side members comprise recesses intended for fastening rolls between the first and second pairs of side members.
In accordance with another embodiment of the frame of the present invention, the lower side members comprise a substantially flat sheet metal element.
In accordance with another embodiment of the frame of the present invention, the upper side members comprise a substantially flat sheet metal element.
In accordance with the present invention, a method has also been discovered for the exchange of wire in a twin-wire press including a frame as set forth above in which an endless lower wire runs in a path around the pair of lower rolls and an endless upper wire runs in a path around the pair of upper rolls, the method comprising disengaging the distance elements from the upper and lower side members of one of the pair of side members, pushing apart the upper and lower side members of the one of the pairs of side members by causing the sheet metal element of the other of the pairs of side members to curve to some extent in a vertical plane transverse to the horizontal plane under which the upper and lower side members of the one of the pairs of side members are pushed apart, removing the distance elements to form a free opening between the upper and lower side members of the one of the pair of side members and removing the at least one of the lower and upper wires through the free opening between the upper and lower side members of the one of the second pairs of side members. Preferably, the sheet metal elements of the one of the pairs of side members are curved by means of at least a press apparatus.
These objects are thus achieved with a frame for a twin-wire press according to the present invention. The frame comprises a first and a second pair of longitudinal side members. The respective pairs of side members comprises an upper side member and a lower side member and are arranged along each opposite longitudinal long side of the twin-wire press, between which first and second pair of side members rolls are arranged to be attached in the twin-wire press. Furthermore, the frame comprises several transverse beams arranged between the first and the second pair of opposite side members. The frame includes respective side members that at least partially comprise sections of flat sheet metal elements. Upper and lower side members of the respective pairs of side members are mutually releasably connected by distance elements. The sheet metal element is formed such that it permits a certain extent of curving in a vertical plane, transverse to the horizontal plane, which facilitate accessibility to the space between the upper and lower rolls for performing work with maintenance, exchange of wire and cleaning.
In view of the fact that the longitudinal side members of the frame partially comprise flat sheet metal elements, the requirement of a hinge structure that is necessary in conventional twin-wire presses can be completely eliminated. In order to reach the space between upper and lower rolls along a long side of the press, the sheet metals' own curvature is utilized. By curving the sheet metal of the side members on one of the longitudinal sides of the press, and disengaging the distance elements between the opposite longitudinal side members on the second long side of the press, the upper and lower side members can be brought apart to facilitate access to the space between the upper and lower rolls. The present invention facilitates that work with maintenance, exchange of wire and cleaning of the twin-wire press can be performed efficiently whereby the operation of the press only needs to be interrupted for a shorter period. Thus, a cost saving can be achieved thanks to a shorter time for interruption and an elimination of the conventional hinge structure. Furthermore, the present invention also means that the production and the assembly of the twin-wire press becomes more effective, since apertures of the sheet metal elements of the side members can be cut out already at the production which results in that there will be no matching difficulties at the assembly. Besides, the flat sheet metal elements of the side members can form attachments for assembly of the bearing housing of the rolls, which results in a simplified assembly. Another advantage is that all apertures that are needed in the sheet metal elements can be machined directly in the sheet metal at the production that leads to that there will be exact positions for fastening of rolls and other details.
The present invention also relates to a method for exchange of wire in a twin-wire press comprising a frame as described above, where upper and lower rolls are arranged between the first and second pair of side members. Furthermore, the twin-wire press comprises an endless lower wire running in a path around the lower rolls, and an endless upper wire running in a path around the upper rolls. According to the method of the present invention, the fixation of the distance elements in attachments to the upper and lower side member of the second pair of side members is disengaged; the upper and lower side member of the second pair of side members are pushed apart, by causing the sheet metal elements of the first pair of side members to some extent to curve in a vertical plane, transverse to the horizontal plane, under which the upper and lower side members of the second pair of side members are pushed apart; the distance elements are removed, whereby a free opening is formed between the upper and lower side members of the second pair of side members; and the lower and/or the upper wire is removed through the free opening between the said upper and lower side members of the second pair of side members.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional preferred embodiments according to the present invention are evident from the following detailed description with reference to the accompanying drawings, wherein:
FIG. 1 is a side, elevational, schematic, cross-sectional view through a twin-wire press according to one embodiment of the present invention;
FIG. 2 is a side, perspective, schematic, view of a frame for a twin-wire press according to one embodiment of the present invention; and
FIG. 3 is a front, partial, perspective, schematic view of a fastening of a bearing housing of rolls in a frame according to FIG. 2 .
DETAILED DESCRIPTION
FIG. 1 shows a twin-wire press 2 according to the present invention. The twin-wire press 2 comprises three lower rolls, namely, a drive roll 4 , a control roll 6 and a tensioning roll 8 . An endless lower wire 10 runs in a path around the lower rolls, 4 , 6 and 8 . In a corresponding manner an upper endless wire 12 runs in a path around three upper rolls, namely, a drive roll 14 , a control roll 16 and a tensioning roll 18 . An upper dewatering table 20 , that supports the upper wire 12 , and a lower dewatering table 22 , that supports the lower wire 10 , forms the dewatering space 24 between the wires, 10 and 12 , in which the fiber suspension/web M is dewatered. “Press section” refers to an ordinary roll arrangement according to the state of the art that can involve a plurality of roll pairs 25 , such as schematically shown in FIG. 1 . An inlet box 26 is arranged at one end of the press.
FIG. 2 shows a frame for a twin-wire press described with reference to FIG. 1 , mainly intended as a frame for the roll arrangement of the press. The frame comprises a first and a second pair of longitudinal side members, 32 and 34 . The first pair of side members 32 comprises an upper side member 32 ′ and a lower side member 32 ″ arranged along a longitudinal first long side of the twin-wire press. The second pair of side members 34 comprises an upper side member 34 ′ and a lower side member 34 ″ arranged along a longitudinal second long side of the twin-wire press. Between the first 32 and second 34 pair of side members in the twin-wire press are rolls intended to be attached. Furthermore, the frame comprises several firmly fastened transverse beams 36 arranged between the first and second pairs of opposite side members, 32 and 34 .
The respective side members, 32 ′, 32 ″, 34 ′, and 34 ″, comprise at least partial sections of flat sheet metal elements. Upper and lower side members, 32 ′ and 32 ″, of the first pair of side members 32 , and respective upper 34 ′ and lower side member 34 ″ of the second pair of side members 34 , are mutually releasably connected by distance elements 38 (in FIG. 2 are the distance elements of the second pair of side members 34 are removed).
The respective side members, 32 ′, 32 ″, 34 ′, and 34 ″, comprise recesses 40 intended for fastening of rolls between the first and second pair of longitudinal side members, 32 and 34 . As shown in the preferred embodiment of the frame in FIG. 2 , substantially the whole lower side members, 32 ″πand 34 ″, respectively substantially the whole upper side members 32 ′ and 34 ′, can comprise flat sheet metal elements. However, the whole side members need not be comprised of flat sheet metal elements according to the most general embodiment, but it is sufficient first of all that the side members at least partially comprises sections of flat sheet metal elements. In that respect, at least those sections of the side members that are adjacent to the distance elements suitably comprises flat sheet metal elements. Preferably, those sections of the side members that are adjacent to the fastening of the rolls to the side members can comprise flat sheet metal elements. The sheet metal elements, and thus the sections of the side members that comprises sheet metal elements, are formed such that, to certain extent, they permit a curving in a vertical plane V, transverse to the horizontal plane H.
At the time of an exchange of wire in a twin-wire press 2 (see FIG. 1 ) comprising the frame according to FIG. 2 , which press comprises upper and lower rolls (see FIG. 1 ; 25 ′, 25 ″) and an upper and lower wire ( FIG. 1 ), the following stages are performed in the given sequence: 1) The fixation of the distance elements 38 in attachments 42 to the upper 34 ′ and lower 34 ″ side member of the second pair of side members 34 are disengaged by removing those screws by which the distance elements are fixed to the attachment 42 . 2) The upper 34 ′ and lower 34 ′, side member of the second pair of side members 34 are pushed apart. The upper side member 34 ′ is transferred in a direction away from the lower side member 34 ″ of the second pair of side members by causing the sheet metal elements of the first pair of side members 32 to curve to some extent in a vertical plane V, transverse to the horizontal plane H under which the upper 34 ′ and lower 34 ″ side member of the second pair of side members are pushed apart. For this purpose a press apparatus is suitably arranged between transverse beams that are adjacent to the first pair of side members. The sheet metal elements of the first pair of side members 32 are curved by means of the press apparatus whereby consequently the upper 34 ′ and lower 34 ″ side member of the second pair of side members 34 is pushed apart in order to be able to disengage the distance elements. 3) The distance elements 38 are removed, whereby a free opening 43 is formed between the upper 34 ′ and lower 34 ″ side members of the second pair 34 of side members. FIG. 2 shows the frame after the distance elements at the second pair of side members have been removed. 4) Possibly the upper 34 ′ and lower 34 ″ side member of the second pair of side members 34 are brought further apart in order to create a larger free opening 43 . The lower and/or the upper wire are removed through the free opening 43 between the said upper 34 ′ and lower 34 ″ side members of the second pair 34 of side members.
With reference to FIG. 3 , fastening of a lower roll 44 and an upper roll 46 to a flat section of a sheet metal element of the upper and lower side members, 32 ′ and 32 ″, respectively, of the first pair of side members 32 in FIG. 2 , is shown according to a preferred embodiment. By means of attachments 48 such as pins, bolts or the similar, a projecting section 50 of a bearing housing 52 of the lower roll 44 is fixed to the flat sheet metal element section 54 of the lower side member 32 ″. In FIG. 3 is also shown the fastening of a hydraulic cylinder 56 between a flat sheet metal element section 58 of the upper side member 32 ′ and a projecting section 60 at a bearing housing 62 of the upper roll 46 . By this arrangement of the bearing housing 52 , 62 of the rolls to the frame according to the present invention, a more effective and uncomplicated fastening of the rolls is achieved in comparison to what has been possible in the conventional existing frameworks in the previously known twin-wire presses.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A frame for a twin-wire press is disclosed including pairs of side members including upper and lower side members arranged on opposite sides of the press, between which upper and lower rolls are attached, a plurality of transverse beams arranged between the pairs of side members which themselves are sections of flat sheet metal and spacers for mutually releasably connecting the side members with the sheet metal being formed so that it permits a degree of curing in the vertical plane to facilitate access to the space between the upper and lower rolls. A method for exchanging wire in a twin-wire press of this type is also disclosed.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of and priority to a U.S. Provisional Patent Application No. 60/662,420 filed Mar. 16, 2005, the technical disclosure of which is hereby incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] This invention relates to a system and method for managing the workflow in a professional workplace, and more particularly pertains to a method and system for collecting, maintaining and using client data. Such method and system provide a means to more efficiently gather, catalog, and store client and other types of information and facilitate the more efficient preparation of documents. Users may use the system and method to interface with software applications such as document assembly engines and databases. Users spend more time productively engaging their business expertise and exploiting their skills, and less time finding and using shared information.
[0004] 2. Description of Related Art
[0005] Many businesses use templates, ones which may contain reusable boiler-plate, recycled or frequently used language. Computers facilitate producing, editing, transmitting, and printing of templates. Law firms, businesses, real estate firms, insurance companies, and others often use such templates in litigation, real estate closings, and claim handling. Forms are often arranged electronically according to task.
[0006] Templates are readily available in both printed and electronic form (e.g., Adobe portable document format files, Microsoft Word files, Corel WordPerfect files). Similarly, legal document-generating software is commercially available (e.g., LexisNexis HotDocs®), Innovative Software Products of Virginia Pathagoras, Keylogix ActiveDocs). However, the prior art does not capture all of the increased efficiency possible through effective re-use of client and other types of information. Typically, users start from templates and pre-existing blocks of text to assemble documents. According to the prior art, documents are assembled by filling in templates with task-specific and client-specific language. This order of adding information is inefficient, especially since client information is usually last to be considered as part of a task to create a document.
[0007] FIG. 1 illustrates a typical document assembly process according to the prior art. With reference to FIG. 1 , a user starts 102 the document assembly process by choosing a document class 104 . Next, a user selects a specific document template 106 before assembling a document 110 , for example, a pourover will. The user subsequently enters all relevant information 108 . Next, the user provides a filename and path to the document and answer file 110 . The user then initiates an assembly process 112 and, in the last step, has an opportunity to review and print an assembled document 114 before ending the process 116 . When a user requires a subsequent document, the process shown in FIG. 1 is repeated. The efficiency in the prior art is in the re-use of pre-existing language found in document templates corresponding to step 106 . However, client information must be re-entered each time a document is generated.
[0008] For example, if a user wishes to create a trust for an existing client, a user might hierarchally select “legal document,” “estate planning,” and finally “trust” before a template having blanks or a set of blocks of text are presented to the user. Once a document is formed, it often has blanks or empty fields for client information. At this point, a user re-enters client information which is likely already stored in the same computer system such as in other saved answer files or documents previously prepared for a client. There does not exist in the prior art a method or apparatus for capturing and efficiently re-using client information from one document to the next. For example, there is no efficient mechanism for creating a reciprocal or “mirror image” document for a spouse using the same basic answers found in a previously created client record.
[0009] Certain patents have disclosed concepts associated with assembling documents, but none meet the needs filled by the present invention. For example, U.S. Pat. No. 5,446,653 issued Aug. 29, 1995 to Miller et al, describes a document generation system that separately stores all paragraphs that might be used in creating an insurance policy document. A policy form is primarily a list of references to the paragraphs that may be included in a policy document. The document generation system merges necessary paragraphs into a policy document as it creates the document. A user supplies the system with data that the system needs to determine which paragraphs are to be included in the document. Thereafter, when creating the document, the system invokes a set of rules by which it determines from the input data which paragraphs are to be included in the document. However, patent '653 does not re-use client information when assembling subsequent documents, especially for the same client as disclosed in the present invention.
[0010] U.S. Pat. No. 5,729,751 issued Mar. 17, 1998 to Schoolcraft describes an interactive document assembly system in which codes are embedded in a form at points where a decision must be made as to whether to include or delete a clause, insert a variable field or make a word choice. Each code value is associated with a set of instructions stored in an instruction database. When creating a document, the system sequences through the form, and whenever it encounters a code it obtains and executes the instructions associated with the code. Since the questions are asked in the order of occurrence as the system scans through a form, the system is not easily adapted for use with user-friendly data entry screens. While such a document generation system is flexible, a system capable of producing a large number of complex documents could require hundreds of such codes. Programmers would find it difficult to update and maintain such a system without duplicating the content codes. Further, there is not an efficient re-use of client information when assembling a document as disclosed in the present invention.
[0011] U.S. Pat. No. 5,893,914 issued Apr. 13, 1999 to Clapp discloses an interactive computerized document assembly system including a model template formed of a sequence of sections and having decisional options including clause repeats, conditional clauses, and questions to be answered, after which a document is assembled. Patent '914 also describes functions for indicating the location in the model template for the decisional options to identify the sequence of sections constituting the model template. A video displays a portion of the template, and an answer index stores answers to questions posed in the portion of the template displayed, each of the questions having a unique identifier. Patent '914 discloses the merging, with each displayed section or part thereof, the answers corresponding to each displayed section or part thereof. Patent '914 also discloses the combination and redisplay in sequence of each merged section or part thereof in order to assemble a document from the model template. However, patent '914 does not store and efficiently re-use client information from one document to another.
[0012] U.S. Pat. No. 6,366,892 issued Apr. 2, 2002 to Altman, et al. discloses a method and system for automatically generating customized legal documents, particularly for institutional commercial loans, from a database of loan provisions including standard clauses and alternate optional clauses for each of the standard clauses. The prospective borrower selects either a standard clause or one or more optional clauses for different loan provisions. A value is assigned to each of the optional clauses and the cost of the loan is determined and based on the clauses selected by the prospective borrower. However, patent '892 does not store, arrange and use client data in a client-centric fashion when assembling documents. If multiple loan documents were to be generated for one particular client, the same client information would have to be entered separately into each form.
[0013] U.S. Pat. No. 6,473,892 issued Oct. 29, 2002 to Porter discloses a document assembly system which prints one or more documents in response to input data describing the nature and circumstances of a transaction to be documented and describing the parties to the transaction. The document assembly system initially produces a separate document definition object for each document to be produced, and a separate party definition object for each party to the transaction. The party definition object includes procedures for generating party-related text that the document is to use when referring to a party. The nature of the text each document definition or party definition object procedure produces depends on the nature of the document or the party as indicated by the input data. The system also includes a set of “text generators,” which are blocks of source code, that when compiled and executed, generate the text that may be included in a document. When the nature of a word or phrase to be included in a document depends on the nature of the document or on the nature of a party, the text generator refers to the word or phrase by referring to a procedure of the document or party definition object which generates the word or phrase. Even though patent '892 stores party information, party or user data for assembling documents is not efficiently re-used as disclosed in the present invention. Further, patent '892 does not disclose arranging and organizing document assembly in a client centric manner. Further, patent '892 does not provide for a client centric interface when a user assembles a document.
[0014] U.S. Pat. No. 6,694,315 issued Feb. 17, 2004 to Grow discloses an online document assembly and docketing method using a user workstation interconnected over a network backbone to a website (i.e., an application server). First, a new user stores identification information in a user table. The user inputs identification information at the user workstation which is received at the website. An assembled document is generated by accessing a template from the form table at the website and inserting stored case data, which has also been previously entered and stored in the application server, into a “form document” or template. The assembled document is then delivered to the user workstation over the network backbone. However, patent '315 does not store, use and arrange user identification and other types of client data in a client-centric fashion when assembling documents as disclosed in the present invention.
[0015] Therefore, a need exists to better utilize previously captured client information, such as, but not limited to, a client's name, contact information, financial assets, business information, and an historical account of pertinent facts. A need exists to provide an interface to a system whereby a user can assemble a document in a client centric fashion instead of a traditional task centric fashion. A need exists to enable a user to quickly copy a correct answer set then re-use it to create a second document for the same or related individual.
[0016] Further, a need exists to manage the workflow of information in a professional setting. A need exists to provide a friendly graphical user interface requiring little or no training. A need exists to provide security over client information. A need exists to provide multi-user access, file locking, and database locking to prevent data loss and corruption of client information. A need exists for managing software licenses of applications and modules for such client centric software. A need exists for providing backup and restore functions of client information, not just client documents. A need exists to provide a more elegant software mechanism to retrieve and use client information than currently available in the prior art.
SUMMARY OF THE INVENTION
[0017] The object of the present invention is to more efficiently use existing client information in the preparation of documents. Certain information from clients is captured in a computer system and is stored separately from ordinary document assembly files such as template and document answer files. A document assembly engine is called and used to more efficiently combine and re-use information to form completed documents.
[0018] Through the use of an intuitive context-sensitive computer software interface, documents are organized in a hierarchal fashion according to client, then matter, and finally in a listing of the documents generated for that client/matter. This hierarchy more closely matches the workflow paradigm of businesses. A template manager organizes the system's legal templates in a hierarchal fashion and links each template to a specific pattern answer file which provides default answers during a document interview process. A template manager also allows users to select correct templates and pattern or answer files which are subsequently merged to form assembled documents.
[0019] A GUID naming convention allows the invention to internally create and track document and answer files so that stored information is not lost while allowing users to give intuitive names and context to their documents. The invention preferably stores information and documents in a central repository. The invention provides a means whereby a document may be accessed by only a single user at any one time. Such means prevents the loss of information when multiple users work with one document. At the same time, the invention allows multiple users to efficiently access and re-use client and other information. Security, license and preference modules facilitate the granting of access rights to individual users and to maintain user and group preferences. The software interface provides context sensitive information to aid a user in working with document assembly and in re-using information.
[0020] The invention accordingly comprises the features described more fully below, and the scope of the invention will be indicated in the claims. The objects of the present invention will become apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
[0022] FIG. 1 is a flow chart showing document assembly according to the prior art;
[0023] FIG. 2 is a flow chart showing one method of document assembly according to the present invention;
[0024] FIG. 3 is an exemplary software form according to one embodiment of the present invention showing login security;
[0025] FIG. 4 is an exemplary software form according to one embodiment of the present invention showing the main user interface wherein document generation is hierarchally based around a client record and which corresponds to step 206 of FIG. 2 ;
[0026] FIG. 5 is an exemplary software form according to one embodiment of the present invention showing a preferences interview corresponding to step 208 of FIG. 2 ;
[0027] FIG. 6 is an exemplary software form according to one embodiment of the present invention showing an add client dialog corresponding to step 210 of FIG. 2 ;
[0028] FIG. 7 is an exemplary software form according to one embodiment of the present invention showing a client interview corresponding to step 212 of FIG. 2 wherein client metadata can be captured in a proprietary database;
[0029] FIG. 8 is an exemplary software form according to one embodiment of the present invention showing an add matter dialog corresponding to step 214 of FIG. 2 ;
[0030] FIG. 9 is an exemplary software form according to one embodiment of the present invention showing a matter interview corresponding to step 216 of FIG. 2 wherein matter metadata can be captured in a proprietary database;
[0031] FIG. 10 is an exemplary software form according to one embodiment of the present invention showing an add document dialog corresponding to step 218 of FIG. 2 wherein a document type or template is selected;
[0032] FIG. 11 is an exemplary software form according to one embodiment of the present invention showing a document interview corresponding to step 220 of FIG. 2 wherein document class metadata can be captured in a proprietary database;
[0033] FIG. 12 is an exemplary software form according to one embodiment of the present invention similar to FIG. 4 showing selection of a document assembly function corresponding to step 222 of FIG. 2 ;
[0034] FIG. 13 is an exemplary software form according to one embodiment of the present invention showing a resource manager;
[0035] FIG. 14 is an exemplary software form according to one embodiment of the present invention showing a preferences manager;
[0036] FIG. 15 is an exemplary software form according to one embodiment of the present invention showing a firm settings manager;
[0037] FIG. 16 is an exemplary software form according to one embodiment of the present invention showing a help manager;
[0038] FIG. 17 is an exemplary software form according to one embodiment of the present invention showing a license manager;
[0039] FIG. 18 is an exemplary software form according to one embodiment of the present invention showing an administration manager;
[0040] FIG. 19 is an exemplary software form of an administration manager according to one embodiment of the present invention showing how a software user may be added to the software application;
[0041] FIG. 20 is an exemplary software form of an administration manager according to one embodiment of the present invention showing how a software user may be assigned rights to a practice system; and,
[0042] FIG. 21 is an exemplary software form according to one embodiment of the present invention showing a customization manager.
DETAILED DESCRIPTION
[0043] While the invention is described below with respect to a preferred embodiment, other embodiments are possible. The concepts disclosed herein apply equally to other systems and methods which gather and organize client information, and assemble documents in a client centric fashion. Furthermore, the concepts applied herein apply more generally to the management and use of client information. The invention is described below with reference to the accompanying figures.
DEFINITIONS
[0044] A template as used herein, is defined as a generic document preferably having form fields such that specific information can be placed therein. Templates are generic in that no client specific data is included, but text common to any similar document is included. Templates can also include sample or instructional text (e.g., <insert first interrogatory here>). Throughout this document, text within angled brackets (“<” and “>”) is user defined, and the exact content of such text is immaterial to the functioning of the invention. Preferably, the templates are formatted in conventionally available word processor formats (e.g., Microsoft Word, Corel WordPerfect, rich text format, ASCII text) so that the templates can be readily edited by a user after being assembled. It is to be understood that any number of template fields can be used and will be limited only by the various documents necessary for a given case.
[0045] An assembled document, as used herein, is defined as a template that has been combined with specific client and other information. Preferably, the assembled document contains text specific to the given client and task, and where text may be added automatically by the software system. Information may be taken from answer files.
[0046] The present invention may be implemented and practiced with a conventional personal computer system having a CPU, storage device, keyboard, mouse and monitor. As used herein, a user is defined as any operator of such personal computer. In one example, the user is an attorney or member of a law firm staff. This example is used throughout the description. It will be understood by those in the art that the application may be practiced by anyone.
[0047] It is to be understood that each personal computer can have individual internal memory. Likewise, internal memory can be random access memory (RAM), read only memory (ROM), any suitable form of storage disk (e.g., magnetic tape, hard disk, floppy disk, ZIP disk, etc.), or any combination thereof. Furthermore, the memory can be a single memory or separate memories, and can reside within the host computer or independently thereof.
[0000] Architecture
[0048] One embodiment of the present invention assembles a document from templates merged with client data. The detailed assembly of documents is done by a third-party document assembly software engine. In a preferred embodiment, HotDocs® (Matthew Bender & Company Inc., part of the LexisNexis Group, Albany, N.Y.) is used. However, other document assembly software applications may be used.
[0049] HotDocs® provides a means to gather, organize, and maintain client, matter, document and other information through “interviews.” An interview as used herein is a series of software forms which prompt and guide a user through the process of storing information. Interviews may consist of software calls through a published API to one or more other third-party software programs. Interviews and interview forms may be conducted using software forms generated by the present invention or generated by third-party software applications. During the time a third-party software interview is open, the present invention transitions from an “active state” to a “wait state.” Upon completion of a third-party software interview, the present invention signals the third-party software to close, whereupon the present invention transitions back to an active state.
[0050] HotDocs® also provides a means for maintaining templates which hold the text and rules for assembling a custom output such as an assembled document. In one embodiment, a run-time version of HotDocs®, known as the HD Player, is delivered along with other software components comprising the present invention. The software system utilizes the HD Player through published software API calls. The software system runs interviews, overlays the data from multiple files into a matter file for each matter, and assembles documents.
[0051] FIG. 5 exemplifies a general embodiment of calling a HotDocs® interview using a published API call and specifically shows a firm preferences interview. This third-party software interview is used to prompt a user for additional information. FIG. 9 illustrates a similar interview to gather matter information which may be stored by the present invention in <matter>.anx (XML-based) answer files. Client information may be stored in <client>.anx answer files. Document class information may be stored in <document class>.anx or <profile>.anx (XML-based) answer files. Firm preferences may be stored in <preferences>.anx (XML-based) answer files. Such files may be accessed for use in subsequent forms and documents. Gathered information also may be stored in a database. The present invention may track time, date and user access information which also may be stored as metadata in files or in a database.
[0052] The software system is conceptually comprised of the following elements: a list of clients, matters and documents arranged and presented hierarchally in a software tree structure; interviews for gathering client, matter and document information; help text; business and legal commentary; and templates and forms. While the software content is platform independent, it must be programmed to run on a particular document assembly engine such as, but not limited to, HotDocs®. While most of the currently available engines are similar in design, some structural and syntactical differences exist.
[0000] Methodology
[0053] Law firms and other businesses have traditionally organized their work hierarchally by clients, matters and documents. Document managers, data managers, and billing software programs designed for law firms have almost universally adopted the client/matter/document (“CMD”) paradigm. Unlike prior art software, the present invention follows the CMD model which parallels traditional CMD workflow processes. By providing a more intuitive system and method, the need for training and support is reduced. Users thereby more efficiently use their time. A software wrapper, built around HotDocs®, is comprised of a number of components, all of which are novel in concept and design except for the Microsoft Access JET engine. The software components are: a graphical user interface (GUI) built on the CMD model; a CMD database which may be built with a Microsoft Access JET database; a resources manager; a preferences manager; a firm settings manager; a profile manager; a help manager; a security and administration manager; a customization manager; and a license manager.
[0000] File Management
[0054] In one embodiment of the invention, the CMD database and software application automatically name, save, and store HotDocs® answer files and final word processing documents. An internal file management mechanism provides insulation to the user from the native file naming and storing mechanism of HotDocs® which is the use of traditional file and folder data storage structures. The CMD database stores metadata about clients, matters, and documents (e.g. date item created, client number, matter information, document & answer file names) in the CMD database. Like a library, the CMD database tracks this information and provides a 128-bit global unique identifier (GUID) for the name of each answer file and document file. The software application, through the CMD database, automatically tracks the location of, and provides access to, these files. GUIDs are appropriate because they eliminate the possibility of duplicates and naming conflicts of files. GUIDs also provide the ability to track files off-line where files are checked out and checked in, much like books are handled at a library. In a checked out state, files are locked and cannot be further edited by other users. When files are checked in, the software system synchronizes the information in the files with the CMD database. With GUIDs, there is no concern about conflicting duplicate file or folder names. Thus, client and other data are not lost. In one embodiment, all answer files and client documents are stored in one directory. For example, a directory listing might appear like the listing in Table 1 where each file name is composed of a GUID and a file extension. In Table 1, a file extension of “.anx” is an answer file, and a file extension of “.rtf” is a document in rich text format.
TABLE 1 Directory listing of files 03f5f6a3-3aab-11d9-9669-0800200c9a66.anx 03f5f6a3-3aab-11d9-9669-0800200c9a67.anx 03f5f6a3-3aab-11d9-9669-0800200c9a68.rtf
[0055] The software application stores interview answers in XML answer files. The system is designed for one or more users. For workgroups, the software may maintain a single database on a shared server. The metadata, interview data, templates, interviews and documents can be accessed by all members of a workgroup with the appropriate access rights. In one embodiment, a CMD database is a JET Microsoft Access database. JET databases support fairly large datasets and accept most basic SQL commands. In another embodiment, a CMD database is any relational database (RDB).
[0000] Main User Interface
[0056] In one embodiment, the software system is a single document interface (SDI) where the software window or form may be referred to as a shell. In one embodiment, the shell is divided into four areas. There may be other software forms such as a login dialog. The shell makes software calls to internal as well as external software functions.
[0057] With reference to FIG. 4 , in one embodiment, the top area 408 of the shell 430 is dedicated to branding. On the left is a navigation menu or menu bar 410 , and in the middle is the work area 412 . The navigation bar 410 is used to access the functions and resources within the software application by triggering switching events. In one embodiment, the menu in the navigation bar 410 is available regardless of where a user chooses to set the focus of the software application or what software function is being executed. In one embodiment, a navigation bar 410 is a simple one-level vertical button bar. As the mouse is dragged over a button, a hover color is applied to the selected button so a user sees where the mouse is positioned. When a button is clicked, it changes color. This type of behavior avoids confusion. Each navigation bar button has an icon which is duplicated in the title bar of a work area header 414 near the top of the shell to provide orientation to a user. In one embodiment, when a user first launches the software application, the form loaded into the work area 412 is a SmartContent form, which corresponds to, and may be selected by, the first button in the navigation bar 410 in FIG. 4 . A SmartContent form contains data structures and logic which may trigger context sensitive information to appear, and which make available software functions and controls in a context-sensitive manner.
[0058] Within the work area 412 of the shell 430 , there is a work area header 414 which provides orientation as a user accesses menu items in the navigation bar 410 , and other functions. The information listed in the work area 412 may be read-only. The functions and controls available in the work area change as previously described in regard to SmartContent. Specifically, as particular data structures and software controls are accessed, different controls and content appear in the work area 412 and in the menu of the navigation bar 410 .
[0059] At the bottom of the shell 430 is a status bar 416 which is dedicated to reporting program status and other information. The system reports the status of certain processing events. The status bar 416 continually appears at the bottom of the shell 430 .
[0060] In one embodiment, at system startup, a login dialog is launched as shown in FIG. 3 . This dialog requires that a user enter a user ID and password into the respective user ID 302 and password fields 304 . Security checks are run on each user so that the application can respond based on the particular user's security rights. For example, if a user is not an administrator, an administration button on the navigation bar 410 will not be displayed.
[0061] When the user selects a button from the navigation bar 410 or a function from the work area 412 , the shell 430 must switch the context sensitive functions 404 in the area on the right of the shell 430 , and “snap in” the appropriate form into the work area 412 of the shell 430 .
[0062] In one embodiment, some software functions launch a dialog or interview which is a collection of additional software forms which may contain fields for data entry. Some information in an interview is system generated and read only.
[0000] Content Management
[0063] The present invention provides access to, and organizes information about, clients, matters, and documents. In one embodiment, a SmartContent tree structure presents information in a hierarchal fashion and provides functions content-sensitively to a user as different entries within the data structure are selected. Specifically, different functions become available for documents, matters, and clients as each of these types of entries in the tree structure are selected. With reference to FIG. 4 , a SmartContent tree structure 426 lists entries 402 from the CMD database and these entries can be sorted by a number of criteria. In one embodiment, one of these criteria is selected from a pick list 406 just above the status bar 416 . Once an entry in the tree structure is selected, a series of context sensitive functions 404 become available for that entry in a list on the right side of the software form. For example, if a user clicks on a matter, he can copy a matter, delete it, or run a matter interview. These functions are listed in the area on the right hand side of the shell 430 . As another example, if the “copy matter” is chosen, it can be used to create mirror image estate planning documents for a husband and wife by allowing the user to copy documents and matter answer files. Such efficient re-use of the same matter information is one of the benefits of the present invention.
[0000] Resources & Help Manager
[0064] The present invention includes a resources manager which provides links to certain useful dynamic information accessible through the Internet. With reference to FIG. 13 , in one embodiment, a resources manager provides a link to a legal knowledgebase 1302 . A knowledgebase is a collection of helpful allied materials available to registered users through such link 1302 . A resources manager may also provide a link to a practitioner network 1304 , a link to an online discussion forum 1306 , and a link to a listserv for a particular topic 1308 . A resources manager may also provide a link to business partners 1310 , and a link to other resources related to a particular practice module. For example, a resources manager may provide a link to other trust and estate resources 1312 . The resources manager may provide links to other useful information. The dynamic information linked through a resources manager and residing on, and served from, a computer server device may be changed periodically to maximize the availability of current information about particular topics.
[0065] Similarly, a help manager provides a user with tutorial and other information. Similar to the resources manager, a help manager also provides links to various help resources through the Internet. For example, with reference to FIG. 16 , a help manager provides a tutorial link 1602 to further information covering various practice modules. A user may also access more detailed product information through a product information link 1604 . A user may also access additional product support information through a product support link 1606 . In another embodiment, a user may be able to access live on-line support through a live support link 1608 . Through such live support link 1608 , a user may access a chat or other interactive support session whereby a human support staff member interacts with the user to answer a question or help solve a user's problem.
[0000] Preferences Manager
[0066] The present invention includes a preferences manager which provides a means to access and change the preferences of each system user. Access to change certain preferences must be granted by a user having administrator privileges. Software forms are presented to a privileged user who may then modify preference settings. FIG. 14 shows one embodiment of a preferences manager. With reference to FIG. 14 , a privileged user has access to personal information about a particular software user. A privileged user may review and modify such personal information by selecting a review personal information link 1406 which provides access to additional forms where such modifications may be made. Additionally, a privileged user may select a security preferences link 1402 which launches subsequent forms which allow for changes to security settings for a particular user. Likewise, a privileged user may select a display preferences link 1404 which launches other subsequent forms which allow for changes to display settings for a particular user. Modifications to preference settings are stored in XML files.
[0067] With reference to FIG. 15 , the present invention also includes a firm settings manager which allows a privileged user to make changes to firm-wide settings. Such settings are global, system-wide preferences which serve as defaults for all users or an entire workgroup comprising a subset of users. A user may belong to one or more workgroups. In one embodiment, a firm-wide settings manager runs a HotDocs® interview designed to gather information about the firm, the employees, and document drafting preferences. A privileged user may access such interview through a review drafting preferences link 1502 . A firm settings manager may also store and provide a means to modify information specific for each state. In one embodiment, a privileged user may access a states table through a states table link 1504 wherein state specific data is presented and may be modified. Settings from a preferences manager and a firm settings manager are stored in XML files.
[0000] Profile Manager
[0068] The present invention includes a profile manager which allows a user to select a document template and a HotDocs® pattern answer file or profile simultaneously. This profile manager combines two HotDocs® interface functions into one. The profile manager appears when the user clicks “Add Document,” and the templates and associated profiles appear in a hierarchical list, organized by topic. After a user selects an item from the profile manager, the software system is instructed to use a particular template and to run one or more HotDocs® overlay/underlay functions, which will copy data from a profile answer file into the current matter file. This functionality provides the user with a first set of default answers in documents.
[0000] Customization Manager
[0069] The present invention includes a customization manager which permits a user with customization rights to customize certain aspects of system templates and to add, maintain, and delete custom profiles. In one embodiment, and with reference to FIG. 21 , a user with customization rights may access a link 2102 which grants access to subsequent software forms through which such user may customize document templates. The customization manager allows for many different types of changes to templates. For example, the customization manager allows changes to definite articles of templates. Likewise, a customization manager provides a custom profiles link 2104 which provides software forms to create, modify and manage profiles or default answer sets. Profiles or default answer sets are merged with templates to assemble a document. The customization manager allows such changes to be preserved despite software updates, hardware failures, and other events. Customization manager metadata is stored in proprietary XML files. The customized templates are stored in rich text format (RTF) files and custom profiles are stored in HotDocs® XML files.
[0000] Security & Administration Manager
[0070] The present invention includes a security and administration manager which stores user and administrator information, including particular settings and preferences, in XML files. A system administrator can assign rights to use individual practice systems to each software user, which provides the ability to internally manage user licenses. Administrators can also assign administrator rights (permitting access to the Administration Manager) and customization rights (permitting access to the Customization Manager). System administrators can perform several functions through the security and administration manager such as: add, maintain, and delete users; assign users to certain practice systems; assign user security rights; manage practice system licenses; access product updates; and run backup and restore functions.
[0071] FIG. 18 shows one embodiment of an administration manager. In this embodiment, a privileged administrator may access and modify user information through additional software forms accessible through a maintain users link 1602 . One such form to modify user information is shown in FIG. 19 . With reference to FIG. 19 , a privileged administrator may add a new user, maintain a user, or delete a user. A privileged administrator may also select certain options 1704 for a particular user through checkboxes. Such options may include allowing a user to store login information locally, permitting the user to waive the requirement to have a password, granting administrator rights to a user, and granting developer rights to a user.
[0072] With reference to FIG. 18 , a privileged administrator may also associate each user with one or more practice systems through a register users link 1604 . Such association may be done through a form as shown in FIG. 20 or through another software means. With reference to FIG. 20 , a privileged administrator may associate particular unregistered users 2004 with a particular practice system 2002 thereby making registered users 2006 . Such users are then authorized to access clients, matters, templates and documents associated with the particular practice system 2002 .
[0073] With reference to FIG. 18 , a privileged administrator may also modify administrator settings of the software system. In one embodiment, such settings may be accessed through a review administrative functions link 1606 . A privileged administrator may backup and restore system preferences. In one embodiment, a privileged administrator accesses these functions through a backup system link 1808 , and a restore system link 1010 , respectively. System preferences are stored in one or more XML files. Further, a privileged administrator may review product information including updates, news and other relevant information through a review product information link 1012 .
[0000] License Manager
[0074] The present invention includes a license manager which is a software utility for managing access rights to certain practice systems of the software. The software and invention are made to work with multiple practice systems. There may be a different number of licenses for each practice system. For example, a firm may have six licenses, corresponding to six authorized users, to an estate planning practice system, but may have only two licenses to an elder law planning practice system. Each software application user is assigned to one or more practice systems by an authorized administrator.
[0075] FIG. 17 shows one embodiment of a license manager form where information 1702 regarding a lifetime estate planning module is presented to an administrator. Such information may include the number of authorized users, installation date, and expiration date. A license manager also may provide practice system administration links 1704 through which an administrative user may purchase additional licenses and may check for product updates. In the license manager, and in other forms of the invention, additional, context sensitive information 1706 is presented to a user. Such information provides guidance to users.
[0076] Once assigned to a practice system through a license manager, a user may only access client information, matter information, and document information which belong to a practice system for which the user is authorized. One embodiment of such restrictive access is illustrated in FIG. 4 and FIG. 10 . With reference to FIG. 4 , when a user attempts to add a new document through an add document dialog, a user will only be able to select or add documents to practice systems to which the user has access rights. With reference to FIG. 10 , a user only has access to estate planning documents 1082 in the hierarchal document tree, and does not have access to elder law planning 1084 . The elder law planning content tree 1084 in the Add Document Dialog is grayed out and is non-accessible such that a non-privileged user cannot select anything from that list.
[0077] Furthermore, there is additional security built into the entries 402 in a SmartContent tree structure as show in FIG. 4 . In one embodiment, if a user is not authorized, all documents belonging to a practice system are grayed out and are not accessible. For example, a user may have access only to estate planning. In such a SmartContent tree list for John Smith, there may be a matter which includes a Medicaid trust. Since the user does not have access to an elder law practice system, the Medicaid trust will be grayed out and non-accessible in the Client/Matter/Document list and the user will not be able to run the corresponding functions such as an HD Interview, assemble, or delete on that document.
[0078] In another embodiment, a license manager may also control licenses based on a subscription model where products will cease to function at the end of a subscription period unless renewed. A subscription model is particularly effective for users in professions such as the legal profession where certain language is time sensitive and may become obsolete such as when laws are repealed, superseded or changed. Each practice system may have different periods of renewal and different periods for renewal reminders. In one embodiment, once a renewal reminder period has begun (e.g. 60 days before expiration), a counter is added to the interface, showing a user the remaining number of days in the subscription. Once a license has expired for a particular practice system, a grace period may be provided. In one embodiment, a 30 day grace period is given. At the expiration of a license, and an optional grace period, users will no longer be able to access documents belonging to expired practice systems.
[0000] Document Assembly
[0079] One embodiment of the document assembly method according to the present invention is outlined in FIG. 2 . With reference to FIG. 2 , a user starts 202 the document assembly process by first entering authorization credentials through a login or security dialog 204 . Next, a user selects an activity 206 . In a preferred embodiment, a user first runs a firm-wide preferences interview 208 which sets some default information for the software application. In a typical scenario, such a preferences interview 208 is only run one time. Next, a user may add a new client record 210 or may select an existing client record through a software interface. A user subsequently runs a client interview 212 in which the user is allowed to add additional information about the client through one or more software forms. The software presents document-specific prompts and input fields which aid the user in storing information for completing an array of various documents associated with the particular client. The information may be stored in a database residing on a computer system, or other hardware or software means, and the information is associated or connected to the client's record for later use. In one embodiment, the information is stored in a Microsoft Access database. Other databases may be used.
[0080] With reference again to FIG. 2 , after a client interview is run, a matter record may be added 214 . Next, a matter interview 216 may be run; matter information may be gathered and stored in a database. A user may then select a document class 218 and thereby add a document class record to a particular matter which is hierarchally associated with a particular client. Along with selecting a document class, a user selects a template and profile 218 to use for the particular document class. At this point, a user may run a document interview 220 before finally assembling a document 222 . A user may then review, edit and print a document 224 before ending 226 the document assembly process or method according to the present invention.
[0081] By entering client information first, according to the inventive method, any number of assembled documents may be subsequently created wherein fields in the templates for client information are automatically populated with client information. Similarly, a user may also enter matter information and generated documents automatically may be populated with matter information. A software embodiment practicing such method provides improved efficient re-use of client information.
[0082] FIGS. 4-12 show embodiments of a software interface in which a user may gather information and assemble a document according to the present invention and the method described in FIG. 2 . FIG. 4 illustrates the main user interface of a client centric software interface from which most tasks are executed. Such interface differs from the prior art in that a client and corresponding client record 402 , and not a document type, is the paradigm of document assembly. In FIG. 4 , a firm settings interview may be launched by selecting the appropriate button found in the menu bar 410 on the left side of the shell 430 .
[0083] FIG. 5 shows one embodiment of a firm settings interview. In this embodiment, and other similar interviews, HotDocs® is called and used to gather information. With reference to FIG. 5 , a firm settings interview allows a user to provide new firm information or modifying existing firm information which may be used in assembling a document. Such information may be accessed and collected on one or more software forms. In one embodiment, firm settings are organized by conceptual groupings. A user may access firm settings by selecting an appropriate entry in a menu structure 502 or menu tab 508 . Firm settings may include document default options which may be selected as check boxes 504 , as pulldown pick menus 506 , or any other software means including user input fields. In one embodiment, the firm preferences are stored in one or more answer files. The name of such files may be shown in a file name field 510 ; a user may be able to edit or select the name of firm preference answer files. FIG. 5 corresponds to step 208 in FIG. 2 .
[0084] In FIG. 4 , a user is given the option of selecting an existing client, or creating a new client, through an add client button 424 or other software means. When a user adds a new client, a form or dialog such as the one shown in FIG. 6 may be launched. A user adds a client by entering a client name into a client name field 602 , and may add optional client information such as a client number and client notes in a respective client number field 604 and client note field 606 . Once a client name is entered, a user may confirm the addition of a client into the software system through a software button or other means; such confirmation closes the add client dialog. FIG. 6 corresponds to step 210 in FIG. 2 .
[0085] Once a user selects a client entry 402 in the main software form such as the one shown in FIG. 4 , a user may initiate a client interview. One embodiment of a client interview is shown in FIG. 7 . With reference to FIG. 7 , a user is given the option of providing new client information or modifying existing client information through user input fields, radio buttons, check boxes, and other software means similar to those shown in the firm preferences interview of FIG. 5 . In FIG. 7 , the user is given the option of completing fields for client information such as, but not limited to, name, street address, date of birth, U.S. citizenship, Social Security number, number of children, and a myriad number of other such details. Client information and corresponding software elements are arranged and organized into conceptual groupings as in FIG. 5 . A user may similarly access, and navigate to, forms through selection of menu entries in a menu structure 502 or menu tab 508 , or through buttons 512 or other software means. Once a user is finished entering or modifying client information, the client interview information is stored in one or more answer files named according to a GUID string. The name of such answer files may be shown in a name field 510 . FIG. 7 corresponds to step 212 in FIG. 2 .
[0086] Once a client is selected and client information is entered into the system, a user may select the type of document to generate through a document class dialog such as the embodiment shown in FIG. 8 . Such dialog is very similar to an add client dialog of FIG. 6 . An add matter dialog allows a user to enter a matter name into a matter name field 802 , and optional matter number and matter notes into corresponding software fields 804 , 806 .
[0087] Once a user enters a matter for a client, a user launches a matter interview from the main software form such as the one shown in FIG. 4 . One embodiment of a matter interview is shown in FIG. 9 . With reference to FIG. 9 , a user may select options and enter information specific to the particular matter. A user may navigate to other forms for such options by selecting an appropriate entry in a menu structure 502 or menu tab 508 . Matter settings may be selected as check boxes 504 , as pulldown pick menus 506 , or any other software means including user input fields. In one embodiment, the matter settings or preferences are stored in one or more answer files. The name of such files may be shown in a file name field 510 ; a user may be able to edit or select the name of matter preference answer files. FIG. 9 corresponds to step 216 in FIG. 2 .
[0088] FIG. 10 illustrates one embodiment of a software dialog to select a document class and enter a new document name for a new document associated under a given matter; such dialog corresponds to step 218 of FIG. 4 . In this step, there are sub-steps. First, and with reference to FIG. 10 , a user selects a template by selecting an appropriate entry in a software tree structure 1020 . A user accesses the tree 1020 by selecting a practice system 1002 , and then by selecting a specific document category 1004 . For example, a document category may be a will, trust or other document class belonging to an estate planning practice group. Subsequently, a user selects a subcategory 1006 and then a specific document class or type 1008 to be added to a matter. For example, in FIG. 10 , an “all options” document class 1008 is selected under the subcategory of comprehensive wills 1006 . In a second sub-step, a user enters a name for the new document in a document name field 1010 and optionally adds document notes in a notes field 1012 . Upon the user's acknowledgement through a button 1014 or other software means, the software dialog enters a new document record 422 under a particular matter 420 which is hierarchally associated with a particular client record 402 in the SmartContent tree structure 426 as shown in FIG. 4 . The new document record has the document name given by the user and is of a type selected as the document template in the first sub-step.
[0089] In one embodiment using HotDocs®, at the time the new document entry 422 is made, the system handles three processes simultaneously. It first associates the correct template with the document entry 422 , selects a corresponding document answer file, and overlays or merges the corresponding matter answer file with a default document answer file. Ordinarily, this is separate steps in HotDocs® and other document assembly systems. Such automation is more efficient and reduces the likelihood for technical and legal errors. Further document specific information is captured in the system by executing a document interview.
[0090] Once a new document entry 422 is made, a user may run a document interview corresponding to step 220 in FIG. 2 by selecting the corresponding context sensitive function 404 in the main user interface shown in FIG. 4 . One embodiment of a document interview is shown in FIG. 11 . With reference to FIG. 11 , a user may select options and enter information specific to the particular document template or type. Like in the other interview forms, a user may navigate to other forms for such options by selecting an appropriate entry in a menu structure 502 or menu tab 508 . Matter settings may be selected as check boxes 504 , as pulldown pick menus 506 , or any other software means including user input fields. In one embodiment, the document information is stored in one or more document answer files. The name of such files may be shown in a corresponding file name field 510 ; a user may be able to edit or select the name of document answer files.
[0091] With reference to FIG. 2 , at the conclusion of a document interview 220 , a user has captured client, matter and document information which subsequently may be reused in other documents created from templates having matching data fields. At this point, a user may assemble a document corresponding to step 222 in FIG. 2 by selecting the corresponding context sensitive function 404 in the main user interface shown in FIG. 4 and FIG. 12 . With reference to FIG. 12 , no dialog or interview is required to complete such task. However, a progress, status or other indicator may be displayed to a user as a document is assembled. In one embodiment, assembly of a document is the formation of a new document from merging a copy of a template file with information from a document answer file and other answer files such as client and matter answer files. An assembled document may then be opened for review, editing, and printing corresponding to step 224 in FIG. 2 .
[0092] Alternatively, and in another embodiment, through a smart document dialog, multiple documents can be selected and assembled as a package. Such documents can be electronically stored together. One advantage of forming packages of documents is that changes made to one document are automatically propagated into other documents in the same package. Information about documents and the associated package is stored in a software means such as a database.
[0093] In another embodiment, a user may not opt to perform a document interview. However, a document assembled with just client information, or client and matter information, may be missing information. Such information must be manually entered into a document at the editing step 224 of the document assembly process illustrated in FIG. 2 and such information is not captured in the system.
[0094] FIG. 4 shows the selection of a document entry 402 in a tree software structure 424 . Available context sensitive functions, which may be performed on a document record, are shown on the right side of the shell 430 in a context sensitive menu 404 . In one embodiment, a user may perform several functions or actions 414 on a document such as run a document interview, assemble a document, open a document, or delete a document.
[0095] Modifications to any of the information associated with each of the records for clients, matters, or documents are persisted in a database. Database records may be arranged according to a hierarchal fashion first according to client, then according to matter, and then according to document. A user may create, update, and delete information in the database through a software interface. The software interface and database allow for the efficient re-use of client and other information in the assembly of documents.
[0096] The foregoing discussion of the invention has been presented for purposes of illustration and description. Further, the description is not intended to limit the invention to the form disclosed herein. Consequently, variation and modification commensurate with the above teachings, within the skill and knowledge of the relevant art, are within the scope of the present invention. The embodiment described herein and above is further intended to explain the best mode presently known of practicing the invention and to enable others skilled in the art to utilize the invention as such, or in other embodiments, and with the various modifications required by their particular application or uses of the invention. It is intended that the appended claims be construed to include alternate embodiments to the extent permitted.
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A system and method allows multiple users to more efficiently access and use client information in the preparation and assembly of documents. A computer software system captures certain information from clients and separately stores it from ordinary document assembly files such as template and answer files. A computer software system provides an intuitive, friendly environment in which to call a document assembly engine. A computer software system enables a more efficient re-use of information to form completed documents. A context-sensitive computer software interface hierarchally arranges a list of documents by client, then client matter, and then document type. Files are internally uniquely named and are accessed by a checkout mechanism from a central repository which avoids data loss associated with multi-user access.
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CLAIM TO PRIORITY OF PROVISIONAL APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e)(1) of provisional application Ser. No. 61/165,257, filed Mar. 31, 2009, by Yan Tong et al.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH & DEVELOPMENT
[0002] This invention was made with U.S. Government support under contract numbers 2007-DE-BX-K191 and 2007-MU-CX-K001. The Government may have certain rights in the invention.
BACKGROUND
[0003] This invention relates generally to image labeling, and more particularly, to a system and method for implementing automatic landmark labeling for a predetermined object class.
[0004] Image labeling for training data is an essential step in many learning-based vision tasks. There are at least two types of prior knowledge represented by image labeling. One is semantic knowledge, such as human IDs for face recognition, or an object's name for content-based image retrieval. The other is geometric/landmark knowledge. The position of an object (face/pedestrian/car) needs to be labeled for all training images, for example, in learning-based object detection. Each training image must be labeled with a set of landmarks which describe the shape of the face for supervised face alignment.
[0005] Geometric/landmark knowledge labeling is typically carried out manually. Practical applications, such as object detection, often require thousands of labeled images to achieve sufficient generalization capability. Manual labeling however, is labor-intensive and time-consuming. Furthermore, image labeling is an error-prone process due to labeler error, imperfect description of the objectives, and inconsistencies among different labelers.
[0006] Some notable and early work on unsupervised alignment denotes the process as congealing. The underlying idea is to minimize an entropy-based cost function by estimating the warping parameter of an ensemble. More recently, a least squares congealing (LSC) algorithm has been proposed which uses L2 constraints to estimate each warping parameter. These approaches estimate affine warping parameters for each image. The embodiments described herein estimate non-rigid shape deformation described by a large set of landmarks, rather than the relatively simple global affine transformation.
[0007] Additional work on unsupervised image alignment has incorporated more general deformation models, though not with the use of a well-defined set of landmarks by including a free-form B-spline deformation model. Bootstrapping algorithms to compute image correspondences and to learn a linear model based on optical flow and the use of an iterative Active Appearance Model (AAM) learning and fitting to estimate the location of mesh vertices, reporting results on images of the same person's face have also been developed. Further work formulates AAM learning as an EM algorithm and extends it to learning parts-based models for flexible objects. Other known techniques include 1) the use of a group-wise objective function to compute non-rigid registration, 2) improvements in manual facial land-mark labeling based on parameterized kernel PCA, 3) an MDL-based cost function for estimating the correspondences for a set of control points, and 4) alignment by tracking the image sequence with an adaptive template.
[0008] Generally, one cannot rely upon unsupervised learning methods to locate landmarks on physically meaningful features of an object, such as mouth/eye corners or nose tip on a face; while supervised facial alignment undesirably requires a large number of labeled training images to train a statistical model so that it can generalize and fit unseen images well.
[0009] It would be desirable to provide a system and method that automatically provides landmark labeling for a large set of images in a fashion that alleviates the foregoing problems.
BRIEF DESCRIPTION
[0010] Briefly, in accordance with one embodiment, a method of determining landmark locations comprises automatically propagating a set of landmark points from a small set of images to a large set of images for a predetermined object class.
[0011] According to another embodiment, a vision system is configured to automatically propagate a set of landmark points from a small set of images to a large set of images for a predetermined object class in response to an algorithmic software.
DRAWINGS
[0012] These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
[0013] FIG. 1 is a simplified diagram illustrating a vision system configured to automatically propagate a set of landmark points from a small set of images to a large set of images for a predetermined object class in response to an algorithmic software according to one embodiment;
[0014] FIG. 2 illustrates exemplary input data and output data for the vision system illustrated in FIG. 1 according to one embodiment;
[0015] FIG. 3 illustrates multi-level partitioning according to one embodiment;
[0016] FIG. 4 is a set of graphs illustrating a performance comparison for SLSC, SSLSC and partition-based SSLSC in terms of NRMSE of landmarks excluding outliers (%) and SOF (%) according to one embodiment; and
[0017] FIG. 5 is a set of graphs illustrating performance analysis by varying partition levels in terms of NRMSE of landmarks and SOF according to one embodiment.
[0018] While the above-identified drawing figures set forth alternative embodiments, other embodiments of the present invention are also contemplated, as noted in the discussion. In all cases, this disclosure presents illustrated embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention.
DETAILED DESCRIPTION
[0019] The following preliminary discussion presents a framework to provide a better understanding of the system and method embodiments described thereafter with reference to the Figures that are directed to automatic landmark labeling for a large set of images in a semi-supervised fashion. These embodiments automatically estimate the landmark locations for a full set of images such as, for example, a complete training set of 300 images using manually labeled landmark locations for a few images such as, for example, 10 manually labeled images.
[0020] According to one aspect, a semi-supervised least squares congealing (SLSC) method minimizes an objective function defined as the summation of pairwise L2 distances between warped images. Two types of distances are utilized including the distance between the labeled and unlabeled images, and the distance between the unlabeled images. The objective function is iteratively minimized via an inverse warping technique. During the optimization process, estimated landmark locations are constrained according to one embodiment by utilizing shape statistics learned from relatively low-error estimations in an on-line manner, which was found to yield better convergence of landmark position estimates.
[0021] Modern work on joint alignment for an image ensemble mainly estimates global affine parameters for each image. The present inventors recognized however that most real-world objects exhibit non-rigid deformation that is not well-modeled by the affine transformation, and that estimating more realistic deformations using a large set of landmarks would provide an important step toward accurately characterizing the shape variation within an object class.
[0022] Hierarchical patch-based embodiments that estimate landmark positions are thus described herein. Patches, starting from a whole warped image region treated as the first level patch, are iteratively partitioned into smaller child patches, in which initial landmark locations are obtained from the parent patch and whose refined landmark estimations result in an accurate landmark labeling based on the local patch appearance. Applications in facial images were found by the present inventors to demonstrate that by labeling only 1% to 3% of the ensemble, the landmarks of the remaining images could be accurately estimated.
[0023] An automatic image labeling framework according to one embodiment has three main contributions including:
[0024] 1) a core methodology for (described herein with reference to Equation 1 below) semi-supervised least-squares-based alignment of an image ensemble, described herein using the inverse warping technique;
[0025] 2) two additional methodologies (described herein with reference to Algorithms 1 and 2 below) for improving landmark estimation via i) a statistical shape model learned on-line to reduce outliers among the ensemble, and ii) patch-based partitioning to improve the precision of landmark estimation; and
[0026] 3) an end-to-end system for automatic estimation of a set of landmarks in an ensemble of the images for a predetermined object class with very few manually labeled images and described herein with reference to FIGS. 1 and 2 .
[0027] FIG. 1 is a simplified diagram illustrating a vision system 10 that may be a computer vision system configured to automatically propagate a set of landmark points from a small set of images 14 to a large set of images 16 =images 12 +images 14 for a predetermined object class in response to an algorithmic software according to one embodiment.
[0028] FIG. 2 illustrates exemplary input data 12 , 14 and output data 16 for the vision system 10 illustrated in FIG. 1 according to one embodiment.
[0029] The embodiments described herein address discovery of non-rigid shape deformation using a specific set of physically defined landmarks enumerated 18 in FIG. 1 and semi-supervised learning in which prior knowledge of landmark location(s) can advantageously be incorporated easily via a few manually labeled examples. Given an ensemble of images 12 , 14 , where a few manually labeled images 14 have known warping parameters, the embodied SLSC approach estimates the warping parameters of the remaining unlabeled images 12 using the cost function:
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[0000] where {tilde over (K)} is the number of labeled images Ĩ={Ĩ n } nε[1,{tilde over (K)}] , and K is the number of unlabeled images I={I i } iε[1,K] , p i is an m-dimensional warping parameter vector to warp I i to a common mean shape using a warping function W(x;p i ), which can be a simple affine warp or a complex non-rigid warp such as the piecewise affine warp. I i (W(x;p i )) is the corresponding N-dimensional warped image vector. {tilde over (p)} n is the known warping parameter vector for Ĩ n . x is a collection of N pixel coordinates within the mean shape. P=[p 1 , . . . p K ] contains all the warping parameters for I that need to be estimated by minimizing ε(P). Since ε(P) is difficult to optimize directly, ε i (p i ) is iteratively minimized for each I i . In the cost function, ε i (p i ) equals the summation of the pairwise difference between I i and all the other images in the warped image space. On the one hand, minimizing the 1 st term of Eqn. (1) makes the warped image content of the i th unlabeled image similar to that of the other unlabeled images, without regard for the physical meaning of the content. On the other hand, the 2 nd term of Eqn. (1) constrains I i (W(x;p i )) to be similar to those of the labeled images and enforces the physical meaning of the content during alignment. Thus, the labels of Ĩ are propagated to I. Since K>>{tilde over (K)}, a weighting coefficient a can balance the contributions of the two terms in the overall cost.
[0030] An inverse warping technique is employed to minimize ε i (p i ). Warping parameter updates Δp i are first estimated by minimizing the following equation:
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[0000] and then update the warping function by:
[0000] W(x;p i )←W(x;p i )∘W(x;Δp i ) (3)
[0000] The function ε i (Δp i ) is nonlinear with respect to Δp i . To support numeric optimization of this function, a first order Taylor expansion is performed on I j (W(W(x;Δp i );p j ) and Ĩ n (W(W(x;Δp i );{tilde over (p)} n ) to yield:
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[0031] The computational cost for solving the second term of Eqn. (4) is negligible. Therefore, semi-supervised congealing has a computational cost similar to that of unsupervised congealing. According to one aspect, a shape-constrained SLSC improves the robustness of the congealing process by reducing outliers. According to another aspect, this is extended to a patch-based approach to achieve an accurate estimate of the landmarks by partitioning the mean shape space.
[0032] Given the warping parameters for all images {P,{tilde over (P)}}=[p 1 , . . . ,p K ,{tilde over (p)} 1 , . . . ,{tilde over (p)} {tilde over (K)} ], and their corresponding landmark locations {S,{tilde over (S)}}=[s 1 , . . . ,s K ,{tilde over (s)} 1 , . . . ,{tilde over (s)} {tilde over (K)} ], where s is a concatenated vector of a set of 2D landmark coordinates s=[x 1 ,y 1 ,x 2 ,y 2 , . . . ,x v ,y v ] T , there are two ways of mapping between {P,{tilde over (P)}} and {S,{tilde over (S)}}. First, the landmarks s i can be obtained from the warping parameter p i via s i =W(x s ;p i ), where x s is a vector containing the coordinates of the target landmarks in the mean shape space. As a result, an incorrect warping parameter, which can result from an outlier in the congealing process, would produce a landmark set that is not a valid shape instance. Second, the warping parameter p i can be obtained given the corresponding landmark pairs (x s and s i ). Consequently, refining the positions of the landmarks can improve the estimation of the warping parameters. A shape-constrained SLSC (SSLSC) approach described herein integrates the shape constraints with the appearance-based congealing process to improve the robustness of the SLSC.
[0033] Given that the objects in the images have the same topological structure, an assumption is made that the shape deformation of s i satisfies a Point Distribution Model (PDM). Since only a few labeled images are available, the PDM is learned from both the labeled landmarks and an automatically chosen low-error subset of the estimated landmarks in an online manner. Then, any other poor estimations can be “corrected” through a PCA reconstruction as follows:
[0000] ŝ i = s +Qz (7)
[0000] where ŝ i is the reconstructed shape vector for the i th image; s and Q are the mean shape and the shape basis obtained through the on-line training; and z is the shape parameter vector that is restricted in some range. Finally, a new warping parameter vector {circumflex over (p)} i is computed from the refined landmark positions ŝ i such that the outliers of the congealing process are discovered and constrained in a principled way.
[0034] The SSLSC is summarized as Algorithm 1 below, where P 0 represents the initial warping parameters for I. The labeled landmarks are fully utilized in the sense that they not only contribute for the cost minimization for Eqn. (2), but also provide guidance for shape deformation.
[0000] Algorithm 1 Shape-constrained SLSC (SSLSC) Input: I, Ĩ, P 0 , {tilde over (P)}, x, and x s Output: P t , S t , and ε t ← 0; Compute {tilde over (s)} i = W (x s ; {tilde over (p)} i ) for i ∈ [1, {tilde over (K)}]; repeat for i = 1 to K do ε i (Δp i ), p i t+1 ← SLSC(I, Ĩ, P t , {tilde over (P)}, x); end for Rank ε i (Δp 1 ), . . . , ε K (Δp K ) in ascending order and pick the first K M images; Compute s i t+1 = W (x s ; p i t+1 ) for i ε[1, K M ]; s , Q, λ ← PCA on S = [{tilde over (s)} 1 , . . . , {tilde over (s)} {tilde over (K)} , s 1 t+1 , . . . , s K M t+1 ] T ; for i = K M + 1 to K do Reconstruct s i t+1 as Eqn. (7); Compute p i t+1 from s i t+1 ; end for P t+1 ← [p 1 t+1 , . . . , p K t+1 ]; S t+1 ← [s 1 t+1 , . . . , s K t+1 ] T ; ɛ ← ∑ i = 1 K ɛ i ( Δ p i ) ; t ← t + 1. until Converge
The warping function W(x;p i ) can be a simple global affine warp to model rigid transformation, or a piecewise affine warp to model non-rigid transformation. The SSLSC algorithm does not however, perform satisfactorily with direct use of the piecewise affine warp. This difficulty is related to the high dimensionality of the warping parameter p i . Looking at the piecewise affine warp closely, it can be noted that the warping function W is a series of affine transformations, each operating within a small triangular patch. While the patch allows a workspace whose dimension is much smaller than the original space, and thus makes the problem easier to solve, directly applying the SSLSC on the small patches is not reliable due to the poor initialization and limited information encoded in the patch. Based on these observations, a coarse-to-fine partition-based congealing method improves the precision of landmark labeling.
[0035] The partitioning strategy is summarized as Algorithm 2 below, where S init is the initial guess of the landmark positions for I. In the algorithm, besides the notation mentioned previously, R represents the indices of the patches to be aligned in the current partition level; d represents the index of the patch. Starting from the initial mean shape space x 1 , the process is conducted by repeatedly partitioning the mean shape space for a selected patch (x k *), which has the maximal congealing error (ε), into multiple child patches. In one embodiment, two equal sized child patches are generated by each partitioning. To enforce a geometrical relationship between the child patches, they are overlapped such that some landmarks reside in both of them. Positions of these landmarks are estimated as averages of the SSLSC results of the two child patches. After the partitioning, the SSLSC is applied on each child patch, independently, to obtain the corresponding landmark positions within the patch itself. The partitioning is stopped when no cost reduction is achieved or the size of the patch is too small. According to one embodiment, the patch reaches its size limit if the number of target landmarks in x d is less than the number of corresponding landmarks required for computing p i . One example of multiple level partitioning is shown in FIG. 3 .
[0000] Algorithm 2 Landmark Labeling by Partition Input: I, Ĩ, S init , {tilde over (S)} Output: S l min ← minimum number of landmarks in a patch; d ← 1; R ← {1}; S init 1 ← S init ; Compute x 1 and x s 1 from {tilde over (S)}; while d < maximum number of patches do for each r ∈ R do Calculate P init r and {tilde over (P)} r from S init r , x s r , {tilde over (S)}, and x s r , respectively; P r , S r , ε r ← SSLSC(I, Ĩ, P init r , {tilde over (P)} r , x r , x s r ); if no cost reduction is achieved in r over its parent patch then return S d−2 // return labeling results of last partition level; end if end for k * = argmax k ɛ k , k ∈ [ 1 , d ] ; child patches x d+1 , x d+1 , x s d+1 , x s d+2 ← Partition the k * th patch; S init d+1 ← S k* ; S init d+2 ← S k* ; ε k* ← 0; if size(x s d+1 ) < l min or size(x s d+1 ) < l min then return S d ; end if d ← d + 2; R ← {d + 1, d + 2}; end while
The top-down congealing strategy performs a coarse-to-fine alignment for the entire image ensemble. The congealing in the coarse level partition focuses on aligning the features that are most similar among the image ensemble such as eyes on the face, whereas the other features like nose and mouth are neglected. Hence, the landmark estimation on the larger patches is often coarse and used to provide a good initialization for the latter levels. With the increasing of the partition level, more details of the target object are revealed. As a result, the estimation of the landmarks becomes more and more precise.
[0036] The effectiveness of the landmark labeling methods described herein has been demonstrated in one application by automatically annotating 33 specific landmarks around facial features (i.e., eyes, eyebrows, nose, mouth, and contour) for a large image set, given a few labeled images. For this application, 300 images were collected from a known database in which the facial regions were unaligned. Then, 33 landmarks were labeled for each image to establish a ground truth and to enable a quantitative evaluation for the labeling performance.
[0037] The 300 labeled images were divided into two non-overlapping sets: a labeled set with {tilde over (K)} images and an unlabeled set with 300−{tilde over (K)} images. The initial value of the j th element of S i was generated for quantitative evaluation by adding a uniformly distributed random noise η ε [−η max ,η max ] to the groundtruth value Ŝ i,j as follows,
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[0000] where ρ i is the eye-to-eye pixel distance of I i , and ρ is the average of ρ i for all unlabeled images. By doing so, the level of deviation in the initialization is relative to face size. In practical applications, the initial landmark positions can be obtained from the approximate face location. A 6-parameter affine transformation was employed in the congealing process, and a 72×72 square region, which encloses all the target landmarks, was used as the common mean shape. The warped face region was normalized by subtracting its mean intensity value and then divided by its standard deviation to accommodate illumination changes.
[0038] The effectiveness was evaluated using two criteria: (1) Normalized Root Mean Squared Error (NRMSE) of landmarks defined as the RMSE with respect to the ground truth divided by the eye-to-eye distance ρ i , and expressed as a percentage; and (2) the Sample “Outliers” Fraction (SOF) defined as the number of images, of which the NRMSE exceeds a threshold (10%), versus the number of unlabeled images. A smaller NRMSE indicates a higher labeling accuracy, and a smaller SOF represents greater robustness.
[0039] The effectiveness of using a shape-constrained SLSC is first compared with using SLSC under the effects of varying number of labeled images {tilde over (K)} ε {1,5,10,20,40,80,160} and different noise levels η max ε {10,30,50}. FIG. 4 illustrates the performance comparison in terms of NRMSE and SOF in which SLSC is represented by the dashed line, SSLSC is represented by the line with circles, and SSLSC is represented by the line with crosses. The left side graphs are in terms of NRMSE of landmarks excluding outliers (%). The right side graphs are in terms of SOF (%). The results in each row correspond to a noise level (η max =10, 30, 50) respectively. Note that, for this result, outliers were excluded from the computation of NRMSE. The results were computed from an average of 5 trials, where {tilde over (K)} images were randomly selected as the labeled set for each trial. Both algorithms were compared under the same conditions. Both algorithms used, for example, the same randomly selected labeled set and the same initialization.
[0040] Comparing the results of SLSC and SSLSC in FIG. 4 , the shape constraints are effective in reducing the outliers significantly, even when the congealing performance of SLSC is poor due to a high initialization noise level and a small number of labeled images. For example, the SOF decreases from 32% (SLSC) to 23.4% (SSLSC) with {tilde over (K)}=1 and η max =50, which is equivalent to removing 26 outliers. Furthermore, an average of 5.2% reduction of SOF is obtained when η max =50. Since the shape constraints are not applied on those low-error estimations, there is no improvement in the NRMSE excluding outliers.
[0041] FIG. 4 also illustrates the improvement of labeling accuracy by partition-based SSLSC. Similar to the previous results for SSLSC, the performance was evaluated under varying {tilde over (K)} and η max values from an average of 5 random trials, as shown in FIG. 4 . Comparing the results of SSLSC and partition-based SSLSC in FIG. 4 , it is obvious that the partition-based approach further improves both precision and robustness in terms of reducing the NRMSE and SOF. The SOF for example, decreases from 23.4% (SSLSC) to 20.3% (partition-based SSLSC), and the NRMSE decreases from 9.92% (SSLSC) to 9.06% (partition-based SSLSC) with {tilde over (K)}=1 and η max =50. In summary, an average of 1% reduction of NRMSE is achieved for all noise levels, and an average of 2% decrease of SOF is obtained for high noise levels (η max =30, 50). FIG. 4 illustrates there is no remarkable improvement when {tilde over (K)}>=10, which means that only using 3% ( 10/300) labeled data, the landmarks can be estimated accurately and robustly.
[0042] FIG. 5 illustrates the performance improvement across different partition levels when {tilde over (K)}=5 and η max =30. The results of level- 0 correspond to the initialization, and those of level- 1 represent the congealing results on the whole mean shape space by SSLSC. Increasing levels of partition, both the NRMSE and SOF decrease and converge at the last partition level as illustrated in FIG. 5 .
[0043] In summary explanation, shape deformation of images of a real-world object is often non-rigid due to inter-subject variability, object motion, and camera view point. Automatically estimating non-rigid deformations for an object class is a critical step in characterizing the object and learning statistical models. The system and method embodiments described herein facilitate such a task by automatically producing labeled data sets. Extensive experiments have demonstrated these methods achieve impressive labeling results on facial images with nearly frontal view and moderate changes in expression, useful for many current applications. The invention is not so limited however as these embodiments can be immediately applied to the task of labeling landmarks in images of other classes of objects such as vehicles or pedestrians using the principles described herein.
[0044] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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A system and method for estimating a set of landmarks for a large image ensemble employs only a small number of manually labeled images from the ensemble and avoids labor-intensive and error-prone object detection, tracking and alignment learning task limitations associated with manual image labeling techniques. A semi-supervised least squares congealing approach is employed to minimize an objective function defined on both labeled and unlabeled images. A shape model is learned on-line to constrain the landmark configuration. A partitioning strategy allows coarse-to-fine landmark estimation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to pneumatic tires and more particularly to a novel bead construction for heavy duty pneumatic tires.
2. Prior Art
Generally, heavy duty or high load bearing pneumatic tires include a radial carcass having at least one ply of rubberized steel cord fabric wrapped about a pair of bead cores formed from tightly packed windings of wires to create carcass flippers or turnups. Bead reinforcement strips may be arranged in a folding zone and extend radially outwardly beyond the turnups, and are usually separated therefrom by rubber masses. Positioned above each bead core and extending radially outwardly therefrom between the turnups if provided and the carcass ply is an apex strip of a hard rubber compound.
The purposes of the bead core are to guarantee a reliable seating of the tire on a wheel rim and to transmit to the rims the forces generated in the steel cords of the carcass due to the inflation pressure of the tire as well as operational loads. These forces are transferred to the individual windings in the bead cores. It has been found that the bead core will function optimumly when all of the wires in the core are uniformly subjected to such loads.
It is known in the art to design the bead core with a rectangular cross-sectional or hexagonal cross-sectional configuration. Such bead core designs are capable of attenuating a large portion of the energy of deformation and reliably transfering to the rim the stresses resulting from the forces in the carcass. These designs however do not guarantee that the bead wires will be subjected to such stresses.
The rims on which tubeless truck tires are mounted may have steep shoulders, i.e., the seat areas are oriented at an angle of 15° with respect to the tire axis. The bead cores are designed with various polygonal cross-sectional configurations such as parallelograms, trapezoids or longitudinally extending hexagons which are oriented obliquely at the same angle to the tire axis that the seat of the steep-shoulder rim is oriented. For example, in U.S. Pat. No. 3,757,844 the bead core is oriented parallel to the shoulder to guarantee that the individual windings of the core bear against the seat with equal pressure.
With conventional tapered rims, which can also be used for high load-bearing capacity tires, the seat of the rim is oriented with respect to the wheel axle at a slope of about 5°. The tires mounted on such tapered rims have as a rule multi-cornered bead cores whose wire windings are oriented parallel to the wheel axle. Such a construction does not guarantee a uniform distribution of the force in the wire windings, particularly the radially inwardmost wires of the bead core.
It is toward elimination of these and other drawbacks that the present invention is directed.
SUMMARY OF THE INVENTION
1. Purposes of the Invention
It is an object of the present invention to provide a pneumatic tire having an improved bead core design capable of transfering elevated forces generated during tire operation to the rim.
Another object of the present invention is to provide a pneumatic tire having an improved bead core design wherein the forces generated during operation of the tire are distributed uniformly over the windings in the bead core.
Still other objects and advantages of the present invention in part will be obvious and in part will become apparent as the description proceeds.
2. Brief Description of the Invention
Generally, a pneumatic tire in accordance with the present invention has a pair of bead cores of polygonal cross-sectional configuration which are formed from multiplicities of wires wound in densely superimposed parallel layers. The layers in each bead core lie on conical first lines whose common axis coincides with the tire axis and whose angles of opening have a value of approximately 10°. The lines open axially outwardly. The width of the layers and the number of wires in each layer vary according to a predetermined pattern.
The two radially innermost layers may have their axially outermost wires lying on a second line making an angle of from about 60° to about 85° with the first line. These layers may have their axially innermost wires lying on a third line making an angle of from about 60° to about 120° with the first line.
Moreover, at least the two radially outermost layers may have their axially outermost wires lying on a fourth line parallel to the third line and may have their axially innermost wires lying on a fifth line parallel to the second line.
In accordance with one embodiment wherein the cross-sectional configuration of the bead core is either hexagonal or octagonal, the number of layers in the bead core is equal to or is one greater than the number of wires in the widest layer. Moreover, the axially innermost and axially outermost wires in at least the two radially innermost layers lie at angles of 60° and the axially innermost and axially outermost wires in at least the three radially outermost layers also lie at angles of 60°.
A substantially triangularly cross-sectionally configured apex strip of a hard rubber compound is provided which extends radially of and from the bead core and forms a rigid unit with the bead core. If the bead core is of a hexagonal or octagonal cross-sectional configuration, the apex strip contacts said bead core along two contiguous radially outward sides of the bead core.
The invention consists of the features of construction and arrangement of parts which will be detailed hereinafter and described in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as the invention herein, it is believed that the invention will be better understood from the following description when read in conjunction with the accompanying drawings, in which:
FIG. 1 is a partial cross-sectional view of a bead area of a pneumatic tire constructed in accordance with the present invention;
FIG. 2 is an enlarged cross-sectional view through the bead core constructed in accordance with the present invention in which the core portions have been moved radially inwardly; and
FIG. 3 is a cross-sectional representation of one of the core portions illustrated in FIG. 2.
FIG. 4 is a cross-sectional representation of one of the core portions represented partially in broken-line construction in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As used in the specification and the claims, the terms "axially inward" and "axially outward" are used with reference to a bead core of the tire, that is, "axially inward" refers to a vector extending from the bead core to the opposite bead core. Conversely, "axially outward" refers to a vector extending outwardly away from the bead core. The terms "radially inward" and "radially outward" are used with reference to the axis of rotation of the tire, that is, "radially inward" refers to a vector directed radially toward the axis, while, the term "radially outward" refers to a vector extending radially from the axis.
With reference to FIG. 1, there is illustrated the bead area 10 of a tire 12 constructed in accordance with one embodiment of the present invention. While only one bead area of the tire is illustrated, it is to be understood that the other bead area not illustrated is the same as that illustrated, but opposite in hand.
The tire 12 is a high load carrying capacity pneumatic tire for use on trucks, heavy duty and/or large size vehicles. It is designed to be mounted on a 5° tapered rim 14 which has a seating area 16 sloped at an angle of approximately 5° to the wheel axle. The general construction of such a tire is known in the art and will not be described in detail herein. Basically, the tire 12 includes a carcass 18 of at least one ply of rubberized cord reinforced fabric having its radially inward end a turnup portion 20 wrapped about an inextensible bead core 22. The terminal edge 24 of the turnup 20 extends radially outwardly of the bead core 22 and is spaced axially outwardly of the carcass 18. Forming generally a radially outward extension of the turnup 20 is at least one reinforcement strip 26 consisting of a ply of rubberized cord fabric wrapped about the bead core 22. As shown, the terminal edge 24 of the turnup 20 and the terminal edge 28 of the reinforcement strip 26 are embedded in a rubber mass 30 having a particularly elastic and high energy absorbing capacity.
The bead area 10 includes a reinforcement unit composed of the bead core 22 and an annular apex strip 32 made of a hard rubber compound which extends circumferentially of the tire and radially outwardly from the bead core 22. The apex strip is of a generally triangular cross-sectional configuration, and along its base 34 bears directly against the radially outwardly oriented faces 36 and 38 of the bead core 22 so that the bead core and the apex strip make contact over a substantial area and together, constitute a rigid reinforcement unit. Compared to its width, the apex strip is of comparatively low radial elevation. Such a bead core and apex strip combination creates a relatively long path of shear between the carcass and the reinforcement unit.
As shown in FIG. 1, the bead area 10 terminates at a toe 40 at its radially and axially innermost edge and at a heel 42 at its radially innermost, axially outermost edge which define a bead sole or seat 44. When the tire is in normal operation, the bead area 10 is mounted on the rim 14 so that the seating area 16 on the rim engages and supports the seat 44 of the bead.
The bead core 22, having a polygonal cross-sectional configuration as described in detail hereinafter, is made from a multiplicity of wires 46 wound in an orientation perpendicular to a vertical plane passing through the bead core, i.e., the wires are oriented concentrically to the circumference of the rim without any helical twist. The wires 46 have identical cross-sectional configurations and are wound in densely superpositioned layers with each of the layers arranged conically in the bead core. The wires in the bead core can be of round or square cross-section. They can be rubber-coated and, in the event of the formation of a lamallae-shaped wire bundle, need not have any rubber coating. The width of the individual layers and consequently the number of wires in each layer may vary according to a predetermined pattern so that the bead core may have different polygonal cross-sectional configurations as will be explained.
As can be seen best in FIG. 2, the annular bead core 48 can be sectioned vertically into portions 48a and 48b. The portion 48a is a mirror image of the portion 48b. In the discussion which follows concerning FIG. 2, the use of a letter suffix "a" with a reference numeral indicates that its associated structure appears in portion 48a and the use of the suffix "b" indicates that its associated structure appears in portion 48b. Associated with the bead core 48 is an apex strip 49.
The bead core 48 is made of a multiplicity of wires 50 of which, only those necessary to adequately explain the invention are shown to preserve clarity. The wires 50, as noted hereinabove, form layers 52 in which the wires are parallel to each other and in which the wires are oriented conically in the bead core. In FIG. 2, the arrow 54 indicates the axially outward direction and the lines A--A and B--B are parallel to the horizontal axis of the tire.
The radially innermost layer 56 is signified by 56a and 56b and is oriented conically so that the center to center connecting lines or first lines 58a and 58b make an angle α of approximately 10°. Lines 58a and 58b lie at angles of 1/2α with respect to the lines A--A and B--B respectively and consequently, angles of 1/2α with respect to the horizontal axis of the tire. The remaining layers in the bead core 48 likewise lie along conical center to center connecting lines making an angle of approximately 10°.
The axially outermost wire 60a in the radially innermost layer 56a and the axially outermost wire 62a in the immediately adjacent layer 64a may lie along a second center to center connecting line 66a which forms an angle β of from about 60° to about 85° with the first line 58a. As will be described hereinafter, the size and shape of the bead core can vary depending on the number of wires in each layer, however, in accordance with the present invention there are at least two layers in each bead core configuration, i.e., the radially innermost layer and the immediately adjacent layer which have their axially outermost wires lying on a center to center connecting line making an angle of from about 60° to about 85° with respect to the center to center connecting line for the layers in the bead core. For example, as shown in portion 48b, two additional layers 68b and 70b have their axially outermost wires 72b and 74b respectively, lying on the same line 66b as the wires 60b and 62b.
Similarly, the axially innermost wires 78a and 80a in the two radially innermost layers 56a and 64a respectively lie along a third center to center connecting line 82a which makes an angle γ of approximately 60° to 120° with the first line 58a. As noted hereinabove with respect to the axially outermost wires, the axially innermost wires of more than the two radially innermost layers may lie along the third line 82a as well.
As can be seen best in portion 48b, at least the two radially outermost layers 84b and 86b have their axially outermost wires 88b and 90b respectively oriented along a fourth center to center connecting line 92b which is parallel to the third line 82b making an angle γ with respect to the center to center connecting line for the layers in the bead core. Moreover, the axially innermost wires 94b and 96b in the layers 84b and 86b respectively have a fifth center to center connecting line 98b which is parallel to the second line 66b. Obviously, depending upon the cross-sectional configuration selected for the bead core, the axially innermost and axially outermost wires in more than the two radially outermost layers may be situated likewise.
Where the bead core 48 assumes a hexagonal or octagonal cross-sectional configuration, there are at least two radially innermost layers having their axially outermost and axially innermost wires lying on second and third lines respectively which make angles β and γ of 60°. Preferably, in addition, there are at least three radially outermost layers having their axially outermost and axially innermost wires lying on fourth and fifth lines respectively which are parallel to the second and third lines.
It was noted hereinabove that the axial width of each layer in the bead core and consequently, the number of wires in each layer can vary according to a predetermined pattern so that the bead core may have different polygonal cross-sectional configurations. With reference to FIG. 3, there is shown a bead core 100 which is composed of a multiplicity of layers 102a through 102i. The arrow 104 indicates the axially outward direction. Note that for clarity, only the axially innermost and axially outermost wires in most of the layers are shown. In accordance with the above discussion, the two radially innermost layers 102a and 102b lie on first center to center connecting lines 106a and 106b. The layer 102b has one more wire than the layer 102a. The axially outermost wires 108a and 108b of at least the layers 102a and 102b respectively lie along a second line 110 which makes an angle β with the first line 106a. Furthermore, the axially innermost wires 112a and 112b of the layers 102a and 102b respectively lie along the line 114 which makes an angle γ with the line 106a.
If the wires 116 and 118 are included in the layers 102c and 102e respectively, the bead core 100 assumes a hexagonal cross-sectional configuration, as represented in FIG. 4. By removing the wires 116 and 118, the bead core assumes an octagonal cross-sectional configuration. Consequently, one can start with a basic bead core design having an octagonal cross-sectional configuration with a circumference of segments 120a through 120h as shown in FIG. 3. From this basic configuration, bead cores of various cross-sectional configurations can be obtained. Such flexibility is required since bead cores of different power absorption capacities are required for different applications. Beginning with the basic bead core, the absorption capacity can be increased by increasing the number of wires along the side of the bead core coming into direct contact with the apex strip. One would add an additional layer of wires 102i along the radially outward side 120a and would increase the number of wires in the layers 102d through 102h by one wire along the axially inward face 120h. In this way, it is possible to enlarge the cross-sectional area of the bead core which results in increased energy absorption without changing the cross-sectional configuration.
If one wishes to enlarge the area over which the apex strip makes contact with the bead core without substantially enlarging the cross-sectional area of the bead core, it is possible to enlarge the radially outwardly situated surface of the bead core in an axially outward direction by adding wires in the area enclosed by dashed lines 122 in FIG. 3. In this case, the cross-sectional configuration of the bead core is changed to orthorhombic and the length of the sides 120e, 120f, 120g and 120h remain unchanged. In this situation, additional wires are added to layers 102e, f, g and h with the same angular orientations as the layers in the basic bead core.
Preferably, in the instances where the bead core is of hexagonal or octagonal cross-section, the number of layers in the bead core equal or is one more than the number of wires in the widest layer in the bead core. Furthermore, as can be seen in FIG. 2, if the bead core 48 has an octagonal cross-sectional configuration, the apex strip 49 contacts the bead core 48 along its two radially outward contiguous surfaces 124a and b and 126a and b. This holds true if the bead core is of a hexagonal cross-sectional configuration as well. In addition, if the bead core is of octagonal cross-sectional configuration, the shape may be asymetrical with respect to the lines 128a and 128b which are parallel to the first center to center connecting lines.
In a bead core constructed in accordance with the above principles, due to the orientation of the layers, the wires in the bead core are subjected to the same strains and stresses. This feature applies not only to the wires located near the wheel rim but also to those radially outwardly therefrom. The bead core is compact, has an increased force absorption capacity and as noted, forms with the apex strip an essentially rigid reinforcement unit. Furthermore, the bead core is a favorable base for anchoring the tire to the wheel rim.
As can be seen from the foregoing, the objects of the present invention, namely to provide an improved bead construction for a heavy duty pneumatic tire have been accomplished by a bead core having a polygonal cross-sectional configuration composed of a multiplicity of wires wound concentrically to the circumference of the wheel rim in densely superpositioned layers. The layers are parallel and are oriented on conical first lines with an angle of opening of approximately 10°. The axially outermost wires in at least the two radially innermost layers have their centers lying on a second line making an angle of from about 60° to about 85° with respect to the first lines. The axially innermost wires in at least the two radially innermost layers may have their centers lying on a third line making an angle of approximately 60° to 120° with respect to the first lines. Similarly, the axially outermost wires in at least the two radially outermost layers may have centers lying on a line parallel to the third line and the axially innermost wires in at least the two radially outermost layers have centers lying on a line parallel to the second line.
The tire also includes an annular apex strip of a hard rubber compound having a substantially triangular cross-sectional configuration extending radially of and from the bead core. The bead core and apex strip form an essentially rigid reinforcement unit.
If the bead core is of a hexagonal or octagonal cross-sectional configuration, the apex strip contacts the bead core along at least two contiguous radially outward surfaces.
While in accordance with the patent statute preferred and alternative embodiments have been described in detail, it is to be understood that the present invention is not limited thereto or thereby.
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A heavy duty pneumatic tire is provided with bead cores having polygonal cross-sectional configurations. The bead cores are composed of a multiplicity of wires arranged in densely superpositioned parallel layers which are situated on conical generating lines whose common axis coincide with the horizontal axis of the pneumatic tire and whose angles of opening are approximately 10°. The axially innermost and axially outermost wires in specified radially inner and radially outer layers lie on centerlines forming angles within selected ranges with the conical lines.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Stage of International Application No. PCT/EP2013/065585 filed Jul. 24, 2013, and claims the benefit thereof. The International Application claims the benefit of European Application No. EP12181150 filed Aug. 21, 2012. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a turbomachine, in particular a steam turbine, comprising a rotor which is mounted rotatably and comprises rotor blades, and a casing which is arranged about the rotor, wherein the casing comprises guide vanes, a first bearing and a second bearing for mounting the rotor.
BACKGROUND OF INVENTION
[0003] Relatively long turbomachines are among the devices employed in the communal supply of power. An example of such a turbomachine is a steam turbine having, in essence, a rotor and a casing arranged about the rotor. In this case, the rotor is a component which can be several meters long and can weigh several tonnes. In general, the rotors are mounted rotatably on two bearings, wherein in operation relatively high rotational speeds such as 50 Hz or 60 Hz or more can be reached. Such high rotational frequencies, together with the weight and the length of the rotors, require precise manufacturing such that safe operation is possible. The maximum length of such a rotor is limited by the fact that the stiffness of the turbine section spool is limited and cannot be lengthened in conjunction with the rotor-dynamic properties. Furthermore, the maximum length of the rotor is strongly dependent on the position of the bearing locations and the manner in which the bearing casing is supported.
[0004] In known turbomachines, current turbine section spools are mounted at the shaft ends. To that end, the bearings must frequently be arranged in the steam space. Furthermore, such bearings must be designed such that the bearing casing is connected via struts with the diffuser supported on the base. Constructions of this type are also termed star bearings.
SUMMARY OF INVENTION
[0005] An embodiment of the invention has the object of indicating a turbomachine which is improved in terms of rotor dynamics.
[0006] This object is achieved with a turbomachine as claimed.
[0007] It has been recognized, according to embodiments of the invention, that the optimal bearing positions, in terms of stiffness, lie in the case of an evenly loaded shaft at what is termed the Bessel points. These Bessel points are located, following calculations, at approx. 22% of the shaft length from the shaft ends. Embodiments of the invention thus proposes displacing at least one bearing such that the rotor-dynamic properties are fundamentally improved. To that end, it is proposed that the bearing is arranged upstream of a guide vane stage, as seen in a flow direction. It is thus proposed that the bearing is not arranged as a separate component at the end of the rotor, but rather that it is integrated into the blade path of the turbomachine. To that end, it is first proposed that the bearing is arranged upstream of a rotor blade stage. Inter alia, an embodiment of the invention presents the advantage that the bearing casing can henceforth be borne by a guide vane stage without additional bearing supports.
[0008] Advantageous refinements are indicated in the subclaims.
[0009] It is thus proposed to arrange the second bearing upstream of a final rotor blade stage. That means that the bearing is arranged in the flow duct such that the bearing is arranged upstream of the final rotor blade stage.
[0010] In a further advantageous embodiment, the bearing casing is arranged on bearing supports which are formed as guide vanes. That means that the bearing supports fulfill a thermodynamic function, specifically the thermodynamic function of a guide vane. That means that the bearing supports are formed such that they follow a fluid-dynamic profile which is predetermined by a guide vane stage. The bearing displaced into the flow path can thus also fulfill thermodynamic properties, in addition to the rotor-dynamic properties, since the bearing supports are also formed as guide vanes.
[0011] A diffuser is preferably arranged downstream of the final rotor blade stage. Henceforth, the diffuser advantageously no longer has any disruptive bearing supports in the flow path and can thus carry out the pressure recovery in a more targeted manner.
[0012] Advantageously, the bearing support formed as a guide vane is designed so as to have a device for exchanging energy and signals.
[0013] The invention delivers the advantage that a bearing integrated in the guide vane stage henceforth requires less axial installation space and permits a smaller separation with respect to the condenser. Since the bearing is borne by the guide vane stage, no bearing supports are required, which would lead to material and manufacturing costs and would hinder the exhaust flow to the condenser. Furthermore, the stiffness of the turbine section spool is substantially increased, leading to markedly improved rotor dynamics. This can permit a reduction in radial clearances in order to further improve efficiency.
[0014] Furthermore, an embodiment of the invention presents the advantage that larger exhaust flow cross sections can be realized and longer blade paths can be used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Aspects of the invention will be explained in more detail with reference to an exemplary embodiment.
[0016] The FIGURE shows a cross section view of a steam turbine.
DETAILED DESCRIPTION OF INVENTION
[0017] The FIGURE shows an embodiment of a turbomachine, designed as a steam turbine 1 . This steam turbine 1 comprises, in essence, a rotor 3 which is mounted such that it can rotate about an axis of rotation 2 , on which rotor a first rotor blade stage 5 , a second rotor blade stage 6 and a third rotor blade stage 7 are arranged on the rotor surface 4 . The steam turbine 1 further comprises a casing (not shown in more detail) which is arranged around the rotatably mounted rotor 3 . A first guide vane stage 8 , a second guide vane stage 9 and a third guide vane stage 10 are arranged on the casing.
[0018] A flow path 11 is formed between the first 5 , second 6 and third 7 rotor blade stages and the first 8 , second 9 and third 10 guide vane stages, through which flow path steam flows in operation. The rotor 3 is mounted on a base 12 by means of a first bearing 13 and a second bearing 14 . The first bearing 13 is arranged at a first end 15 of the rotor 3 . The second bearing 14 is arranged at a second end 16 .
[0019] In this context, the second bearing 14 is arranged in the flow path 11 upstream of the third rotor blade stage 7 , that is to say consequently the final rotor blade stage. The bearing comprises a bearing casing 17 which is arranged around the second bearing 14 . A bearing support 19 formed as a guide vane is arranged on the bearing casing. Since the bearing support 19 formed as a guide vane is arranged in the flow path 11 , this bearing support 19 formed as a guide vane participates in the conversion of the energy of the steam in the flow path 11 .
[0020] A diffuser 20 , in which a pressure recovery of the steam in the flow path 11 takes place, is arranged downstream of the third rotor blade stage 7 .
[0021] In alternative embodiments, the bearing support 19 formed as a guide vane, with the second bearing 14 , can also be arranged upstream of the second rotor blade stage 6 or even further upstream in the flow path 11 .
[0022] Devices 21 for exchanging energy and signals are provided in the bearing support 19 formed as a guide vane.
[0023] The rotor ( 3 ) has, as seen in the flow direction, a first, second, penultimate and final rotor blade row.
[0024] The casing has, as seen in the flow direction, a first, second, penultimate and final guide vane row.
[0025] The second bearing is arranged between the penultimate and the final rotor blade rows.
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A steam turbine having a rotor and a housing is provided herein, wherein the bearing for supporting the rotor is arranged in front of the last vane stage.
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This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/045,734 entitled "Surfboard Side Fin" and filed on May 6, 1997 and which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to quick and controlled turning with stabilizing fins on personal watercraft and to roll stability for personal watercraft. More particularly, the present invention relates to a stabilizing turning and control-enhancing side fin for a surfboard or the like to increase the performance and maneuverability of the surfboard or the like.
2. Background Information
The stability of small watercraft has been addressed in a variety of prior art devices. For example, U.S. Pat. No. 4,752,262 provides a pair of adjustable wings extending oppositely off of the deck surface of a sailboard. The proposed wings of the '262 patent are substantial structures, extending approximately 44 inches from the wing pivot axis to the wing tip. U.S. Pat. No. 3,090,978 discloses the use of a pair of retractable wings on the rear of water skis for improving the performance of the water skis at low speeds. U.S. Pat. No. 4,296,511 discloses a water ski having a chamber attached thereto which has the configuration of a venturi tube. The construction of the chamber is intended to lock the chamber and the associated structure in the water to enhance the stability and operating characteristics of the water ski.
The above-described prior art devices are not easily or meaningfully adapted for use in a surfboard environment. These prior art designs do not address the particular problems associated with a surfboarding environment. They do not provide the user control which is necessary in surfboarding.
It is an object of the present invention to overcome the aforementioned drawbacks of the prior art. It is a further object of the present invention to provide a side fin for a surfboard or the like which increases the stability of the surfboard, and provides a more controlled and quicker maneuverability for the surfboard. It is another object of the present invention to provide a side fin for a surfboard which selectively modifies the lift and drag and thrust distribution while surfboarding. It is another object of the present invention to provide a surfboard side fin which is easily manufactured and easy to utilize.
SUMMARY OF THE INVENTION
The above objects are achieved by providing a selectively submergible side fin for personal watercraft, particularly a surfboard, according to the present invention. The side fin of the present invention may be provided on the right or left side, or both sides of the surfboard near the rear portion of the board, but it may also be used preferably near the middle and forward portion for example for "nose riding". The side fin of the present invention may be detachably mounted to the surfboard or, alternatively, may be permanently attached to the surfboard.
A side fin of the present invention includes a deck portion extending from a portion of the upper surface of the surfboard but preferably shaped with a lifting surface that is activated in a turn. The side fin of the present invention additionally includes a rollover edge at a side thereof extending substantially parallel to the body of the surfboard. The roll over edge enhances the full range of performance for the side fin and enhances quick rail performance for a surfboard with the side fin attached.
The side fin is specifically configured to provide a lift and thrust feel to the board when going through the water. In operation, when stepping on the deck portion of the side fin, the side fin is submerged and the board will turn in that direction. Stepping on the deck surface lightly will produce a gradual turn and stepping on the deck surface heavily produces a sharper turn in that direction. Normally, the surfboard will turn in the direction of the submerged side fin, however, it may be possible for a surfer to have the board turn in a direction opposite the submerged side fin, but this operation would be an exception. The side fin may be submerged by a method other than stepping on the side fin, such as shifting the user's weight toward the selected side fin. As discussed above, the side fin produces both a lift, drag, and moreover a thrust feel to the board. The lift and drag allow the board essentially to climb up on the wave. The lift gives the board the ability to maneuver and to ride even small waves.
These and other advantages of the present invention will be clarified in the description of the preferred embodiments taken together with the attached figures wherein like reference numerals represent like elements throughout.
BRIEF DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a top perspective view of a surfboard and side fin according to a first embodiment of the present invention;
FIG. 2 is a rear elevational view of the surfboard and side fin illustrated in FIG. 1;
FIG. 3 is a top view of the side fin illustrated in FIGS. 1-2;
FIG. 4 is a side view of the side fin illustrated in FIG. 1;
FIG. 5 is a cross-sectional view of the side fin illustrated in FIG. 4;
FIG. 6 is a longitudinal section view along a roll over edge mid-point of the side fin illustrated in FIG. 5;
FIG. 7 is an end view along a bottom edge of the roll over edge of the side fin illustrated in FIG. 5;
FIG. 8 is a top view of a side fin according to a second embodiment of the present invention;
FIG. 9 is a side view of the side fin illustrated in FIG. 8;
FIGS. 10a and 10b are cross-sectional views of the side fin illustrated in FIG. 9;
FIG. 11 is a longitudinal section view along a roll over midpoint of the side fin illustrated in FIGS. 10a-10b;
FIG. 12 is an end view along a bottom edge of the roll over of the side fin illustrated in FIGS. 10a-10b;
FIG. 13 is a top view of a side fin according to a third embodiment of the present invention;
FIG. 14 is a side view of the side fin illustrated in FIG. 13;
FIGS. 15a, 15b and 15c are cross-sectional views of the side fin illustrated in FIG. 13;
FIG. 16 is a longitudinal sectional view along a roll over midpoint of the side fin illustrated in FIGS. 15a-c;
FIG. 17 is an end view along a bottom edge of the roll over of the side fin illustrated in FIGS. 15a-c; and
FIG. 18 is a top perspective view of a surfboard and side fins according to a fourth embodiment of the present invention;
FIG. 19 is a top view of the surfboard and side fin illustrated in FIG. 18;
FIG. 20 is a rear elevational view of the surfboard and side fins illustrated in FIG. 18;
FIG. 21 is a top view of a surfboard and side fins according to a fifth embodiment of the present invention;
FIG. 22 is a side view of the surfboard and side fins illustrated in FIG. 1;
FIGS. 23A-23C are sectional views of the surfboard and side fins illustrated in FIG. 21;
FIG. 24 is a top view of a surfboard and side fins according to a sixth embodiment of the present invention;
FIG. 25 is a side view of the surfboard and side fins illustrated in FIG. 24; and
FIG. 26 is a rear elevational view of the surfboard and side fins illustrated in FIG. 24.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a top perspective view of a surfboard 5 with a selectively submergible side fin 10 according to a first embodiment of the present invention. The FIGS. 1-7 illustrate a right side fin 10 for the surfboard 5 or the like. A left side fin may be formed as a mirror image of the right side fin 10 shown in the figures. The surfboard 5 according to the present invention may include either a right side fin 10 as shown in FIGS. 1-2, a left side fin or both. The side fin 10 extends laterally of the body of the surfboard 5 as shown in FIGS. 1-2.
The side fin 10 includes a deck portion 12 extending substantially parallel and adjacent to the upper surface of the surfboard 5. The deck portion 12 provides a foot support for the user as will be described. The side fin 10 additionally includes a rollover edge 14 adjacent the deck portion 12. The rollover edge 14 is most clearly illustrated in FIG. 5 and turns at least 90° with respect to the deck portion 12. The forward edge 16 of the front of the deck portion 12 is tapered away from the attached surfboard 5 as shown in FIG. 1 and forms a leading edge of a wing-type structure as will be described. The tapering of the forward edge 16 also allows the user's legs to more easily slide past the extension of the surfboard 5 provided by the side fin 10.
The side fin 10 forms a wing member and is specifically designed to provide a lift, drag and thrust feel to the surfboard when the side fin 10 is pushed through or on the water. The specific contouring of the side fin 10 can be shown by separate contouring lines in FIG. 4 representing specific contours of the side fin 10 along spaced sections. FIGS. 6 and 7 illustrate the longitudinal cross-sectional configuration of the roll over edge 14 taken along a midpoint of the roll over edge 14 and a bottom edge of the roll over edge 14, respectively, shown in FIG. 3. The side fin 10 of the present invention can be formed in an economical fashion as a laminate skin formed over a foam core. For example, the laminate skin may be formed of two layers of six-ounce E glass cloth, combined with a polymer resin matrix material.
The side fin 10 of the present invention is preferably permanently attached to the surfboard 5. Specifically, the inside side fin edge flares into the rail of the surfboard 5. A laminate layer forms a C-cup that is compatible with the surfboard 5 and is laminated to the surfboard top and bottom to permanently attach the side fin 10 thereto. However, if desired, alternative construction can be performed to make the side fin 10 removable through various attachment mechanisms such as are known in the art.
In operation, the user of the surfboard 5 with a right side fin 10 (and/or a left side fin) according to the present invention operates as follows. When standing on the surfboard 5 after catching a wave and the user desires to turn to the right, the user steps on the deck portion 12 of the side fin 10 on the right side of the surfboard 5 to selectively submerge the side fin 10. By stepping lightly, the surfboard 5 will turn gently to the right. Stepping more heavily will result in a significantly sharper turn. The side fin 10 may be selectively submerged by other than stepping directly on the deck portion 12, such as shifting the user's weight toward the side fin 10. The side fins 10 of the present invention, as discussed above, are specifically designed to provide a lift, drag and also a thrust feel to the surfboard 5 based upon the specific profile. This configuration will allow the user to quickly climb the wave in a timely fashion. The roll over edge 14 with built in lift will allow the user to ride relatively small waves. The side fin 10 of the present invention increases the stability and maneuverability of the surfboard 5.
With regard to specific dimensions, the side fin 10 is approximately 24 inches long with the deck portion 12 being about two inches wide and the rollover edge 14 being at least approximately an inch or so in depth. However, it will be apparent to those of ordinary skill in the art that these dimensions can be easily altered within a significant range and still be within the scope of the present invention as exemplified in the embodiments discussed below.
FIGS. 8-12 illustrate a side fin 30 according to a second embodiment of the present invention. The side fin 30 illustrated in FIGS. 8-12 is a right side fin 30 for a long board (not shown) of approximately 9.6 inches long. A left side fin for the long board can be formed as a mirror image of the right side fin 30. The side fin 30 is substantially similar to the side fin 10 illustrated in FIGS. 1-7. The side fin 30 includes a deck portion 32 extending substantially parallel and adjacent to the upper surface of the long board. The side fin 30 additionally includes a roll over edge 34 adjacent the deck portion 32. The roll over edge 34 is most clearly illustrated in sectional views 10a and 10b. The side fin 30 additionally includes a upper forward edge 36 on the front of the deck portion 32 similar to the forward edge 16 of side fin 10. Side fin 30 most noticeably differs from side fin 10 by including a tapered rear edge 17 along the back of the deck portion 32 as shown in FIG. 8. The selectively submergible side fin 30 operates substantially the same manner as side fin 10 discussed above. The side fin 30 may be formed essentially the same manner as side fin 10 discussed above and attached to the surfboard in substantially the same manner. It is also anticipated the laminated skin of side fin 30 may further include an outside layer of 4 ounce CSM over the two layers of 6 ounce E-glass cloth. The side fin 30 merely intends to illustrate a different embodiment within the scope of the present invention. The specific dimensions of side fin 30 differ from side fin 10 in that the side fin 30 is specifically designed for a long board. The side fin 30 is approximately 28 inches long with the deck portion 32 being about two inches wide and the roll over edge 34 being at least approximately an inch or so in depth.
FIGS. 13-17 illustrate a side fin 50 according to a third embodiment of the present invention. The side fin 50 is a right side fin specifically designed for a short board(not shown)of approximately 6 foot 2 inches long. A left side fin for a short board to be formed as mirror image of the right side fin 50 illustrated in FIGS. 13-17. The side fin 50 is substantially the same as side fin 10 and 30 discussed above and includes a deck portion 52, roll over edge 54, forward edge 56, and rearward edge 57. The operation, construction and attachment of the selectively submergible side fin 50 to the short board is substantially the same as discussed above in connection with side fins 10 and 30. Side fins 30 and 50 have been added to illustrate specific modifications of the present invention associated with various dimensions of boards. The side fin 50 has dimensions different from the side fins 10 and 30 discussed above and includes the length of approximately 16-17 inches. The deck portion 52 is about two inches wide and the roll over edge 54 is at least approximately an inch or so in depth. As with side fins 10 and 30 discussed above it will be apparent to those skilled in the art that the specific dimensions illustrated in the figures for the side fin 50 can be easily altered within a significant range to provide an operational side fin within the scope of the present invention.
FIGS. 18-20 illustrate a surfboard 5 with a pair of side fins 60 according to a fourth embodiment of the present invention. The side fins 60 can be attached to or made integral with a surfboard 5 as illustrated. Each side fin 60 is essentially the same as side fins 10, 30 and 50 discussed above. Each side fin 60 includes a deck portion 62, a roll over edge 64 and a forward edge 66. The operation, construction and attachment of the submergible side fins 60 to the surfboard 5 is essentially the same as discussed above in connection with the side fins 10, 30 and 50. The deck portion 62 of each side fin 60 is illustrated as extending at a slightly greater angle relative to the top surface of the surfboard 5 than the deck portions 12, 32 and 52 of the previous side fins 10, 30 and 50. The side fin 60 is shown to illustrate the various shapes and configurations within the scope of the present invention.
FIGS. 21, 22 and 23A-C illustrate a surfboard 5 with a pair of side fins 70 according to a fifth embodiment of the present invention. Each side fin 70 is similar to the side fins 10, 30, 50 and 60 described above and includes a deck portion 72, a roll over edge 74, a forward edge 76 and a rearward edge 77. The operation, construction and attachment of each selectively submergible side fin 70 to the surfboard 5 is essentially the same as discussed above in connection with the previous side fins 10, 30, 50 and 60. The side fin 70 most significantly differs from the previous side fins 10, 30, 50 and 60 by the provision of a concavely curved forward edge 76 and rearward edge 77 which serves to minimize the deck portion 72 as best illustrated in FIG. 21. This construction is believed to highlight or increase the relative effect during operation of the roll over edge 74. Specifically, the inner surface of the roll over edge 74 is believed to be a key element in this specific design as a turning surface. The side fin 70 is primarily illustrated to demonstrate the wide variations possible with side fins according to the present invention.
FIGS. 24, 25 and 26 illustrate a surfboard with a pair of side fins 80 according to a sixth embodiment of the present invention. Each side fin 80 is substantially the same as the side fins 10, 30, 50 and 70 described above and includes a deck portion 82, roll over edge 84, a forward edge 86 and a rearward edge 87. As illustrated in FIGS. 25 and 26, the side fin 80 most significantly differs from the previous side fins by the inclusion of a downwardly extending vertical fin 89. As will be apparent to those of ordinary skill in the art when the selectively submergible side fin 80 is placed in the water the vertical or stabilizing fin 89 will also be submerged and will effect the operational characteristics of the surfboard 5 with side fin 80. The side fin 80 is primarily illustrated to demonstrate some of the many variations possible within the scope of the present invention.
Various changes may be made to the present invention without departing from the spirit or scope thereof. For example, while the present invention is particularly suited for surfboarding, it may have other applications such as sailboards or body boards also referred to as Boogie boards. The examples discussed above are merely illustrative of the present invention and not restrictive thereof. The scope of the present invention is defined by the appended claims and equivalents thereto.
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A stabilizing, turning and controlling side fin for a surfboard or the like increases the performance and maneuverability of the surfboard or the like. The side fin may be provided on the right, left or both sides of the surfboard near the rear or middle portions of the surfboard. The side fin includes a deck portion forming a foot support and a roll over edge at the side thereof. The side fin is selectively submergible and provides a lift and thrust feel to the board when going through the water. In operation, when stepping on the deck portion of the side fin, or otherwise submerging a selected side fin, the board will turn in that direction. Stepping on the deck surface lightly will produce gradual turn and stepping on the deck surface heavily will produce a sharper turn. The side fin allows the board to essentially climb up on to the wave, giving the user the ability to maneuver and ride even small waves.
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BACKGROUND OF THE INVENTION
This invention relates generally to electronic test instruments, particularly digital multimeters having a current sensing clamp. Digital multimeters, or DMM's, are used to measure a variety of electrical parameters, such as AC voltage, DC voltage, resistance and current. Clamp-type DMMs, also known simply as clamp meters, can measure current without interfering with the current carrying conductor. One such clamp meter is described in U.S. patent application Ser. No. 09/774,526, the disclosure of which is hereby incorporated by reference. In addition, clamp meters have the ability to measure fairly high levels of current.
Clamp meters measure current flow in a conductor without having to make electrical connection with the conductors forming the circuit. Instead two clamp jaws having electrical coils embedded therein encircle the conductor and sense the magnetic field created by the current flow in order to measure the current. However, the physical arrangement of the measured conductor in relation to the clamp jaws, housing and display dictates the orientation in which the clamp meter must be used. This can make it difficult to read the display in certain situations.
Typically, clamp meters have an elongated rectangular housing designed to be held in one hand. A pair of clamp jaws extends from the top of the housing. The jaws are situated in a fixed plane that is generally parallel to the plane of the front face of the housing. The meter's display is normally also disposed in the front face of the housing. Accordingly, when the clamp jaws are placed around a conductor the display can be forced into a position which may make reading the display difficult, if not impossible. This occurs most often when the current-carrying conductor is overhead or disposed in tight physical spaces such as an electrical cabinet.
It has been determined that adding a display to the side of a multimeter housing disposed on a plane generally perpendicular to the plane formed by the clamp jaws facilitates the reading of measurements even when the clamp meter is in an awkward position dictated by the need to surround a current-carrying conductor.
SUMMARY OF THE INVENTION
A primary object of the present invention is a clamp meter having multiple displays mounted in separate planes. At least one of the displays will be readily visible regardless of the orientation of the meter. The clamp meter has a housing having at least first, second and third faces. A pair of rigid jaws extends from the first face of the housing. The jaws define a jaw plane with at least one rigid jaw being pivotally movable in the jaw plane. A first display is disposed on the second face of the housing in a plane approximately parallel to the jaw plane. A second display is disposed on the third face of the housing in a plane approximately perpendicular to the jaw plane. One of the displays may be selectably covered by a pivotable flap.
In an alternate embodiment a single display is pivotally mounted in the housing so it can be tilted to a suitable viewing position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation view of a clamp meter of the present invention, with the clamp jaws closed to encircle a conductor shown in phantom lines.
FIG. 2 is a front elevation view of a clamp meter of the present invention, with the clamp jaws open.
FIG. 3 is a bottom plan view of the clamp meter of the present invention, showing a protective flap in a closed position for covering a display.
FIG. 4 is a bottom plan view of the clamp meter of the present invention, showing the protective flap in an open position to expose a display.
FIG. 5 is a front elevation view of a second embodiment of a clamp meter according to the present invention, with the clamp jaws open to receive a conductor shown in phantom lines and the display shown in a retracted position.
FIG. 6 is a bottom plan view of the clamp meter of FIG. 5 , with the display shown in a raised position.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1–4 illustrate a clamp meter 10 according to the present invention. The clamp meter has an elongated housing 12 that mounts a first digital display 14 . The display is mounted such that its outer surface is generally contiguous with the front face 16 of the housing. Two input jacks 18 , 20 are provided for receiving test leads (not shown). The housing 12 is made from a hard, durable, lightweight plastic material. Also included on the front face 16 is a series of pushbuttons 22 A– 22 D for selecting one or more of the testing functions of the meter. A selector knob or dial 24 is disposed on the front face 16 for choosing an electrical measurement mode.
Extending from the top of the housing is a pair of rigid clamp jaws 26 , 28 . Typically one of the jaws is pivotally mounted in the housing. In the embodiment shown jaw 26 is movable. Jaw 26 is spring-biased to a closed position against fixed jaw 28 . The jaws 26 , 28 have an arcuate shape to present outer convex surfaces 30 and inner concave surfaces 32 . The ends of the outer surfaces are slightly offset to form a tip 34 at the end of fixed jaw 28 . Tip 34 permits manipulation of electrical wires. Inside the jaws are electrical coils (not shown) which are connected to appropriate circuitry in the housing for detecting electrical properties of a conductor placed within the clamp jaws. These coils and circuitry are conventional. The internal circuitry displays the selected parameter on the displays.
A trigger 36 extends from the side of the housing 12 and is attached to the movable jaw. Preferably, as shown in FIG. 2 , the trigger 36 is integrally formed with the movable jaw 26 . Depressing the trigger 36 toward the housing causes the movable jaw 26 to pivot away from the fixed jaw 28 and move to the open position, as shown in FIG. 2 . Once the clamp jaw 26 is in the open position, the multimeter 10 can be positioned to pass the jaws 26 , 28 around a conductor. This is illustrated schematically in FIG. 2 where the conductor C is shown in two different positions; one just as it clears the opening between the jaws 26 , 28 and one where it is seated against the top of the housing 12 . When the trigger 36 is released, movable clamp jaw 26 closes around the conductor C, as shown in FIG. 1 , to permit a current measurement to be taken. The clamp jaws 26 , 28 can be designed to accommodate a number of different conductor diameters. Although conductor C is shown contacting the inner surfaces 32 of jaws 26 , 28 in FIG. 1 , it is not necessary that they do so. However, in order to measure the current carried by a conductor, the clamp jaws 26 , 28 must surround the conductor as shown in FIG. 1 .
A protective flap 38 is included on the bottom face 40 of the housing, as shown in FIGS. 3 and 4 . Flap 38 is connected to the housing by a hinge 42 . A second digital display 44 is mounted in the housing on the bottom face. When the flap 38 is closed it protects the second display 44 . Two flexible beads 46 engage indentations 48 in the bottom face 40 to frictionally retain the flap in the closed position.
Second display 44 lies in a plane approximately perpendicular to the plane defined by the clamp jaws and to the plane defined by the front face 16 of the housing. Accordingly, the second display 44 is generally perpendicular to the plane of the first display 14 . This arrangement of first display 14 and second display 44 permits a measurement to be read even when the clamp meter is forced into an awkward or difficult viewing position by the necessary placement of the clamp jaws. If the position of the clamp meter affords the user a decent view of the first display 14 , the flap 38 may remain closed. However, if the location of a conductor requires placement of the clamp meter housing in a position where the first display 14 is obscured or otherwise unavailable for viewing, the flap 38 may be opened to expose the second display 44 . Second display 44 provides a readout of the same data as in first display 14 . Thus, regardless of the orientation of the clamp meter housing, one of the displays will be readily visually accessible.
A second embodiment of a multimeter 50 according to the present invention is shown in FIGS. 5 and 6 . Multimeter 50 has a housing 52 with clamp jaws 54 and 56 extending from one end. The jaws 54 , 56 are the same as jaws 26 , 28 . The knob, jacks and buttons of the housing 52 are the same as those described above. Housing 52 itself is similar to housing 12 except that instead of two displays lying in perpendicular planes, multimeter 50 has a single pivoting display 58 connected to the housing 52 by a hinge 60 . Preferably the display 58 when in a retracted position is disposed in a recess 62 of the front face 64 of the housing 52 . The display 58 is shown in FIG. 5 in a retracted position so that the display defines a plane that is substantially parallel to the plane defined by the clamp arms 54 , 56 . In FIG. 6 , the display 58 is shown in a fully raised position such that the plane defined by the display is substantially perpendicular to the clamp arm plane. A depression 66 is provided in the housing to permit a user's thumb or finger to access the display 58 so that it can be raised out of the recess 62 .
A flexible electrical connection to the display is provided. The electrical connection is arranged to accommodate the pivoting motion of the display. A flexible polyester film with printed electrodes thereon would be suitable for this purpose.
Preferably, hinge 60 has sufficient friction or stiffness to hold or retain the display 58 in a multitude of positions relative to the clamp plane, from fully upright and perpendicular to the clamp plane to fully recessed and parallel to the clamp plane and every angle in between. In other words, the hinge is loose enough to permit a user to tilt the display from one angle to another but stiff enough to prevent the display from moving out of position by gravity or normal movement of the multimeter. As shown in FIG. 6 , the display 58 may also include protruding detents 68 on both sides of the display. The housing recess 62 includes complementary notches (not shown) that are engaged by the detents to frictionally retain the display in the recess.
Alternatively, a torsion spring (not shown) could be used to bias the display 58 to an upright or raised position as shown in FIG. 6 . In that case a catch or latch would be formed on or in the housing. The latch could be released by a trigger mechanism on the side of the housing. When engaged the latch would hold the display in the retracted position against the biasing force of the torsion spring. A further alternate would be to hold the display in an upright position by means of a releasable support arm. In addition, although a piano-type hinge is shown, the hinge could have other configurations and the display may be pivotally attached to the housing in any number of ways known to those skilled in the art. Yet another alternate would be to pivotally attach the display 58 to the bottom face of the housing.
Although the invention has been described with reference to certain preferred embodiments, the invention is not meant to be limited to those preferred embodiments. Alterations to the preferred embodiments described are possible without departing from the spirit of the invention. Rather the scope of the invention is defined by reference to the appended claims.
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A clamp type digital multimeter has one or more digital displays mounted so as to permit at least one of the displays to be read even when attachment of the clamp jaws about a conductor forces the display into an orientation that renders it inaccessible. The meter either has a single display that can be pivoted to an orientation convenient for viewing, or it has dual displays mounted on separate surfaces of the meter's housing. A protective flap may cover one or both of the displays when it is not needed for viewing.
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This application claims benefit of Japanese Patent Application No. 2008-150052 filed in Japan on Jun. 9, 2008, the contents of which are incorporated by this reference.
BACKGROUND OF THE INVENTION
The present invention relates to solid-state imaging apparatus, and more particularly relates to the solid-state imaging apparatus in which pixels can be reset at high speed.
A fundamental construction and drive method of a prior-art MOS type solid-state imaging apparatus will first be described by way of FIGS. 1 , 2 , 3 , 4 , and 5 . FIG. 1 shows a pixel construction used in the MOS solid-state imaging apparatus. What is denoted by a numeral 100 in FIG. 1 is a unit pixel a plurality of which are two-dimensionally arranged into a matrix to acquire image information. The unit pixel 100 includes: a photodiode 101 for effecting photoelectric conversion; an amplification transistor 104 where a photo-generated electric charge occurring at the photodiode 101 is converted into a voltage and is read out as it is amplified for example by means of a pn junction capacitor or gate capacitor; a transfer transistor 102 for transferring the photo-generated electric charge occurring at the photodiode 101 to a gate terminal of the amplification transistor 104 ; a reset transistor 103 for resetting the gate terminal of the amplification transistor 104 and the photodiode 101 ; and a select transistor 105 for selecting the pixel so as to transmit an output of the amplification transistor 104 to a vertical signal line 110 .
Here, all components but the photodiode 101 are shielded from light.
What is denoted by a numeral 106 is a pixel power supply line for supplying power to all the pixels in common, which is electrically connected to the drain terminal of the amplification transistor 104 and to the drain terminal of the reset transistor 103 . 107 is a row reset line for resetting pixels corresponding to one row, which is electrically connected respectively to the gate terminal of the reset transistor 103 of the pixels corresponding to one row. 108 is a row transfer line for transferring the photo-generated electric charge of the pixels corresponding to one row to the gate terminal of the amplification transistor 104 of the respective pixel, which is electrically connected respectively to the gate terminal of each transfer transistor 102 of the pixels corresponding to one row. 109 is a row select line for selecting the pixels corresponding to one row, which is electrically connected respectively to the gate terminal of each select transistor 105 of the pixels corresponding to one row. A photoelectric conversion function, a reset function, a memory function, an amplification/read function, a select function are achieved with such pixel construction.
FIG. 2 typically represents a fundamental construction of the MOS solid-state imaging apparatus. In FIG. 2 , a numeral 200 represents a pixel section where unit pixels 100 are two-dimensionally arranged into a matrix that corresponds to pixels P 11 to P 33 . For ease of explanation, the unit pixels 100 in this case are placed side by side into 3 rows by 3 columns. 202 represents a vertical scanning circuit for effecting row selection, which sequentially outputs a vertical scanning signal φ VSR(i) (i=1, 2, 3). 203 represents a vertical selecting section which is to respectively transmit a row select signal φ SE(i) (i=1, 2, 3), a row reset signal φ RS(i) (i=1, 2, 3), and a row transfer signal φ TR(i) (i=1, 2, 3) to the row select line 109 , the row reset line 107 , and the row transfer line 108 of each pixel P 11 to P 33 in accordance with the vertical scanning signal φ VSR(i). While in FIG. 2 , the lines for transmitting the row select signal φ SE, the row reset signal φ RS, and the row transfer signal φ TR to each row are indicated by one solid line and the outputs of vertical select circuits (MV 1 , MV 2 , MV 3 ) of the vertical selecting section 203 are indicated by one solid line for each row, these in actual setting are respectively provided as a number of lines that are independent from each other.
FIG. 3 shows a specific construction of the vertical select circuit (MV 1 , MV 2 , MV 3 ) in the vertical selecting section 203 . Referring to FIG. 3 , 202 is the vertical scanning circuit, and φ SE, φ RS, φ TR are the row select signal, row reset signal, and row transfer signal, respectively. A signal φ SE(i) (i=1, 2, 3) taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) outputted from the vertical scanning circuit 202 and the row select signal φ SE is connected to the row select line 109 in the pixel section 200 ; a signal φ RS(i) (i=1, 2, 3) taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) and the row reset signal φ RS is connected to the row reset line 107 in the pixel section 200 ; and a signal φ TR(i) (i=1, 2, 3) taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) and the row transfer signal φ TR is connected to the row transfer line 108 in the pixel section 200 .
Referring to FIG. 2 , 201 represents a current supply section where current supply ML 1 , ML 2 , ML 3 provided column by column and the vertical signal line 110 as described in FIG. 1 are respectively connected. A source follower circuit is thereby formed column by column with the amplification transistor 104 of each pixel and the current supply ML 1 to ML 3 . Here the current supply ML 1 to ML 3 has a function for causing a flow of constant bias current.
Referring to FIG. 2 , 204 represents a column processing circuit section where pixel signals outputted from the above described source follower circuits are respectively subjected to correlation double sampling (CDS) by means of column processing circuit CDS 1 , CDS 2 , CDS 3 provided for each column whereby signal processing is effected for example to remove such offset variance as fixed pattern noise of pixel, and then a result of the signal processing is stored. 205 represents a horizontal scanning circuit for effecting column selection from which horizontal scanning signals φ HSR(j) (j=1, 2, 3) are sequentially outputted. 206 represents a horizontal select switch section where the signal processing result stored at the column processing circuit section 204 is transmitted to the horizontal signal line 207 in accordance with the horizontal scanning signal φ HSR(J) (j=1, 2, 3). 208 represents an amplifier for amplifying and outputting to the outside the signal processing result stored at the column processing circuit 204 which has been transmitted to the horizontal signal line 207 .
A drive timing at the time of taking moving picture with thus constructed MOS solid-state imaging apparatus will now be described by way of a timing chart in FIG. 4 . When the vertical scanning signal of the first row φ VSR( 1 ) is outputted from the vertical scanning circuit 202 , the pixels in the first row are made drivable. More particularly, for the pixels of the first row, the row select signal φ SE may be transmitted to the gate terminal of the select transistor 105 of the first row pixels as the select signal of the first row φ SE( 1 ) through the vertical select circuit MV 1 and the row select line 109 . Further, the row reset signal φ RS may be transmitted to the gate terminal of the reset transistor 103 of the first row pixels as the reset signal of the first row φ RS( 1 ) through the vertical select circuit MV 1 and the row reset line 107 . Furthermore, the row transfer signal φ TR may be transmitted to the gate terminal of the transfer transistor 102 of the first row pixels as the transfer signal of the first row φ TR( 1 ) through the vertical select circuit MV 1 and the row transfer line 108 .
An operation in period Tv will first be described. When the vertical scanning signal φ VSR( 1 ) attains “H” level and then the row select signal φ SE( 1 ) attains “H” level, an output of the amplification transistor 104 may be transmitted onto the vertical signal line 110 . In other words, a period for effecting reading of signal and processing of signal is started. Next, when the row reset signal φ RS( 1 ) attains “H” level, the gate terminal of the amplification transistor 104 is reset to the level of a pixel power supply VDD. Next, the row reset signal φ RS( 1 ) is brought to “L” level so that a reset level output outputted from the amplification transistor 104 at this time is sampled at the column processing circuit section 204 .
Next, the row transfer signal φ TR( 1 ) is driven to “H” level to transfer photo-generated electric charges accumulated at the photodiode 101 are transferred to the gate terminal of the amplification transistor 104 . The row transfer signal φ TR( 1 ) is then brought to “L” level to sample again at the column processing circuit section 204 a signal level output outputted at this time. Subsequently at the column processing circuit section 204 , a differential processing between the sampled signal level output and reset level output is performed and the signals after the differential processing are stored respectively at the column processing circuits CDS 1 , CDS 2 , and CDS 3 . The row select signal φ SE( 1 ) is then brought to “L” level whereby the period for effecting signal read and signal processing is ended. When transfer of the photo-generated electric charges accumulated at the photodiode 101 to the gate terminal of the amplification transistor 104 is complete, the photodiode 101 is reset and an accumulation of photo-generated electric charge is started at the photodiode 101 .
An operation in period Th will next be described. When the horizontal scanning signal φ HSR(j) (j=1, 2, 3) is sequentially outputted from the horizontal scanning circuit 205 , the signals after the differential processing stored at the column processing circuits CDS 1 , CDS 2 , CDS 3 in the column processing circuit section 204 are sequentially read out onto the horizontal signal line 207 respectively through horizontal select switches MH 1 , MH 2 , and MH 3 in the horizontal select switch section 206 . The signals read out onto the horizontal signal line 207 are amplified at the output amplifier 208 and are outputted to the outside. The signal to be outputted to the outside is shown as Vout in FIG. 4 . At this time, a suitable bias current in accordance with signal band is supplied to the output amplifier section 208 .
Signals of the pixels corresponding to one row are read out with the above operation. By sequentially effecting this operation from the first row to the third row, signals of all the pixels in the pixel section 200 can be read out. In particular, the pixel signals of the pixels P 11 to P 33 in the light receiving pixel section 200 are sequentially outputted as Vout from the output amplifier section 208 . The periods of the above constitute 1 frame period Tf which in this description, corresponds to an accumulation period of photo-generated electric charge at the photodiode 101 .
A description will next be given with respect to case where a still picture is taken with using the solid-state imaging apparatus shown in FIG. 2 . In the still picture taking, a mechanical shutter is used to determine an exposure time. In the operation at the time of still picture taking, all pixels are reset (initial reset) in a condition shielded from light by closing the mechanical shutter, and an exposure is subsequently started by opening a first blind of the mechanical shutter. After passage of a desired time, then, light is cut off by closing a second blind of the mechanical shutter so as to end the exposure.
After the end of the exposure, a read operation is rendered.
In transition to the still picture taking from a moving picture taking for example in a live view mode, since the mechanical shutter is always opened at the time of taking moving picture, the mechanical shutter must be closed once and a time lag in the transition is inevitable with the above described method for determining exposure where mechanical shutter is used. In recent years, there is thus provided a method in which an exposure is started by reset operation (initial reset) of the solid-state imaging apparatus to eliminate the time lag in the transition, and the exposure is ended by a mechanical shutter. This method will be referred to hereinafter as first blind electronic shutter. In the first blind electronic shutter operation, it is necessary to perform an initial reset operation and an operation of the mechanical shutter at the same speed so as to match the exposure time between the upper and lower sides of an image. At this time, since mechanical shutter operates at such a high speed as several ms, the initial reset operation must also be performed at a high speed in several ms.
FIG. 5 is a timing chart showing drive timing at the time of still picture taking with using the first blind electronic shutter. When the vertical scanning signal of the first row φ VSR( 1 ) is outputted from the vertical scanning circuit 202 , the first row pixels are made drivable. When the vertical scan signal φ VSR( 1 ) attains “H” level and then the row reset signal φ RS( 1 ) attains “H” level, the reset transistors 103 of the pixels corresponding to one row are turned ON. Next, when the row transfer signal φ TR( 1 ) attains “H” level, the photodiodes 101 of the first row attain the power supply voltage VDD whereby the photodiodes 101 are reset and an exposure is started. The second row and after are treated in like manner. After passage of a desired time, then, the exposure is ended by closing the mechanical shutter and signals are read out. The reading of the signals is similar to the signal read operation described in FIG. 4 . In the still picture taking, however, since light is cut off at the time of reading, an exposure is not started even after the transferring of photo-generated electric charge is ended.
At the time of initial reset in first blind electronic shutter operation, while the initial reset operation is rendered as shown in FIG. 5 as the reset operation alone is sequentially effected on each row, an initial reset period becomes longer when the number of rows is increased with an increase in the number of pixels; it becomes impossible to meet the mechanical shutter operation.
To make the initial reset operation correspond to the mechanical shutter operation, therefore, the vertical selecting operation must be rendered at a high speed.
Further, a method has been disclosed in Japanese Patent Application Laid-Open 2005-176105 as the method for performing a high-speed initial reset operation. In the method, a plurality of rows is simultaneously reset and this is repeated to achieve the high-speed initial reset operation.
SUMMARY OF THE INVENTION
In a first aspect of the invention, there is provided a solid-state imaging apparatus including: a pixel section having two-dimensionally arranged pixels each containing a photoelectric conversion device for converting a light signal into a signal electric charge and accumulating the signal electric charge, an amplification means for amplifying and outputting as a pixel signal the signal electric charges accumulated at the photoelectric conversion device, a transfer means for transferring the accumulated signal electric charges to the amplification means, and a reset means for resetting the signal electric charges; a vertical scanning section for outputting a vertical scanning signal to drive/control the pixel section row by row; and a vertical selecting section for generating a row transfer signal in accordance with the vertical scanning signal to drive the transfer means and for generating a row reset signal having a falling edge delayed by a predetermined amount from the row transfer signal to drive the reset means.
In a second aspect of the invention, the row reset signal in the solid-state imaging apparatus according to the first aspect is generated with delaying the whole of the transfer signal.
In a third aspect of the invention, the solid-state imaging apparatus according to the first aspect further includes a control section for, in a still image taking to be performed with the step of sequentially outputting the pixel signal row by row after passage of a desired exposure period subsequently to an initial reset operation where reset operation alone is sequentially performed row by row of the pixels in the pixel section, effecting a control so that the row transfer signal and the row reset signal are generated at the time of the initial reset operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing a general pixel construction to be used in MOS solid-state imaging apparatus.
FIG. 2 is a block diagram showing a fundamental construction of MOS solid-state imaging apparatus.
FIG. 3 is a circuit diagram showing a specific construction of the vertical select circuit in the MOS solid-state imaging apparatus shown in FIG. 2 .
FIG. 4 is a timing chart for explaining an operation at the time of taking moving picture with the MOS solid-state imaging apparatus shown in FIGS. 2 and 3 .
FIG. 5 is a timing chart for explaining an operation at the time of taking still picture with using a first blind electronic shutter in the MOS solid-state imaging apparatus shown in FIGS. 2 and 3 .
FIG. 6 is a block diagram showing an entire construction of the first embodiment of the solid-state imaging apparatus according to the invention.
FIG. 7 is a circuit diagram showing a specific construction of a portion of the vertical select circuit and the pixel in the first embodiment shown in FIG. 6 .
FIG. 8 is a block diagram showing construction of a digital camera using the solid-state imaging apparatus according to the first embodiment shown in FIGS. 6 and 7 .
FIG. 9 is a timing chart for explaining an operation at the time of taking still picture with using a first blind electronic shutter in the digital camera shown in FIG. 8 .
FIG. 10 is a timing chart for explaining a drive operation in a second embodiment.
FIG. 11 is a block diagram showing an entire construction of the solid-state imaging apparatus according to a third embodiment.
FIG. 12 is a circuit diagram showing a specific construction of the vertical select circuit in the third embodiment shown in FIG. 11 .
FIG. 13 is a timing chart for explaining an operation at the time of taking moving picture in the third embodiment shown in FIGS. 1 and 12 .
FIG. 14 is a timing chart for explaining an operation at the time of taking still picture with using a first blind electronic shutter in the third embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Some embodiments of the solid-state imaging apparatus according to the invention will be described below with reference to the drawings.
(Embodiment 1)
A first embodiment of the solid-state imaging apparatus according to the invention will now be described by way of FIGS. 6 , 7 , 8 , and 9 . This embodiment corresponds to the first to third aspects of the invention. FIG. 6 is a block diagram showing construction of the solid-state imaging apparatus as a whole according to the first embodiment. The solid-state imaging apparatus according to this embodiment has a construction identical to the prior-art example shown in FIG. 2 but the construction of vertical select circuits MV 10 , MV 20 , MV 30 of the vertical selecting section 203 and that a control section 209 for controlling these is provided. Its description on the whole will be omitted. FIG. 7 is a circuit diagram showing a specific construction of the vertical select circuit (MV 10 , MV 20 , MV 30 ). Since the pixels used here are identical to those in the prior-art example shown in FIG. 1 , the pixel construction will not be described.
Referring to FIG. 7 , 202 is a vertical scanning circuit for sequentially outputting a vertical scanning signal φ VSR(i) (i=1, 2, 3). φ SE, φ RS, φ TR, and φ CTL are a row select signal, a row reset signal, a row transfer signal, and delay circuit control signal for controlling a delay circuit 21 , respectively; these signals are controlled by the control section 209 . A signal φ SE(i) (i=1, 2, 3) taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) outputted from the vertical scanning circuit 202 and the row select signal φ SE is connected to the row select line 109 in the pixel section 200 . A signal φ TR(i) (i=1, 2, 3) taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) and the row transfer signal φ TR is connected to the row transfer line 108 in the pixel section. Further, a signal φ RS(i) (i=1, 2, 3) is generated by taking OR of a signal taking AND of the vertical scanning signal φ VSR(i) (i=1, 2, 3) outputted from the vertical scanning circuit 202 and the row reset signal φ RS or a signal taking AND of the delay circuit control signal φ CTL and the transfer signal of i-th row i φ TR(i) (i=1, 2, 3); the signal φ RS(i) (i=1, 2, 3) is connected to the row reset line 107 in the pixel section 200 . While the delay circuit 21 is shown as constituted of AND circuit and OR circuit, it may also be constructed for example with using switches, delay devices, etc.
A construction of digital camera will now be described by way of FIG. 8 with respect to a case where the solid-state imaging apparatus according to the first embodiment constructed as the above is applied to the digital camera. Referring to FIG. 8 , 1 is a lens section for forming object image on a solid-state imaging apparatus 5 . At the lens section 1 , zoom, focus, and aperture are driven and controlled by a lens control apparatus 2 . 3 is a shutter serving as a light-shielding member, which in this case is a focal-plane type shutter mechanism to be used in the so-called single lens reflex camera. The shutter 3 is driven and controlled by a shutter drive apparatus 4 . 5 is the solid-state imaging apparatus having construction as shown in FIG. 6 where object formed into an image at the lens section 1 is taken in as image signal.
Further, 6 is an A/D conversion section for converting signal outputted from an output terminal of the solid-state imaging apparatus 5 into a digital signal; and 9 is an imaging signal processing circuit for rendering various types of processing on the signal outputted from the A/D conversion section 6 . Amplification of image signal, various types of correction on image data, compression of image data, etc. are effected at the imaging signal processing circuit 9 . 7 is a drive circuit for driving and controlling the solid-state imaging apparatus 5 ; 11 is a control apparatus for controlling the digital camera as whole; 8 is a memory section for temporarily storing image data; and 10 is an attachable/detachable recording medium such as of semiconductor memory for recording or reading image data.
An operation at the time of taking still picture with using the first blind electronic shutter in the digital camera having the above construction will be described below by way of a timing chart in FIG. 9 . At the time of initial reset, the row select signal φ SE and the row reset signal φ RS are continuously at “L” level, and the row transfer signal φ TR and the delay circuit control signal φ CTL are continuously at “H” level. When the vertical scanning signal of the first row φ VSR( 1 ) is outputted from the vertical scanning circuit 202 , the pixels of the first row are made drivable. When the vertical scan signal φ VSR( 1 ) attains “H” level, the transfer signal of the first row φ TR( 1 ) becomes a signal like the vertical scanning signal φ VSR( 1 ) because the row transfer signal φ TR is at “H” level. Since the row reset signal φ RS is continuously at “L” level, the signal taking AND of the vertical scanning signal φ VSR( 1 ) and the row reset signal φ RS attains “L” level.
Further, since the delay circuit control signal φ CTL is continuously at “H” level, the signal taking AND of the first row transfer signal φ TR( 1 ) and the delay circuit control signal φ CTL is a signal like the first row transfer signal φ TR( 1 ). Accordingly, since the reset signal of the first row φ RS( 1 ) becomes a signal taking OR of its “L” level or the row transfer signal of the first row φ TR( 1 ), the first row reset signal φ RS( 1 ) becomes a signal like the first row transfer signal φ TR( 1 ). The timing of the first row reset signal φ RS( 1 ), however, occurs as it is delayed correspondingly to the fact that it goes through the delay circuit 21 where AND and OR are taken as compared to the first row transfer signal φ TR( 1 ). An accumulation of photo-generated electric charge at the pixels of the first row is started from a point in time when the reset signal of the first row φ RS( 1 ) is changed from “H” level to “L” level. After passage of a desired time, then, the accumulation is ended as the mechanical shutter is closed to cut off an incident light. The second row and after are treated in like manner.
A signal read operation at the time of this still picture taking is similar to the signal read operation in the prior-art example described in FIG. 4 . At the time of taking a still picture, however, an exposure is not started even after the transferring of photo-generated electric charge is ended because light is cut off when the signal is read out.
Thus, the solid-state imaging apparatus having the above described construction is used to generate a transfer signal from the vertical scanning signal, and the transfer signal is delayed to generate a reset signal. Since it is thus not necessary to make allowance for timing margin between the signals and since a sequential reset is ended row by row, a high-speed initial reset becomes possible without causing exposure unevenness in image. Accordingly, the solid-state imaging apparatus may be achieved as capable of meeting a high-speed mechanical shutter operation.
(Embodiment 2)
A second embodiment of the invention will now be described by way of FIG. 10 . This embodiment also corresponds to the first to third aspects of the invention.
The construction of the solid-state imaging apparatus in this embodiment itself is identical to the first embodiment shown in FIG. 6 . With the present embodiment, the drive in the first embodiment is so adapted that resetting is more securely effected. FIG. 10 shows a timing chart in the case where a reset time of each row at the time of initial reset is made longer in the solid-state imaging apparatus used in the first embodiment. As shown in FIG. 10 , when time twice that in the first embodiment shown in FIG. 9 is provided as the period during which the vertical scanning signal φ VSR is at “H” level, the periods during which the row transfer signal of i-th row φ TR(i) (i=1, 2, 3) and the row reset signal of i-th row φ RS(i) are at “H” level are similarly provided as twice the time shown in FIG. 9 .
In this manner, it is possible to reset more securely by providing a longer period during which the vertical scanning signal φ VSR contributing to the resetting is at “H” level. Further, the interval of reset end timing, i.e. timing for starting exposure between each row is equal to the interval between each row of the timing at which the vertical scanning signal φ VSR attains “L” level. For this reason, a high-speed initial reset becomes possible without causing exposure unevenness in image, and thus it is possible to meet a high-speed mechanical shutter operation. Naturally, the period of “H” level of the vertical scanning signal φ VSR is not limited to the time duration shown in FIG. 10 .
(Embodiment 3)
A third embodiment of the invention will now be described by way of FIGS. 11 , 12 , 13 , and 14 . This embodiment also corresponds to the first to third aspects of the invention. The solid-state imaging apparatus according to the third embodiment is constructed so that an operation for taking moving picture can also be effected in addition to the still picture taking in the case where the solid-state imaging apparatus capable of generating a transfer signal from vertical scanning signal and of generating a reset signal by delaying the transfer signal is used in a digital camera. FIG. 11 shows the construction as a whole of the solid-state imaging apparatus according to the third embodiment. It is different from the first embodiment shown in FIG. 6 in that the vertical scanning circuit and the vertical selecting section are respectively provided in 2 units, i.e. a first vertical scanning circuit 202 - 1 and a second vertical scanning circuit 202 - 2 , and a first vertical selecting section 203 - 1 and a second vertical selecting section 203 - 2 . The first vertical scanning circuit 202 - 1 and the first vertical selecting section 203 - 1 are identical to those in the prior-art example previously shown in FIG. 2 , and are to control signals to be used at the time of reading.
In the second vertical selecting section 203 - 2 shown in FIG. 12 , φ RS 2 and φ TR 2 are a row reset signal and a row transfer signal, respectively, which are to control signals used in reset. Signals φ SE, φ RS 1 , φ RS 2 , φ TR 1 , and φ TR 2 inputted to the first and second vertical selecting section 203 - 1 , 203 - 2 are controlled by a control section 209 . A delay circuit 22 in the second vertical selecting section 203 - 2 has a construction as shown in FIG. 12 where the delay circuit control signal φ CTL is removed from the delay circuit 21 in the first embodiment shown in FIG. 7 and a buffer is placed instead of AND circuit. The construction of the delay circuit 22 , however, is not limited to the above construction.
As shown in FIG. 12 , a signal taking OR of reset signals of each row outputted respectively from the first vertical selecting section 203 - 1 and the second vertical selecting section 203 - 2 becomes the row reset signal of i-th row φ RS(i) (i=1, 2, 3), and a signal taking OR of transfer signals of each row respectively outputted from the first vertical selecting section 203 - 1 and the second vertical selecting section 203 - 2 becomes the row transfer signal of i-th row φ TR(i) (i=1, 2, 3). The above described reset signal φ RS(i) (i=1, 2, 3) and the row transfer signal φ TR(i) (i=1, 2, 3) are respectively connected to each row reset signal line 107 and each row transfer signal line 108 in a pixel section 200 consisting of pixels P 11 to P 33 . In FIG. 11 , while the lines for transmitting the row select signal φ SE( 1 ), φ SE( 2 ), φ SE( 3 ), the row reset signal φ RS( 1 ), φ RS( 2 ), φ RS( 3 ), and the row transfer signal φ TR( 1 ), φ TR( 2 ), φ TR( 3 ) to each row is indicated by one solid line, and outputs of the first and second vertical select circuits (MV 1 - 1 , MV 1 - 2 , MV 1 - 3 , MV 2 - 1 , MV 2 - 2 , MV 2 - 3 ) are indicated by one solid line for each one row, these in actual setting are respectively provided independently from each other. It should be noted that, while the row select signal φ SE( 1 ), φ SE( 2 ), φ SE( 3 ) is not one taking OR of signals from the first and second vertical selecting section but is a signal coming from the first vertical selecting section alone, it is shown in FIG. 11 in a manner as outputted through OR circuit so as to facilitate illustration.
FIG. 12 as described above shows a specific construction of the vertical select circuits (MV 1 - 1 , MV 1 - 2 , MV 1 - 3 , MV 2 - 1 , MV 2 - 2 , MV 2 - 3 ) of the first and second vertical selecting section 203 - 1 , 203 - 2 in the third embodiment. The construction will now be described in more detail. Referring to FIG. 12 , 202 - 1 , and 202 - 2 are a first and a second vertical scanning circuits, and φ SE; φ RS 1 , φ RS 2 ; and φ TR 1 , φ TR 2 are a row select signal, row reset signals, and row transfer signals, respectively. The signals φ RS 1 (i) (i=1, 2, 3) and φ TR 1 (i) (i=1, 2, 3) outputted from the first vertical selecting section 203 - 1 are a signal taking AND of the first vertical scanning signal φ VSR 1 (i) (i=1, 2, 3) from the first vertical scanning circuit 202 - 1 and the row reset signal φ RS 1 , and a signal taking AND of the first vertical scanning signal φ VSR 1 (i) (i=1, 2, 3) and the row transfer signal φ TR 1 , respectively. Further, the signal φ SE(i) (i=1, 2, 3) outputted from the first vertical selecting section 203 - 1 is a signal taking AND of the first vertical scanning signal φ VSR 1 (i) (i=1, 2, 3) and the row select signal φ SE.
The signals φ RS 2 (i) (i=1, 2, 3) and φ TR 2 (i) (i=1, 2, 3) outputted from the second vertical selecting section 203 - 2 are a signal taking AND of the second vertical scanning signal φ VSR 2 (i) (i=1, 2, 3) from the second vertical scanning circuit 202 - 2 and the row reset signal φ RS 2 , and a signal taking AND of the second vertical scanning signal φ VSR 2 (i) (i=1, 2, 3) and the row transfer signal φ TR 2 , respectively.
The row reset signal φ RS(i) (i=1, 2, 3) to be transmitted to the row reset signal line 107 in the pixel section 200 is obtained as one taking OR of the signal φ RS 1 (i) (i=1, 2, 3) outputted from the first vertical selecting section 203 - 1 or the signal φ RS 2 (i) (i=1, 2, 3) outputted from the second vertical selecting section 203 - 2 .
The row transfer signal φ TR(i) (i=1, 2, 3) to be transmitted to the row transfer signal line 108 in the pixel section 200 is obtained as one taking OR of the signal φ TR 1 (i) (i=1, 2, 3) outputted from the first vertical selecting section 203 - 1 or the signal φ TR 2 (i) (i=1, 2, 3) outputted from the second vertical selecting section 203 - 2 .
An operation at the time of taking moving picture in the third embodiment will now be described by way of a timing chart shown in FIG. 13 . While reset operation and read operation are consecutively effected row by row in the taking of moving picture, the reset operation is effected by the second vertical scanning circuit 202 - 2 and the second vertical selecting section 203 - 2 and the read operation is effected by the first vertical scanning circuit 202 - 1 and the first vertical selecting section 203 - 1 . At the time of reset, the row reset signal φ RS 2 is continuously at “L” level and the row transfer signal φ TR 2 is continuously at “H” level. When the second vertical scanning signal of the first row φ VSR 2 ( 1 ) is outputted from the second vertical scanning circuit 202 - 2 , the pixels of the first row are made drivable. When the second vertical scanning signal φ VSR 2 ( 1 ) attains “H” level, the transfer signal of the first row φ TR 2 ( 1 ) becomes a signal like the second vertical scanning signal φ VSR 2 ( 1 ) because the row transfer signal φ TR 2 is at “H” level. Since the row reset signal φ RS 2 is continuously at “L” level, the signal taking AND of the second vertical scanning signal φ VSR 2 ( 1 ) and the row reset signal φ RS 2 attains “L” level.
Accordingly, since the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 becomes a signal taking OR of “L” level or the transfer signal of the first row φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 , it is a signal like the first row transfer signal φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 . The timing of the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 , however, occurs as it is delayed correspondingly to the fact that it goes through the delay circuit 22 consisting of buffer and OR circuit as compared to the first row transfer signal φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 .
The reset signal of the first row φ RS( 1 ) connected to the row reset line 107 in the pixel 100 is an OR of the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 or the reset signal of the first row φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 . Then, at the time of reset, since the first row reset signal φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 is controlled by the control section 209 so that it is at “L” level, the first row reset signal φ RS( 1 ) connected to the row reset line 107 becomes a signal like the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 . An accumulation of photo-generated electric charge is started at the pixels of the first row from a point in time when the first row reset signal φ RS( 1 ) is changed from “H” level to “L” level. The second row and after are treated in like manner.
At the time of reading, the first vertical scanning circuit 202 - 1 and the first vertical selecting section 203 - 1 operate similarly to the timings of the prior-art example shown in FIG. 4 . At this time, the reset signal of the first row φ RS( 1 ) is an OR of the reset signal of the first row φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 or the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 .
Then, in the read period, since the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 is controlled by the control section 209 so that it is at “L” level, the first row reset signal φ RS( 1 ) connected to the row reset line 107 becomes a signal like the first row reset signal φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 . A reset level output outputted when the row reset signal φ RS 1 ( 1 ) is brought to “L” level is sampled at the column processing circuit section 204 .
The transfer signal of the first row φ TR( 1 ) connected to the row transfer line 108 in the pixel 100 is an OR of the transfer signal of the first row φ TR 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 or the transfer signal of the first row φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 . Then, in the read period, since the first row transfer signal φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 is controlled by the control circuit 209 so that it is at “L” level, the first row transfer signal φ TR 1 connected to the row transfer line 108 becomes a signal like the first row transfer signal φ TR 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 . At the time of reading, the first row transfer signal φ TR( 1 ) is driven to “H” level to transfer photo-generated electric charges accumulated at the photodiode 101 to the gate terminal of the amplification transistor 104 . The row transfer signal of the first row φ TR( 1 ) is then brought to “L” level so that a read processing is effected by sampling again at the column processing circuit section 204 a signal level output outputted at this time. The second row and after are treated in like manner. It should be noted that an exposure period from the resetting to the reading shown in the timing chart of FIG. 13 corresponds but otherwise is not limited to one row.
An operation at the time of taking still picture with using the first blind electronic shutter will next be described by way of a timing chart shown in FIG. 14 . At first in the taking of still picture, a reset operation is effected by the second vertical scanning circuit 203 - 2 . At the time of initial reset, the row reset signal φ RS 2 is continuously at “L” level and the row transfer signal φ TR 2 is continuously at “H” level. When the second vertical scanning signal of the first row φ VSR 2 ( 1 ) is outputted from the second vertical scanning circuit 202 - 2 , the pixels of the first row are made drivable. When the second vertical scanning signal φ VSR 2 ( 1 ) attains “H” level, the transfer signal of the first row φ TR 2 ( 1 ) becomes a signal like the second vertical scanning signal φ VSR 2 ( 1 ) because the row transfer signal φ TR 2 is at “H” level. Since the row reset signal φ RS 2 is continuously at “L” level, the signal taking AND of the second vertical scanning signal φ VSR 2 ( 1 ) and the row reset signal φ RS 2 attains “L” level.
Accordingly, since the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 becomes a signal taking OR of “L” level or the transfer signal of the first row φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 , it becomes a signal like the first row transfer signal φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 . The timing of the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 , however, occurs as it is delayed correspondingly to the fact that it goes through the delay circuit 22 consisting of buffer and OR circuit as compared to the transfer signal of the first row φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 .
The reset signal of the first row φ RS( 1 ) connected to the row reset line 107 in the pixel 100 is an OR taken from the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 or the reset signal of the first row φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 . Then, at the time of reset, since the first row reset signal φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 is controlled by the control section 209 so that it is at “L” level, the first row reset signal φ RS( 1 ) connected to the row reset line 107 becomes a signal like the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 . An accumulation of photo-generated electric charge is started at the pixels of the first row from the point in time when the first row reset signal φ RS( 1 ) is changed from “H” level to “L” level. The second row and after are treated in like manner. Subsequently, after passage of a desired time, the exposure is ended by the mechanical shutter.
A read operation is then effected by causing the first vertical scanning circuit 203 - 1 alone to operate. At the time of reading, the first vertical scanning circuit 202 - 1 and the first vertical selecting section 203 - 1 operate similarly to the timing in the prior-art example shown in FIG. 4 . At this time, the reset signal of the first row φ RS( 1 ) is an OR taken from the reset signal of the first row φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 or the reset signal of the first row φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 .
Then, in the read period, since a control is effected by the control section 209 so that the first row reset signal φ RS 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 attains “L” level, the first row reset signal φ RS( 1 ) connected to the row reset line 107 is obtained as a signal like the first row reset signal φ RS 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 . A reset level output outputted when the row reset signal φ RS 1 ( 1 ) is brought to “L” level is sampled at the column processing circuit section 204 .
The transfer signal of the first row φ TR( 1 ) connected to the row transfer line 108 in the pixel 100 is an OR taken from the transfer signal of the first row φ TR 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 or the transfer signal of the first row φ TR 2 ( 1 ) outputted from the second vertical selecting section 203 - 2 .
Then, in the read period, since a control is effected by the control section 209 so that the first row transfer signal φ TR 2 ( 1 ) outputted form the second vertical selecting section 203 - 2 attains “L” level, the first row transfer signal φ TR 1 ( 1 ) connected to the row transfer line 108 becomes a signal like the first row transfer signal φ TR 1 ( 1 ) outputted from the first vertical selecting section 203 - 1 .
At the time of reading, the first row transfer signal φ TR( 1 ) is driven to “H” level to transfer photo-generated electric charges accumulated at the photodiode 101 to the gate terminal of the amplification transistor 104 . The transfer signal of the first row φ TR( 1 ) is then brought to “L” level so that read processing is effected by sampling again at the column processing circuit section 204 a signal level output outputted at this time. The second row and after are treated in like manner.
With the solid-state imaging apparatus according to the third embodiment having circuit construction as shown above in FIGS. 11 and 12 , the operation shown in the timing charts in FIGS. 13 and 14 is effected, whereby a high-speed mechanical shutter operation can be met in still picture taking without causing exposure unevenness in image and at the same time with making a high-speed initial reset possible, and taking of moving picture is also made possible.
According to the first and second aspects of the invention as has been described by way of the above embodiments, it is not necessary to take timing margin into consideration by generating the row transfer signal and the row reset signal from the vertical scanning signal; and at this time, since the row reset signal is generated with delaying the falling of the row transfer signal, the row reset signal attains “L” level as it is delayed from the row transfer signal so that reset operation is more securely effected. Accordingly, it is possible to achieve a solid-state imaging apparatus where the speed of an initial reset operation in the vertical direction can be increased so as to meet a high-speed mechanical shutter operation. Further, according to the third aspect of the invention, since it is not necessary to take timing margin into consideration similarly to the first and second aspects, a high speed reset operation can be rendered at the time of an initial reset operation in still picture taking.
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A solid-state imaging apparatus including: a pixel section having two-dimensionally arranged pixels each containing a photoelectric conversion device for converting a light signal into a signal electric charge and accumulating the signal electric charge, an amplification means for amplifying and outputting as a pixel signal the signal electric charges accumulated at the photoelectric conversion device, a transfer means for transferring the accumulated signal electric charges to the amplification means, and a reset means for resetting the signal electric charges; a vertical scanning section for outputting a vertical scanning signal to drive/control the pixel section row by row; and a vertical selecting section for generating a row transfer signal in accordance with the vertical scanning signal to drive the transfer means and for generating a row reset signal having a falling edge delayed by a predetermined amount from the row transfer signal to drive the reset means.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to semiconductor devices and, more particularly, relates to electrostatic discharge protection transistors for integrated circuits.
BACKGROUND OF THE INVENTION
[0002] Electro-static discharge (ESD) or electrical overstress (EOS) is a significant problem in integrated circuit design, especially for devices with high pin counts and circuit speeds. ESD refers to the phenomena wherein a high energy electrical discharge of current is produced at the input and/or output nodes of an integrated circuit (IC) device as a consequence of static charge build-up on the IC package. The static charge build up can result from handling of the IC device by a human body or from handling by IC device manufacturing equipment. Electrostatic discharge has the potential to disable or destroy an entire device, at worst, and to decrease the device's reliability at best.
[0003] In general, smaller scale metal oxide semiconductor (MOS) devices with thinner gate oxides are more sensitive to ESD than larger scale devices with thicker oxides. For MOS devices having 1 micron or smaller geometries, discharges of approximately 1.5 amperes can damage or even destroy gates if adequate ESD protection is not provided. Modem flash memory devices with small cell sizes, including traditional floating gate and SONOS memory devices, are highly vulnerable to ESD and require sensitive and fast acting ESD protection circuits.
[0004] A variety of ESD protection circuits are available. These circuits can be based on small diodes, Zener diodes, bipolar junction transistors, and/or field effect transistors (FETs). The circuits can be connected between input or output pins and Vcc or Vss power supply pins. Power supply clamps, such as Vcc/Vss clamp structures, are also available. However, there remains an unsatisfied need for more sensitive and faster responding ESD circuits.
SUMMARY OF THE INVENTION
[0005] The following presents a simplified summary of the invention in order to provide a basic understanding of some of its aspects. This summary is not an extensive overview of the invention and is intended neither to identify key or critical elements of the invention nor to delineate its scope. The sole purpose of this summary is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.
[0006] One aspect of the present invention provides a process for forming IC devices with ESD protection transistors. According to one aspect of the invention, an ESD protection transistor is provided with a light doping and then, after forming spacers, a heavy doping. The heavy doping with spacers in place can lower the sheet resistance, enhance the bipolar effect for the transistor, reduce the transistor's capacitance, and reduce the junction breakdown voltage, all without causing short channel effects. The invention thereby provides ESD protection transistors that are compact, highly sensitive, and fast-switching. The spacers can be formed at the same time as spacers for other transistors, such as other transistors in a peripheral region of the device. According to another aspect of the invention, the number of processing steps is reduced by providing the heavy ESD protection transistor implant without masking other transistors of the same type (n-channel or p-channel).
[0007] Other advantages and novel features of the invention will become apparent from the following detailed description of the invention and the accompanying drawings. The detailed description and drawings provide certain illustrative examples of the invention. These examples are indicative of but a few of the various ways in which the principles of the invention can be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 is a schematic illustration of an integrated circuit with an ESD protection transistor according to one aspect of the present invention.
[0009] [0009]FIG. 2 illustrates a flow chart of a process according to another aspect of the present invention.
[0010] [0010]FIG. 3 is a schematic illustration of a gate stack for ESD protection transistors.
[0011] [0011]FIG. 4 is a schematic illustration of the gate stack of FIG. 3 after patterning to form a transistor.
[0012] [0012]FIG. 5 is a schematic illustration of the transistor of FIG. 4 after LDD doping and depositing a spacer material.
[0013] [0013]FIG. 6 is a schematic illustration of the transistor of FIG. 4 after the spacer material has been etched.
[0014] [0014]FIG. 7 is a schematic illustration of the transistor of FIG. 4 after a heavy dopant implant.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention involves a process for fabricating IC devices. The IC devices typically include core and peripheral regions. For example, the IC devices can be non-volatile memory devices with core memory cells and peripheral region gates for selectively addressing the core memory cells. The IC devices include ESD protection and other transistors. The ESD protection transistors are MOSFETs with source and drain regions that include lightly doped regions immediately adjacent the channel and heavily doped regions spaced apart from the channel. The heavily doped regions can be spaced apart from the channel by employing spacers formed simultaneously with spacers used in doping source and drain regions of other MOSFETs of the IC device. The heavily doped regions around the ESD protection transistors can be employed to lower sheet resistance, lower junction break down, and/or increase the bipolar effect, without causing short channel effects.
[0016] The IC devices can be, for example, memory devices or logic devices. Memory devices can be, for example, electrically erasable programmable memory devices, such as flash memory devices. Flash memory devices can have floating gates or can be of SONOS type. The memory structure can be NAND or NOR and can be a virtual ground array with buried bit lines. The invention is particularly well suited for use in manufacturing very small scale MOS devices, such as the foregoing nonvolatile memory devices, with ESD protection.
[0017] The present invention is now described with reference to the figures, wherein like features are referred to with like numbers throughout. FIG. 1 schematically illustrates a portion of the peripheral region of an IC device 100 according to one aspect of the present invention. IC device 100 comprises isolation regions 126 , transistor 106 , and ESD protection transistor 112 on substrate 102 . Substrate 102 comprises a semiconductor such as Si, GaAs, or InP. For example, the substrate can be a silicon wafer or silicon on insulator (SOI). The semiconductor can be doped n-type or p-type. The doping can include multiple layers or wells.
[0018] Transistor 106 includes an insulating layer 110 , which is generally an oxide, and a poly layer 108 . A poly layer is a layer containing amorphous silicon or polysilicon. Source and drain regions adjacent transistor 106 include lightly doped regions 120 and heavily doped regions 118 . Transistor 106 can be n-channel or p-channel. IC device 100 may have both n-channel and p-channel transistors.
[0019] ESD protection transistor 112 includes an insulating layer 116 , which is generally an oxide, and a poly layer 114 . Poly layers 108 and 114 are generally formed at the same time. On the other hand, insulating layers 110 and 116 often have different thicknesses. In one aspect of the invention, the thicknesses of insulating layer 116 is in the range from about 30 to about 500 Å. In another aspect of the invention, the thicknesses of insulating layer 116 is in the range from about 50 to about 120 Å. In a further aspect of the invention, the thicknesses of insulating layer 116 is in the range from about 60 to about 100 Å.
[0020] Source and drain regions adjacent ESD protection transistor 112 include lightly doped (LDD) regions 124 and heavily doped regions 122 . Symmetric source and drain regions are illustrated, however, the invention extends to devices having ESD protection transistors with asymmetric source and drain regions. ESD protection transistor 112 is generally a p-channel transistor, but it can also be n-channel.
[0021] There are generally differences in the dopant concentrations among ESD protection transistor 112 and other transistors of IC device 100 , such as transistor 106 , particularly with respect to the dopant concentrations of heavy doped regions adjacent the transistors. However, the spacing of the heavily doped regions from the channels of the transistors generally provides evidence that heavy doping took place with spacers in place and that the spacers for the different types of transistors were formed simultaneously.
[0022] The channel length of ESD protection transistor 112 can be relatively small. In one aspect of the invention, the channel length is less than or equal to about 1.0 μm. In another aspect of the invention, the channel length is less than or equal to about 0.25 μm. In a further aspect of the invention, the channel length is less than or equal to than about 0.15 μm.
[0023] Substrate 102 , at least in the channel region of ESD device 112 , is generally implanted to set the threshold voltage (VT). The implant can be light (n− or p−) or heavy (n+ or p+). Examples of suitable dopants include one or more of arsenic, boron, and phosphorus. The doping can involve several layers or wells. Generally, the uppermost well is p-type.
[0024] LDD regions 124 are generally doped n-type, with arsenic or phosphorus, for example. In one aspect of the invention, LDD regions 124 are doped to a concentration of about 1×10 15 to about 5×10 18 atoms per cm 3 . In another aspect of the invention, LDD regions 124 are doped to a concentration of about 3×10 15 to about 1×10 18 atoms per cm 3 . In a further aspect of the invention, LDD regions 124 are doped to a concentration of about 1×10 16 to about 5×10 17 atoms per cm 3 .
[0025] Heavily doped regions 122 are generally doped n-type as well. In one aspect of the invention, heavily doped regions 122 are doped to a concentration of about 1×10 17 to about 1×10 21 atoms per cm 3 . In another aspect of the invention, heavily doped regions 122 are doped to a concentration of about 1×10 18 to about 3×10 20 atoms per cm 3 . In a further aspect of the invention, heavily doped regions 122 are doped to a concentration of about 5×10 18 to about 1×10 20 atoms per cm 3 .
[0026] During an ESD event, a large current flows through IC device 100 . When the voltage applied to the drain of ESD device 112 exceeds a critical value, current flows through ESD device 112 , at first by avalanche breakdown. Subsequently, the mechanism shifts to low impedance bipolar operation, whereby a large current can flow with a low voltage.
[0027] [0027]FIG. 2 provides a flow chart showing certain actions in a process 200 in accordance with another aspect of the invention, which can be employed to produce IC device 100 . Act 202 is forming isolation regions. These isolation regions include a dielectric material, usually an oxide, and are generally distributed in a grid pattern across the semiconductor substrate. In one aspect of the invention, the isolation regions are from about 50 nm to about 5000 nm thick. In another aspect of the invention, the isolation regions are from about 100 nm to about 1000 nm thick. In a further aspect of the invention, the isolation regions are from about 250 nm to about 650 nm thick.
[0028] The isolation regions can be formed by any suitable method, including LOCOS (local oxidation of silicon) and STI (shallow trench isolation) processes. In both processes, the substrate is first masked leaving only the future sites for the isolation regions exposed. In the LOCOS process, the substrate is heated in the presence of an oxidizing gas, such as air, whereby oxide grows on the exposed regions. In the STI process, the exposed substrate is etched away, forming trenches. The trenches are then filled with a dielectric material such as an oxide and/or a nitride. For example, the trenches may be filled by CVD depositing tetraethyl orthosilicate (TEOS). There generally follows an etching step where the surface is planarized, whereby dielectric outside the trenches is removed. A LOCOS process can also be combined with an STI process to form trenches coated with oxide.
[0029] Act 204 is implanting channel regions for ESD protection transistors to set the threshold voltage (V T ). Channel regions for other transistors can also be implanted at this time. The channel regions of the ESD protection transistors can be doped lightly (n− or p−) or heavily (n+ or p+). Examples of suitable dopants include one or more of arsenic, boron, and phosphorus. The doping can comprise several layers or wells. Generally, the uppermost well is made p-type. For example, boron can be implanted to a dosage of about 1×10 11 atoms per cm 2 to about 1×10 13 atoms per cm 2 . The implant can be carried out with an energy of about 10 kev to about 300 keV. In one aspect of the invention, the channel regions are doped to a concentration of about 1×10 16 to about 1×10 21 atoms per cm 3 . In another aspect of the invention, the channel regions are doped to a concentration of about 1×10 19 to about 3×10 20 atoms per cm 3 . In a further aspect of the invention, the channel regions are doped to a concentration of about 5×10 19 to about 1×10 20 atoms per cm 3 .
[0030] Subsequently, transistor gate stacks are formed. These include ESD and non-ESD protection transistor gate stacks. FIG. 3 illustrates an ESD protection transistor gate stack, which includes gate oxide layer 304 and poly layer 306 formed over semiconductor substrate 302 . Gate stacks in the core generally have thinner gate oxides than gate stacks in the peripheral region. Aside from gate oxide layer 304 , two oxide thicknesses are often employed in the periphery, one for low voltage gates and another for high voltage gates. For example, the peripheral region can comprise low voltage gates with gate oxides from about 50 Å to about 150 Å thick and high voltage gates with gate oxides from about 150 Å to about 400 Å thick. All gate oxides are typically grown in part at the same time. Additional oxidation steps are employed where greater thickness of gate oxide is required.
[0031] Gate oxides can be formed by any suitable processes including chemical vapor deposition (CVD), dry oxidation, wet oxidation, or thermal oxidation. For example, the gate oxide layer 304 can be formed by dry oxidation at temperatures over about 900° C. in an atmosphere comprising oxygen, HCl and argon.
[0032] The poly layer 306 contains amorphous silicon or polysilicon. Poly layer 306 can be shared by all transistors in the periphery. In one aspect of the invention, the poly layer has a thickness from about 500 Å to about 6,000 Å. In another aspect of the invention, the poly layer has a thickness from about 750 Å to about 3,000 Å. In a further aspect of the invention, the poly layer has a thickness from about 1,000 Å to about 2,000 Å. The poly layer can be formed by any suitable means. For example, an amorphous silicon layer can be deposited via CVD at 530° C. and 400 mTorr with a gas containing SiH 4 and helium.
[0033] Where the core region contains memory cells, a memory cell stack in the core region can be formed around the same time as gate stacks for ESD protection transistors and other transistors of the peripheral region. The memory cell stack can be a conventional floating gate stack, including a gate oxide, a polysilicon or amorphous silicon floating gate, a multi-layer dielectric, and a poly layer.
[0034] The memory cell stack can also be a SONOS type memory cell stack. A SONOS memory cell stack includes a charge trapping dielectric under a poly layer. The charge trapping dielectric can be any layer or layers that are capable of, or facilitate, electron trapping. For example, charge trapping dielectrics include an ONO trilayer dielectric, an oxide/nitride bilayer dielectric, a nitride/oxide bilayer dielectric, an oxide/tantalum oxide bilayer dielectric (SiO 2 /Ta 2 O 5 ), an oxide/tantalum oxide/oxide trilayer dielectric (SiO 2 /Ta 2 O 5 /SiO 2 ), an oxide/strontium titanate bilayer dielectric (SiO 2 /SrTiO 3 ), an oxide/barium strontium titanate bilayer dielectric (SiO 2 /BaSrTiO 2 ), an oxide/strontium titanate/oxide trilayer dielectric (SiO 2 /SrTiO 3 /SiO 2 ), an oxide/strontium titanate/barium strontium titanate trilayer dielectric (SiO 2 /SrTiO 3 /BaSrTiO 2 ), and the like (in each case, the first layer mentioned is the bottom layer while the last layer mentioned is the top layer). Although the term SONOS is suggestive of an ONO layer, as used herein the term encompasses nonvolatile memory devices containing any of the charge trapping dielectrics described above. In other words, a SONOS type nonvolatile memory device contains any dielectric layer or layers that are capable of or facilitate electron trapping, and does not require an ONO charge trapping dielectric.
[0035] Where the charge trapping dielectric is an ONO dielectric, one or both of the silicon dioxide layers can be a silicon-rich silicon dioxide layer. One or both of the silicon dioxide layers can also be an oxygen-rich silicon dioxide layer. One or both of the silicon dioxide layers can be a thermally grown or a deposited oxide. One or both of the silicon dioxide layers can be nitrided oxide layers. A nitride layer can be a silicon-rich silicon nitride layer or a silicon nitride containing oxygen. The nitride can also be a nitrogen-rich silicon nitride layer.
[0036] The ESD protection transistors are formed in act 208 by patterning layers 304 and 306 . A patterned ESD protection transistor 308 is illustrated in FIG. 4. Other IC device components can also be patterned at this time. Patterning can be carried out with any suitable method, including, for example, a lithographic process.
[0037] In the case of a memory device, patterning is also employed to divide the poly layer of the core region into word lines. Source/drain regions, forming buried bit lines, can occupy spaces between word lines in the finished device. In one aspect of the invention, the spacing between word lines, except where contacts are placed, is from about 0.15 μm to about 1.5 μm. In another aspect of the invention, spacing between word lines is from about 0.18 μm to about 1 μm. In a further aspect of the invention, the spacing between word lines from about 0.2 μm to about 0.75 μm. The widths of the word lines are comparable to the spaces between word lines.
[0038] Act 210 involves one or more LDD doping processes, which are applied at least in the periphery and to at least the ESD protection transistors. FIG. 4 illustrates an LDD doping process, which results in lightly doped regions 310 as illustrated in FIG. 5. During this process, other transistors or sections of the device can be masked, if necessary or desired. There can be several LDD doping steps, wherein n-channel and p-channel transistors are masked and implanted separately. Act 210 provides an implantation for ESD protection transistors at a dosage, for example, of about 1×10 11 atoms/cm 2 to about 1×10 14 atoms/cm 2 at an energy of about 20 keV to about 80 keV. Suitable dopants can include, for example, arsenic, boron, or phosphorus.
[0039] Act 212 is depositing a spacer material, such as the coating of spacer material 312 over device 308 illustrated in FIG. 5. Any suitable material can be used, including a nitride and/or an oxide, for example. An oxide layer can be formed by depositing than oxidizing TEOS. Using CVD techniques, a nitride layer can also be deposited. The spacer material is deposited at least over the ESD protection transistors, and generally over other transistors as well.
[0040] The spacer material is etched in act 214 . Any suitable etching process can be used that leaves a comparatively thick layer of spacer material to the sides of the ESD protection transistors. The etching is usually an anisotropic etching process, such as reactive ion etching. Choice of a suitable process and reagents depends on the spacer material. Reactive ion etching of an oxide spacer can be carried out with CF 4 , for example. FIG. 6 illustrates spacers 312 formed by anisotropically etching spacer material 312 .
[0041] Act 216 is heavily doping source and drain regions for ESD protection transistors, as illustrated in FIG. 6. The spacers limit doping immediately adjacent the ESD protection transistors, whereby the resulting heavily doped regions 314 are spaced apart from the channel region of ESD protection transistor 308 , as illustrated in FIG. 7. In one aspect of the invention, the dopants are implanted to a dosage from about 1×10 14 to about 1×10 16 atoms/cm 2 . In another aspect of the invention, the dopants are implanted to a dosage from about 5×1 14 to about 7×10 15 atoms/cm 2 . In a further aspect of the invention, the dopants are implanted to a dosage from about 1×10 15 to about 5×10 15 atoms/cm 2 . Suitable energies are, for example, in the range from about 60 keV to about 100 keV.
[0042] Transistors other than ESD protection transistors may or may not be masked during the act 216 . In one aspect of the invention, however, non-ESD protection transistors of the same type (n-channel or p-channel) as the ESD protection transistors are unmasked during act 216 . The spacers prevent the heavy doping from causing a short channel effect in the non-ESD protection transistors.
[0043] Further processing is performed to complete the fabrication of the IC device. Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to those skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, circuits, etc.), the terms (including any reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired and advantageous for any given or particular application
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One aspect of the present invention provides a process for forming IC devices with ESD protection transistors. According to one aspect of the invention, an ESD protection transistor is provided with a light doping and then, after forming spacers, a heavy doping. The heavy doping with spacers in place can lower the sheet resistance, enhance the bipolar effect for the transistor, reduce the transistor's capacitance, and reduce the junction breakdown voltage, all without causing short channel effects. The invention thereby provides ESD protection transistors that are compact, highly sensitive, and fast-switching. The spacers can be formed at the same time as spacers for other transistors, such as other transistors in a peripheral region of the device.
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This application is a continuation-in-part of copending application Ser. No. 07/148,584 filed Jan. 26, 1988, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for applying liquid finish to a moving continuous filament yarn. More particularly, it relates to an improved groove-type finish applicator that provides uniform finish application to a moving continuous filament yarn with a capability to compensate for yarn misalignment in the slot.
U.S. Pat. No. 4,397,164 of common assignee discloses a yarn finish applicator in which finish is metered to a slot running from top to bottom of the applicator. The configuration of the body of the applicator and its slot provides an edge at the exit end of the applicator and a slot that is slightly wider at the location at which finish is metered to the slot than at exit of the slot.
The yarn finish applicator includes a body member that has top, opposed side, front and back surfaces. A slot with bottom and side walls is formed in the front surface running from top to bottom of the body member. The slot has bottom and side walls with a passage connecting the back surface of the body member through which is metered the desired quantity of liquid finish. The lower portion of the front and back surfaces of the body member are angled downwardly toward each other and in conjunction with the opposed side surfaces which taper downwardly toward each other form an adge at the bottom wall of the slot. The side walls of the slot taper inwardly toward the bottom wall while tapering toward each other from top to bottom. This unique slot configuration not only facilitates placing the moving yarn line in the applicator slot but also prevents the finish from migrating by surface-tension-induced spreading away from the yarn path.
In the apparatus disclosed in the above-noted patent, liquid finish is applied to the yarn through a passage 30 in the bottom wall 28 of the slot 20. When the threadline is aligned in the slot a uniform finish application to the threadline results. However, it has been found that the requirements to adapt these applicators to certain existing equipment are extremely difficult to implement and as a consequence, on occasion, threadline misalignment occurs with respect to the slot in the applicator resulting in less than the desired uniformity of finish application to the threadline passing through the applicator. This is particularly true when the threadline is moving at speeds greater than 3500 meters/minute and applying low finish levels, i.e. about 1%, to the threadline.
SUMMARY OF THE INVENTION
The present invention provides an improvement in the apparatus described in U.S. Pat. No. 4,397,164. In the apparatus of the present invention, the passage supplying liquid to the slot extends through the bottom wall and partially up the side walls of the slot to provide a uniform finish application regardless of threadline alignment within the slot.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the finish applicator of this invention.
FIG. 2 is a cross-sectional view of FIG. 1 taken along line 2--2.
FIG. 3 is an enlarged view of the cross-sectioned applicator body member as seen in FIG. 2.
FIG. 4 is an enlarged front view of the applicator body member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the embodiment chosen for purposes of illustration includes an applicator body member 10, a pipe 13, and a bracket 15. The pipe 13 is held in a bore through the upper portion of bracket 15 by means of a set screw 17. The pipe is connected to a source of liquid finish (not shown) by means of fitting 19. The applicator body member 10 which is cemented into the outlet end of pipe 13 has a top surface 12, opposed side surfaces 14, 16 and a front surface 22 which terminates in a lower portion 22a. The slot 20 runs from the top surface 12 to the bottom of the applicator body member and is defined by side walls 24, 26 and bottom wall 28. A passage 30 is configured to connect the back surface 22 of the body member with the bottom wall 28 and sidewalls 24, 26 of the slot for supplying a liquid finish to the slot. More particularly, the passage 30 extends through the bottom wall 28 and through a portion 24a, 26a of each side wall 24, 26, adjacent the bottom wall. Portions 24 a and 26 a thus become extensions of passage 30. The cross sectional area of each side wall portion of passage 30 generally does not exceed 25 percent and must be at least 15 percent of the cross sectional area of the passage 30 where it extends through the bottom wall. The yarn 11 runs from top to bottom of the applicator as indicated by the arrow.
As best seen in FIGS. 2-4 the slot 20 is defined by side walls 24, 26 and a bottom wall 28. The side walls 24, 26 taper inwardly toward each other as they approach bottom wall 28 and also taper toward each other as they progress from top to bottom of the applicator body member. The configuration of the slot 20 is a critical feature of the invention. More particularly, the slot is tapered where the filament bundle of the moving yarn line 11 contacts the bottom wall 28. Finishing liquid is applied to the yarn at the initial point of contact with the bottom and/or side walls of the slot, as the case may be; i.e., at passage 30.
In operation, the yarn picks up finish at the point of initial yarn contact with the bottom wall or side walls of or both of the slot depending on threadline alignment in the slot at the location where finish is introduced through passage 30 and carries it forward along the tapered slot 20 and exits the slot tangentially with the bottom surface 28 with no separation between the bottom surface 28 and the threadline. The combination of the fully wiped bottom surface and the tangential exit of the yarn from the slot permits all of the finish to leave the slot wit the yarn giving a uniform finish application on the yarn without the formation of drops at the exit end of the applicator.
The applicator of this invention may be used to apply liquid materials which are not harmful to the yarn or the applicating system. Examples of liquids which may be applied are solutions, dyes, dispersions, or emulsions of conventional treating agents such as lubricants, antistatic agents, binders, softeners and the like. The liquid may be applied to such man-made continuous filament yarns as, for example, polyamides, polyesters, polyacrylics, spandex, rayon, and cellulose acetate.
In a series of test runs with extensions 24a and 26a having varying cross sectional areas as a percentage of the cross sectional area of passage 30, all other conditions being essentially the same, it was observed (Table I) that finish application was more uniform, evidenced by dye spread along-end and end-to-end of the yarn when the cross sectional areas of each of the extensions 24a and 26a were at least 15 percent of the cross sectional area of passage 30 where it extends through the bottom wall of the slot.
TABLE I______________________________________ Average Dye Spread % FinishExtensions Along-End End-to-End on Yarn______________________________________None 5.5 7.5 .75% of slot area 6.0 7.5 .7510% of slot area 5.5 7.0 .815% of slot area 2.5 3.5 .8______________________________________
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A yarn finish applicator in which finish is metered to a slot running from top to bottom of the applicator. The configuration of the body of the applicator its slot and the passage supplying liquid to the slot provides a slot configuration that is relatively insensitive to the yarn threadline alignment within the slot.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a magnetometer. it is used in the precise measurement of weak magnetic fields (typically in the range 20 to 70 μT corresponding to the values of the earth's magnetic field).
2. Discussion of Background
The magnetometer according to the invention concerns a so-called resonance magnetometer type, a description of such a type is given in the article by F. HARTMAN entitled "Resonance Magnetometers", published in the journal "IEEE Transactions on Magnetics", vol. MAG-8, No. 1, March 1972, pp. 66-75.
A resonance magnetometer is an apparatus which, immersed in a magnetic field Bo, supplies an electric signal of frequency F, whose value is linked with Bo by the so-called LARMOR relation:
F=γBo
where γ is a gyromagnetic ratio (of an electron or nucleon as a function of the substance used). For example, for the electron this ratio is equal to 28 Hz/nT.
The excitation of the magnetic resonance is obtained by a winding positioned around the substance used and the sampling of a resonance signal takes place either by another winding (electrical variant) or by a pumping light beam (optical variant).
Although the invention is applicable to all magnetic resonance magnetometers, the optical pumping magnetometer will more particularly be considered hereinafter, but without in any way restricting the scope of the invention.
An optical pumping magnetometer is diagrammatically shown in FIG. 1. An at least partly transparent cell 10 is filled with a gas 12, which is generally helium, at a pressure of 1 to a few Torr. A light source 14 supplies a light beam 18, whose wavelength is approximately 1.1 μm. This beam is appropriately polarized by a means 16 and is then injected into the cell 10.
In addition, a radio frequency or high frequency discharge of a so-called weak or gentle type is produced in the gas by a generator 30 connected to two electrodes 32,33 arranged around the cell 10. This discaharge produces atoms in a metastable state (2 3 S 1 in the case of helium). The incident light beam "pumps" these atoms from the metastable state to bring them into another excited state (2 3 P).
In the presence of a magnetic field Bo, the energy levels are subdivided into so-called ZEEMAN sublevels. A resonance between such sublevels can be established by a high frequency field (magnetic resonance) or by light modulation (double optical resonance; COHEN, TANNOUDJI, Ann. Phys. 7, 1962, p. 423). In the case of isotopic helium 4, the resonance is established between two ZEEMAN electronic sublevels of the metastable state.
This resonance is revealed by various known means, whereof one variant is shown in FIG. 1. It is a winding 20 located on either side of the cell 10 (in a so-called HELMHOLTZ arrangement) of a high frequency generator 22, a photodetector 24 receiving the light radiation which has traversed the cell, an amplifier 25, a synchronous detection means 21 and an integrator 23. The means 21 to 26 will be designated CC hereinafter. The generator 22 supplies the winding 20 with current at frequency F, which creates an oscillating magnetic field, whereof one component maintains the resonance and on its return modulates the light frequency which is passed through the cell, said modulation constituting the signal. It is revealed by the synchronous detection at the output of the photodetector, via the amplifier. The reference is given by the generator. The synchronous detection output corresponding to the component of the signal is in phase with the reference serves as an error signal. The static error is eliminated therefrom by the integrator. This error signal readjusts the frequency F of the synthesizer to the LARMOR frequency. For this purpose it is necessary for the synthesizer to be voltage-controllable and it can also be replaced by a voltage-controlled oscillator (V.C.O).
An electric resonance signal S is consequently established in this loop at the LARMOR frequency. A frequency meter 26 gives the value F thereof. The field to be measured Bo is deduced therefrom by the relation Bo=F/γ.
Helium magnetometers of this type have firstly made use of helium lamps. The recent arrival of lanthanum-neodymium aluminate (or LNA) crystals have made it possible to produce lasers tunable about the wavelength of 1.083 μm precisely corresponding to the optical pumpling line of helium. Naturally this type of laser has taken the place of these lamps with a significant performance improvement, so that once again interest have been aroused in such magnetometers. Such a magnetometer equipped with a LNA laser is described in FR-A-2 598 518.
Although satisfactory in certain respects, these magnetometers still suffer from disadvantages. The most important disadvantage is the existance of a frequency shift due to the so-called BLOCH-SIEGERT effect caused by one of the components of the high frequency exciting field. This phenomenon is illustrated in FIG. 2, which shows the respective orientations of the magnetic fields used.
Ideally, the radio frequency or high frequency field B1 should be perpendicular to the field Bo to be measured. In practise, these two fields form an angle between them of θ. The component of B1 projected onto a plane perpendicular to Bo consequently has for the amplitude B1 sin θ. The amplitude of the resonance signal is consequently dependant on the angle between the field to be measured and the high frequency field, the magnetometer not being isotropic in amplitude.
The alternating field B1 sin θ can be considered as the result of the composition of two circular components b + 1 and b - 1 rotating in opposite directions. Only one of these components (b + 1 in FIG. 2) rotates in the precession direction of the spins Sp and is able to maintain the precession about the field Bo. The other component b - 1 does not directly participate in the resonance phenomenon, but induces a frequency shift of value: ##EQU1## This is the BLOCH-SIEGERT effect described in the journal "Physical Review", 57, 1940, p.522.
When the orientation of the cell (with its winding) varies, the angle θ varies and the frequency shift changes and the magnetometer is not isotropic in frequency.
In order to illustrate the extent of this phenomenon, it is possible to consider the case of a helium 4 magnetometer (for which the resonance is electronic, the nucleus of such isotope being spin-free.) located in a diameter 6 cm sphere. the high frequency field B1 is created by two 4.5 cm diameter coils in the HELMHOLTZ position and 2.25 cm apart. They are constituted by three 0.5 mm diameter, copper wire turns. When they are traversed by a 10 mA current, the field at the centre of the cell is 600 nT. In our latitudes, the earth's magnetic field Bo is 70 μT.
If θ=0°, the high frequency field B1 is parallel to the field Bo and there is no resonance signal. If θ=90°, the high frequency field B1 is perpendicular to the field Bo, the resonance signal is at a maximum, but so is the BLOCH-SIEGERT effect. The frequency shift is 55 Hz, i.e. an error on the field Bo to be measured of 2 nT (approx. 3.10 - 5). If θ=45°, the resonance signal is only 70% of its maximum value and the frequency shift is 40 Hz, i.e. an error on the field to be measured of 1.4 nT.
This frequency anisotropy can be corrected by compensation formulas, if it is possible to determine the direction of the static field Bo relatively to the sensor using appropriate means (e.g. a directional magnetometer). However, this solution is costly and difficult to put into effect, because all instrumentation must be amagnetic and rigidly linked with the cell.
SUMMARY OF THE INVENTION
The present invention specifically aims at obviating these disadvantages. Therefore the invention proposes a resonance magnetometer, which is isotropic in frequency, i.e. free from any error linked with the BLOCH-SIEGERT effect, and which remains simple and lightweight.
According to the invention, this objective is achieved by the use of three exciting windings (instead of one), whose axes are directed in accordance with three orthogonal directions (in other words, whose axes form a trirectangular trihedron). These windings are multiplexed i.e. are successively switched on.
This apparent complexity leads to the following essential advantage. Each winding gives rise to a resonance signal specific thereto and having a frequency Fi (in which i is an index used for x, y or z on designating the axes of the three windings by the standard notations Oxyz). This frequency Fi generally suffers from an error ΔFi, as a function of the orientation of the winding with respect to Bo in the manner described hereinbefore (except if one of the axes of the windings is strictly perpendicular to Bo): Fi=γBo+ΔFi.
The invention makes use of the property according to which the sum of the errors ΔFx+ΔFy+ΔFz on the three frequencies Fx, Fy and Fz is independent of the direction of the field Bo. This sum is given by the quantity: ##EQU2## Thus, taking the mean of the three frequencies, i.e. 1/3(Fx+Fy+Fz), we obtain a quantity which is independent of the orientation of Bo, so that the magnetometer is isotropic in frequency.
Thus, the invention specifically relates to a magnetometer having the known means described hereinbefore and which is characterized in that the exciting winding comprises three windings having axes forming a trirectangular trihedron Ox, Oy, Oz, the magnetometer also having a multiplexer able to sequentially connect each of the three windings to the exciting circuit and means for measuring the mean Fm of the three frequencies Fx, Fy and Fz of the three resonance signals, corresponding to the three windings, the value of the ambient magnetic field Bo then being given by Bo=Fm/γ.
According to a special embodiment, the means able to maesure the mean frequency Fm also measure the three frequencies Fx, Fy and Fz, which makes it possible to obtain information on the direction of the field to be measured Bo. The magnetometer is then no longer solely scalar i.e. giving the modulus of the field), but is also vectorial, (i.e. giving the components of the field on the three axes of the windings).
According to other embodiments, the measuring means give the mean amplitude Am of the three resonance signals, whose value is never 0, no matter what the orientation of the field, which reduces the amplitude anisotropy. These means can also give the three amplitudes relative to the three windings, which also provides information on the orientation of the field to be measured in the trihedron formed by the windings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to non-limitative embodiments and with reference to the attached drawings, wherein show:
FIG. 1 already described, a resonance and optical pumping magnetometer according to the prior art.
FIG. 2 already described, the relative arrangement of the various magnetic fields.
FIG. 3 the arrangement of the three multiplexed exciting coils according to the invention.
FIG. 4 an optical pumping, resonance magnetometer according to the invention.
FIG. 5 a timing diagram showing different quantities in a magnetometer according to the invention.
FIG. 6 an embodiment of the means for measuring the mean frequency and the mean amplitude of the resonance signal.
FIG. 7 another embodiment of the measuring means for the mean frequency and the mean amplitude of the resonance signal.
FIG. 8 a timing diagram corresponding to the embodiment of FIG. 7.
FIG. 9 an embodiment of the means for measuring three resonance signal frequencies, the mean frequency, three amplitudes and the mean amplitude.
FIG. 10 a timing diagram corresponding to the embodiment of FIG. 9.
FIG. 11 another embodiment of the measuring means of the three frequencies and their means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus shown in FIG. 3 has three windings 20x, 20y and 20z used in accordance with the invention. They are shown in a HELMHOLTZ arrangement, i.e. formed by two half-windings wound on either side of the cell 10. The axis of these windings constitute a trirectangular trihedron Ox, Oy and Oz. When traversed by a current, these windings create three oscillating fields B1x, B1y and B1z, which are orthogonal in pairs.
A resonance magnetometer according to the invention, in the case of an optical pumping variant, is then in the form shown in FIG. 4. It firstly comprises the known means illustrated by FIG. 1 and which for the same reason carry the same reference numerals. They consist of the helium-filled cell 10, the laser 14, the polarizing means 16 and the circuit CC (incorporating the high frequency generator 22, the photodetector 24, the amplifier 25, the synchronous detection means 21 and the integrator 23) and the discharge generator 30. In accordance with the invention, it also comprises three windings 20x, 20y and 20z arranged in the manner of a trirectangular trihedron around the cell 10 (the representation of FIG. 4 being diagrammatically in this respect, but it is clear that the real arrangement is like that of FIG. 3).
These three windings are switched on by a multiplexer 50, which diagrammatically comprises a generator 52 of three multiplexing pulse trains respectively Mx, My and Mz (and optionally a fourth train Mc, whose function will become apparent hereinafter) and three switches Ix, Iy and Iz able to put into operation each of the windings, i.e. connect them to the exciting circuit 22.
The timing diagrams of FIG. 5 explain the operation of this apparatus. Part (a) shows three multiplexing pulse trains Mx, My and Mz emitted by the generator 52. The pulse times defined switching on or scanning intervals of the windings.
The frequencies of the resonance signals relative to these windings are shown in part (b). As explained hereinbefore, these frequencies suffer from an error, which is dependent on the orientation of the winding axis with respect to the field to be measured. Thus, in general, these three frequencies Fx, Fy and Fz differ. The mean frequency Fm is also shown. It is pointed that, according to the invention, it is not dependent on the orientation of the field.
Part (c) shows the free amplitudes Ax, Ay and Az, corresponding to the three resonance signals and the mean amplitude Am. Bearing in mind the arrangement chosen for the windings, at least two of them supply a signal and at least one supplies an amplitude signal equal to or higher than 80% of the maximum signal. The latter is obtained when the winding axis is perpendicular to the field to be measured.
It is stressed that the directions for which the weakest amplitude signal is obtained are also those for which there is a minimum frequency shift.
A number of embodiments of the means 28 for measuring the mean frequency Fm will now be described in conjunction with FIGS. 6 to 11.
According to FIG. 6, the means 28 for measuring the mean Fm comprise a phase comparison loop with a phase comparator 60, a low-pass filter 62, a voltage-controlled oscillator 64 (or VCO) and a frequency meter 66. The means 28 can also comprise an amplitude detector 68 and a low-pass filter 70, whose cut-off frequency is well below the mean frequency Fm.
The operation of the circuit 28 is as follows. It receives on input E, the resonance signal, which is modulated both as regards frequency and amplitude to the multiplexing frequency, which can be approximately 1 kHz. A first output S1 supplies the sought frequency Fm and an auxiliary output S'1 supplies a voltage (that which is applied to the voltage-controlled oscillator 64) reflecting the said frequency. The circuit 28 also comprises a second output S2 supplying the mean amplitude Am.
According to another variant illustrated by FIG. 7, the means 28 comprises a counting frequency meter 72 having a control input 73 connected to the generator 52 of the multiplexer 50 and receiving from the latter a counting signal Mc of duration well above the period of the recurrent switching on pulses.
The timing diagram of FIG. 8 explains the operation of this circuit. The first three lines show the three multiplexing pulse trains Mx, My and Mz controlling the switching on of the free windings and consequently the appearance intervals of a resonance signal on the input E. The fourth line shows a control signal Mc, whose duration greatly exceeds that of the pulses Mx, My and Mz. For example, the latter will last 1 ms and Mc 999 ms.
The frequency meter 72 counts all the zero passages of the signal during the time of Mc. The number of pulses is the same for Mx, My or Mz (in the example taken 999). The number of passages counted consequently reflect the mean frequency Fm, which is obtained on the output S1.
As for FIG. 6, the processing of the mean amplitude is carried out by an amplitude detector 68 and a low-pass filter 70, the value of Am appearing on an output S2.
According to a more detailed variant, the means 28 for measuring the mean frequency Fm also measure the values of each of the three frequencies Fx, Fy and Fz.
According to a first development of this variant illustrated in FIG. 9, the means comprise:
a counting frequency meter 80 having a control input 81 connected to the generator 52 of the multiplexer 50 from where it receives a count control pulse Mc,
a demultiplexer 82 having a digital input 83 connected to the counting frequency meter 80, three control inputs 84 connected to the generator 52 of the multiplexer 50 and respectively receiving the control pulses Mx, My and Mz for the three windings, three digital outputs 85x, 85y and 85z connected to three general outputs S"1 supplying the three frequency Fx, Fy, Fz,
a digital adder-divider having three inputs connected to the three digital outputs of the demultiplexer and an output connected to the general output S1 supplying the mean Fm of the three frequencies.
The timing diagram of FIG. 10 explains the operation of this circuit. On the three first lines appear the three multiplexing signals Mx, My, Mz for the putting into operation of the windings. On the fourth line is shown in the control signal Mc for the frequency meter 80. The duration of said signal is less than that of the multiplexing pulse Mx, My and Mz. It can e.g. be a time of 1 s compared with 2 s for multiplexing.
The information supplied by the frequency meter 80 consequently relates to Fx, Fy and Fz. Said digital information is distributed over three digital channels by the demultiplexer 82, which is controlled by the multiplexing pulses Mx, My and Mz. Thus, on the digital outputs 85x, 85y, 85z are obtained the values of Fx, Fy and Fz. These outputs are connected to the general output S"1. The general output S1 continues to supply the value of the mean frequency Fm supplied by the adder-divider 86.
In the circuit of FIG. 9, the amplitude processing channel comprises in addition to the amplitude detector 68 and the low-pass filter 70, three sample and hold circuits 90x, 90y and 90z respectively controlled by the three multiplexing signals Mx, My and Mz. The chain 68, 70 supplies the mean value Am of the amplitude on the general output S2 and the sample and hold circuits supply the values Ax, Ay and Az of the three resonance signals.
According to another embodiment illustrated in FIG. 11, the means for measuring each of the three frequencies and the mean value of these frequencies comprise:
a demultiplexer 92 having an input receiving the measuring signal, three control inputs 93x, 93y and 93z connected to the generator 52 of the multiplexer 50 and receiving the three switching on pulses Mx, My and Mz for the said windings and three outputs 94x, 94y and 94z respectively supplying three measuring signals,
three counting frequency meters 96x, 96y and 96z respectively connected to the three outputs 94x, 94y and 94z of the demultiplexer 92 and respectively supplying the three frequencies Fx, Fy and Fz on an output S"1.
a digital adder-divider 98 connected to the three frequency meters 96x, 96y and 96z and supplying the mean value of the frequencies Fm on a general output S1.
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A magnetometer having three trirectangular trihedron windings (20x, 20y, 20z) which are put into service successively by a multiplexer (50). The means frequency (F m ) of the three measurement signals is independent of the orientation of the weak magnetic field which is to be measured.
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FIELD OF THE INVENTION AND INTRODUCTION
[0001] The invention relates to novel methods for manipulating protein and polysaccharide/starch components of food products or ingredients, and in particular cocoa-containing products, as a food ingredient and as a final food product. In one aspect, the invention encompasses a chocolate composition comprising a gel network formed by cocoa starches and/or proteins, or milk proteins and cocoa solids, and also comprising crystallized cocoa butter as a dispersed component, and water or milk or skim milk as the continuous phase or aqueous phase of a suspension. Previously, chocolate compositions employed cocoa butter as the continuous phase in compositions and suspensions, generally with sugar, milk solids and cocoa solids as the dispersed phase. Both liquid cocoa compositions and solid compositions traditionally follow this standard. The compositions, products, and ingredients possible according to the invention, however, can utilize the gel forming potential of starch and protein components of cocoa ingredients and/or other ingredients to create a wide range of oil-in-water suspensions with advantageous properties. For example, recipes for a low or reduced calorie chocolate product or ingredient having the same cocoa content as conventional chocolate and/or falling within the standard of identity for chocolate products can be designed. In addition, the production and packaging options for chocolate products are expanded by the use of the invention as the viscosity of the chocolate product or ingredient can be varied easily without specific reliance on cocoa butter content.
DESCRIPTION OF RELATED ART
[0002] Chocolate products and ingredients conventionally exist as suspensions, with fat or oil as the continuous phase. Polymorphic crystals of cocoa butter form an important part of the fine structure of these suspensions and the methods to control crystallization of cocoa butter are well known. In general, the setting of cocoa butter crystals into the most stable form is desirable. The failure to account for the difference in forms within the fat suspension can result in poor color and blooming.
[0003] From a production point of view, cocoa butter content has been changed to vary the viscosity of chocolate compositions, so that higher cocoa butter content results in a more viscous final product or ingredient. While heating may be used to increase flowabilty or solubility of certain ingredients in chocolate processing or packaging, heating is not used as a method to change the properties of cocoa-containing compositions.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a food product or ingredient having a crystallized and gelatinized structure in an oil-in-water suspension. The combination of a gelatinized structure, a crystallized structure, and an oil-in-water suspension made possible and demonstrated by the methods, food products and ingredients of the invention provide numerous advantages in the food processing field. For example, the invention provides products with improved viscosity characteristics over a greater range of temperatures and allows sugar free or low or reduced calorie products to be produced while maintaining other desirable characteristics, such as texture, taste, mouthfeel, and viscosity. Furthermore, the invention can be said to incorporate methods and ingredients, or more particularly moisture levels, that standard practices report as inappropriate or undesirable in the chocolate manufacturing field. For example, Beckett (Industrial Chocolate Manufacture and Use, 3d Ed., Beckett ed., 1999 Blackwell Science Ltd., see Chaps. 9 and 20 in particular) notes that it is necessary to remove moisture during processing of chocolate to avoid the requirement to use additional fat and to avoid or minimize the possibility of microbial growth. In addition, Minifie (Chocolate, Cocoa, and Confectionery, 3d Ed., 1999, Aspen Publishing, see Chap. 5 in particular) notes the importance of minimizing the introduction of water in chocolate processing in order to maintain a desired viscosity. Thus, in one aspect, by using water or water-based solutions as the aqueous phase in an oil-in-water solution for cocoa and/or chocolate food ingredients or products, the invention utilizes counter-intuitive methods and ingredients as compared to typical chocolate product and ingredient manufacturing.
[0005] In one embodiment, the food ingredient comprises an oil or fat phase comprising at least about 2% or at least about 3% cocoa solids and at least about 2% or at least about 3% cocoa butter, the cocoa solids being in suspension and/or at least partially crystallized in the final ingredient or product at room temperature. In various embodiments involving cocoa or chocolate, the cocoa butter and cocoa solids content from one or more of a variety of added cocoa-containing products can be selected to generate a range of final weight percent values, including from about 2% to about 3% cocoa butter, about 3% to about 5% cocoa butter, about 5% to 10% or higher cocoa butter, and about 2% to about 3% cocoa solids, about 3% to about 5% cocoa solids, and about 5% to 10% or higher cocoa solids, and any combination of these ranges. In one aspect, the invention does not encompass prior or conventional chocolate milk mixtures that do not possess or are not treated to generate a gelatinized and/or oil-in-water suspension as described here. Generally, prior chocolate milk mixtures do not form stable suspensions, as one of skill in the art understands.
[0006] The food ingredients or products of the invention or used in the invention are not limited to any particular state or temperature, for example room temperature. The reference to crystallized or partially crystallized structures at room temperature means the food ingredient or product is capable of exhibiting a crystallized or partially crystallized structure or microstructure when at room temperature. Thus, in part, the suspension has a crystallized structure. The food ingredient further comprises an aqueous phase comprising water or milk or skim milk, such as a composition of at least about 5% milk solids and at least about 5% nutritive carbohydrate sweetener. The soluble starches or polysaccharides and protein present in at least the cocoa solids, or other cocoa product, are capable of forming a gel network in the suspension. Thus, in part, the suspension has a gelatinized structure. The insoluble particles from at least the cocoa, such as the cocoa cell wall materials, are dispersed within the gel network forming part of the suspension. While cocoa-containing compositions are routinely referred to, the invention is not limited to cocoa-containing compositions. Other food ingredients or edible compositions can be used.
[0007] In a specific embodiment, the food ingredient of the invention has at least about 15%, or at least about 18%, or at least about 20% cocoa solids by weight in its final ingredient form or product form. Thus, the methods and ingredients and products of the invention can be used in the production of various chocolate products that fall within the standard of identity for chocolate, milk chocolate, bittersweet chocolate, and white chocolate that may exist in a desired market or under a particular regulatory setting. Furthermore, artificial or non-nutritive sweeteners can be used in conjunction with the invention to produce low calorie or low carbohydrate products or sugar free products. Also, vitamin and/or mineral food additives can be optionally added to improve the nutritional content of chocolate or cocoa-containing foods, for example.
[0008] In another aspect, the invention comprises a method of making a food ingredient where a fat or oil phase composition comprising cocoa butter, milk fat and/or other edible fat, and optionally an emulsifier, is mixed with an aqueous or continuous phase comprising water or milk. The mixing can be performed by a variety of methods known to the food and food ingredient industries, and specifically includes homogenizer, dynamic mixer, or static mixer processes. After preparing the oil-in-water suspension, the mixture of the oil or fat phase with the aqueous or continuous phase can be heated under conditions where the protein and starch components of the cocoa solids produce a gel network. In general terms, the gel network is functionally a gelatinized composition having an increased viscosity compared to its pre-treatment or pre-heated form. It can be prepared from biopolymer-containing components, such as protein and/or carbohydrate containing components, particularly cocoa products such as cocoa solids and milk products such as milk solids. One of skill in the art is familiar with methods and equipment for measuring the viscosity of compositions, including the compositions noted here. Without limiting the invention to any particular mechanism, the protein and/or soluble carbohydrate or starch components in a composition of food ingredients, such as a cocoa-containing composition, can be effectively swelled or water-saturated by particular treatments or heating processes depending on the components of the composition. In preferred treatments, the gel network formation occurs efficiently by heating to a range between about 52° C. to about 68° C. for cocoa-containing compositions. Gel network formation in the same cocoa-containing compositions can also occur through prolonged standing, with or without mechanical shearing. Functionally, the treating or heating step should disrupt the native protein conformation and/or swell carbohydrate or starch or bioploymer components from their existing state in order to form a gel network. Since the swelling of cocoa product components can take long periods of time and/or employ mechanical treatments, the preferred method of preparing a gel network according to this invention is by heating.
[0009] In the photomicrographs of FIGS. 5 and 6 , one can see the difference between the treated or heated cocoa components and the same components after conventional cocoa processing. In general, the methods of the invention allow for a microstructure of cocoa-containing compositions or suspensions where the cocoa butter droplets can be from about 0.5 to about 100 microns in diameter, or more preferably about 0.5 to about 30 microns in diameter. Furthermore, the carbohydrate or starch components of the cocoa products used or the cell components from the cocoa products used are visibly swelled in the methods and products of the invention (see FIG. 6 ), while in the conventional dark chocolate composition of FIG. 5 , by comparison, they are typically present as crystallized and/or amorphous components in the suspension. In addition, the sugar in the suspension of FIG. 6 is dissolved in the continuous phase rather than in crystalline structures as shown in the conventional composition of FIG. 5 , thus leading to a more uniform and smoother texture.
[0010] In another aspect, the invention provides a novel oil-in-water suspension at temperatures below the melting point of the cocoa butter in a cocoa butter containing composition. In this and other aspects of the invention, cocoa butter is discussed as part of the fat or oil phase. However, other cocoa containing products can be used, such as cocoa liquor or cocoa powder. In addition, one of ordinary skill in the art is familiar with adding emulsifiers and/or hydrocolloids and/or other biopolymers to cocoa products, and emulsifiers and hydrocolloids and protein and starch compositions can optionally be added or replaced by cocoa butter in the food ingredients, products and compositions of the invention. Beyond cocoa butter or other cocoa products, additional fat components can be added in the methods to produce the food ingredients or products of the invention, especially including those with a melting point above room temperature or at or above about 25° C. or at or above about 35° C. As shown below, fractionated and/or hydrogenated and/or interesterified palm kernel oil, palm oil, coconut oil, cottonseed oil, sunflower oil, canola oil, and corn oil, or cocoa butter substitute, for example, can be used as an edible oil with a melting point above room temperature.
[0011] In particular aspects, the invention includes processing a food ingredient into a processed product or composition. The processed products or compositions can be prepared by any method of the food and confectionary industry. For example, in-process steps can include adding components, such as adding vitamins, minerals, food grade gas, and one or more of the variety of ingredients available. Processing can also or in addition involve producing a marketable food product by coating, forming, molding, extruding, enrobing, injecting, baking, freezing, packaging, layering, rolling, cutting, depositing, panning, casting, or any other available method (see, for example, Minifie, “Chocolate, Cocoa, and Confectionery,” 3d ed., Aspen Publishers). Additionally, filtration or separation processes can be included to, for example, remove substantially all insoluble particles from an ingredient or food product.
[0012] As noted above, the preferred process for forming a gel network is heating. For the cocoa product containing compositions, heating the mixed oil and aqueous phases can comprise heating to about 121° C. for about 8.5 minutes, or to about 150° C. for at least about 4 seconds, or simply heating to about 68° C. for a period of time sufficient to form a gel network. In general, for cocoa containing products, cocoa starch can be formed into a gel network if it is subjected to a temperature of about 52° C. to about 68° C., so any heating process that results in the cocoa starch reaching this temperature should suffice. Other, lower temperatures can also be selected and used if longer periods of time are employed. The higher temperatures noted here can be used in optional processing methods or optional sterilizing methods. Other methods include allowing the mixture to rest at room temperature for a period of time sufficient to form a gel network, or using high shear conditions, for example with a high pressure homogenizer.
[0013] In some of the many possible food products that can be produced, the food ingredient of the invention can be further processed into a product containing milk chocolate, sweet chocolate, bittersweet chocolate, semisweet chocolate, or white chocolate. In addition, the product can comprise one or more of chocolate liquor, cocoa powder, heavy cream, anhydrous milk fat, whey protein concentrates, non-fat milk protein, whole milk powder, sugar, lecithin, vanillin, and skim milk, as shown in the examples below.
[0014] In a more general aspect, the invention involves preparing an oil-in-water suspension using one or more cocoa containing products. The cocoa containing products are those processed from, or some degree of processed form of, the cacao bean that are commonly available. As noted above, certain microstructure environments can be created using the protein and starch components from the cacao bean products. While the production of oil-in-water emulsions in chemical processes is not new, the use of oil-in-water suspensions for cocoa containing products in particular, and food products more generally, is not common. In addition, the use of oil-in-water suspensions for chocolate products falling under one or more of the many standards or identity for these products has not been described previously. In another general aspect, the invention comprises preparing an edible gelatinized and crystallized microstructure within an oil-in-water suspension by using a gel network forming biopolymer containing product, such as a cocoa product, a fruit product, a berry product, or a vegetable product. A gel network-forming amount of a biopolymer is used and the suspension comprises an aqueous phase and a dispersed oil or fat phase, wherein the gel network is capable of being formed from the biopolymer after heating the suspension, and the components of the oil or fat phase are at least partially crystallized at room temperature and stably present in the suspension. By the phrase “stably present in suspension,” the components of the suspension remain substantially in suspension for a period of up to 3 months, or up to 6 months, or up to 8 months, or up to 12 months, or up to 18 months, or up to 24 months or longer. The microstructures of the dispersed phase can be selected to have a size of about 100 um or less in diameter while in the suspension. The food ingredient made from these suspensions can have a biopolymer originally provided in the form of a cocoa containing product, a fruit containing product, a berry containing product, or other similar product, or even a hydrocolloid containing product. This food ingredient can also or alternatively comprise a component in the oil or fat phase that is at least partially crystallized at room temperature and can be selected from one of more of cocoa butter, fractionated and/or hydrogenated and/or interesterified palm kernel oil, palm oil, coconut oil, cottonseed oil, sunflower oil, canola oil, and corn oil, 17-sterine, cocoa butter substitutes or equivalents, milk fat, or any oil or fat that is at least partially solid or crystallized at room temperature, or about 20° C., or about 25° C., or about 30° C. In addition, the invention specifically includes a final food product that comprises any of the food ingredients noted or any food ingredient produced by a method noted throughout this disclosure.
[0015] As discussed here, the oil-in-water suspension refers to a suspension of, for example, oil droplets and/or insoluble particles in a continuous medium or phase, whereas in an emulsion, by contrast, all components are dissolved in the continuous phase. In general for the food rheology field, a suspension is at least one solid dispersed within a continuous phase, where the continuous phase is at least one liquid (see, for example, Van Nostrand's Scientific Encyclopedia, D. Van Nostrand Co., Inc., Princeton, N.J., 4 th ed. 1968, pp. 620 and 1782; Rheologie der Lebensmittel, Weipert/Tscheuschner/Windhab, Behr's Verlag, Hamburg, Germany, 1993, pp. 108 and 122). The edible oil-in-water suspension of this invention refers to a dispersed phase of oil droplets and insoluble particles that are suspended in a substantially stably manner within an aqueous continuous phase, whereas in an emulsion all of the dispersed phase components must be liquid and are merely mixed in the continuous phase and are not, generally, stably suspended. Furthermore, emulsions do not necessarily employ the gel network as mentioned here. In fact, there are no reports of cocoa-based gel networks used to produce edible oil-in-water suspensions as described here. Thus, in general, the suspensions of the inventions comprise a dispersion of crystalline and/or non-soluble droplets and/or particles dispersed in a gel network or gelatinized continuous aqueous phase. While cocoa-based oil-in-water suspensions are noted as a preferred embodiment, other biopolymer-containing compositions can be used also.
[0016] In one aspect of a method of producing a cocoa-based oil-in-water suspension, the method involves mixing a fat phase comprising one or more cocoa products, including cocoa butter, and having cocoa protein and/or starch or carbohydrate components, with an aqueous phase. In preferred embodiments, the final non-fat cocoa solids content is at least about 2% or about 3% or about 4% or more by weight of the final suspension. Also in preferred embodiments, the aqueous phase comprises water, a sugar or sweetener or both, and/or milk and/or skim milk and/or cream. Other liquids or solutions can also be used as the aqueous phase and the invention specifically includes chocolate or cocoa compositions prepared without milk or milk products, even chocolate or cocoa beverages without milk. Once mixed, a swelling or heating step occurs to form a gel network comprised of cocoa proteins and cocoa starch components. The formation of a gel network can be detected by a variety of methods known in the art, including microscopy, direct viscosity measurements, ultrasonic methods, and light scattering methods. If a viscosity measurement is used, one preferred detectable change is where the viscosity of the suspension increases after heating when measured as shear rate. More particularly, the viscosity increase is at least about two-fold or double in the measurable 30 sec-1 shear rate. If microscopy is used, one of skill in the art can measure gel formation by the effects on the final suspension and the appearance of component parts within the suspension. For example, starch granules in cocoa-containing compositions can be visualized prior to swelling and after gelatinization, and cocoa butter droplets can be visualized in the suspension at about room temperature in the range of between 0.5-100 um, or between 0.5-30 um.
[0017] Throughout this disclosure, applicants refer to journal articles, patent documents, published references, web pages, and other sources of information. One skilled in the art can use the entire contents of any of the cited sources of information to make and use aspects of this invention. Each and every cited source of information is specifically incorporated herein by reference in its entirety. Portions of these sources may be included in this document as allowed or required. However, the meaning of any term or phrase specifically defined or explained in this disclosure shall not be modified by the content of any of the sources. The description and examples that follow are merely exemplary of the scope of this invention and content of this disclosure and do not limit the scope of the invention. In fact, one skilled in the art can devise and construct numerous modifications to the examples listed below without departing from the scope of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 depicts a graph of the viscosity of a various cocoa compositions during a heating process over time. The levels of cocoa powder in water used in each composition are indicated next to each curve (5%, 10%, 15%, 20%, 25%, and 30%). The heating temperature is indicated at the top. The results show the impact of heating on the formation of a higher viscosity gel network from the components of the cocoa powder. In each case, some change or increase in viscosity can be seen during heating. However, marked increases in viscosity are apparent at 15% cocoa powder and above.
[0019] FIG. 2 shows a comparison of conventional chocolate drinks (“o” skim milk+chocolate syrup and “♦” after 5 hours) to a composition prepared according to the invention (▴). The viscosity is much higher for the compositions of the invention.
[0020] FIG. 3 shows the viscosity characteristics of cocoa butter and skim milk compositions at various (5%, 10%, 15%, 20%, and 25%) concentrations of cocoa butter and over a temperature change. At these temperatures and these periods of time, the change in viscosity represents a change in the crystallization state of cocoa butter droplets in the compositions. From 0-10 minutes, each composition was kept at 20° C.; at 10 minutes each composition was heated until it reached 45° C. at 15 minutes, where the temperature is maintained for 12 minutes. After the heating period, the compositions are allowed to return to 20° C. Viscosity measurements over the changing temperature reflect the melting of oil in the cocoa butter droplets. As is the case in conventional cocoa and chocolate containing compositions, the higher the cocoa butter content the higher the viscosity. Here and throughout unless otherwise stated, a TA Instruments AR2000 concentric cylinder is used, DIN 53 019, and a shear rate of 30/sec.
[0021] FIG. 4 schematically represents the differences between a conventional composition (“Crystallized Suspension”) and the compositions of the invention (“Crystallized/Gelatinized O/W Suspension”). In the conventional composition, cocoa butter is the continuous phase in the suspension. The level of cocoa butter, the solubility of components in cocoa butter, and the physical properties of the suspension, among other things, necessarily limit the characteristics and additives available if one desires to produce a chocolate product or ingredient falling within the standard of identity for chocolate in many countries of the world. In general, hydrophilic molecules are not soluble in oil, or an oil phase like cocoa butter. Consequently, the microstructure of such an oil and hydrophilic combination is referred to as a suspension. However, one fat or oil can be dissolved within another fat or oil, sometimes with an added emulsifier. In contrast, the oil-in-water suspension of the invention contains a continuous phase that can actually be an aqueous phase and the additives and variety and proportion of components is increased and is not limited to fats or oils.
[0022] FIG. 5 is a photomicrograph showing a diluted conventional chocolate composition. Sugar crystals are indicated at ( 1 ). Cell wall particles from the cocoa are indicated at ( 2 ). The continuous phase is labeled ( 3 ).
[0023] FIG. 6 is a photomicrograph of a diluted cocoa composition of the invention or one prepared according to the methods of the invention. The aqueous phase or continuous phase of the suspension is marked at ( 3 ). Number ( 1 ) points to a fragment or element of the gel network formed by starch and/or protein components, here from cocoa, and can include the cell wall components of cocoa. Crystallized cocoa butter droplets are present in the suspension and the refraction from droplets can be seen as lipid or fat droplets, as pointed out in ( 2 ).
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0024] Throughout this disclosure, applicants refer to texts and other sources of information. One skilled in the art can use the entire contents of any of the cited sources of information to make and use aspects of this invention. Each and every cited source of information is specifically incorporated herein by reference in its entirety. Portions of these sources may be included in this document as allowed or required. However, the meaning of any term or phrase specifically defined or explained in this disclosure shall not be modified by the content of any of the sources. The description and examples that follow are merely exemplary of the scope of this invention and content of this disclosure and do not limit the scope of the invention. In fact, one skilled in the art can devise and construct numerous modifications to the examples listed below without departing from the scope of this invention. In general and as used in this invention, the various chocolate and cocoa-containing products and compositions noted here refer to the terms as used in Minifie (Chocolate, Cocoa, and Confectionery, 3d ed., Aspen Publishers), specifically incorporated herein by reference. The cacao bean refers to the cacao bean, also called cocoa bean, in nature and a cocoa containing product is a product derived from or having some component derived from the cocoa bean. The nib refers to the cacao bean without the shell and is approximately 54% fat and 46% non fat solids on a dry basis. Non fat cocoa solids are the processed non fat solids of chocolate liquor. Cocoa powder refers typically to cocoa solids with a total of 10% to 12% fat, where the fat is generally cocoa butter. Breakfast cocoa is cocoa solids with 20 to 24% fat, where the fat is generally cocoa butter. Chocolate liquor (or cocoa liquor) is ground cocoa nibs and it can be separated into cocoa butter and cocoa solids. Cocoa butter is the fat component of chocolate liquor, whereas the remaining part of chocolate liquor is cocoa solids or the cocoa mass. As one of skill in the art understands, a certain amount or percentage of cocoa solids in a food ingredient can be achieved, inter alia, by using or adding an amount of cocoa powder, chocolate liquor, or other chocolate or cocoa ingredient containing the requisite amount of cocoa solids. Similarly, a certain amount or percentage of cocoa butter in a food ingredient can be achieved, inter alia, by using or adding an amount of chocolate liquor or other chocolate or cocoa ingredient containing the requisite amount of cocoa butter. Furthermore, while many different countries specifically define food products containing cocoa or cocoa products as having certain ranges or ingredients, the terms chocolate, milk chocolate, and dark chocolate, are as used commonly in the US food industry and do not imply, unless stated otherwise, a specific content. In addition, while a cocoa containing product having a particular anti-oxidant or polyphenol level is not required, the invention encompasses the use of cocoa containing products with enhanced, altered, or increased levels of anti-oxidants or polyphenol compounds as compared to conventional cocoa containing products. Other nutritional, therapeutic, or preventative ingredients can be added as well, as known in the art.
[0025] As noted above, in one general aspect, the invention provides a method for producing a gel network or gelatinized structure with a cocoa-containing product. The following table depicts the results of using a heating a process with cocoa powder in water to generate a gelatinized suspension.
TABLE 1 Viscosity values of various cocoa powder in water compositions before and after heating to 90° C. Cocoa Powder [90% non-fat cocoa solids 10% cocoa butter] Initial viscosity Peak Final wt/wt [mPas at 30 sec −1 ] viscosity viscosity 5% 2 0.5 3 10% 4.5 4 8 15% 11 130 70 20% 30 750 350 25% 300 3300 1500 30% 1500 8200 2500
[0026] The results shown in Table 1 and FIG. 1 compare various cocoa powder in water combinations and the production of a functional gel network, as determined by measuring viscosity. The cocoa powder and water is first mixed in a rotor stator mixer for about 5 sec to about 1 min or 2 min. A homogenizer or high pressure homogenizer can be used, which produces a minimum droplet size almost instantaneously. Then the compositions of cocoa powder in water are heat treated to produce a gel network. More specifically, cocoa powder is dissolved in water and a 12.2 ml sample poured into a concentric cylinder DIN 53 019 TA Instruments AR2000 Rheometer. A temperature sweep is performed from 25° C. to 90° C. at 10° C./min, holding at 8 minutes at 90° C., cooling from 90° C. to 25° C. at 10° C./min, and holding at 25° C. for 40 minutes. A shear rate of 30/sec is used. At concentrations of about 5%, there is little effect on the viscosity, although it is increased compared to the pre-heating composition. Beginning at 10% cocoa powder, the viscosity increase is about two-fold or more. Even at the low level of 8 mPas, it is possible to affect the viscosity of cocoa-containing products and ingredients. As one of skill in the art is aware, the ability to monitor changes in viscosity and the microstructure of compositions have a number of processing advantages, including stabilization. Above 15%, there is a significant increase in measurable viscosity. The protein and starch components in cocoa products have been discussed in the past (see, for example, Voigt et al., Food Chemistry 47: 145-151 (1993); Schmieder and Keeney, J. Food Sci. 45: 555 (1981); Gellinger et al., Starch/Starke 33: 76-79 (1981)). However, none of these reports mentions the advantages of using the gelatinization of cocoa components to produce food products and ingredients as oil-in-water suspensions, or to produce stable suspensions with cocoa. In fact, the stable suspensions of this invention can be used to prepare cocoa or chocolate products that are stable for months, or from between about 3 months to about 2 years. Equivalent products using the prior methods, such as for example a chocolate drink or beverage, do not remain stable suspensions and must be mixed or shaken. Furthermore, the products and ingredients of the invention can be designed to provide superior characteristics through a broader range of temperatures, such as freezing temperatures, freezing and thawing conditions, and long term room temperature storage, for example. Food emulsions used today do not have these characteristics.
[0027] Using this basic principle and of the ability of cocoa containing compositions to produce a gel network, examples using a variety of other cocoa containing products can be used. In addition, other ingredients commonly used in chocolate products or defined by the standard of identity for certain chocolate products can be used. For example, chocolate liquor (cocoa and cocoa butter), cocoa butter, milk, concentrated milk, evaporated milk, sweetened condensed milk, dried milk, skim milk, concentrated skim milk, evaporated skim milk or sweetened condensed skim milk, cocoa powder, heavy cream, flavors, whey protein, anhydrous milk fat, non fat milk protein, whole milk powder, soy milk, soy milk proteins, lecithin, sugar and different corn syrups can be used. In general, moisture levels or water levels are not generally mentioned in the chocolate product standard of identity. Therefore, the invention can be used to manipulate a variety of ingredients, and substitute a variety of ingredients, for those previously used in chocolate products. While cocoa containing gel networks are described in details in these examples, the invention is not limited to cocoa-based gel networks and suspensions involving cocoa products. Other biopolymer compositions, such as those containing proteins, hydrocolloids, polysaccharides, and the like can be used to produce a gel network and combined with at least one fat component having a melting point higher than room temperature, or higher than about 20° C., or higher than about 20-25° C. In addition, other ingredients, such as fruit products, nuts, nut products, and other larger particle additives can be used in the gelatinized/crystalized suspensions of the invention, such as in certain fruit pudding compositions. In fact, any compatible group or set of ingredients can be selected as long as the components do not substantially inhibit the formation of or substantially destroy or substantially reduce the gel network forming properties of the biopolymer components selected.
EXAMPLES
[0028] Using the typical ingredients and substitutions available to the food and confectionery artisan, one can combine the cocoa products, such as cocoa powder above, in a solution to generate a gel network. As an example, in the Examples 1-3 below, the ingredients can be prepared first as fat or oil phase ingredients (for example cocoa butter containing product, such as chocolate liquor) and water or aqueous ingredients (for example milk or skim milk). In addition, typical ingredients for one or more of the chocolate products or food ingredients of the invention include one or more of soy lecithin or lecithin, cream, milk fat, butter, concentrated milk, evaporated milk, concentrated skim milk, evaporated skim milk, concentrated buttermilk, dried buttermilk, malted milk, dried milk, sweeteners, and vegetable fat. After the fat or oil phase ingredients are mixed or homogenized, the two groups of ingredients are mixed and heated to a desired temperature, for example 65° C., or about 52° C. to about 68° C. for inducing a gel network with cocoa-based components, or about 120° C. for 15 minutes for sterilization in addition to gel network formation. One of skill in the art is familiar with ultra high temperature or ultra high temperature and pressure sterilization processes that can be selected or adapted for use. Alternatively, swelling in solution can occur after longer periods of time.
[0029] Specific examples can be selected using the standards of identity for various countries, including:
[0030] U.S. Standard of Identity for Chocolate Products: for semisweet or bittersweet chocolate 35% or more chocolate liquor and less than 12% total milk solids; for milk chocolate 10% or more chocolate liquor, 3.39% or more milk fat, and 12% or more total milk solids; and for white chocolate 3.5% or more milk fat, 14% or more total milk solids, 20% or more cocoa butter, and 55% or less nutritive carbohydrate sweetener.
[0031] The CODEX chocolate standards: for chocolate 35% or more total cocoa solids, 18% or more cocoa butter, and 14% or more fat-free cocoa solids; for sweet chocolate 30% or more total cocoa solids, 18% or more cocoa butter, and 12% or more fat-free cocoa solids; for milk chocolate 25% or more total cocoa solids, 2.5% or more fat-free cocoa solids, between 12% and 14% milk solids, and between 2.5% and 3.5% milk fat; for white chocolate 20% or more cocoa butter, 14% or more milk solids, and between 2.5% and 3.5% milk fat.
[0032] The Brazilian standard of identity: chocolate (milk and dark) 25% or more total cocoa solids; for white chocolate 20% or more total cocoa butter solids.
[0033] The European standard Relating to Cocoa and Chocolate Products: chocolate 35% or more total cocoa solids, 18% or more cocoa butter, and 14% or more fat-free cocoa solids; for milk chocolate 25% or more total cocoa solids, 2.5% or more fat-free cocoa solids, 14% or more milk solids, 3.5% or more milk fat, and 25% or more total fat (cocoa butter, cocoa butter equivalents (CBE), and milk fat); for white chocolate 20% or more cocoa butter, 14% or more milk solids, 3.5% or more milk fat.
[0034] The Canadian standard for Cocoa and Chocolate Products: for bittersweet or semisweet chocolate 35% or more total cocoa solids (from liquor, cocoa butter or cocoa powder), 18% or more cocoa butter, 14% or more fat-free cocoa solids, and 5% or less milk solids; for milk chocolate 25% or more total cocoa solids (from liquor, cocoa butter or cocoa powder), 15% or more cocoa butter, 2.5% or more fat-free cocoa solids, 12% or more total milk solids, 3.39% or more milk fat; for white chocolate 20% or more cocoa butter, 14% or more milk solids, 3.5% or more milk fat.
[0035] The Mexican standard of identity: for chocolate 35% or more total cocoa solids, 18% or more cocoa butter, 14% or more nonfat cocoa solids; for bitter chocolate 40% or more total cocoa solids, 22% or more cocoa butter, 18% or more nonfat cocoa solids; semibitter chocolate 30% or more total cocoa solids, 15.6% or more cocoa butter, 14% or more nonfat cocoa solids; milk chocolate 25% or more total cocoa solids, 20% or more cocoa butter, 2.5% or more nonfat cocoa solids, 14% or more total milk solids, 2.5% or more milk fat, and 40% or more total cocoa and milk solids; for white chocolate 20% or more total cocoa solids, 20% or more cocoa butter, 14% or more total milk solids, 3.5% or more milk fat, and 34% or more total cocoa and milk solids.
[0036] The following three examples demonstrate the possible changes in chocolate product ingredients that can be used. These recipes can be manipulated to follow or take into consideration any of the above-mentioned, or any other for that matter, standard of identity for a chocolate product or ingredient. There are advantageous properties in at least the reduction of calories and the reduction in costs. Additional advantages include the ability to manipulate viscosity levels and produce desirable microstructures. The percentage listed in the Examples below are approximate and one of skill in the art can vary the percentages and even use additional components of the recipes without departing from the invention.
Example 1
[0037]
Recipe 01
[%]
[kcal]
chocolate liquor
23
151.0
anhydrous milk fat
3.4
30.5
NFMP
3.1
10.8
Sugar
20
79.9
Lecithin
0.1
0.9
skim milk
50.4
11.2
calories [kcal/100 g]
284.4
REDUCTION CAL [%]
47
Example 2
[0038]
Recipe 02
[%]
[kcal]
chocolate liquor
10.75
70.6
heavy cream
8.7
34.8
NFMP
3.23
11.3
Sugar
21.5
85.9
lecithin
0.1
0.9
skim milk
55.72
12.4
Calories [kcal/100 g]
215.8
REDUCTION CAL [%]
60
Example 3
[0039]
Recipe 03
[%]
[kcal]
chocolate liquor
13
85.3
heavy cream
8.1
32.4
NFMP
6
21.0
Sugar
20
79.9
lecithin
0.1
0.9
skim milk
52.8
11.7
calories [kcal/100 g]
231.2
REDUCTION CAL [%]
57
[0040] All of the chocolate products from the above three specific examples result in light textured, chocolatey flavored compositions that are generally light and indulgent in flavor. The reduction in calories listed above (Reduction Cal [%]) refers to a comparison with Hershey's Milk Chocolate bars. Products such as these are stable at room temperature and can be frozen and thawed without adversely changing the texture or mouthfeel. In addition, the invention reduces the cost of preparing a standard of identity chocolate product and reduces the total calories of a standard of identity chocolate product.
[0041] The chocolate products in FIG. 6 employed a simple method of preparation as noted above. The FIG. 5 sample is conventional semisweet chocolate product of the US market. To prepare the samples for microscopy, an aliquot is hand mixed with a spatula with 10 parts of mineral oil for FIG. 5 and demineralized water in FIG. 6 . About ¼ of drop is deposited on a clean glass slide, spread with spatula, and covered with a glass cover slip and pressed for uniform thickness. Images can be viewed with transmitted, polarized compensated light using 16× objectives and the image captured with digital camera. FIG. 6 shows the microstructure of the gelatinized/crystallized oil-in-water suspension of the invention. Microparticles of cocoa bean material and cocoa butter oil droplets can be seen.
Example 4
[0042] The following recipes can be used to produce an oil-in-water suspension of the invention without a cocoa product, although cocoa product can be used. The nuts and fruit particles, such as seeds for strawberries, can be part of the insoluble particles in the suspension. As above, the percentages given are approximate and one of skill in the art can vary the percentages and even add additional ingredients without departing from the invention.
Strawberry puree 56.8% Sugar 20% Fractionated palm kernel oil (Cebes 27-75) 20% Tapioca Starch 3% Lecithin 0.2% Banana puree 51.8% Sugar 20% Fractionated palm kernel oil (Cebes 27-75) 20% Guar gum 1% Lecithin 0.2% Pecans, grinded 7% Pear puree 54.3% Sugar 20% 17-Sterine 17% Xanthan 1.5% Lecithin 0.2% Macadamia nuts, ground 7% Banana puree 69.8% Sugar 20% Cocoa Liquor 10% Lecithin 0.2% Strawberries puree 69.8% Sugar 20% Cocoa Liquor 10% Lecithin 0.2%
[0043] In each case above, the ingredients are mixed in a rotor stator mixer and then heated to about 68° C. The products can be sterilized by longer term heating or ultra high temperature or ultra high temperature and pressure conditions prior to packaging. The fruit pudding examples, such as those above, allow one to produce stable products where the added ingredients, such as crushed nuts, stay in suspension over a period of time, for example 4 months or more.
Example 5
[0044] The following recipes refer to a chocolate liquid or hot chocolate embodiments of the invention. As above, the ingredients are listed as approximate percentages and one of skill in the art can vary the percentages and even use additional ingredients without departing from the invention.
Recipe 1 Whole liquid milk 68% ADM 11-N Cocoa Powder 2% Hershey Special Dark paste 30% Recipe 2 Liquid skim milk 75% ADM 11-N Cocoa Powder 2% Hershey Special Dark paste 23%
[0045] For recipes 1 and 2, milk is heated to 40° C. in a kettle, run through a liquefier to mix for 3 minutes, homogenized at 1500 psi and a second stage at 5 psi, and then run through a MicroThermics UHT processor at 260° F. for 8 seconds.
Recipe 3 Milk (2% milk) 74% NFMP 2.5% ADM 11-N cocoa powder 2.5% Hershey Special Dark paste 21%
[0046] For recipe 3 above, the ingredients are mixed together with a rotor/stator mixer and cooked in an open pan to about 90° C.
[0047] In each case, the resulting suspensions for recipes 1-3 above remain stable at room temperature, have a good chocolatey flavor, and good mouthfeel.
[0048] In addition, in any of the above examples or in the invention in general, micronized particles, ingredients, fat droplets, or the like can be used in addition to or as a substitute the a particular ingredient. The micronized components may further define a desired microstructure for a particular product or may provide beneficial stability characteristics to the product. One of skill in the art could select any available micronization technique and/or products for use.
[0049] The examples presented above and the contents of the application define and describe examples of the many food ingredients and products that can be produced according to the invention. None of the examples and no part of the description should be taken as a limitation on the scope of the invention as a whole or of the meaning of the following claims.
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The invention provides novel means and methods for manipulating cocoa and milk ingredients, for example, to produce edible oil-in-water suspensions. In one embodiment, cocoa products are used to produce a gel network formed by cocoa starches and/or proteins. The suspension is formed with milk proteins and cocoa solids and also comprises crystallized cocoa butter as a dispersed component, and water or skim milk as the continuous phase or aqueous phase. The compositions, products, and ingredients possible according to the invention provide novel methods and components for low or reduced calorie or sugar free chocolate products or ingredients having the same cocoa content as conventional chocolate and/or falling within the standard of identity for chocolate products. In addition, the production and packaging options for chocolate products are expanded by the use of the invention as the viscosity of the chocolate product or ingredient can be varied easily without specific reliance on cocoa butter content.
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FIELD OF THE INVENTION
The present invention relates to improvements in or relating to downhole tools, and is more particularly, although not exclusively, concerned with reamer tools.
BACKGROUND TO THE INVENTION
Earth formation drilling utilises a long string of drilling pipes and tools coupled together. All elements of the drilling string are rotated together in order to rotate a cutting bit at the end of the drilling sting. The cutting bit creates a hole in a formation through which the rest of the drilling string moves in a drilling direction. An under-reamer, coupled between two other elements of the drilling string, is used to widen the walls of the hole created by the drill bit. The under-reamer, also known as a reamer, normally has an overall diameter in its retracted position which is the same as or less than the diameter of the hole being drilled. When in its deployed position, cutting elements are moved away from the body of the under-reamer to define a diameter which is larger than the diameter of the hole being drilled. As the under-reamer moves downhole rotating with the drilling string, it widens the hole in the formation behind the drill bit. In addition, an under-reamer may be used to open a collapsed formation on its way back up to the surface.
WO-A-2005/124094 describes one such under-reamer or reamer tool. The reamer tool comprises a tubular body having an axial cavity and housings arranged around its periphery to define external openings. In each of these openings, a cutter element is housed which comprises two cutter arms that can be moved between a retracted position where each cutter element is fully retained within its associated housing, and an expanded position where each cutting element extends outside its opening so that more material can be cut away the walls of the hole in a formation thereby enlarging its diameter. A drive mechanism is provided within the tubular body to move the cutter elements between their retracted and expanded positions.
In the reamer tool described in WO-A-2005/124094, one cutter arm is pivotally connected to the tubular body at one end and to the other cutter arm at the other end, the other cutter arm being connected to the drive mechanism so that both cutter arms can be retracted and expanded. The arrangement formed by the two cutter arms when deployed is a ‘V’-shape where the vertex of the V is outside the opening.
Typically, such reamer tools are operated by the pressure of fluid passing through the drill string, and in particular, through the tool section itself. The pressure of fluid is controlled by the operation of a pump associated with the drill string. In US-A-2010/0006339, the pressure of fluid passing through the tool is used to operate the reamer so that it is expanded or retracted in accordance therewith. Here, the reamer assembly comprises cutter elements and stabiliser pads mounted for sliding movement on grooves. In the retracted position, the reamer assembly is housed within a recess, the reamer assembly being moved to the expanded position by movement along the grooves so that it is outside the recess. Fluid pressure is sensed to activate the expansion and retraction of the reamer.
US-A-2010/0096191 discloses an under-reaming and stabilisation tool in which a blade element is moved from a retracted position to an expanded position by wedge elements coupled to a drive tube, the wedge elements interact with an inclined face of the blade element to effect the raising (expansion) and lowering (retraction) of the blade element relative to a guide channel. As the drive tube moves along the length of the tool body, the wedge elements are drawn along therewith and they slide under the inclined face of the blade element causing radial movement of the blade element to raise out (expand) out of its guide channel. Movement of the drive tube in the opposite direction along the length of the tool body withdraws the wedge elements from under the inclined face of the blade element allowing radial movement of the blade element to lower (retract) into its guide channel. The expansion of the blade element is limited by the actuation mechanism, that is, the drive tube and wedge elements coupled thereto.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved reamer tool in which the cutter arms or blades are maintained parallel to the axis of the reamer tool in both its retracted and deployed positions as well as during expansion and retraction whilst providing a higher opening range.
It is a further object of the present invention to provide a reamer tool in which the opening can be adjusted at the surface in accordance with a value within the opening range whilst providing a more efficient reamer tool.
In accordance with a first aspect of the present invention, there is provided a reamer tool comprising:
a substantially hollow body having a longitudinal axis and including an external wall having a first outer diameter;
at least one arm bay formed in a portion of the external wall around the periphery of the body;
at least one expandable arm located in an associated arm bay and mounted for expansion between a retracted position within the body and an expanded position in which each expandable arm describes a second outer diameter which is greater than the first outer diameter; and
at least one expansion mechanism for expanding an associated expandable arm between the retracted and expanded positions;
characterised in that each expansion mechanism comprises two elongate links pivotally connected to the associated expandable arm at one end position and to its associated arm bay at another end position, each expandable arm being pivotally mounted at the two end positions with respect to its associated arm bay so that each expandable arm is maintained substantially parallel to the longitudinal axis of the body in both the retracted and expanded positions and during its expansion and retraction between the retracted and expanded positions.
By having links connecting each expandable arm to its associated arm bay, the expandable arm can be maintained substantially parallel to the longitudinal axis of the reamer tool thereby providing an opening range which is greater than that possible with expansion mechanisms comprising wedge elements or the like.
In the case where the downhole tool comprises a reamer tool, the advantage of maintaining the expandable arm parallel to the longitudinal axis of the body is that the attack point for each cutting blade is reliable, the attack point being the point at which a leading cutting element engages with the material or formation to be cut.
Naturally, an actuation mechanism is also provided for activating the expansion mechanism, each expandable arm being pivotally connected at another end position to the actuation mechanism.
Advantageously, the expansion mechanism further comprises a third elongate link pivotally connected to each expandable arm and to the actuation mechanism.
In this way, the actuation mechanism directly moves the expandable arm and the other elongate links serve to maintain the substantial parallelism with the longitudinal axis. In a preferred embodiment, the actuation mechanism comprises a piston.
The downhole tool may further comprise at least one return member for deactivating each deployment mechanism. In one embodiment, each return member comprises a spring biased against the action of the actuation mechanism.
A shoulder block may be provided which is locatable in each arm bay to limit the expansion of the expandable arm. By selecting a suitably sized shoulder block, the expansion of the expandable arm can be determined to provide a desired outer diameter for engagement with a formation.
In a preferred embodiment, the second outer diameter may be up to 1.3 times the first outer diameter. For example, if the outer diameter of the downhole tool is 100 cm, the expandable arms may be expanded to describe an outer diameter of up to 130 cm.
Preferably, the downhole tool comprises a reamer tool and each expandable arm comprises a cutter arm.
In accordance with another aspect of the present invention, there is provided an expandable cutter arm for a downhole tool, the expandable cutter arm comprising at least a front cutting blade and a back cutting blade, each cutting blade comprising a plurality of cutting elements, one cutting element on each of the front cutting blade and the back cutting blade providing an attack point for the associated cutting blade.
Such an expandable cutter arm may further comprise a first side and a second side located either side of a plane, each side being spaced at respective predetermined distances from a plane so that the attack point for the front blade and the attack point for the back blade are equi-spaced from the plane.
By having the attack point for each cutter arm equi-spaced from the plane, efficiency of the reamer tool is improved. In addition, a more flexible reamer tool is provided in which a range of opening sizes can be accommodated.
The predetermined distance for the first side may be different to the predetermined distance for the second side.
In one embodiment, the cutting elements may comprise polycrystalline diamond cutting elements.
In accordance with a further aspect of the present invention, there is provided a reamer tool having at least one expandable cutter arm as described above.
In accordance with another aspect of the present invention, there is provided a reamer tool having a longitudinal axis, the reamer tool comprising at least one expandable cutter arm having a plurality of cutting elements arranged to form at least a front cutting blade and a back cutting blade, one of the cutting elements on the front cutting blade and one of the cutting elements on the back cutting blade providing respective attack points for their associated cutting blades, characterised in that the attack point for the front cutting blade and the attack point for the back cutting blade are equi-spaced from a plane extending through the longitudinal axis.
The reamer tool preferably further comprises at least one expansion mechanism for expanding an associated expandable cutter arm between a retracted position and an expanded position, and an actuation mechanism for activating each expansion mechanism.
In a preferred embodiment, each expansion mechanism comprises at least two elongate links pivotally connected to the associated expandable cutter arm at one end position and to its associated arm bay at another end position, each expandable cutter arm being pivotally mounted at the two end positions with respect to its associated arm bas so that each expandable cutter arm is maintained substantially parallel to the longitudinal axis in both the retracted and expanded positions, and, during expansion and retraction between the retracted and expanded positions.
The expansion mechanism advantageously further comprises a third elongate link pivotally connected to each expandable cutter arm and to the actuation mechanism, each expandable cutter arm being pivotally connected at another end position to the actuation mechanism.
The actuation mechanism preferably comprises a piston. The reamer tool may further comprise at least one return member for deactivating each expansion mechanism.
A shoulder block may be provided which is locatable in each arm bay to limit the expansion of the expandable cutter arm. The cutter arm may have an opening range up to 1.3 times the outer diameter of the reamer tool, the shoulder block limiting the opening in accordance with it size.
In accordance with another aspect of the present invention, there is provided a control module for a downhole tool, the downhole tool including a substantially hollow body having a longitudinal axis, at least one arm bay formed around the periphery of the substantially hollow body, at least one expandable arm located in an associated arm bay and mounted for expansion between a retracted position within the substantially hollow body and an expanded position in which the expandable arm describes a second outer diameter which is greater than the first outer diameter, at least one expansion mechanism for expanding an associated expandable arm between the retracted and expanded positions, and a piston for operating each expandable arm, the control module comprising:
an element mounted within the body which is moveable between a first position and second position;
a motor controlling the movement of the element; and
a gearing mechanism associated with the motor for transferring drive from the motor to the element;
characterised in that the control module further comprises a chamber and a port, the chamber being associated with the piston and the port having an open position and a closed position, the open and closed position being determined by the second and first positions respectively of the element;
and in that the port, in its open position, allows fluid to flow into the chamber and to increase the pressure therein for operation of the piston to expand each expandable arm.
In a preferred embodiment, the motor and gearing mechanism are mounted between the element and the external wall of the body. A power source is preferably located within the body of the reamer tool. This has the advantage of protecting the control module, that is, the motor, gearing mechanism and power source from the environment in which the reamer tool operates.
In one embodiment, the power source comprises a battery. In another embodiment, the power source comprises a turbine arranged to generate power for the motor.
The control module may further comprise at least one positional sensor for sensing the position of the element within the body. In addition, at least one pressure sensor may also be provided for sensing the pressure within the chamber.
In addition, at least one sensor may be provided for sensing at least a change in pressure in fluid flowing through the downhole tool, each sensor providing a control signal for the motor. Moreover, at least one sensor may be provided for sensing a change in rotational speed of the downhole tool, each sensor providing a control signal for the motor.
Additionally, a communications system may be provided through which control signals are provided for the motor. In one embodiment, the communications system includes a wired link over which control signals are transmitted.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference will now be made, by way of example only, to the accompanying drawings in which:
FIG. 1 illustrates a schematic sectioned view of a reamer tool in accordance with the present invention, the reamer tool being shown in a retracted position;
FIG. 2 is similar to FIG. 1 but illustrates the reamer tool in an expanded position;
FIG. 3 illustrates cutters mounted on an arm of the reamer tool shown in FIGS. 1 and 2 ;
FIG. 4 illustrates a sectioned view of a control system for the reamer tool shown FIGS. 1 and 2 with the reamer tool in the stowed position;
FIG. 5 is similar to FIG. 4 but illustrates the control system with the reamer tool in the expanded position.
DESCRIPTION OF THE INVENTION
The present invention will be described with respect to particular embodiments and with reference to certain drawings but the invention is not limited thereto. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes.
It will be understood that the terms “vertical” and “horizontal” are used herein refer to particular orientations of the Figures and these terms are not limitations to the specific embodiments described herein. In addition, the terms “top” and “bottom” are used to refer to parts of a drill string that face towards the surface, or top of the drill string, and away from the surface, or bottom of the drill string, respectively.
The present invention relates to an improved reamer tool and a control system for operating such a reamer tool or other downhole tool. The reamer tool is described below with reference to FIGS. 1 to 3 and the control system is described with reference to FIGS. 4 and 5 .
Although the present invention is described below with respect to a reamer tool having cutter arms, it is equally applicable to a downhole tool that may also be used for stabilisation. In this case, the cutter arms are replaced by stabilising pad arms which, when expanded, contact the walls of a formation to stabilise the drill string of which the tool forms a part. In addition, although the control system is described with reference to use with a reamer tool, it is not limited to use with a reamer tool and can be used with any other downhole tool.
Reamer tools, as well as other downhole tools, are operated, that is, expanded and retracted by changes in the pressure of fluid flowing through the associated drill string. The fluid flow is controlled by a pump associated with the drill string. Changes in fluid pressure are detected by sensors located at appropriate positions in the drill string.
Referring initially to FIGS. 1 and 2 , a longitudinal sectioned view of reamer tool 100 is shown. The reamer tool 100 comprises a reamer body 105 having three cutter arms 110 mounted within respective housings or arm bays 115 formed in the reamer body 105 . The three cutter arms 110 are equi-spaced around the periphery of the reamer body 105 but only one such cutter arm is shown in FIGS. 1 and 2 .
Each cutter arm 110 comprises a cutting element or cutting blade 120 which is pivotally mounted on each of three elongate links 125 , 130 , 135 at respective pivot points 140 , 145 , 150 as shown. Two of the elongate links 125 , 130 are also pivotally attached to the housing or arm bay 115 at respective pivot points 155 , 160 . The third elongate link 135 is also pivotally mounted, by means of a pivot point 165 , on a piston 170 .
The piston 170 comprises an actuation mechanism and is operated to move from a first position as shown in FIG. 1 to a second position as shown in FIG. 2 to expand the cutter arms 110 , and more particularly, the cutting elements or cutting blades 120 , from a retracted position to an expanded position where the cutting elements or cutting blades 120 extend outside the reamer body 105 and define an outer diameter which is up to 1.3 times that of the normal outer diameter of the reamer body 105 .
It will be appreciated that, in other embodiments of the reamer tool 100 in accordance with the present invention, the outer diameter defined by the three cutter arms 110 and their cutting elements or cutting blades 120 may have other ratios compared to the outer diameter of the reamer body 105 as required, and, is therefore not limited to up to 1.3 times the outer diameter of the reamer body 105 . The outer diameter is limited by a shoulder block 175 and the size of the shoulder block 175 is chosen at the surface before introduction of the drill string of which the reamer tool 100 forms a part into a wellbore in a formation in accordance with the outer diameter of the reamer tool 100 required to from the wellbore in the formation.
It will be appreciated that shoulder blocks of different sizes can be provided with the reamer tool 100 and an appropriately sized shoulder block is chosen to limit the expansion of the cutter arms 110 to control the outer diameter defined by the expanded cutter arms 110 and cutting elements or cutting blades 120 within an opening range from the same outer diameter of the reamer body 105 to 1.3 times that outer diameter.
In the deployment of the cutter arms 110 from inside their respective housings or arm bays 115 formed in the reamer body 105 , the cutting structure (not shown) of each cutter arm 110 always remains parallel to a longitudinal axis 180 of the reamer body 105 . The pivot points 140 , 145 , 150 , 155 , 160 , 165 formed on respective ones of the links 125 , 130 , 135 , as described above, effectively provide pivoting axes about which rotation can occur to expand and retract the cutter arms 110 and cutting elements or cutting blades 120 out of and into their respective housings or arm bays 115 . However, pivot points 140 , 145 provided on respective links 125 , 130 ensure that the cutter arms 110 remain parallel to the reamer body 105 as they are expanded, used for cutting and retracted into their respective housings or arm bays 115 . Pivot point 150 provided on elongate link 135 is used to expand and retract the associated cutter arm 110 in accordance with the movement of the piston 170 or other actuation mechanism as will be described in more detail below.
By using an expansion mechanism which utilises elongate links pivotally connected to both the cutter arm 110 and the housing or arm bay 115 as well as to the piston 170 or other actuation mechanism, the effective outer diameter of the cutter arm 110 and cutting element or cutting blade 120 can extend up to 1.3 times the outer diameter of the reamer body 105 . In addition, the amount of expansion can easily be limited by a suitable shoulder block 175 .
The force for expanding the cutter arms 110 is provided by pressure applied to the piston 170 , and, the force for retracting the cutter arms is provided by a spring 185 (described below with reference to FIGS. 4 and 5 ). The applied pressure is provided by fluid flow through the reamer body 105 as will be described in more detail below.
As shown in FIGS. 1 and 2 , the reamer body 105 is substantially tubular with a hollow central portion 190 which defines a fluid flow path. The piston 170 is mounted within the reamer body 105 and is operated by fluid flowing therethrough as will described in more detail with reference to FIGS. 4 and 5 below.
In the embodiment of the reamer tool 100 described above, it is essential to ensure that the cutting elements, for example, polycrystalline diamond cutters known as PDC cutters, function adequately during the expansion stages to make contact with the formation in which the reamer tool is to be used. This is described in more detail with respect to FIG. 3 .
In FIG. 3 , a portion 200 of a cutter arm 110 of the reamer tool 100 shown in FIGS. 1 and 2 is shown in more detail. The positioning of the cutting elements with respect to the cutter arm 110 is shown. The portion 200 shows a single cutter arm 110 ( FIG. 1 ) having two cutting blades 205 , 210 , a front cutting blade 205 and a back cutting blade 210 . [The terms “front” and “back” refer to the order in which the cutting blades make contact with the walls of a wellbore formed in a formation and is determined by the direction of rotation of the drill string (not shown) of which the reamer tool 100 ( FIG. 1 ) forms a part.]
In the embodiment shown in FIG. 3 , five cutting elements 215 , 220 , 225 , 230 , 235 are visible on front cutting blade 205 , and six cutting elements 240 , 245 , 250 , 255 , 260 , 265 are visible on back cutting blade 210 . Cutting element 215 on front cutting blade 205 and cutting element 240 on back cutting blade 210 have respective attack points 270 , 275 which are equi-spaced from a plane 280 that is coincident with the longitudinal axis 180 of the reamer body 105 ( FIG. 1 ). This means that the distance from side 285 of front cutting blade 205 to the plane 280 is shorter than the distance from side 290 of back cutting blade 210 to plane 280 .
In the embodiment shown in FIG. 3 , the cutting elements 215 , 220 , 225 , 230 , 235 , 240 , 245 , 250 , 255 , 260 , 265 comprise PDC elements as shown. Although eleven PDC elements are visible, the number of PDC elements present on each blade 205 , 210 is determined in accordance with the dimensions of the PDC element and the dimension of the reamer tool itself. However, it will be appreciated that other types of cutting elements may also be used, for example, impregnated cutting elements.
By having the attack points 270 , 275 equi-spaced from the plane 280 , attack points 270 , 275 will contact the formation for any opening size in the opening range. If the attack points 270 , 275 are not equi-distant from the plane 280 , the cutter arms will only have one possible opening size to ensure that both the front and back cutting blades make contact with the formation.
The front and back blades 205 , 210 as described above have different numbers of cutting elements 215 , 220 , 225 , 230 , 235 , 240 , 245 , 250 , 255 , 260 , 265 which are not aligned with one another so that the attack points 270 , 275 of cutting elements 215 , 240 are at different heights with respect to the reamer body 105 .
The effective outer diameter of the reamer tool 100 , that is, the opening size is determined by the positions of attack points 270 , 275 .
Referring now to FIGS. 4 and 5 , a schematic longitudinal sectioned view of the reamer tool 100 is shown. Components that have previously been described with reference to FIGS. 1 and 2 have the same reference numerals.
The reamer tool 100 comprises the reamer body 105 having cutter arms 110 mounted within respective housings or arm bays 115 formed in the reamer body 105 as described above. The links and the pivot points that operate the cutter arms 110 as described above are not shown for clarity. The spring 185 that is used to return the expanded cutter arms to their retracted position is shown schematically as a block.
As described above, the force for expanding the cutter arms 110 is provided by pressure applied to the piston 170 due to fluid flow through the reamer tool 100 , and, the force for retracting the cutter arms is provided by the spring 185 . During expansion of the cutter arms, the pressure exerted on the piston 170 creates a force which is greater than the force provided by the spring 185 . Once the pressure exerted on the piston 170 falls sufficiently so that the force exerted becomes less than the force provided by the spring 185 , the spring 185 causes the cutter arms 110 to be retracted into their respective housings or arm bays 115 . This is described in more detail below.
A control system 300 for deploying the cutter arms 110 is provided within the reamer body 105 and comprises an electric motor 310 , a gearing system 315 and a moveable sleeve 320 , the electric motor 310 and gearing system 315 being housed between the sleeve 320 and an external wall 325 of the reamer body 105 . The electric motor 310 rotates at a first predetermined speed and the gearing system 315 reduces that first predetermined speed to a second lower predetermined speed which is used for operating the moveable sleeve 320 . In one embodiment, a ball screw (not shown) may be used to transfer the rotational output from the gearing system 315 to a linear movement which is used to move the sleeve 320 to open and close port 385 as will be described in more detail below. However, it will be appreciated that other arrangements may be used for transferring rotary motion from the gearing system 315 to linear motion of the moveable sleeve 320 , for example, a pinion or worm gear forming part of the gearing system 315 may engage with a rack element provided on the moveable sleeve 320 .
The electric motor 310 may be powered by a battery (not shown) or from a turbine provided in the drill string (also not shown), the turbine generating a current from the fluid flow therethrough. Although a gearing system 315 is described, it will be appreciated that drive from the motor may be converted into linear movement by any suitable means for converting the output of the motor into linear movement.
The housing or arm bay 115 for each cutter arm 110 is defined by a wall 330 of the hollow central portion 190 and a portion 335 of the external wall 325 of the reamer body 105 . The piston 170 is defined by a chamber 340 adjacent the cutter arm 110 , the chamber 340 being defined by the wall 330 of the central portion 190 , external wall 325 of the reamer body 105 , sleeve 320 , first cylindrical portion 345 , second cylindrical portion 350 and end wall 355 as shown. End wall 355 also forms barrier between the electric motor 310 and gearing system 315 of the control system 300 .
Annular seals 360 , 365 are provided between the first cylindrical portion 345 and respective ones of wall 330 and sleeve 320 . Additional annular seals 370 , 375 are provided between sleeve 320 and second cylindrical portion 350 and with wall 380 of hollow central portion 190 . Seal 360 can be mounted on either the first cylindrical portion 345 or the wall 330 as the first cylindrical portion 345 does not move relative to the wall 330 .
The first and second cylindrical portions 345 , 350 define the port 385 which is sealed by the moveable sleeve 320 when in a first position, as shown in FIG. 4 , so that fluid flows through the hollow central portion 190 as indicated by arrow 390 . When the sleeve 320 is in a second position, as shown in FIG. 5 , the port 385 is open and fluid can flow into chamber 340 as shown by arrow 395 .
An additional seal 400 is also provided between the piston 170 and the external wall 325 of the reamer body 105 as shown to prevent ingress of drilling fluid as the piston 170 moves from the position shown in FIG. 4 to the position shown in FIG. 5 .
Operation of the electric motor 310 effectively moves the sleeve 320 in the same direction as arrow 390 to open the port 385 and in the opposite direction to close the port 385 , drive from the electric motor 310 being transmitted to the sleeve 320 via the gearing system 315 . A control signal for the electric motor 310 is provided by way of an increased fluid flow rate through the hollow central portion 190 and/or speed of rotation of the drill string (not shown). At least one suitable sensor (not shown) is provided to sense the change in pressure and/or rotational speed and to provide a control signal for the electric motor 310 , for example, a pressure sensor for sensing changes in pressure and an accelerometer for sensing the change in rotational speed. However, other sensors may also be used for sensing the change in rotational speed.
It will be appreciated that the electric motor 310 may be a bi-directional motor that operates in two directions to effect opening and closing of the port 385 . As an alternative to the electric motor 310 , a solenoid may be used to effect opening and closing of the port 385 .
Naturally, the electric motor 310 and gearing system 315 are sealed within a region 410 defined by the sleeve 320 and an external wall 325 so that it is protected from the drilling environment, that is, the mud, rock etc., that finds its way into the hollow central region 190 . In a preferred embodiment, the region 410 is filled with oil to prevent the ingress debris from the drilling environment.
Before the cutter arms 110 are expanded, they are housed in their respective housings or arm bays 115 as described above. Fluid flow is through the hollow central portion 190 as indicated by arrow 390 ( FIG. 4 ). When a control signal is sent to the electric motor 310 , by way of a change in pressure of the fluid flowing through the hollow central portion 190 and/or a change in the rotational speed of the drill string as described above, the electric motor 310 operates the moveable sleeve 320 to move it in the same direction as the fluid flow as indicated by arrow 390 to open port 385 ( FIG. 5 ).
When the port 385 is opened, fluid flows into the chamber 340 and pressure builds up therein. When the pressure in the chamber 340 reaches a value where the force exerted by the piston 170 is greater than the force exerted by the spring 185 , the piston 170 is pushed from the position shown in FIG. 4 towards the arm bays 115 to expand the cutter arms 110 as shown in FIG. 5 . Movement of the piston 170 towards the arm bays 115 causes each cutter arm 110 to pivot about pivot point 150 on link 135 , as well as pivot points 140 , 145 on links 125 , 130 , so that it is expanded from the within its associated arm bay 115 as shown in FIGS. 1 and 4 , to the position as shown in FIGS. 2 and 5 . Fluid built up in the chamber 340 flows out of nozzles 415 associated with the cutter arms 110 maintaining the position of the piston 170 as shown in FIGS. 2 and 5 , and hence the expansion of the cutter arms 110 , until the port 385 is closed by the sleeve 320 by the operation of the motor 310 and gearing mechanism 315 .
On receipt of a further control signal, that is, another change in pressure of the fluid flow and/or a change in rotational speed of the drill string, the motor 310 is activated once again to move the moveable sleeve 320 from the position shown in FIG. 5 back to the position shown in FIG. 4 , thereby closing the port 385 so that no more fluid flows into the chamber 340 as indicated by arrow 395 . Fluid flows out of nozzles 415 until the pressure in the chamber 340 is reduced so that the force of the spring 185 causes the cutter arms 110 to be returned to their associated housing or arm bay 115 to be returned to the position shown in FIGS. 1 and 4 . In addition, the piston 170 is pushed back but the force exerted by the spring 185 to its initial position as shown in FIGS. 1 and 4 .
Alternatively, instead of operating the motor 310 , the cutter arms 110 may be retracted by turning the pump off that is associated with the drill string so that fluid flow is switched off through the drill string, and the pressure in the chamber 340 falls as no further fluid flows through the port 385 and into the chamber 340 . Once the pressure in the chamber 340 falls to a value where the force exerted by the spring 185 exceeds that of provided by the pressure in the chamber 340 , the piston 170 is moved back to the position shown in FIGS. 1 and 4 and the cutting arms 110 retracted whilst still parallel to the longitudinal axis 180 due to their pivoting about points 140 , 145 , 150 ; pivoting of the links 125 , 130 about points 155 , 160 in the respective housing or arm bay 115 ; and pivoting about pivot point 165 due to movement of the piston 170 as it moves from the position shown in FIG. 5 back to the position shown in FIG. 4 .
As mentioned above, the control system 300 includes a power supply (not shown), but it may also include other electronic equipment, for example, pressure sensors for sensing the pressure in the chamber 340 , accelerometers for measuring the speed of movement of the sleeve 320 and piston 170 and the rotational speed of the drill string, as well as the speed of the cutter arm 110 during its expansion and retraction phases. In addition, a communication device (not shown) may be provided through which control signals can be provided for the electric motor in the case where the control signals are not supplied by changes in pressure of the fluid flow or rotational speed of the drill string as described above.
The power supply may be provided by one or more batteries or via a wired link from the surface. Additionally, the wired link may form part of the communication device through which the control signals may be transmitted to the electric motor.
It will be appreciated that the cutter arm expansion mechanism can be used with other tools, for example, downhole stabilisers, and the cutter arms can be expanded using other expansion mechanisms.
Although a specific embodiment of the present invention is described, it will be appreciated that this embodiment is not limiting and other embodiments may fall within the scope of the invention as defined by the appended claims.
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Described herein is a reamer tool ( 100 ) having a body ( 105 ) with bays ( 115 ) in which cutter arms ( 110 ) are mounted for deployment between a stowed position and a deployed position. A deployment mechanism is provided for deploying the cutter arms from their stowed position to their deployed position that maintains each cutter arm in a position that is substantially parallel to a longitudinal axis of the body ( 105 ) whilst in its stowed position and in its deployed position as well as during its deployment from its stowed position to its deployed position. A control module ( 300 ) is also described for controlling the deployment of the cutter arms ( 110 ). The control module ( 300 ) comprises a motor ( 310 ), a gearing mechanism ( 315 ) and a moveable element ( 320 ) that closes a port ( 385 ) in a first position and opens the port ( 385 ) in a second position. Fluid flow enters a chamber ( 340 ) behind a piston ( 170 ) through the port ( 385 ) to allow pressure to build up before actuating the piston ( 170 ) and thereby the deployment mechanism for the cutter arms ( 170 ).
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This is a continuation of application Ser. No. 561,911 filed Dec. 15, 1983 which was abandoned upon the filing hereof, itself a continuation of Ser. No. 291,611 filed Aug. 10, 1981, now abandoned, and a continuation-in-part of Ser. No. 173,001 filed July 28, 1980, now U.S. Pat. No. 4,307,717
BACKGROUND OF THE INVENTION
This invention relates to an improved skin reservoir which contains a medicament that is topically released into the skin.
Attempts have been made to develop reservoir delivery systems which are self-adhesive and water absorbent. For example, U.S. Pat. No. 3,339,546 discloses a self-adhesive reservoir which is adapted to adhere to moist surfaces such as the moist mucosa of the oral cavity. However, one of the essential materials of this self-adhesive reservoir is an adhesive gum, preferably polyisobutylene, which is hydrophobic. Similarly, U.S. Pat. Nos. 3,598,122 and 3,598,123 disclose reservoirs which contain drugs that are continually released from an adhesive layer. These reservoirs are formed of layered materials which have drugs encapsulated in the adhesive layer. Even though the reservoirs disclosed in these prior art patents are said to be self-adhesive and are satisfactory vehicles for drugs, specific process steps are required for encapsulating or stratifying the drugs.
Hydrophilic polymers plasticized with hydric alcohol and/or water have been used for ostomy gaskets (U.S. Pat. No. 3,640,741) and for the conduction of electrical current to and from the skin (U.S. Pat. Nos. 4,125,110, 4,273,135 and 4,066,078). The polymeric formulations specifically contain organic or inorganic ions physically dissolved in the plasticizers for electron transfer. More recently, Silastic polymers (U.S. Pat. No. 4,336,243) have been used to release a nitroglycerine medicament solubilized in the plasticizer for transfer into a body through the skin. However, this matrix reservoir system tends to dry out and is not self-adherent.
SUMMARY OF THE INVENTION
Therefore, it is a general object of this invention to provide a self-adhesive, novel matrix reservoir in which a medicament is molecularly dispensed for release to the affected area. The matrix reservoir is comprised of a flexible backing element and a self-adhesive substrate which becomes increasingly tacky in the presence of moisture and which absorbs liquid and releases the medicament to the affected area while remaining dimensionally stable.
Another form of the substrate contains cross-linked polysaccharides plasticized with water and/or hydric alcohol which are not self-adhering, but dry very slowly and are dimensionally stable even when in the environment of 100% water.
It is pointed out that the present reservoir system is not formed of a gelatinous base, but is formed of a polymeric base, and is therefore not biodegradable in the manner of certain prior art devices. It is also pointed out that the medicament is progressively released from the reservoir until the contents thereof are substantially diminished so that the reservoir system, in effect, is dynamically altered as a drug dispensing device. When a medicament is incorporated into the reservoir structure, the formation and structure of the basic matrix system is changed because the new molecule may become integrated into the polymeric formation and change the method of formulation. Each medicament is associated with a particular polymer or polymers. These formulations are designed so that the medicament will be available for active and/or passive diffusion into the skin. The skin becomes part of the reservoir system and the matrix reservoir becomes active when applied to the skin.
Finally, and most importantly, the present reservoir system is formed of a hydrophilic substance which moisturizes the skin and enhances absorption of a medicament by building a hydrophilic bridge so that the medicament can diffuse from the reservoir into the skin.
These and other objects and advantages of this invention will more fully appear from the following description made in connection with the accompanying drawings, wherein like reference characters refer to the same or similar parts throughout the several views.
FIGURES OF THE DRAWING
FIG. 1 is a perspective view illustrating the novel reservoir applied to the arm of a patient;
FIG. 2 is a perspective view of a reservoir illustrated in FIG. 1;
FIG. 3 is a perspective view of a large size reservoir;
FIG. 4 is a cross-sectional view taken approximately along line 4--4 of FIG. 2 and looking in the direction of the arrows; and
FIG. 5 is a modified form of the reservoir.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The reservoir of the present invention may have adhesive properties for maintaining contact with the skin, as well as possessing a certain amount of elasticity for movement with the skin. The reservoir is intended to be easily handled and is non-irritating to the patient's skin.
Referring now to the drawings, it will be seen that the drug delivery system of the present invention is thereshown. This reservoir, designated generally by the reference numeral 10, includes a backing member 11 and a self-adhesive substrate 12 which is secured to one end surface of the backing. The backing element 11 and the substrate 12 are both illustrated as rectangular sheets of material of uniform thickness. It is pointed out that the reservoir 10 is intended to be regular in shape, but may have any other configuration, although the rectangular shape is preferred. In use, the reservoir is applied with the substrate 12 in direct contact with the skin.
Referring now to FIG. 5, it will be seen that a different embodiment of the reservoir, designated generally by the reference numeral 10a, is thereshown. The reservoir includes a pressure-sensitive adhesive element 11a which serves as the backing element and also serves as the means for securing the bandage to the surface of the skin. The pressure-sensitive adhesive element 11a may be formed of any of the materials used in commercially available adhesive elements, such as a foam-type adhesive element. It will be appreciated that most of the commercially available adhesive elements maintain an excellent bond with the skin.
Primary to the unique structure of the reservoir is the hydrophilic adhesive properties of the substrate which enhance the adhesion thereof to the skin. The substrate not only absorbs moisture, but the substrate becomes tackier as it absorbs moisture.
Alternatively to the hydrophilic adhesive properties, is a very wet, slowly drying and dimensionally stable reservoir made from cross-linked guar in water.
The substrate 12 may be formed from naturally occurring materials such as gum karaya, gum acacia, locust bean gum and other polysaccharides, and synthetically formulated polysaccharides such as guar and celluloses such as carboxy-methyl cellulose. The substrate may also be formed from synthetic polymers such as polyacrylamide and its cogeners, polyacrylic acid molecular weights 250,000, 450,000, 1,000,000 and 4,000,000, and polyacrylamide sold under such trademarks as Reten by Hercules Company. When monomers such as acrylic acid or acrylamide are polymerized, it is necessary to use activators. Activators, which are used during polymerization, may include ferrous sulfate, sodium metabisulfite, potassium persulfate, as set forth in the co-pending application, Ser. No. 424,342. The disclosure of the co-pending application Ser. No. 424,342 is incorporated herein by reference. Alternatively, the polymeric portion may be synthetically made of combined polymers of acrylamide and saccharides (guar) and starch-g-poly made by Henkel Corporation, St. Paul, Minnesota.
The synthetic polymers and/or synthetic or natural gums and other polysaccharides constitute the solid phase of the matrix. The liquid phase of the matrix preferably consists of hydric alcohols such as glycerol and/or propylene glycol, and/or water. Solutions or emulsions of saccharides and/or polysaccharides and/or proteins may also be used in plasticizing the matrix. Alternatively, a combination of a solution or emulsion of polysaccharides, saccharides or proteins may be used in the liquid phase of the matrix.
The substrate 12, which is a stable matrix, includes a solid phase comprising a synthetic polymer mixture, a large molecular weight polysaccharide matrix, or a matrix of a large molecular weight polysaccharide and synthetic polymer. The solids of the matrix comprise 2% to 50% by weight of the matrix. The liquid phase of the matrix, such as hydric alcohol and/or water, comprises 50% to 98% by weight of the matrix. The reservoir also includes a suitable backing member which may include cotton fabric, woven or standard paper, synthetic fabrics, and/or plastics.
The substrate 12 also contains a medicinal substance for release to the surface to which the reservoir is applied. The medicinal substance is molecularly dissolved and/or suspended in the matrix rather than being encapsulated as in the prior art. The medicinal substance may include an antibacterial, antiseptic, or antifunginal agent such as boric acid, bacitracin, acriflavin, formaldehyde, gential violet, mercuric sulfide, mercurochrome, neomycin, and iodine. Nitroglycerine may be used as a coronary vasodilater agent. Suitable antipruretic agents include benzoin, calamine, camphor, menthol, phenol, and sulfer. The substrate may also include frangrances such as cinnamon oil, fir needle oil, lemon oil, peppermint oil, and spearmint. Suitable healing agents include allantoin, Peruvian balsam, Vitamin A, and Vitamin E. Hormonal agents may include hydrocortisone or similar steroids, estrogen, progesterone, and testosterone. Protective agents may include benzoin, charcoal, talc, and zinc oxide. Salicylic acid is a suitable keratolytic agent and methyl salicylate is a suitable rubefacient. An examplary antihistamine is chlorpheniramine. Glucose lowering agents such as insulin and tolbutamide may be used.
It has been found that vinyl acetate dioctyl maleate copolymer may also be advantageously used in forming the solid phase of the matrix. Vinyl acetate dioctyl maleate copolymer (sold under the trademark "Flexbond 150" by Air Products and Chemicals, Inc., and sold under the trademark "Bostik 8761" by the Bostik Company, Inc.) will intensify the tackiness of the reservoir.
Another important gum material which may be used in forming the matrix is a starch graft copolymer sold under the trade name "SGP 502S Absorbent Polymer" by the Henkel Corporation, St. Paul, Minnesota. The starch graft copolymer product is derived from corn starch and acrylonitrile, and is a graft terpolymer of starch, acrylamide and sodium acrylate. The technical name for this starch graft copolymer product is starch-g-poly (acrylamide-co-sodium acrylate). The starch-g-poly material may be used alone to form the substrate or it may be used in combination with a synthetic gum such as acrylamide or a natural gum such as karaya. The starch-g-poly material is very effective as the skin contacting substrate, since it does maintain its structural integrity and is non-toxic.
One of the distinct advantages of the present reservoir system is that it is a hydrophilic substance which prepares the skin for absorbing medicaments. The present reservoir system is not a drug delivery device for merely releasing a drug locally, but also may deliver medicaments transdermally for systemic use.
______________________________________ Nominal Amounts of Range of Ingredients Ingredients______________________________________EXAMPLE 1Polyacrylamide 5% 1-50%Karaya 38% 5-45%Glycerol 55% 30-70%Povidone-Iodine 2% 0.1-10%EXAMPLE 2Polyacrylic acid 10% 2-40%Polyacrylamide 10% 2-40%Karaya 18% 5-45%Glycerol 60% 30-70%Povidone-Iodine 2% 0.1-10%EXAMPLE 3Polyacrylamide 15% 2-40%Polyacrylic acid 15% 2-40%Glycerol 68% 30-70%Povidone-Iodine 2% 0.1-10%EXAMPLE 4Polyacrylamide 30% 2-40%Glycerol 62% 50-70%Methyl Salicylate 8% 0.1-15%EXAMPLE 5Polyacrylamide 21.5% 2-40%Polyacrylic acid 12.5% 2-40%Glycerol 42% 30-70%Vinyl acetate-dioctyl maleate 16% 10-20%Methyl salicylate 8% 0.1-15%EXAMPLE 6Polyacrylamide 31% 2-40%Glycerol 55% 30-70%Water 6% 1-10%Methyl salicylate 8% 0.1- 15%EXAMPLE 7Povidone-Iodine 2% 0.1-10%Hydroxy-propylcellulose (Klucel) 6% 0.1-10%Glycerin 56% 30-70%Water 6% 0.1-10%Polyacrylamide (Reten 421) 30% 2-40%EXAMPLE 8Povidone-Iodine 10% 0.1-15%Reten 421 (polyacrylamide) 5% 2-40%Karaya 35% 5-45%Glycerol 50% 30-70%EXAMPLE 9Povidone-Iodine 2% 0.1-10%Karaya 43% 5-45%Glycerol 55% 30-70%EXAMPLE 10Camphor 2% 0.1-5%Methylene bisacrylamide 3% 0.1-10%Acrylic acid 8% 0.1-10%Glycerol 86% 45-90%Activators* 1% 0.1-2%*Potassium persulfate 0.6% -Sodium metabisulfate 0.2%Ferrous sulfate 0.1%EXAMPLE 11Camphor 2% 0.1-5%Glycerol 55% 30-70%Karaya 43% 5-45%EXAMPLE 12Methyl salicylate 2% 0.1-10%Methylene bisacrylamide 5% 0.1-10%Acrylic acid 8% 0.1-10%Glycerol 84% 30-70%Activators 1% 0.1-2%EXAMPLE 13Methyl salicylate 8% 0.1-15%Acrylic acid 2% 0.1-10%Methylene bisacrylamide 1% 0.1-10%Glycerol 48% 30-70%Karaya 40% 5-45%Activators 1% 0.1-2%EXAMPLE 14Starch-g-poly 35% 15-50%Glycerol 35% 30-70%10% Nitroglycerine in propylene glycol 30% 10-40%EXAMPLE 15Starch-g-poly 25% 1-40%Glycerol 30% 30-70%Karaya 15% 5-30%10% Nitroglycerine in propylene glycol 30% 10-40%EXAMPLE 16Guar derivative 1.9% 1-3%Potassium pyroantimonate crosslinkers 0.1% 0.03-1.0%Water 88% 80-95%50% Isosorbide dinitrate in lactose 10% 5-20%EXAMPLE 17Guar derivative 3.4% 0.8-7%Potassium pyroantimonate crosslinker 0.6% 0.1-1%Karaya 15% 5-25%Glycerol 35% 25-45%50% Isosorbide dinitrate in lactose 10% 5-20%Water 36% 25-55%EXAMPLE 18Ester of (α-, β-olefinically 49.08% 10-90%Unsaturated carboxylic acid crosslinker 0.02% 0.01-0.05%Glycerol 20% 15-50%10% Nitroglycerine in propylene glycol 30% 15-50%EXAMPLE 19Locust bean gum 2.5% 0.25-5%Xyanthan gum 2.5% 0.25-5%Water 85% 75-95%50% Isosorbide dinitrate in lactose 10% 4.5-20%EXAMPLE 20Karaya 30% 20-50%Glycerol 55% 30-70%Salicylic acid 15% 8-20%EXAMPLE 21Karaya 35% 25-45%Glycerol 45% 35-70%Aloe Vera 20% 5-30%______________________________________
It is pointed out that 50% glucose in water can be substituted in the above examples for glycerol in equivalent percentages. Similarly, 5-10% albumen in water or 5-10% casein in water can be substituted in equivalent percentages for glycerol or hydric alcohols in the above example. Combinations of aqueous solutions of carbohydrates or larger molecular weight polysaccharides and/or aqueous solutions of proteins may also be substituted for glycerol or other hydric alcohols.
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A flexible, liquid-absorbing, adhesive skin reservoir includes a backing element and a substrate attached to the backing element. The substrate comprises a homogeneous, hydrophilic, stable matrix including a solid phase formed of a synthetic polymer and/or a long chain natural or synthetic polysaccharide, or a combination thereof. The liquid phase of the matrix consists of water, hydric alcohol, carbohydrates and/or proteins in an aqueous solution, and/or a combination thereof. The matrix contains a medicament therein for release to the affected areas for local and/or systemic medicinal effect.
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