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BACKGROUND OF THE INVENTION
1. Field of the Invention.
The present invention relates to systems for removably attaching a dental model to an articulator.
2. Description of the Prior Art.
In order to prepare dental plates, or inlays, crowns and bridges, die-stone or plaster dental casts are made of and then fixed in various ways in so-called articulators for further treatment. Articulators are well known in the dental industry as mechanical devices that simulate the movement of a human jaw and most often include an upper frame member spaced opposite a lower frame member, these members connected to each other for relative hinging and sliding movement. Upper and lower dental models are mounted to the upper and lower frame members respectively so that the dental models are held in relative alignment to allow precise dental measurements and relationships to be determined during the fabrication of the relevant dental prosthesis.
In earlier dental articulator systems it was required to perform the necessary processing with the dental casts remaining attached to the articulator. Because of limitations attendant to such systems, and the need to shorten dental appliance processing time, efforts ensued to develop techniques by which dental models could be removable, retractable and realignable upon an articulator. Various articulators are shown in U.S. Pat. Nos. 4,600,385, 4,923,398, and 4,245,987. The systems shown therein as well as the most widely used articulator systems can be generally characterized by the dental casts being mounted to the articulator frame by means of a mounting plate that supports a cast on one of its sides, and which mounting plate is removably attachable to the respective frame members by use of a threaded fastener. The mounting plate used is generally a flat disc-like member having a threaded hole to receive the threaded portion of a knob-equipped mounting screw which extends through the frame member to secure the mounting plate. In U.S. Pat. No. 4,923,398 a dental cast is removable from the articulator frame so that it can be worked upon effectively at other work stations and then reconnected, as required, to the articulator. In spite of the advances represented by these various prior art systems there remains a need for improvements beyond the conventional base plate and screw arrangement represented therein.
SUMMARY OF THE INVENTION
In view of the foregoing it is a general object of the present invention to provide improved means for removably attaching a dental model to an articulator.
Another object of the present invention is to provide a system that quickly, easily and simply mounts and dismounts a dental model to an articulator.
A still further object of the invention is to provide such a system in which proper alignment of the dental cast upon the articulator is maintained after repeated disconnections and reconnections.
Yet another object of the invention is to provide a system that incorporates the foregoing advantages in a reliable and economical plastic construction.
A further object of the invention is to provide a system, for removably attaching a dental model to an articulator, that can be used in conjunction with a large number of currently available articulator designs.
These, and other objects and advantages can be provided by the system of the present invention for use on an articulator having an upper frame member spaced opposite a lower frame member, for removably and reattachably mounting dental models, to the articulator frame members, the new system including a base plate having a configuration commensurate with a full upper or lower dental quadrant, with one side of the base plate being adapted to support a die-stone dental model, the other side of the base plate having fastening and alignment means including a plurality of spaced-apart vertical bores therethrough. The system includes an adapter plate that has one of its sides generally flat and adapted for being adhesively bonded to the upper or lower frame member of the articulator. The other side of adapter plate is adapted to releasably secure the dental model base plate, and has a plurality of support posts extending outwardly therefrom, the outer end of each of the posts having a outwardly facing abutment surface and resiliently depressible latching means. The latching means of each support post is adapted to be resiliently deformed and frictionally and releasably locked within a corresponding one of the vertical bores in the base plate, and the abutment surfaces will abut generally flat surfaces at the peripheries of the bores, to hold the base plate relative to the adapter plate against lateral and inward movement.
The system can further include an alignment wall on the adapter plate having slot means for receiving laterally extending alignment tongues carried on the base plate, for holding the components against relative longitudinal movement. In a preferred embodiment the system also includes laterally spaced-apart alignment walls on the adapter plate, including a curved interconnecting portion which are designed to be snugly engaged against inside surfaces of spaced-apart walls and adjoining curved wall portion on a base plate, to provide additional stability and support against relative movement of the connected components.
A greater appreciation of the invention will be obtained by resort to the detailed description, including drawings, and the claims which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmented, exploded perspective view illustrating a mounting system according to the present invention;
FIG. 2 is a top plan view of an adapter plate used in the present invention;
FIG. 3 is a side elevational view of the adapter plate of FIG. 2;
FIG. 4 is a side elevational view showing a dental model supported on an articulator using the present invention;
FIG. 5 is a sectional view taken along the line 5--5 of FIG. 4 and;
FIG. 6 is a perspective view, with parts broken away for the sake of clarity, of a system according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 indicates by reference numeral 11 a preferred embodiment, according to the present invention, of a system for mounting a dental model to an articulator. The system includes a base plate assembly 13 which supports on one face as shown, a die-stone dental model 15. Base plate assembly 13 is preferably of a unique advantageous plastic modular construction that can support a full upper or lower bilateral dental replica such as dental model 15 which is directly molded to a plurality of mounting blocks 17 that are releasably secured to an upper surface of a base plate 19. Such apparatus for supporting a dental model is described in detail in U.S. Pat. No. 5,197,874 which disclosure is incorporated herein by reference. It will be seen that the base plate assembly 13, while still capable of carrying out the invention of U.S. Pat. No. 5,197,874, has been uniquely adapted to serve the attachment system that is being described herein. Thus as FIGS. 1 and 6 best show, the base plate assembly 13 includes a base plate flange 21 for supporting the mounting blocks 17, and has spaced-apart walls 23 that are interconnected by a curved wall portion 25, which walls combine to provide a continuous upper edge 27. It is also seen that walls 23 and 25 provide upright, vertical inside surfaces 29. Finally it is noted that there are a pair of transverse alignment tongues 31, and that circular bores 33 are provided through the horizontal walls 35 of the base plate 19.
Although FIGS. 1 and 4 illustrate the system of the invention in conjunction with a lower articulator frame member 37, it is to be understood that the attachment system described will be equally applicable to an upper articulator frame member.
The system of the invention also features an adapter plate 41, also constructed of a suitable durable plastic material by conventional molding techniques of the plastics industry, and it has a back wall with a generally flat surface 43 which can be given a deliberate textured or roughened configuration in order to enhance its application in what is known in the art as hot-melt adhesive bonding. In this regard it is noted here that the system of the invention is advantageously made available for use with a large variety of existing articulators, since all that is necessary on such articulators is an outward surface on frame member, such as surface 45 in FIG. 1, that is sufficiently large to provide a bonding surface for a suitable hot melt adhesive.
FIGS. 1, 2 and 3 show that the other side of adapter plate 41 is characterized by four mounting posts 47 extending outwardly from surface 49, a pair of holding walls 51 including an interconnecting arcuate wall portion 53, transverse slots 55 in the walls 51, and finally a flat flange surface 57 extending from the perimeter of the walls 51 and 53 as shown. FIG. 3 best shows that the outer end of each mounting post 47 has a flat, annular abutment surface 59, from which surface extends a bifurcated latching tab 61 comprising a pair of spaced-apart latch elements 63 which are resiliently deformable towards each other. Note that each element 63 has an inclined upper surface 65 and a lower, under-surface 67, and each tab 61 is adapted to be snapped into releasable locking engagement within a base plate bore 33. The latching tab 61 ordinarily having a larger diameter than that of a bore 33 however when tab 61 is pushed into a bore 33 the resulting sliding contact with the sloped surfaces 65 results in a camming action that pushes the elements 63 towards each other to reduce the effective diameter of tab 61 sufficiently to allow full insertion of tab 61. The outer annular surface 59 of a post 47 is designed to abut the flat surface of walls 35 at the perimeter of a hole 33, and lower surfaces 67 are adapted to engage the other side of a hole 33, that is, the base plate surface 64, shown in FIG. 5. The resilient elements 63 will spring back substantially to their original spaced-apart configuration when the tab 61 is fully inserted in a bore 33, and the lower surfaces 67 have slopes sufficient to result in the frictional engagement required to firmly hold a base plate, yet sufficient to cam the elements 63 towards each other when a tab 61 is deliberately pulled from a bore 33 during removal of a base plate 13 from an adapter plate 41 in a manner to be described hereinafter.
It is further noted that in the preferred embodiment of the invention that the walls 51 and 53 of adapter plate 41 provide outer surfaces 69 that are adapted to conform to and be fit snugly into engagement with the inside wall surfaces 29 of a base plate as FIG. 5 illustrates. It is also to be noted that the two slots 55 of base plate 41 are designed to receive the laterally extending alignment tongues 31 of a base plate 19.
A further noteworthy aspect of this preferred embodiment of the invention is that the flange surface 57 of adapter plate 41 is adapted, when a base plate is mounted to an adapter plate 41, to make flush abutting engagement with the upper edge 27 of the base plate walls 23 and 25 so as to additionally stabilize the base plate on the adapter plate 41.
In using the attachment system according to the invention a suitable conventional hot-melt adhesive is first applied to the surface of an articulator frame such as lower frame member 37. FIG. 4 shows an adhesive layer 71 between articulator frame surface 45 and adapter plate 41. After being properly oriented and located on the frame member 37 an adapter plate 41 can thusly be secured in place. A dental base plate can then be quickly and conveniently mounted to the adaptor plate 41. This can be accomplished by aligning the mounting posts 47 with corresponding bores 33 of the base plate 19, and then pressing the latching tabs 61 simultaneously into bores 33. The fully inserted elements 63 will snap in place such that the posts' annular surfaces 59 will abut the surface 35 of the base plate to stabilize the base plate against relative inward movement to the adapter plate.
Thus the base plate 19 is secured against movement from the adaptor plate with sufficient holding force to meet the ordinary requirements of model processing on an articulator, while at the same time allowing the components to be disconnected by pulling them apart by hand when required. Engagement of the posts in bores 33 also serves to hold the base plate against relative lateral movement. Finally it is noted that the alignment tongues 31 engage the two slots 55 in the adapter plate to additionally secure the mounting plate against relative longitudinal movement. The engagement of the outside wall surface 69 snuggly against the base plate wall surfaces 29 will further register the base plate on the adapter plate and hold the base plate against relative twisting movement.
While the preferred embodiment has been described herein it should be appreciated that other variations of the invention will be apparent to a person skilled in the art after reading the foregoing disclosure. Accordingly, it is intended that the invention include all such modifications and alterations as fall within the true scope and breath of the invention as defined in the claims which follow.
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Disclosed is a system for removably supporting dental models on the upper and lower frame members of an articulator, the system including a base plate having one side adapted to support a die-stone dental replica, and an opposite side provided with shaped registration and socket structure, the system further including an adapter plate having one side adapted to be adhesively bonded to the upper or lower articulator frame-member, and the other side of each adapter plate structured for being snapped into engagement with the opposite side of the base plate to releasably hold it on the adapter plate.
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BACKGROUND
[0001] 1. Field
[0002] The present invention relates to a method and system for adaptive continuously variable transmission gear ratio control.
[0003] 2. Description of the Related Art
[0004] Conventional automobiles containing conventional continuously variable transmission systems change gear ratios based on an amount of depression of an acceleration pedal as indicated by a user. The greater the depression of the acceleration pedal, the greater the gear ratio. Likewise, the less the depression of the acceleration pedal, the lower the gear ratio. The changing of the gear ratios can cause acceleration or deceleration of the automobile.
[0005] However, in certain situations the user of the automobile may wish to accelerate more quickly or decelerate more quickly. Yet, in other situations, the user of the automobile may not care if the automobile accelerates quickly or decelerates quickly. Conventional automobiles, however, do not distinguish between either situations, and instead change gear ratios based only on the amount of depression of the acceleration pedal, which results in the automobile changing gear ratios in a less responsive manner to the user. Furthermore, such changing of the gear ratios has the potential to be inefficient and unnecessarily consume fuel.
[0006] Thus, there is a need for a method and system for an adaptive continuously variable transmission gear ratio control which is more efficient and responsive to the user.
SUMMARY
[0007] The present invention relates to a method and system for an adaptive continuously variable transmission gear ratio control which is more efficient and more responsive to the user. In one embodiment, an automobile can include a continuously variable transmission (“CVT”) system including an acceleration input device, a CVT, and a processor. The acceleration input device can generate acceleration input data indicating not only an amount of change in the acceleration input device, but also a rate of change in the acceleration input device.
[0008] The CVT can include a power source and a transmission output system. The power source can operate at a transmission input speed, while the transmission output system can operate at a transmission output speed. The transmission input speed over the transmission output speed comprises a gear ratio. In one embodiment, the CVT can be any type of transmission which has a minimum gear ratio, a maximum gear ratio, and can infinitely change gear ratios between the minimum gear ratio and the maximum gear ratio. In another embodiment, the CVT can include an electric motor, a hydraulic pump, gears, belts or any other type of equipment which can allow the CVT to have the minimum gear ratio, the maximum gear ratio and infinitely change gear ratios between the minimum gear ratio and the maximum gear ratio.
[0009] The processor analyzes the acceleration input data to determine a target gear ratio and to determine a rate of change in the acceleration input data. The processor can also instruct the CVT to change the gear ratio to a target gear ratio, with a rate of change in the gear ratio corresponding to the rate of change in the acceleration input data.
[0010] Thus, the gear ratio changes based on the rate of change in the acceleration input data. Therefore, if the acceleration input data changes quickly, such as if the user is depressing the acceleration input unit quickly or the gear ratio is changed to the target gear ratio quickly. However, if the acceleration input data changes slowly, such as if the user is depressing the acceleration input unit slowly or the gear ratio is changed to the target gear ratio slowly. This can allow a quick acceleration when the user wishes to accelerate quickly and for fuel efficiency when the user does not care if he accelerates quickly. Thus, the present invention is more response to the user's intentions and can also expend fuel more efficiently.
[0011] In one embodiment, the present invention is a continuously variable transmission system including a continuously variable transmission operating at a gear ratio, an acceleration input device detecting acceleration input data, and a processor connected to the continuously variable transmission and the acceleration input device, the processor detecting a rate of change in the acceleration input data and changing the gear ratio based on the rate of change in the acceleration input data.
[0012] In another embodiment, the present invention is an automobile including a power source operating at a transmission input speed, a transmission output system operating at a transmission output speed, wherein the transmission input speed over the transmission output speed comprise the gear ratio, an acceleration input device detecting acceleration input data, and a processor connected to the power source, the transmission output system, and the acceleration input device, the processor determining a target gear ratio based on the acceleration input data, detecting a rate of change in the acceleration input data, and changing the gear ratio to match the target gear ratio based on the rate of change in the acceleration input data.
[0013] In yet another embodiment, the present invention is a method for varying a gear ratio of a continuously variable transmission system including operating a continuously variable transmission at a gear ratio, detecting acceleration input data, detecting a change in the acceleration input data, and changing the gear ratio at a rate based on the rate of change in the acceleration input data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The features, obstacles, and advantages of the present invention will become more apparent from the detailed description set forth below when taken in conjunction with the drawings, wherein:
[0015] FIG. 1 is an automobile including a continuously variable transmission system according to an embodiment of the present invention;
[0016] FIG. 2 depicts an acceleration input data graph according to an embodiment of the present invention;
[0017] FIG. 3 depicts gear ratios corresponding to various acceleration input data according to an embodiment of the present invention; and
[0018] FIG. 4 is a process of varying a gear ratio of a continuously variable transmission system according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0019] Apparatus, systems and methods that implement the embodiments of the various features of the present invention will now be described with reference to the drawings. The drawings and the associated descriptions are provided to illustrate some embodiments of the present invention and not to limit the scope of the present invention. Throughout the drawings, reference numbers are re-used to indicate correspondence between referenced elements.
[0020] As seen in FIG. 1 , the present invention can include, for example, an automobile 100 . The automobile 100 can include, for example, a continuously variable transmission (“CVT”) system 102 . The automobile 100 can be, for example, an electric automobile, a hybrid automobile, a gasoline automobile, a natural gas automobile, an ethanol automobile, or any other type of motor or engine driven automobile. The CVT system 102 can include an acceleration input device 104 , a processor 112 , and a CVT 106 .
[0021] The acceleration input device 104 is connected to the processor 112 and can generate, for example, acceleration input data. The acceleration input device 104 can be, for example, an acceleration pedal and the acceleration input data can indicate, for example, a percent (%) application of the input device 104 and a rate of change in the percent (%) application of the acceleration input device 104 . The acceleration input device 104 , however, can be any type of device which receives acceleration input data indicating a user's desire to maintain a speed of the automobile 100 , decrease the speed of the automobile 100 , and/or increase the speed of the automobile 100 .
[0022] The CVT 106 is connected to the processor 112 . The CVT 106 includes, for example, a power source 108 and a transmission output system 110 . The power source 108 can be, for example, an engine, a motor, or any other type of system or object which can controllably move the automobile 100 . The power source 108 can operate at a transmission input speed. The transmission output system 110 can operate at a transmission output speed.
[0023] The transmission input speed over the transmission output speed comprises the gear ratio. Thus changes to the transmission input speed or the transmission output speed can affect the gear ratio. For example, when the transmission output speed remains constant, any increase in the transmission input speed results in an increase in the gear ratio. Likewise, when the transmission output speed remains constant, any decrease in the transmission input speed results in a decrease in the gear ratio. In the previous examples, when the transmission output speed remains constant, any change in the transmission input speed affects the gear ratio. However, as previously noted, the gear ratio can still be changed by changing the transmission input speed, even when the transmission output speed is not constant. In one embodiment, the gear ratio can also be changed by changing the transmission output speed and/or a combination of the transmission input speed and the transmission output speed.
[0024] The processor 112 is connected, for example, to the CVT 106 and/or the acceleration input device 104 . The processor 112 receives the acceleration input data, determines a target gear ratio, and adjusts the gear ratio in the CVT 106 to match the target gear ratio. Thus, if the target gear ratio is greater than the gear ratio, the processor 112 increases the gear ratio to match the target gear ratio. However, if the target gear ratio is smaller than the gear ratio, the processor 112 decreases the gear ratio to match the target gear ratio.
[0025] The processor 112 controls the rate of change in the gear ratio to match the target gear ratio. To determine the rate of change in the gear ratio, the processor 112 analyzes the acceleration input data and determines a rate of change in the acceleration input data. The rate of change in the acceleration input data indicates a rate of change in the acceleration input device 104 . The processor 112 sets the rate of change in the gear ratio corresponding to the rate of change in the acceleration input data.
[0026] Thus, if the rate of change in the acceleration input data is large, then the rate of change in the gear ratio is large. However, if the rate of change in the acceleration input data is small, then the rate of change in the gear ratio is small. Thus, if the user depresses the acceleration input device 104 quickly, the gear ratio changes quickly to reach the target gear ratio. However, if the user depresses the acceleration input device 104 slowly, the gear ratio changes slowly to reach the same target gear ratio. This can be seen, for example, in FIG. 2 and FIG. 3 .
[0027] In FIG. 2 , curve 114 and curve 116 indicate acceleration input data depicting a percent (%) application of the acceleration input device 104 over time. Line 118 indicates the final value of the percent (%) application of the acceleration input device 104 . That is, line 118 represents the final position of the acceleration input device 104 when the user steps on the acceleration input device 104 . As can be seen, the user depresses the acceleration input device 104 by the same percentage, but at different rates.
[0028] In a first case, as represented by the curve 114 , the user depresses the acceleration input until the percent (%) application of the acceleration input device 104 reaches the final position of the acceleration input device 104 represented by line 118 . Once the percent (%) application of the acceleration input device 104 reaches the line 118 , the user has stopped depressing the acceleration input device 104 . In a second case, as represented by the curve 116 , the user depresses the acceleration input until the percent (%) application of the acceleration input device 104 reaches the final position of the acceleration input device 104 represented by line 118 , but at a faster rate than the first case.
[0029] In the first case, the percent (%) application of the acceleration input device 104 reaches the final position indicated by the line 118 at time t 2 . In the second case, the percent (%) application of the acceleration input device 104 reaches the final position indicated by the line 118 at time t 1 , which is less than the time t 2 . Thus, the user depresses the acceleration input device 104 at a faster rate in the second case than in the first case as seen by a comparison of the curves 114 and 116 .
[0030] The rate of change in the gear ratio corresponds to the rate of change in the percent (%) application of the acceleration input device 104 . In FIG. 3 , the line 124 represents the target gear ratio. The curve 120 represents the change in the gear ratio corresponding to the first case with an application of the acceleration input device 104 represented by the curve 114 in FIG. 2 . The curve 120 reaches the target gear ratio at time t 2 . The curve 122 represents the change in the gear ratio corresponding to the second case with an application of the acceleration input device 104 represented by the curve 116 in FIG. 2 . The curve 122 reaches the target gear ratio at time t 1 . The time t 1 is less than the time t 2 .
[0031] As can be seen, the processor 112 changes the gear ratio at a rate corresponding to the rate of change in the percent (%) application of the acceleration input device 104 . Thus, in the curve 122 , since the corresponding application of the acceleration input device 104 is faster than in the curve 120 , the curve 122 reaches the target gear ratio at time t 1 , which is less than time t 2 .
[0032] By changing the gear ratio at a rate corresponding to the change in the percent (%) application of the acceleration input device 104 , the CVT 106 can be more responsive to the user of the automobile 100 . For example, if the user wants to accelerate the automobile 100 quickly, the user typically depresses the acceleration input device 104 more quickly. By changing the gear ratio quickly, the CVT 106 reaches the target gear ratio at a shorter period of time. This allows the CVT 106 to spend more time at the target gear ratio, which is higher than the gear ratio. By spending more time at the target gear ratio, the CVT 106 is providing more torque to the automobile 100 for a longer period of time, which translates to a quicker acceleration for the automobile 100 .
[0033] Likewise, if the user is nonchalant about accelerating and does not care if the automobile 100 accelerates quickly, or wants to accelerate the automobile 100 slowly, the user typically depresses the acceleration input device 104 slowly. By changing the gear ratio slowly, the CVT 106 reaches the target gear ratio at a longer period of time. This allows the CVT 106 to spend more time reaching the target gear ratio instead of at the target gear ratio, which is higher than the gear ratio.
[0034] By spending more time reaching the target gear ratio instead of being at the target gear ratio, the CVT 106 is providing more torque to the automobile 100 for a shorter period of time, which translates to a slower acceleration for the automobile 100 . This can also lead to a more efficient operation of the automobile 100 since the automobile 100 can consume less fuel when the user does not want to accelerate quickly. The examples described above are equally applicable to situations where the user wants to decelerate instead of accelerate.
[0035] In one embodiment, the present invention is a process of varying a gear ratio of a continuously variable transmission system as shown in FIG. 4 . In Step S 402 , a CVT is operated at a gear ratio. For example, the CVT 106 can operate at a gear ratio, which is the transmission input speed of the power source 108 over the transmission output speed of the transmission output system 110 . In Step S 404 , acceleration input data is detected. For example, the acceleration input device 104 can detect acceleration input data. In Step S 406 , a change in the acceleration input data can be detected. For example, the processor 112 can analyze the acceleration input data and can determine changes in the acceleration input data. Furthermore, the processor 112 can determine a rate of change in the acceleration input data.
[0036] In Step S 408 , a target gear ratio is determined. For example, based on the acceleration input data, the processor 112 can determine the target gear ratio. In Step S 410 , the gear ratio can be changed to match the target gear ratio based on the acceleration input data. For example, the processor 112 can change the gear ratio at a rate corresponding to the rate of change in the acceleration input data. Thus, if the user is depressing the acceleration input device at a fast rate, the gear ratio will be changed to the target gear ratio at a fast rate. Likewise, if the user is depressing the acceleration input device at a slow rate, the gear ratio will be changed to the target gear ratio at a slow rate.
[0037] Those of ordinary skill would appreciate that the various illustrative logical blocks, modules, and algorithm steps described in connection with the examples disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. Furthermore, the present invention can also be embodied on a machine readable medium causing a processor or computer to perform or execute certain functions.
[0038] To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the disclosed apparatus and methods.
[0039] The various illustrative logical blocks, units, modules, and circuits described in connection with the examples disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
[0040] The steps of a method or algorithm described in connection with the examples disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. The steps of the method or algorithm may also be performed in an alternate order from those provided in the examples. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an Application Specific Integrated Circuit (ASIC). The ASIC may reside in a wireless modem. In the alternative, the processor and the storage medium may reside as discrete components in the wireless modem.
[0041] The previous description of the disclosed examples is provided to enable any person of ordinary skill in the art to make or use the disclosed methods and apparatus. Various modifications to these examples will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other examples without departing from the spirit or scope of the disclosed method and apparatus. The described embodiments are to be considered in all respects only as illustrative and not restrictive and the scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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An automobile comprising a continuously variable transmission (“CVT”) system including an acceleration input device, a CVT, and a processor. The acceleration input device generates acceleration input data indicating an amount of change in the acceleration input device, and a rate of change in the acceleration input device. The CVT includes a power source and a transmission output system. The power source operates at a transmission input speed, while the transmission output system operates at a transmission output speed. The transmission input speed over the transmission output speed comprises a gear ratio. The processor analyzes the acceleration input data to determine a target gear ratio. The processor can instruct the CVT to change the gear ratio to the target gear ratio at a rate corresponding to the rate of change in the acceleration input device.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION
This application claims the benefit of Korean Patent Application No. 10-2010-0103672, filed on Oct. 22, 2010, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND
1. Field
The described technology generally relates to flat panel displays, and more particularly, to displays that may readily block electromagnetic waves and may facilitate heat dissipation from a driving chip.
2. Description of the Related Technology
With the recently increased interest in displays that employ flat panels, much research has been conducted in relation to different emission technologies. Among the display apparatuses, liquid crystal displays or organic light-emitting displays have drawn particular attention since they can be manufactured as portable thin flat displays.
A display system generally includes a display unit that emits light, and a driving chip that applies electrical signals to the display unit. The signals are generally generated on a flexible circuit board.
SUMMARY
One inventive aspect is a display apparatus that may readily block electromagnetic waves and may facilitate heat dissipation from a driving chip.
Another aspect is a display apparatus including: a substrate; a sealing member disposed to face the substrate; a display unit disposed between the substrate and the sealing member; a driving chip disposed on the substrate and transmitting an electric signal to the display unit; and a circuit board including a signal line that is electrically connected to the driving chip, and a conductive cover layer disposed to cover the driving chip, wherein the circuit board includes a heat dissipating unit that dissipates heat generated by the driving chip.
The display apparatus may further include an insulating layer that insulates the signal wire and the conductive cover layer from each other. The conductive cover layer may include a metal. The conductive cover layer may be spaced apart from the driving chip. The substrate may include an extension unit that extends beyond the sealing member, and the driving chip may be disposed in the extension unit. The display apparatus may further include a protecting layer on the conductive layer, the protecting layer including an insulating material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of a display apparatus according to an embodiment.
FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1 .
FIG. 3 is a schematic plan view of a display apparatus according to another embodiment.
FIG. 4 is a schematic plan view of a display apparatus according to another embodiment.
FIG. 5 is a schematic plan view of a display apparatus according to another embodiment.
FIG. 6 is a cross-sectional view of a display unit in FIG. 1 , according to an embodiment.
DETAILED DESCRIPTION
In a high-resolution display apparatus using high-frequency signals, due to the complicated structure of applying electric signals, electromagnetic waves are generated near a driving chip. These electromagnetic waves may cause the driving chip to generate heat, which may damage other components near the driving chip and degrade image quality.
Embodiments will now be described more fully with reference to the accompanying drawings.
FIG. 1 is a schematic plan view of a display apparatus 100 according to an embodiment. FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1 .
Referring to FIGS. 1 and 2 , the display apparatus 100 includes a substrate 101 , a sealing member 102 , a display unit 150 , a driving chip 105 , and a circuit board 140 .
The substrate 101 may include a transparent glass material containing SiO 2 as a main component. The substrate 101 may include, but is not limited to, a transparent plastic material. The plastic material for forming the substrate 101 may include an insulating organic material selected from the group consisting of polyethersulphone (PES), polyacrylate (PAR), polyetherimide (PEI), polyethyelenen napthalate (PEN), polyethyeleneterepthalate (PET), polyphenylene sulfide (PPS), polyallylate, polyimide, polycarbonate (PC), cellulose triacetate (TAC), and cellulose acetate propionate (CAP).
The sealing member 102 is disposed on the substrate 101 . The sealing member 102 , which may protect the display unit 150 from external moisture or oxygen, may have an alternating structure of multiple layers including glass and plastic, or organic and inorganic materials. The sealing member 102 may include a material that is the same as that of the substrate 101 .
An extension unit 101 a extends beyond the sealing member 102 on a side of the substrate 101 . Signal interconnects (not shown) that are electrically connected to the display unit 150 may be disposed on the extension unit 101 a.
The display unit 150 is arranged between the substrate 101 and the sealing member 102 , which are bound together by a sealant 103 . If the sealing member 102 has a thin film structure of alternating organic and inorganic materials, the sealing member 102 may be directly bound to the substrate 101 without using the sealant 103 .
The driving chip 105 may be disposed on the extension unit 101 a . The driving chip 105 may transmit an electric signal to the display unit 150 . The driving chip 105 may be a driver IC. The driving chip 105 includes an output pin (not shown) and an input pin (not shown) via which the signal interconnects on the extension unit 101 a are electrically connected to the driving chip 105 . The driving chip 105 is electrically connected to the display unit 150 via the signal interconnects of the extension unit 1010 . The driving chip 105 and the signal interconnects of the extension unit 101 a may be connected by, for example, an anisotropic conductive film (ACF).
The circuit board 104 is disposed on the substrate 101 to be electrically connected to one end of the driving chip 105 . The circuit board 140 may transmit an external driving signal to the driving chip 105 . The circuit board 140 may include a material that provides flexibility so that the circuit board 140 can bend to reach a rear surface of the substrate 101 .
The circuit board 140 may be a flexible circuit board. The circuit board 140 may include a signal wire 142 , a conductive cover layer 144 , and a heat dissipating unit 160 . The signal wire 142 may be connected to the driving chip 105 to transmit a signal to the driving chip 105 . The signal wire 142 may be arranged on a base film 141 . The base film 141 , which may be formed of an insulating, flexible material, protects the signal wire 142 . The base film 141 may enhance the overall durability of the circuit board 140 .
An insulating layer 143 is disposed on the signal wire 142 . The signal wire 142 and the conductive cover layer 144 may be insulated from each other by the insulating layer 143 . The insulating layer 143 may include any of various insulating materials.
The conductive cover layer 144 may be disposed on the signal wire 142 to extend beyond the signal wire 142 . The conductive cover layer 144 may extend to substantially entirely cover the driving chip 105 . In one embodiment, the conductive cover layer 144 extends to be spaced apart from the driving chip 105 . The conductive cover layer 144 may include any of various conductive materials. In one embodiment, the conductive cover layer 144 includes a metal in consideration of conductivity, flexibility, and durability.
Electromagnetic waves are generated around the driving chip 105 due to electrical signals. In particular, in the case of a high-resolution image display, the display apparatus 100 may need to process great amounts of data, and thus, may use high-frequency electric signals. High-frequency signals may cause generation of many electromagnetic waves near the driving chip 105 .
In one embodiment, the conductive cover layer 144 is disposed to cover the driving chip 105 . The conductive cover layer 144 may shield the electromagnetic waves generated around the driving chip 105 . That is, the conductive cover layer 144 may serve as a kind of ground to reduce the electromagnetic waves.
As a result, degradation in image quality caused due to the electromagnetic waves may be prevented. Also, damage of components of the display apparatus 100 due to heat generated from the electromagnetic waves damages may be prevented.
Furthermore, the conductive cover layer 144 , which is disposed to cover the driving chip 105 , may protect the driving chip 105 from being damaged by an external impact.
A protecting layer 145 containing an insulating material may be further disposed on the conductive cover layer 144 .
The circuit board 140 may further include the heat dissipating unit 160 . The heat dissipating unit 160 may externally dissipate the heat generated by the driving chip 105 . The heat dissipating unit 160 may include at least one hole 160 a that penetrates through opposite surfaces of the circuit board 140 . The hole 160 a may penetrate through the insulating layer 143 , the conductive cover layer 144 , and the protecting layer 145 . The hole 160 a may correspond to the driving chip 105 to externally expose a portion of the driving chip 105 . Consequently, the heat generated by the driving chip 105 may be readily externally dissipated through the hole 160 a.
FIG. 3 is a schematic plan view of a display apparatus according to another embodiment. Referring to FIG. 3 , the heat dissipating unit 160 may include a plurality of holes 160 a and 160 b arranged in two rows. At least two rows of holes may be arranged in the heat dissipating unit 160 .
FIG. 4 is a schematic plan view of a display apparatus according to another embodiment. Referring to FIG. 4 , the heat dissipating unit 160 may include a plurality of holes 160 a and 160 b having different shapes. For examples, the holes 160 a may have a substantially circular shape, while the holes 160 b may have a substantially rectangular or square shape. Alternatively, a plurality of holes having various other polygonal shapes may be arranged in the heat dissipating unit 160 .
FIG. 5 is a schematic plan view of a display apparatus according to another embodiment. Referring to FIG. 5 , the heat dissipating unit 160 may have a mesh structure.
FIG. 6 is a cross-sectional view of the display unit 150 in FIG. 1 , according to an embodiment. In one embodiment, the display unit 150 of the display apparatus 100 includes an organic light-emitting device. In another embodiment, the display unit 150 includes a liquid crystal display device.
A structure of the display unit 150 will now be described in detail with reference to FIG. 6 . Referring to FIG. 6 , one organic light-emitting device 120 is disposed between the substrate 101 and the sealing member 102 . Although only one organic light-emitting device 120 is illustrated in FIG. 6 for convenience of explanation, the display unit 150 may include a plurality of organic light-emitting devices 120 .
A buffer layer 111 is disposed on the substrate 101 . The buffer layer 111 may be disposed to planarize an upper surface of the substrate 101 and prevent moisture and foreign materials from permeating into the substrate 101 . An active layer 112 having a predetermined pattern is disposed on the buffer layer 111 . The active layer 112 may include an inorganic semiconductor material, such as amorphous silicon or polysilicon, or an organic semiconductor material. The active layer 221 may include a source region, a drain region, and a channel region between the source and drain regions.
The source and drain regions may be formed by doping the active layer 112 formed of an amorphous silicon or polysilicon with impurities. A Group 3 element, for example, boron (B), may be doped to form a P-type semiconductor. A Group 5 element, for example, nitrogen (N), may be doped to form a N-type semiconductor.
A gate insulating layer 113 is disposed on the active layer 112 , and a gate electrode 114 is disposed in a predetermined region of the gate insulating layer 113 . The gate insulating layer 113 , which insulates the active layer 112 and the gate electrode 114 from each other, may include an organic material, or an inorganic material, for example SiN X , or SiO 2 .
The gate electrode 114 may include a metal or a metal alloy, for example, selected from among gold (Au), silver (Ag), copper (Cu), nickel (Ni), platinum (Pt), palladium (Pd), aluminum (Al), molybdenum (Mo), Al:Nd, and Mo:W. However, the material of the gate electrode 114 is not limited thereto, and various appropriate materials may be used in consideration of adhesion, flatness, electric resistance, processability, and the like. The gate electrode 114 is connected to a gate line (not shown) that applies an electric signal.
An interlayer insulating layer 115 is disposed on the gate electrode 114 . The interlayer insulating layer 115 and the gate insulating layer 113 may be formed to expose the source and drain regions of the active layer 112 . A source electrode 116 and a drain electrode 117 are disposed to contact the exposed regions of the active layer 112 .
The source electrode 116 and the drain electrode 117 may each independently include a metal or an alloy of at least two metals, for example, may each include, but not limited to, among gold (Au), palladium (Pd), platinum (Pt), nickel (Ni), rhodium (Rh), ruthenium (Ru), iridium (Ir), osmium (Os), aluminum (Al), molybdenum (Mo), an Al:Nd alloy, or an MoW alloy.
A passivation layer 118 is disposed to cover the source electrode 116 and the drain electrode 117 . The passivation layer 118 may include at least one of an inorganic insulating layer and an organic insulating layer. The inorganic insulating layer may include at least one SiO 2 , SiNx, SiON, Al 2 O 3 , TiO 2 , Ta 2 O 5 , HfO 2 , ZrO 2 , BST, or PZT. The organic insulating layer may include at least one a common polymer for example, polymethylmethacrylate (PMMA) or polystyrene (PS), a polymer derivative having a phenol group, an acryl-based polymer, an imide-based polymer, an acrylether-based polymer, an amide-based polymer a fluorine-based polymer, a p-xylene-based polymer, a vinylalcohol-based polymer, or a blend thereof. The passivation layer 118 may include a composite stack of an inorganic insulating layer and an organic insulating layer.
The passivation layer 118 may be formed to expose the drain electrode 117 , and the organic light-emitting device 120 is disposed to be connected to the exposed drain electrode 117 . The organic light-emitting device 120 may include a first electrode 121 , a second electrode 122 , and an intermediate layer 123 . In particular, the first electrode 121 may contact the drain electrode 117 .
The intermediate layer 123 may include an organic emission layer, and may emit visible light when a voltage is applied between the first electrode 121 and the second electrode 122 .
A pixel define layer 119 that includes an insulating material may be disposed on the first electrode 121 . The pixel define layer 119 may be formed to have a predetermined opening that exposes the first electrode 121 . The intermediate layer 123 is disposed on the exposed first electrode 121 . The second electrode 122 is disposed to contact the intermediate layer 123 .
The first electrode 121 and the second electrode 122 may function, respectively, as an anode and a cathode. Alternatively, the first electrode 121 and the second electrode 122 may function, respectively, as a cathode and an anode. The sealing member 102 is disposed on the second electrode 122 .
As described above, according to at least one of the disclosed embodiments, the conductive cover layer 144 is disposed to cover the driving chip 105 , thereby facilitating shielding of the electromagnetic waves generated around the driving chip 105 , and thus, improving image quality of the display apparatus 100 and preventing the components from damaging. The conductive cover layer 144 may prevent the driver chip 105 from damaging due to external pressure or foreign materials.
Furthermore, a display apparatus may facilitate blocking of electromagnetic waves and externally dissipating heat generated in a driving chip.
While embodiments have been shown and described with reference to the accompanying drawings, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the following claims.
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A display apparatus that facilitates shielding of electromagnetic waves and heat dissipation is disclosed. The display apparatus may include: i) a substrate, ii) a sealing member disposed to face the substrate, iii) a display unit disposed between the substrate and the sealing member, iv) a driving chip disposed on the substrate and transmitting an electric signal to the display unit and v) a circuit board including a signal line that is electrically connected to the driving chip, and a conductive cover layer disposed to cover the driving chip. In one embodiment, the circuit board includes a heat sink for dissipating heat generated by the driving chip.
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RELATED APPLICATION
[0001] This application relates to and claims the benefit of priority of prior copending U.S. Provisional Application No. 60/420,807, filed Oct. 23, 2002, said Provisional Application being hereby incorporated by reference into the present specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a concrete forming panel which includes a forming face which has a reinforcement on the rear side of the forming face adapted for gripping elements removably attached thereto. The reinforcement is configured to resist expansion of openings through the forming face. More particularly, it is concerned with a concrete form and method of its use in connection with the pouring of low concrete walls or pads where the form may be held in place by stakes driven into the ground.
[0004] 2. Description of the Prior Art
[0005] The formation of concrete walls and pads is well known and often involves the use of wooden or metal forms. Metal forms are more expensive, but also more durable and may be repeatedly used. When concrete pads are to be poured in residential construction, there is a need for concrete forms which can be quickly and economically set up and dismantled for use at the next site. Examples of known forming panels include those shown in U.S. Pat. Nos. 4,708,315, 4,958,800, 5,058,855, 5,184,439 and 5,965,053, the disclosures of which are incorporated by reference herein.
[0006] One problem especially presented by the use of metal forms for pouring foundations such as concrete pads involves their use on rough ground. The metal forms have a permanent shape, and there is a desire to avoid permanently altering or damaging the forms by drilling openings to receive tie rods, bars or tensioning cables therethrough, or driving nails through the frame or face plate of the form to indicate level lines so that the concrete can be poured to a desired depth with a level, horizontal surface. Also, rocks, stumps or other solid objects maybe buried just below grade, and stakes conventionally used for anchoring the forms may encounter such objects. are particularly presented in using concrete forms for form.
[0007] In addition, it is known to post-tension concrete slabs by the use of such tensioning cables. Post-tensioning concrete slabs uses tensioning cables surrounded by sheaths which are positioned in the pouring area and after the poured concrete is hardened, stretching the cable by applying tensioning at the ends through the use of a stressing jack and then anchoring the cable ends in the concrete. Such a practice improves the response of the resulting concrete slab to loading, and reduces deflections and cracking. Further, the use of post-tensioning in concrete slabs may result in slabs which are generally thinner, relatively longer, and reducing the weight of the resulting poured structure. However, in order to initially position the live end anchor which is typically received within a cone to create a pocket for access after concrete hardening and the dead end anchor which is encased within the hardened concrete, it has been heretofore largely necessary as a practical matter to employ wooden forms which must be discarded after use.
[0008] There is thus a need for an improved concrete forming panel and method of use which overcomes these problems.
SUMMARY OF THE INVENTION
[0009] These and other needs are largely met by the concrete forming panel of the present invention. That is to say, the concrete forming panel hereof is particularly useful in forming foundations such as concrete pads where it is desirable to anchor the forming panel to the ground by stakes, and wherein the forming panel may need to be penetrated through the front side of the face plate. To this end, the concrete forming panel hereof includes at least one and preferably a plurality of sets of reinforcing ribs on the back side of the face plate which are configured and position for gripping a variety of elements passing through the face plate, either themselves or with the use of wedges depending on the orientation of the element relative to the front side of the face plate.
[0010] Broadly speaking, the concrete forming panel of the present invention includes a face plate having a frame, a front side and a rear side, and at least one set of reinforcing ribs received on the back side, the ribs being positioned closely adjacent one another and parallel for gripping objects placed therebetween. The face plate may be formed with a face panel having the front side and rear side which is separate from the frame, or a portion of the frame may be cast by extruding or the like or forged so that the face panel is integral with some of the rails and the reinforcing ribs. The elongated reinforcing ribs preferably extend longitudinally along the back side of the face plate, but alternatively or in addition may extend along the frame. The face plate and the ribs are preferably provided of aluminum, which as used herein includes both elemental aluminum and alloys wherein the primary constituent is aluminum. Because aluminum is relatively soft and subject to wear, the ribs may include longitudinally extending slots which receive therein reinforcing elements of a harder material, such as steel. Most preferably, the reinforcing elements are shiftably received in the slots, thereby permitting the reinforcing elements to be moved along the slots to vary the locations where wear occurs and also permitting the reinforcing elements to be located to engage an element to be gripped.
[0011] The face plate is preferably provided with opposing top and bottom rails, and at least one set of holes in the frame on each of the top and bottom rails. A stake may be placed through one of the holes of each set, so that the stake penetrates the ground and holds the forming panel in place. The stake may be positioned perpendicular or skew to the rails to avoid rocks or other impediments to penetration into the soil. The ribs may themselves engage the stake, or more preferably a wedge may be placed between the ribs and engage the stake to secure it and therefore the form in the desired placement. The wedge may be driven into engagement with the stake by a hammer or the like, whereby the face plate is firmly held in place. Two or more stakes may be used to resist movement of the forming panel.
[0012] It may also be desirable to provide openings in through the face side of the face plate for the passage of tie rods, anchoring cables or the like. After their use, the openings would permit leakage of concrete therethrough. However, the forming panel of the present invention permits these holes to be plugged through the use of elements such as plugs or the like which may be gripped by the ribs. This not only permits the forming panel to be reused, but permits removal of the elements as desired when it is again necessary to use the opening.
[0013] Further, it may be desirable to penetrate the face plate during its use. Because the face plate is preferably provided of aluminum, a nail or other fastener may be driven through the face plate so that it passes between the ribs. The nail may be used to connect the forming panel to lumber on a face of the forming panel or to wood forming panels, reinforcements or stakes. This may be especially advantageous where tensioning cables are used to hold spaced-apart and opposed panels in position during the pouring and curing of the concrete, and there is a need to attach the cable to the panel.
[0014] These and other advantages will be readily apparent to those skilled in the art with reference to the drawings and the description of the preferred embodiment which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a rear perspective view of a concrete forming panel in accordance with the present invention, showing the reinforcing ribs along the back side of the face plate, the concrete forming panel being anchored to the ground by stakes and connected to and opposing other forming panels by live end and dead end anchors and tensioning cables passing through a pouring area between the forming panels for receiving flowable concrete for curing and hardening;
[0016] [0016]FIG. 2 is a rear elevational view thereof, showing one of the stakes perpendicular to the upper rail and another stake skew thereto, and showing in dashed lines the position of a stake when held by a hanger on the forming panel;
[0017] [0017]FIG. 3 is an enlarged, fragmentary horizontal cross-sectional view taken along line 3 - 3 of FIG. 2, showing the receipt of a plug element in an opening extending through the face panel of the face plate, a reinforcing rod received in a slot in the reinforcing ribs, and a wedge gripped between the ribs;
[0018] [0018]FIG. 4 is an enlarged, fragmentary vertical cross-sectional view taken along line 4 - 4 of FIG. 3, showing a nail fastener penetrating through the front side of the face plate and gripped between one of the pairs of reinforcing ribs for attachment of wood blocks or the like to the panel; and
[0019] [0019]FIG. 5 is an enlarged, fragmentary vertical cross-sectional view taken along line 5 - 5 of FIG. 2, showing the plug element gripped by a pair of ribs and a hanger for retaining the stake prior to use, the hanger including an elastomeric grommet.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring now to the drawings, a forming panel 10 for use in forming structures from flowable cementatious material such as concrete broadly includes a face plate 12 and at least one, and preferably a plurality of pairs of, reinforcing ribs 14 . A hanger 16 may be provided for holding a steel stake 18 used with the forming panel 10 . A fastening element 20 may be used with the forming panel 10 , and one or a plurality of plug elements 22 may be used to close openings in the face plate 12 . As shown in FIG. 2, the forming panel 10 is particularly useful for forming foundations such as concrete pads which rest directly on the ground 24 .
[0021] In greater detail, the face plate 12 is preferably fabricated of an aluminum alloy such as ASTM 6061 T-6, and includes a frame 26 and a face panel 28 having a front side 30 and a back side 32 . The frame 26 preferably includes a top rail 34 and a bottom rail 36 , and first and second side rails 38 and 40 which together with the back side 32 of the face panel 28 define a rear area 41 inwardly of the margins of the rails. The face panel 28 may be formed separately and welded to the frame 26 , or alternatively as shown in the drawings, the face panel 28 and top and bottom rails may be integrally formed by casting, such as extrusion, and the side rails 38 and 40 then welded to the extrusion. The frame 26 including the rails is fabricated of a greater thickness of material along at least some parts thereof than the face panel 28 .
[0022] The top rail 34 and the bottom rail each include at least one, and preferably a plurality of sets 42 of holes 44 therethrough. As used herein, a set 42 of holes 44 is meant to mean a plurality of holes 44 more closely spaced together than the distance between holes 44 of different sets 42 . As shown in FIG. 1, the top rail 34 thus includes four sets 42 A, 42 B, 42 C and 42 D of three holes 44 each, and the bottom rail 36 includes four sets 42 E, 42 F, 42 G and 42 H of three holes 44 each, the set 42 A being positioned in registry above and opposite the set 42 E, and the same respective relationship existing between set 42 B and 42 F, set 42 C and 42 D, and set 42 D and 42 G.
[0023] In addition, the side rails 38 and 40 are each provided with a plurality of holes 44 for receiving therethrough couplers, such as pins 46 and their associated wedges for coupling the forming panel 10 to similar or compatible adjacent forming panels as shown in FIGS. 1 and 2. Furthermore, the side rails 38 and 40 may include recesses 48 on their outer surface which, in some applications, may facilitate the receipt of tie bars or the like which may be secured by pins 46 for connecting the forming panel 10 to an opposite forming panel 10 A or to an adjacent forming panel. A pouring area 50 into which flowable concrete maybe poured is located between opposed forming panels 10 and 10 A for forming the structure between front sides of the opposing face panels. The face panel 28 may be smooth or textured on its front side 30 , texturing being provided to form a pattern to be imparted to the concrete hardening thereagainst, such as a brick pattern.
[0024] The pairs of reinforcing ribs 14 preferably extend longitudinally across the back side 32 and may either extend the width of the form between the side rails 38 and 40 as shown with respect to the pair of reinforcing ribs 14 C, or may be interrupted by openings 52 in the face panel 28 as shown by pairs of reinforcing ribs 14 A and 14 B as described below. Each pair of ribs 14 includes an elongated first rib 54 and an elongated second rib 56 which are preferably mirror images and cantilevered from the back side 32 of the face panel 28 . The ribs 54 and 56 may be cast by extrusion or the like as a part of the face plate 12 as shown in FIGS. 4 and 5, or may formed separately and secured by welding, brazing or the like to the face panel 28 .
[0025] Each of the ribs 54 and 56 preferably includes a longitudinally extending slot 58 which faces the opposite rib and the gap 60 therebetween, so that the slot 58 communicates with the gap 60 . The gap 60 is preferably less than about 25 centimeters across between the ribs in order that the ribs 54 and 56 of each pair 14 may grip elements received therebetween. One or a plurality of reinforcing elements 62 are preferably of a shorter length than the ribs and thus slidably received in the slot 58 which permits the reinforcing elements 62 to be shifted longitudinally along the slot.
[0026] The reinforcing elements 62 are preferably steel rods 64 . Aluminum has a much lower hardness than steel (about 30 on the Brinnell hardness scale (Bhn) for cold rolled ASTM 6061 aluminum versus a Bhn number of about 111 for hot rolled SAE 1020 steel and a Bhn of 179 for hardened, tempered SAE 1020 steel). Thus, the use of the steel reinforcing element 62 greatly reduces wear on the ribs. The use of steel for the reinforcing element 62 also provides increased strength to the rib 54 or 56 to which it is attached. For example, ASTM 6061 aluminum has a tensile strength of about 20,000 to 40,000 psi and a yield strength of about 8,000 psi, whereas hot rolled SAE 1020 steel has a tensile strength of about 55,000 psi and a yield strength of about 30,000 psi and hardened, tempered SAE 1020 steel has a tensile strength of about 90,000 psi and a yield strength of about 60,000 psi. A particularly preferred steel for use as the wear element is an ASTM-228-93 steel wire having a tensile strength of about 254,000 psi to about 259,000 psi and a Bhn of about 518 to 529.
[0027] The hanger 16 is provided for retaining the stake 18 in place on the form when form 10 is not in use. The hanger 16 is typically provided of two aluminum brackets 64 and 66 longitudinally spaced along the back side 32 and secured thereto by welding, brazing, rivets or the like, each having a passage 68 of sufficient size to receive the stake 18 therethrough as shown in FIGS. 1 and 2. At least one of the brackets 64 , 66 includes an elastomeric grommet 70 of synthetic resin or rubber to grip and hold the stake.
[0028] As shown in FIGS. 3, 4 and 5 , the pairs of reinforcing ribs 14 are configured to grip elements received in the rear area 41 . Openings 52 may be provided in the forming panel 10 , preferably along the longitudinal length of the pairs of reinforcing ribs 14 , to permit the use of tie rods or cables which must pass through the face plate 12 . When it is desired to block or close an opening 52 in the face plate 12 which extends from the front side 30 through to the rear side 32 , a plug element 22 may be held by the opposing ribs 54 and 56 . The plug 22 preferably is provided of aluminum or other durable material, but may also be provided of synthetic resin or rubber and includes a central, substantially cylindrical body 72 and wings 74 extending diametrically opposite therefrom. The body 72 may be placed in the opening 52 with the ribs 54 and 56 holding the wings 74 as shown in FIGS. 1, 2, 3 and 5 .
[0029] The pairs of reinforcing ribs 14 are also useful to grip a fastening element 20 , such as a nail 76 driven through the face plate 12 . The nail 76 penetrates the face plate 12 which is typically of aluminum, and then may be gripped between the rods 64 as shown in FIG. 4 to provide steel-to-steel contact and thus avoid wear to the face plate 12 , the cantilevered arrangement of the ribs 54 and 56 permitting them to yield and thus grip the nail. Nails 76 or other fastening elements 20 are useful if a piece of wood 77 needs to be attached to the forming panel 10 , or when an anchor 78 is used when a tensioning cable 79 received in a surrounding sleeve (not shown) is passed through the pouring area and connected to the anchors 78 for anchoring an end of the cable 79 . The head of the nail 76 may be exposed to facilitate removal of a piece of wood or the anchor. The provision of several pairs of reinforcing ribs 14 A, 14 B and 14 C is especially useful for receiving and gripping nails 76 at different heights for different depths of concrete.
[0030] In addition, the pairs of reinforcing ribs 14 are particularly useful in connection with fixing the reinforcing panel 10 relative to the stakes 18 . The position of the holes 44 in each set 42 causes the stakes to pass through the rear area 41 . Retaining elements such as wedges 80 of mild steel or other suitably hard material may be provided for receipt in the gap and gripping by the ribs 54 and 56 . The wedges 80 are shown in detail in FIG. 3 and are preferably flat and of a thickness complemental to the gap 60 .
[0031] The wedges have a front margin 82 and a back margin 84 which is at an acute angle relative to the front margin. Fingers 86 and 88 are located along the sides of the wedge 80 and extend toward the back margin 84 to aid in placement of the wedge in the gap and permit driving of the wedge 80 longitudinally along the pair of reinforcing ribs 14 which receives it. The depth between the front margin 82 and back margin 84 thus varies as shown in FIG. 3, whereby a stake received in the holes 42 may initially pass by the narrowest part of the wedge 80 , and the wedge then driven longitudinally along the pair of reinforcing ribs 14 receiving it until the back margin 84 engages the stake 18 as shown in FIG. 3. Because the holes 42 have a greater diameter than the diameter of the stakes 18 , the stake may be angled to avoid rocks 90 in the ground as shown in FIG. 2, but the forming panel 10 may nonetheless remain fixed to the stake 18 whether the stake is substantially perpendicular to the top rail or at an acute angle thereto, each of which is shown in FIG. 2.
[0032] [0032]FIGS. 6, 7 and 8 illustrate an alternative forming panel 10 B in accordance with the present invention, with like numbers used to indicate features common to forming panels 10 and 10 A, wherein the face plate 12 B includes a frame 26 B having first and second side rails 38 B and 40 B, top rail 34 B and a bottom rail (not shown), and wherein the pairs of reinforcing ribs 14 B are integrally formed with hats 94 . The hats 94 may extend either parallel to the top and bottom rails 34 B and 36 B or extend perpendicular or at other angles relative to the top and bottom rails as shown in FIG. 6.
[0033] The frame 26 B may also include reinforcing plates 96 of steel or aluminum alloy which are interior to the rails and serve to reinforce the rails in the vicinity of the holes 44 through the rails. The hats 94 serve to reinforce the face panel 28 B against deflecting loads imparted by the cementations material received thereagainst, and preferably include sloping sidewalls 98 and 100 connected by stretch 102 . The pairs of reinforcing ribs 14 B are preferably integrally formed by extrusion as a part of the hat 94 , and as shown in FIGS. 7 and 8, are positioned adjacent each of the sloping sidewalls 98 and 100 .
[0034] The ribs 54 B and 56 B are similar in configuration to ribs 54 and 56 , but include a web 104 connecting the ribs 54 B and 56 B. The web 104 lies against the back side 34 B of the face panel 28 B. The web 104 may be provided with elongated slots 106 at longitudinally spaced intervals therealong to facilitate the passage of fastening elements 20 through the web and the face panel, so that openings 108 created by drilling or driving a nail through the face panel are in registry with the slots 106 . Reinforcing elements 62 B such as rods 64 B are received in slots 58 B in each of the ribs 54 B and 56 B so that the rods 64 B oppose one another to grip elements inserted therebetween as described with regard to the forming panel 10 .
[0035] In use, the forming panels 10 , 10 A or 10 B hereof are assembled into forming walls 92 by the use of couplers, and depending on the distance between opposing forming walls, tie bars, tie rods, cables or other connecting structures may be used to hold the forming walls in the desired shape. When cables or tie rods are used which must pass through the forming panel 10 , they pass through the openings 52 in the face plate 12 . Otherwise, plugs 22 are used to close the openings, the plugs being held in place by the clamping action of the ribs 54 and 56 of a pair 14 .
[0036] The wedges 80 are placed at desired locations along the length of the pairs of reinforcing ribs 14 proximate to the desired alignment for the corresponding holes 42 of a particular set 40 where the stake 18 is to pass through. The stake 18 is removed from the hanger 16 and driven into the ground, and then the wedge 18 is driven longitudinally along one of the pairs of reinforcing ribs 14 until it engages with the stake 18 . If desired, nails may be driven through the face plate 12 to attach pieces of wood for use as a part of the forming wall or as otherwise needed. Concrete is then poured into the pouring area 50 between the forming walls and against the front side 30 . After curing and hardening of the concrete into the pad or other concrete structure, the stakes are pulled and the forming walls 92 are disassembled for reuse.
[0037] As shown in FIG. 1, the forming panel 10 is useful in connection with a post tensioning system, where anchors 78 include both dead end anchor 110 and live end anchor 112 , and a cone 114 is provided between the live end anchor 112 and the forming panel to create a pocket for access. The cable 79 , having a first end 116 connected and fixed to the dead end anchor 110 and a second end 118 which initially passes through the live end anchor 112 , extends through the pouring area between the forming panels 10 and through an opening 52 in the face plate. The anchors 78 maybe held in place by nails driven into the form and gripped by the ribs 14 prior to pouring of the concrete. After the concrete is hardened, the forming panels 10 may be removed, the dead end anchor 110 holding the first end of the cable being encased in the concrete. The cable, permited to shift because it is encased within its sheath, then has its second end 118 connected to a stressing jack to apply a tensioning load on the cable 79 . This tensioning force is transmitted to both of the anchors when the tensioned cable is fixed to the live end anchor 112 . As a result, the tension is then imparted to hardened concrete because the anchors 78 are embedded in the hardened concrete. The cone 114 creating a pocket in the concrete may then be filled and grouted.
[0038] Although preferred forms of the invention have been described above, it is to be recognized that such disclosure is by way of illustration only, and should not be utilized in a limiting sense in interpreting the scope of the present invention. Obvious modifications to the exemplary embodiments, as hereinabove set forth, could be readily made by those skilled in the art without departing from the spirit of the present invention.
[0039] The inventors hereby state their intent to rely on the Doctrine of Equivalents to determine and assess the reasonably fair scope of their invention as pertains to any apparatus not materially departing from but outside the literal scope of the invention as set out in the following claims.
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A concrete forming panel and its method of use is provided wherein the forming panel has a face plate including a frame, a front side and a back side, and one or a plurality of pairs of ribs which extend longitudinally along the back side. The pairs of ribs are provided sufficiently closely together to grip an element passing through the face plate or to grip a wedge which in turn engages the element. The element may be a nail, stake, or other fastener used to hold the forming panel in the ground, to connect the forming panel to other forming panels, or to indicate a desired level for concrete poured against the front side to be cured and hardened into a finished structure, such as a foundation for a building. The ribs may be provided with slots for receiving a reinforcing element of a relatively harder material, and the reinforcing element may be shiftably received in the slot so that its position may be changed as the reinforcing element wears during use.
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BACKGROUND OF THE INVENTION
A. Field of the Invention
This invention relates to a method and apparatus for a fast heat rise resistor that can be used as a resistive igniter. More particularly, this invention relates to the use of resistive foil and photolithographic production to produce a fast heat rise resistor, the resistor suitable for use as an igniter in autoignition-deployed safety devices.
B. Problems in the Art
There are numerous needs for fast heat rise resistors. One such need relates to the use of a resistor as an igniter used to ignite a pyrotechnic or other explosive material. In these resistive igniter applications, it is desirable that the resistive igniter act quickly for rapid ignition. One such application is in vehicle airbag inflators where it is crucial that an igniter act quickly to ignite a gas-generating pyrotechnic in order to ensure that an air bag is deployed in a timely fashion. As the resistor is driven by current, the heat of the resistor increases to a point where other material such as pyrotechnic material can be ignited. There are numerous other applications of resistive igniters, including in other auto-ignition devices such as seatbelt pretensioners, battery cable disconnects, fuel line shut off devices, roll bars, safety devices, and other applications.
There have been attempts made at a resistive igniter in the prior art. Previous attempts have been made that have used metal wire or film bridges. In metal wire or bridgewire devices, a metal filament also known as a bridgewire is used. Some problems with bridgewire devices involve the difficulties involved in manufacturing bridgewires. In order to predict performance of a bridgewire, there must be uniform thermal and electrical properties. Problems remain in manufacturing bridgewires of the needed uniformity.
Another problem with bridgewire devices is that the response time is too slow or else too much activation energy is required. This is problematic where a fast response time is needed or else there are limited power resources that can not support large activation energies. One example of a situation where there are limited power resources is in a vehicle where a 12 volt battery is used to activate an igniter.
Yet another problem with bridgewire devices involves reliability. In bridgewire devices pyrotechnic powder is pressed against the bridgewire. This process can result in detachment of the bridgewire. Thus there are reliability problems with bridgewires as well.
Other attempts at creating resistive igniters have used metal film bridges that are either thin film or thick film. One problem with a thick film or thin film approach is the increased cost of manufacturing associated with these approaches, and in particular with the thin film approach. Another problem with a metal film approach is that there is contact between the metal film bridge and a substrate. This contact between the metal film bridge and the substrate results in a loss of heat from the metal film bridge to the substrate, resulting in an increase in the amount of time for the metal film bridge to reach a particular temperature or alternatively, an increase in the amount of current required in order for the metal film bridge to reach a particular temperature in a given time.
Another problem with film bridges relates to their reliability. Pyrotechnic powder is pressed against the bridge, however, this powder may become displaced during handling. Thus, the pressed powder may or may not constantly touch the wire or film. Where a liquid pyrotechnic is used, the same contact problems may also arise, as the liquid pyrotechnic may not be in constant contact with the wire or film. These problems result in an igniter that is not reliable.
Thus there is a need for a reliable heat rise resistor which has fast response and can be manufactured in a uniform fashion. There is a further need for a heat rise resistor that can be easily packaged and delivered to customers.
Thus, it is a primary object of the present invention to provide an igniter which improves upon the state of the art.
Yet another object of the present invention is to provide an igniter with a fast response time.
Another object of the invention is to provide an igniter that is reliable.
It is another object of the present invention to provide an igniter that requires decreased activation energy.
Yet another object of the present invention is to provide an igniter that can be manufactured uniformly.
Another object of the present invention is to provide an igniter suitable for use in auto-ignition safety devices.
A still further object of the present invention is to provide an igniter suitable for use in an airbag deployment system.
Yet another object of the present invention is to provide a fast heat rise resistor that does not lose heat to a substrate.
It is another object of the present invention to provide a fast heat rise resistor and method of making a fast heat rise resistor that can be easily packaged and distributed.
A still further object of the present invention is to provide a resistor capable of having all of its sides in contact with a pyrotechnic.
These and other objectives, features, or advantages of the present invention will become apparent from the specification and claims.
SUMMARY OF THE INVENTION
This invention describes a method and apparatus for a fast heat rise resistor using resistive foil with photolithographic production. The invention provides for a fast heat rise resistor that results in a fast response and is suitable for use as an igniter to ignite pyrotechnic material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional diagram of the substrate of the resistor.
FIG. 2 is a cross-sectional diagram depicting the substrate with KAPTON® (Polyimide) layered on top.
FIG. 3 is a cross-sectional diagram showing a substrate, KAPTON® (Polyimide) layer, and copper-plated foil.
FIG. 4 is a cross-sectional diagram showing the resistor after the copper-plated foil has been preferentially dissolved away.
FIG. 5 is a top view depiction of the resistor after excess foil has been dissolved away.
FIG. 6 is a cross-sectional diagram after the excess foil has been dissolved away.
FIG. 7 is a cross-sectional diagram after KAPTON® (Polyimide) has been removed.
FIG. 8 is a cross-sectional diagram showing the resistor and pyrotechnic.
FIG. 9 is a top view of the step and repeat array of resistors.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, the same reference numerals or letters will indicate the same parts or locations throughout the drawings unless otherwise indicated.
Method of The Invention
The steps of creating a fast heat rise resistor according to the present invention are shown in detail in the drawings. FIG. 1 shows a substrate 2 . The substrate may be a polyimide substrate or other substrate such as are well known in the art. The layer of polyimide has a thickness of approximately two mil. The polyimide is preferably fully cured and surface etched. The present invention contemplates that the layer of polyimide may be a sheet of convenient size such as one that is 4 inches by 5 inches, or other standard or convenient size.
In the next step, as best shown in FIG. 2, a layer of material such as KAPTON® (Polyimide) 4 , is bonded or otherwise attached to the substrate 2 . The present invention is not limited to KAPTON® (Polyimide) and contemplates that other types of material such as photoresistive film may be used in place of KAPTON® (Polyimide).
A photoresistive step is then applied to print a pattern on the KAPTON® (Polyimide) and to then develop the KAPTON® (Polyimide) so as to leave a series of stripes of KAPTON® (Polyimide) on the polyimide. The present invention contemplates that stripes of different dimensions may be used. The present invention further contemplates that film can be bonded in stripes as well such that the photoresistive step is not required, even though the photoresistive print and develop step provides a. convenient method of obtaining the KAPTON® (Polyimide) stripes. Stripes of 20 mils can be placed every 60 mils across the long dimension of the polyimide. It is to be appreciated that other configurations and dimensions of stripes can be used and the present invention contemplates these and other variations.
As shown in FIG. 3, copper plated foil 6 is applied over the layer of KAPTON® (Polyimide) 4 and the substrate 2 . The copper plated foil has a copper side 8 and a foil side 10 . The foil used may be a Ni/Cr foil or other foil as may be known in the art. The copper plating is of a thickness of 1 mil, or of other thickness as required by the particular application of the resistor. The foil is of a thickness of 0.1 mil. The present invention contemplates other thicknesses of foil and copper plating. The selection of the foil material and of the thickness of the foil should be made so as to reflect the properties desired in the resulting resistor including the activation time and activation energy required. These requirements will be discussed later in the context of an exemplary embodiment of the fast heat rise resistor apparatus.
A first etching step is then applied to the resistor of FIG. 3 . Through a Kodak® photo resistive process (KPR) or other photolithography process, a defined length of foil is printed on the copper side 8 of copper plated foil 6 . The printing on copper plated foil 6 defines a length of the resistors in the array. The length of the resistor path may be 20 mils at this point, although the present invention contemplates other variations. After this printing and developing, the copper is ten preferentially etched away, leaving the portion desired. The resistor after the etching step is applied is best shown in FIG. 4 . As FIG. 4 shows, the foil 10 is now exposed as the layer of copper on the foil 8 has been preferentially etched away.
A second print and etching step is then applied. In this step, the foil 10 is printed on to expose a defined width of the resistor trays. The present invention contemplates various widths of the traces but 1 mu is preferable. The high resistivity of foil 10 increases the amount of heat generated when current is passed through trace 10 . The heat generated further increases as the width of foil 10 is reduced. The resulting resistor is shown in FIG. 5 . As shown in FIG. 5 . the foil trace 12 is now suspended between the copper terminals 14 . FIG. 6 shows a perspective view of the resistor after this step has been completed. The resistive trace 12 of did foil remains suspended above KAPTON® (Polyimide) 4 .
It is to be appreciated that many such resistors of the present invention may be manufactured at the same time. This is shown best in FIG. 9 . In FIG. 9, a step and repeat array of resistors is shown prior to singulation. The resistors can then be singulated for shipping to customers. The KAPTON® (Polyimide) 4 is still a part of the resistor at this point. KAPTON® (Polyimide) 4 provides stability to the foil traces 12 . This reduces or eliminates the possibility of foil traces 12 breaking or otherwise being damaged in transit.
Prior to use, KAPTON® (Polyimide) 4 can be dissolved or otherwise removed resulting in the resistor best shown in FIG. 7 . This removal may be through application of a chemical solvent. The resistor is then mounted onto the squib and connected to posts. This connection may be made by soldering the resistor in place, applying a conductive epoxy, welding the resistor in place, or other means such as are well known in the art.
In this resistor, foil trace 12 is suspended between the copper terminals on copper plating 8 . Thus, when current is passed through the resistor from terminal to terminal, the foil trace 12 will quickly increase in temperature. This increase in temperature is due to the material used for the foil trace 12 , the width of the foil trace, and the fact that as the foil trace is not in physical contact with substrate 2 , heat is not absorbed by substrate 2 .
The customer may include the resistor of the present invention in applications where the resistor serves as an igniter. This is shown beat in FIG. 8 where the resistor is surrounded by a first pyrotechnic material 16 and a second pyrotechnic material 18 . Because the foil resistor is suspended, the pyrotechnic material can completely surround the foil resistor. As the foil resistive trace 12 is not attached to a substrate, heat is not absorbed by the substrate due to conduction. As resistor 12 heats, pyrotechnic material 16 is ignited. This results in an explosion which can be used to ignite the second pyrotechnic material 18 . One example where this configuration can be used is in an air bag. In an air bag, a current passed through a resistor can be used to ignite a first pyrotechnic 16 which in turn ignites a gas-generating pyrotechnic material 18 which can inflate an air bag. In such application, it is important that the air bag is inflated as quickly as possible thus the fast rising action of resistor 12 is desirable.
Apparatus of The Invention
The apparatus of the present invention is best shown in FIG. 7 . The fast heat rise resistor includes a polyimide substrate 2 . On top of substrate 2 is KAPTON® (Polyimide) 4 . The KAPTON® (Polyimide) is used to secure the resistive trace 12 in place during handling and shipping to a customer. Resistive trace 12 is a foil trace preferably of Ni/Cr, but may be of other types of foil as requirements of the heat rise resistor may require. The foil trace 12 is elevated above the substrate 2 as the foil trace 12 is on top of the KAPTON® (Polyimide) layer 4 . The resistor also has a top layer 8 of copper plating on the copper plated foil 6 . The underside of the copper plating foil is foil and that portion of the foil that extends across the gap is the resistive trace 12 . The resistor is secured on place onto a circuit board or other structure through soldering with solder 16 onto solder patch 14 . The present invention contemplates that the resistor may be mounted by other methods such as conductive epoxy or welding.
FIG. 7 best shows the resistor after the layer of KAPTON® (Polyimide) 4 has been removed. When the layer of KAPTON® (Polyimide) 4 is removed, such as by application of a chemical solvent, the foil trace is suspended over substrate 2 . This results in the heat of foil 12 increasing more rapidly as current is passed through the resistor. As the foil trace 12 is not in physical contact with substrate 2 , heat is not absorbed by the substrate 2 which would increase the time that it would take for a given current passed through the resistor to cause foil trace 12 to reach a particular temperature. The apparatus of the present invention is shown in one environment in FIG. 8 . In this environment, the resistor is surrounded by pyrotechnic material 16 . Thus, when foil trace 12 reaches a particular temperature, pyrotechnic material 16 is ignited. The ensuing explosion serves to ignite a gas generating pyrotechnic 18 . The amount of time that is needed to ignite is reduced because the foil trace 12 is heated more thickly than in the prior art.
Due to the fast rise time and reliability, the present invention contemplates use in a variety of applications, including, without limitation, auto-ignition applications, safety applications, airings, seat belt pretensioners, battery cable disconnects, fuel line shut off devices, roll bars, and numerous other uses.
Thus, an apparatus and method for a fast heat rise resistor using foil work with photolithographic production has been disclosed which solves problems and deficiencies in the art. It will be readily apparent to those skilled in the art that different types of substrates and types of foil may be used in the foil resistor. It will also be clear to those skilled in the art that different materials, dimensions, and other variations may be used including different types of foil, different thicknesses and widths of foil, different thicknesses of plating, different lengths of foil, different films in place of KAPTON® (Polyimide), and other variations as required by particular applications and environments.
It is therefore seen that this invention will achieve at least all of its stated objectives.
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A fast heat rise resistor comprising a substrate, a foil bridge on the surface of the substrate, the foil bridge having an elevated portion and a contact portion, the elevated portion above the substrate, the contact portion in contact with the substrate, a conductive layer attached to the contact portion of said foil bridge. The activation energy and/or response time is reduced as the foil bridge is suspended over the substrate. Another aspect of the invention include a method of manufacturing the foil bridge and application to autoignition vehicle airbags.
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CROSS REFERENCE TO OTHER PATENT APPLICATION
[0001] This is a division of applicants' co-pending U.S. patent application Ser. No. 10/256,266 filed Sep. 25, 2002, entitled SUBGRADE VAULT.
FIELD OF THE INVENTION
[0002] A vault to provide an enclosed region beneath a surrounding surface. The vault comprises a body, a lid, and a retainer for holding the lid closed across an opening formed by the vault body.
BACKGROUND OF THE INVENTION
[0003] Subgrade vaults are widely used to provide internal enclosed regions where connections can be made and housed. Classical examples of such connections are joinder of electrical cables used in street lighting, in telephone and communication systems, and water valves such as for golf courses.
[0004] Such vaults are by necessity placed below grade with their upper surfaces at grade where loads from pedestrians and vehicles are to be anticipated. Generally they will be used by municipalities, utilities, and other capital installations where longevity of the vaults, and affordability are important.
[0005] While it is possible to make an almost ultimately strong and long-lived product by using very expensive materials in excessive amounts, the realities of the marketplace will not support such a product. Accordingly, the use of less expensive materials that can be affordably processed is a logical objective. Of course such materials often have lesser inherent physical properties to resist mechanical loads and ravages of time and weather. These must be compensated by effective design.
[0006] In addition to resistance to outside forces, easiness of use is necessary. This is because labor costs associated with the servicing of systems accommodated in the vault are generally quite high. A lid to give access to the enclosed region must not only be strong enough, but must be simple to remove and replace, while reliably holding the lid onto the body while access is not needed.
[0007] It is another object of this invention to provide for various levels of protection against unauthorized removal of the lid such as by friction grips or fasteners with non-symmetrical arrays of driving surfaces.
[0008] It is an object of this invention to provide an improved vault, affordably manufactured as a molded organic plastic product, and especially to provide a reliable, readily manufactured clip to join with a bolt, removably to hold the lid to the body.
BRIEF DESCRIPTION OF THE INVENTION
[0009] A vault according to this invention includes a body having a peripheral wall to bound an enclosed region. The body has an open lower end and an open upper end. The upper end is bounded by a rim, and preferably forms a seat beneath the rim. A lid fits across the upper end, preferably with an underside plug that fits in the seat.
[0010] According to another preferred but optional feature of the invention, the body is a molded structure in which the seat includes a re-entrant wall and an inwardly extending flange to provide additional support for the lid when in place.
[0011] According to yet another preferred but optional feature of the invention, a U-shaped clip fits onto a lip on the flange. The clip includes a chimney-like projection with an internal thread on one arm, and a hole through the other arm. When placed on the lip, a bolt retained to the lid can be threaded into the clip to hold the lid onto the body.
[0012] According to another preferred but optional feature of the invention, the body is a molded structure in which the seat includes a re-entrant flange and an inwardly extending lip to provide additional support for the lid when in place.
[0013] According to yet another preferred but optional feature of the invention, an outwardly and upwardly extending skirt surrounds the bottom end of the body to provide positive resistance to distortion of the body which could be caused by loads exerted by earth, rocks or concrete while being placed around the vault.
[0014] The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a side view of a body according to the invention;
[0016] FIG. 2 is a top view taken at line 2 - 2 in FIG. 1 ;
[0017] FIG. 3 is a bottom view taken at line 3 - 3 in FIG. 1 ;
[0018] FIG. 4 is a cross-section taken at line 4 - 4 in FIG. 3 ;
[0019] FIG. 5 is a side view of a lid according to the invention;
[0020] FIG. 6 is a top view taken at line 6 - 6 in FIG. 5 ;
[0021] FIG. 7 is a bottom view taken at line 7 - 7 in FIG. 5 ;
[0022] FIG. 8 is an exploded side view showing the assembly of a body, a lid, a fastener and a clip which together form the preferred embodiment of the vault;
[0023] FIG. 9 is a fragmentary cross-section showing the fastener and clip holding the lid to the body;
[0024] FIG. 10 is a side view of a clip according to the invention;
[0025] FIG. 11 is a top view of FIG. 10 ;
[0026] FIG. 12 is a bottom view of FIG. 10 ;
[0027] FIG. 13 is a perspective view of the fastener of FIG. 10 ;
[0028] FIG. 14 is an end view of the clip of FIG. 12 ; and
[0029] FIG. 15 is a cross-section taken at line 15 - 15 in FIG. 13 .
DETAILED DESCRIPTION OF THE INVENTION
[0030] As best shown in FIG. 8 , a vault 20 according to this invention comprises a body 21 , a lid 22 , a clip 23 and a fastener 24 . When the lid is brought down onto the body and the fastener is fastened to the clip, the joinder and assembly are exemplified in FIGS. 8 and 9 .
[0031] When the vault is assembled, it forms an enclosed region 25 within which connections (not shown) can be placed and accessed through the top end 30 . Conventionally the conduits, cables, or valves being connected are brought into the region through the open bottom end 31 of the body. Customarily the body is buried in a surrounding region, such as soil, or abutted by gravel or concrete poured around it to stabilize it in place. The upper end of the body will be placed where, when the lid is attached, the upper surface of the lid will be at grade.
[0032] The peripheral wall 32 of the body is a quadrilateral frustum, sloping upwardly from the bottom end. If preferred, the bottom end could be the larger end, but structural consideration will prefer the illustrated shape over the reverse, or from a prismatic shape (which could also be used). Circular vaults are also in this scope of this invention, but quadrilaterals are generally preferred.
[0033] The illustrated shape is well-suited to manufacture by injection molding processes, which is an advantage in the reduction of cost. It is also amenable to rotational molding. The lower end includes an upwardly extending peripheral skirt 33 . Attention is called to buttresses 34 which are integral with (or attached to) the inside of the skirt and the outside of the peripheral wall. These provide strong support for the skirt, which in turn provides significant rigidity to the lower end so that side forces are less likely to distort the shape of the body.
[0034] A rim 40 is formed at the top end of the body, where a seat 41 is formed by a re-entrant wall 42 that terminates in an inwardly-extending flange 43 . A lip 44 is formed as an inward extension from flange 43 , with a hole 45 therethrough for a purpose to be described.
[0035] Buttresses 46 fit between the outer surface of wall 42 and the inner surface of the peripheral wall. These buttresses may be molded as part of the body or later cemented or solvent welded in as preferred. However, it will be noted that all elements of the body as shown are suitable for molding in a single operation, perhaps drilling the hole as a second operation.
[0036] In the event that a positive lock for the lid is not necessary a rise 49 , which may be one or more dimples, or a circumferential band, is formed on the inside of the re-entrant wall. It will frictionally engage to the lid to be described, and require extra force to remove the lid.
[0037] Lid 22 is best shown are FIGS. 5-7 . It includes a top plate 50 with an upper surface 51 and an optional shoulder 52 that extends around the edge of the lid.
[0038] The underside of the lid is formed as a plug 53 which is intended to fit in seat 41 , bearing against re-entrant wall 42 and, depending on preference, with shoulder 52 bearing on the rim or the lower end of the plug bearing on flange 43 , or both. To reduce its weight and cost, the bottom is relieved by a honeycombing with intersecting plates 53 forming voids between them. Rise 49 will engage the lid, and perhaps slightly indent into it.
[0039] As best shown in FIG. 9 a recessed opening 55 is formed through the lid near its edge. It has a shoulder 56 around the edge of the opening. A second opening 57 through the opposite edge of the lid is provided to facilitate removal of the lid from the body.
[0040] Lock means 60 comprise clip 23 and fastener 24 . If desired, an E-ring 61 can be placed on the fastener at a spacing from the head. The E-ring can be removed with difficulty. While it is in place it will hold the fastener to the lid, but permit substantive axial movement of the fastener.
[0041] As best shown in FIG. 9 , clip 25 is pressed over lip 44 , where it overhangs hole 45 . Fastener 24 , which is a threaded, headed bolt, carries a washer 62 and passes through opening 55 , bearing against the lid as shown. The E-ring can be used if ready separation of the bolt from the lid is not desired. The bolt is threaded into the clip, and the lid is locked in place. The lid can be removed after the bolt is unthreaded from the clip.
[0042] As a security measure, the head of the fastener may be coded in shape so as to require a special wrench to engage it. The conventional means for this is to provide an array of curving surfaces which is non-symmetrical. Basically this means avoiding parallel driving surfaces, or not providing any array at all, for example a circular head. A pentagonal array is a suitable example.
[0043] Clip 23 is uniquely advantageous to this vault, because it can readily be pushed onto the lip where it will retain itself even when not engaged by the fastener. Furthermore it can readily and inexpensively be manufactured from a strip of suitably strong metal, usually a stainless steel.
[0044] As shown in FIGS. 11-14 , the clip has a pair of arms 70 , 71 which are joined by a bight 72 . The arms confront one another. Installation of the clip is facilitated by oppositely directed bends 73 , 74 at the tips of the arms.
[0045] Upper arm 70 has an opening 75 therethrough with a partial circumference 76 from which a retainer 77 has been punched. The retainer has a complete hole 78 therethrough, and is formed as a catch, angled inwardly from its base area 70 . In side view the retainer has a small bend 80 which enables the retainer to slide over the lip without digging into the plastic as a sharp end would. After installation, the retainer exerts a strong retentive force that may indent into the lip.
[0046] Lower arm 71 has a pair of catches 81 , 82 punched in from the outside, further to retain the lip.
[0047] A neck 85 is formed on the lower arm, extending outwardly from the clip. It has a tubular wall 86 with an internal thread 87 . The thread and the hole in the upper arm are aligned, and when the clip is installed these will be aligned with hole 45 in the lip, and with the fastener. The assembly with the lid is best shown in FIG. 9 .
[0048] The neck may be made separately and fastened to the arm if desired. However, it is an advantage of the clip that it can be made from a single strip of metal by successive operations. The neck may readily be formed by impact extrusion, in which metal is deformed from the plane of the strip and extruded to form the neck. The free end of the neck will be squared off, and the inside threaded.
[0049] The retainer can be formed in a single or double blow, forming the hole in it, and then severing the metal around only part of the retainer while bending it to shape. The folds at the end of the bight are made by a simple folding operation.
[0050] The organic plastic material for the body and lid may be any suitable for the intended purpose. High density polyethylene or polypropylene family is one suitable example.
[0051] This invention provides a vault made up from a number of unique and readily manufactured parts. The parts themselves are economically made by routine procedures.
[0052] This invention is not limited by the embodiment shown in the drawings and described in the description, which is given by way of example and not of limitations but only in accordance with the scope of the appended claims.
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A subgrade vault to provide an enclosed housing for utility connections. The housing is made of a moldable material with a reinforcing skirt at one end and a seat in the other. A lid is received in the seat to close its upper end. A clip is optionally provided for fastening the lid to the housing body that can be clipped on the body and engaged by a fastener carried by the lid.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to the field of ergonomic keyboards. More specifically, the present invention is related to a method and apparatus which provides continuous movement of a computer keyboard and associated wrist rest, movement to include height and angle changes.
2. Discussion of Prior Art
Throughout the development of the PC, various efforts have been practiced to ergonomically enhance the keyboard. Many designs have included height or angle adjustments. Typical keyboards have user adjustable legs which extend from the underside and raise the back or front of the keyboard to an angle comfortable to the user. The user is required to turn the keyboard over and individually adjust each leg in height. While these adjustments may provide some additional level of comfort, they may not be used properly, or at all, for terminals which are frequented by multiple users. Without the active participation of the user, the keyboard will remain in the previous adjustment position throughout the use period. The prior art has failed to provide either an easy adjustment method, i.e. adjustment from the top of the keyboard, an automatically adjustable keyboard or a continuously adjustable keyboard. The following patents include various prior art methods of wrist rest height adjustment, but each fail to include the graphic, electronic, or computer controlled continuous adjustment of a keyboard/wrist rest as per the present invention.
The patent to Daneshvar (U.S. Pat. No. 5,374,018) allows for the adjustment of keyboard height as well as its angulation. One or more inflatable balloons are used to implement the height adjustment. The balloons may be filled with air or with liquids, e.g., water, inert oil, or gel. Further adjustment of keyboard height and angulation is implemented by using flat boards, boards of different shapes or screws (FIG. 16). The boards are located in a space under the keyboard unit. Soft pads comprised of mosaics of soft plastic bubbles provide for wrist and palm comfort.
The patent to Deuitch et al. (U.S. Pat. No. 5,435,508) provides for a Wrist Rest Support. This reference teaches a bladder having an elongated length, arcuate (bow-curved) cross section, and enclosed sealed ends. A viscous fluid within the bladder provides support for the wrists. An outer shell which is washable and flexible surrounds the bladder and provides a pleasant-to-touch feeling.
The patent to Wolfe et al. (U.S. Pat. No. 5,568,907) provides for a Dynamic Wrist Rest. This reference provides an up and down motion of the wrist by means of an internally-mounted pressure-sensitive air bladder or motorized oblong roller assembly located in this wrist-rest unit.
The patent to Peart (U.S. Pat. No. 5,601,264) provides for a Wrist Rest. This reference incorporates a bladder for holding a fluid. A pump connected to the bladder selectively fills the bladder with fluid and a valve selectively releases the fluid from the bladder. The bladder includes two (2) elongated lobes interconnected by an isthmus. The elongated lobes filled with fluid are used to provide a fluid-cushioned support for the keyboard user's wrists and/or palms.
Whatever the precise merits, features, and advantages of the above cited references, none of them achieve or fulfills the purposes of the present invention. Accordingly, it is an object of the present invention to provide for a method and apparatus for continuously controlling the height or angle of a keyboard and its associated wrist rest.
It is another object of the present invention to provide for a method and apparatus for automatically controlling the height or angle of a keyboard and its associated wrist rest.
It is another object of the present invention to provide computer control of a keyboard and associated wrist rest's height and angle.
It is an additional object of the present invention to provide a GUI to enable easy user selection of possible computer controlled keyboard and associated wrist rest positions.
It is an additional object of the present invention to provide patterned control of a keyboard and associated wrist rest's height and angle.
It is an additional object of the present invention to include a retrofit embodiment of the above described computer controlled keyboard.
These and other objects are achieved by the detailed description that follows.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method of adjusting the height and/or angle of a keyboard/wrist rest during use. A modified standard keyboard includes a processor, motors, motor controllers and height adjusting legs to create a keyboard device which changes angle over time. In an alternative embodiment, a retrofit solution for existing keyboards is disclosed. The keyboard may be adjusted incrementally, infinitely, according to a pattern or impulse, over a period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an internal component diagram of the present invention as shown from a bottom view.
FIG. 1a illustrates an enlarged view of the legs of FIG. 1.
FIG. 2 illustrates a side view of the device shown in FIG. 1.
FIG. 3a illustrates the keyboard user controls of the present invention.
FIG. 3b illustrates the GUI controls of the present invention.
FIG. 4 illustrates a retrofit version of the present invention.
FIG. 5a illustrates a motor controlled screw-type height adjuster.
FIG. 5b illustrates a motor controlled rack-and-pinion height adjuster.
FIG. 6 illustrates a general circuit board layout for the present invention computer controller.
FIG. 7 illustrates a typical height adjustment pattern for each adjustable section of the keyboard and wrist wrest over time.
FIG. 8 illustrates the implementation of the height adjustment pattern of FIG. 7 for each adjustable section of the keyboard and wrist rest over time.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is illustrated and described in a preferred embodiment, the device may be produced in many different configurations, forms and materials. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications of the materials for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will envision many other possible variations within the scope of the present invention.
FIG. 1 illustrates keyboard 100 which can be any PC keyboard, to include various shapes, sizes and styles, e.g. a standard "101-key" keyboard, split-hands or other modified version. Section 101 represents the bottom section of keyboard 100. In a typical keyboard, a plurality of manually adjustable legs extend from the bottom section. Most frequently, only one set of legs will be located along the front or back edge to provide corresponding height adjustment to the front or back of the keyboard. By adjusting the height of the legs, an adjustment to the angle of the keyboard is made. In some cases, a keyboard will include a front and back set to enable multiple adjustments. In the preferred embodiment, keyboard 100 is shown with four legs 102, 103, 104 and 105 located evenly spaced, and in close proximity, to each corner.
Unlike the prior art, each leg has been modified as shown in figure la, to include a hole 118 and pivoting nut 119 receiving threaded rod 117. Each threaded rod 117 extends into the internal cavity of the keyboard 100 and is connected to respective motor 106. Motor 106 is an electric dc motor such as a TMC2832A or equivalent imparting approx. 200 RPM to threaded rod 117. Each motor is secured to the internal keyboard cavity by suitable fasteners known in the art. Alternatively, solenoids can replace the motors and their respective linkages and controllers.
Provided within the internal cavity of the keyboard is a printed circuit board (PCB) 114 which includes a processor module 116 and a multiplicity of motor controllers 115 (see FIG. 6). The processor module includes a processor (CPU) such as the 80C751, associated memory, I/O interfaces, and various power and timing controls (e.g. clock/oscillator not shown). The invention is not to be limited to a specific PCB configuration, known computer boards could be substituted without departing from the scope and spirit of the present invention. DC power is provided to the circuit board and motors through AC/DC adapter 121.
Motor controllers 115 receive electrical signals from the processor and actuate their associated motors 106. Specific electrical connections to the motors 106 are not shown within the drawings, however, any known connection method may be used. In addition, the motor controllers 115 can be located on the PCB or be separated and located individually with each motor 106.
Attached to keyboard 100 is associated wrist rest 110. Wrist rest 110 may comprise a typical gel, foam, or otherwise cushioning material, or include solid non-impact absorbing materials. Wrist rest 110, in the preferred embodiment, is attached to keyboard 100 in a tethered configuration 112. The tethered attachment may include a flexible material or be modified to include an articulating mechanism.
Wrist rest 110 includes legs 108 and 109, evenly spaced in the outermost corners and which are the same or functionally similar to the legs 102-105 of the keyboard 100. Each leg also includes hole 118 and pivoting nut 119 configuration as previously described and illustrated in figure la. Threaded rods 117 are attached to motors 107 in a similar manner to that described heretofore and are individually activated by associated motor controllers 115 or locally provided controllers. The power and control functions may be provided through connections 113 or be integrated within the tether element 112. FIG. 2 illustrates a side view with the connections shown. A dust cover section "live hinge" 220 prevents dust, debris and other objects, e.g. pens and pencils, from entering the connection area. In an alternative embodiment, wrist rest 110 is made self-sufficient to include its own PCB and associated power (e. g. AC/DC adapter 121) and control elements.
FIGS. 3a and 3b illustrate two alternative methods of controlling the keyboard and associated wrist rest. FIG. 3a shows a control panel 300 which is located on the top surface of the keyboard or on a separate control box (not shown) controlled by an attached cable or wireless/RF method. The control panel 300 includes a separate up/down selector 301, 302, 303 and 304 for each leg on the keyboard, as well as the wrist rest 308 and 309. The number of controls varies with the number of legs and whether the legs are controlled in groups, e.g. front and back pairs operated simultaneously. In addition, if no wrist rest is provided, controls 308 and 309 are eliminated. Knob 305 allows the operator to select from a range of operating times 306, typically minutes. Section 307 allows the operator to sequence through a list of preselected patterns of adjustment, to be described further hereafter.
FIG. 3b illustrates a GUI to enable an operator the ability to make the keyboard and wrist rest height/angle selections as described above on the PC screen. The interface includes: time selection 351 with display 352 and up/down selection 353; pattern selection section 354 with various preselected patterns 355; keyboard height selection 356 with up/down selections for both front 358 and back 359 and wrist rest control 357 with left 360 and right controls 361. Controls 360 and 361 may also be front and back controls depending on leg placement, or be replaced by a single up/down control selection moving both legs simultaneously.
FIG. 4 illustrates a retrofit embodiment of the present invention. The retrofit version comprises a keyboard receiving section 400 and two side sections 401. Sections 400 and 401 are manufactured from sheet metal or polymer compositions or equivalent materials. The side sections contain the motors 402, motor controllers 403, height adjustable legs 404, threaded rods 405 and PCB 408 as described previously in the description of the FIGS. 1-3. A PC keyboard 100 is placed in the keyboard receiving section 400. Instead of the keyboard legs being adjusted, as per the preferred embodiment, the legs extending through the bottom of sections 401 are adjusted in height to adjust the angle of the keyboard. PCB 108 includes, in a preferred embodiment, the motor controllers for the right side motors, with the left side motor controllers 403 being located in close proximity to the left motors 402. Other than the motor controllers and location of the PCB, the left and right sides are to be considered to be symmetrical and include similar elements, power and controls.
An adjustable wrist rest structure includes wrist rest receiving section 410, side sections 412 containing motors 409, height adjustable legs, threaded rods and motor controllers 413 similar to those found in the side sections 401 of the keyboard receiving section. As in the preferred embodiment configuration, the adjustable wrist rest section may be tethered 411 and include power and control connections 406. The retrofit embodiment is controlled by the control panel of FIG. 3a located generally over the PCB area 108 and on a top surface of the section 401 (right side). The invention is not limited to a specific location of the control panel. As with the preferred embodiment, the entire retrofit apparatus is alternatively operated from a GUI as shown in FIG. 3b.
FIGS. 5a and 5b illustrate alternative mechanical embodiments of the height adjustable legs and connections to the motors. FIG. 5a shows a motor 500, securing clamp 501, screw shaft 502, co-acting screw shaft (threaded rod) 504, shaft retaining ring 509, keyboard case opening 506 and foot 507. Rotating movement of the motor screw shaft 502 is translated into up/down movement of screw shaft 504. FIG. 5b illustrates a rack-and-pinion version to include motor 500, securing clamp 501, grooved pinion 503, grooved rack 505, keyboard case opening 506 and foot 507. Rotating movement of the pinion 503 is translated into up/down movement of rack 505.
OPERATION
The operation of the present invention, in both the preferred and retrofit embodiments, is as follows. In a manual mode, under computer/processor control, the user selects either individual leg height adjustments, paired leg adjustments, or multiple leg adjustments to the keyboard, the wrist rest, or both. Upon selection, using the control panel or GUI of FIGS. 3a and 3b respectively, the processor/computer actuates the appropriate motor controller which in turn rotates the threaded shaft to produce up/down movement of the legs/feet. In a timed mode, the user selects a specified amount of time for the processor/computer to control the raising and lowering of the various legs in either a fixed or a user selectable computer controlled pattern. The processor will adjust the height of the legs of the keyboard and/or wrist rest throughout the time period in a continuous sequence according to prestored patterns stored within the memory of the processor/computer. In a pattern selection mode, the user can select a specific leg adjustment pattern which will be implemented by the computer throughout the computer session until power removal or a new pattern is selected.
FIGS. 7 & 8 illustrate a sample pattern over time of movement of the rear, front, and wrist rest pairs. During the first two minutes, all legs are at their minimum adjustment (e.g. zero displacement); during the 2-3 minute period, the rear legs of the keyboard start to elevate; during the 3-4 minute period, the rear legs continue to elevate while the front keyboard legs start to elevate; during the 4-5 minute period, the rear legs reach maximum adjustment (i.e. full height obtainable); during the 6-7 minute period, the rear legs start to descend, the front legs reach maximum adjustment and the wrist rest legs begin to elevate; during the 7-11 minute period the rear legs descend to their minimum adjustment position, while the front and wrist rest legs obtain maximum adjustment; during the 12-13 minute period all legs are at minimum adjustment position. The cycle may then repeat or be truncated at some specified time or be changed by the user by a specific leg adjustment or a new pattern selection.
A very important aspect of the present invention, is that the computer controlled feature allows for infinite adjustment capabilities. Any number of programmable patterns can be designed and stored within the memory, limited only by memory storage space. Some very useful patterns would be sinusoidal or wave patterns, ramping patterns, quick period patterns to produce a massaging effect or replicate the patterns in music. In addition, the keyboard could be sent an impulse signal from the processor/computer which would produce a sudden noticeable height adjustment to indicate that you had just received an email message or have a voice mail waiting.
The computer PC hardware described throughout the disclosure is consistent with known IBM compatible, Macintosh or equivalent systems. The programming code to select specific motor controllers for actuation, or specific patterns for download, is considered to be within the scope of a computer programmer and can be modified without departing form the scope and spirit of the present invention.
CONCLUSION
A system and method has been shown in the above embodiments for the effective implementation of a computer controlled height adjustable keyboard. While various preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims. For example, the present invention should not be limited by size, materials, connection methods, leg styles, number or placement, processor elements, motors specifications, methods of transferring movement from the motors to the legs, specific user controller elements, patterns, or times for adjustment. The keyboard can be interchangeably configured with or without a wrist rest or include a fixed integrated wrist rest. Keyboard/wrist rest control is through controls located on the keyboard, a CRT GUI, or by remote wireless or rf control.
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An apparatus and method of adjusting the height and/or angle of a keyboard/wrist rest during use. A modified standard keyboard includes a processor, motors, motor controllers, and height adjusting legs to create a keyboard device which changes angle over time. In an alternative embodiment, a retrofit solution for existing keyboards is disclosed. The keyboard may be adjusted incrementally, infinitely, by a pattern, or impulse over a period of time.
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BACKGROUND OF THE INVENTION
The present invention relates to semiconductor inspection systems and/or processing, and more particularly to chambers for processing or inspecting substrates such as semiconductor wafers, reticles, and the like for the manufacture of integrated circuits (ICs). Integrated circuits are manufactured by building semiconductor devices on one or more substrates in a process chamber. The semiconductor devices are interconnected to form the IC. A semiconductor wafer may have one, or many, or a few ICs.
Semiconductor devices are fabricated on substrates such as silicon wafers by processes that involve depositing, patterning, and removing of materials on the substrates. Deposition processes such as chemical vapor deposition (CVD) or physical vapor deposition (PVD) may be used to deposit a layer of material on a substrate. Photolithography techniques may be used to create a pattern on a layer of material to control where etching, depositing, or implanting will occur. Etch processes may be used to remove portions of a deposited layer, so that other materials may be deposited in the removed portions. Ion implantation processes may be used to change the properties of a deposited layer of material by physically bombarding and implanting dopants into the deposited layer. By using various ones of these process steps, semiconductor devices, and, thus, integrated circuits are created on the substrate.
In fabricating ICs, specialized process chambers are used sequentially to perform the steps required to build the semiconductor devices and the ICs. Each chamber usually has an internal chamber in which predefined conditions, such as a certain vacuum level, are maintained during the process. For a complex integrated circuit, hundreds of individual process steps may be involved in building and interconnecting all of the underlying semiconductor devices. To streamline the manufacturing process, process chambers may be integrated into a cluster tool, so that the different process steps may be executed sequentially and efficiently, using less factory space than stand-alone chambers, and requiring less distance to transport wafers from process step to process step. A cluster tool provides process sequence integration by “clustering” several different process chambers into one platform.
In some inspection tools and process chambers a substrate is moved along various directions during the inspection/ or manufacturing process respectively. The inspection tool/process chamber has an internal chamber in which various predefined conditions (such as a certain vacuum level) are maintained. When some processing chambers are integrated into a cluster tool the substrate may be shifted from one process chamber to another without the need to break pressure seals in the process environment. As a result, there may be fewer opportunities for unwanted contamination to occur. In addition, it is possible to save some or all of the time involved in completely venting up an internal chamber, moving a substrate from stand-alone chamber to stand-alone chamber, and then pumping down each succeeding internal chamber to achieve the necessary level of vacuum to conduct the next process sequence.
Because of the complexity of the manufacturing process, there is frequent inspection of substrates to ensure that the process steps are executed properly and that the substrates are reasonably free of defects, preferably as free of defects as is practicable. Currently, processing and inspection of semiconductor substrates are done separately, in stand-alone tool.
Accordingly, there is a need to provide an efficient method and system for allowing to integrate an inspection tool into a cluster tool. An inspection chamber that can be integrated into a cluster tool would further streamline the manufacturing process for integrated circuits.
There is a further need to provide a chamber with an internal chamber that may be pumped rapidly. There is yet a further need to allow efficient and relatively contamination free system and method for moving a substrate while maintaining predefined conditions within an internal chamber in which the substrate is placed.
SUMMARY OF THE INVENTION
The present invention provides a movable internal chamber that is defined by chamber elements whereas at least some of the chamber elements can move in relation to other chamber elements while maintaining predefined conditions within the internal chamber.
According to an aspect of the invention the internal chamber is relatively small thus allowing a fast generation of the predefined conditions after the internal chamber is opened and closed.
According to an aspect of the invention the internal chamber is opened by means of introducing a relative movement between some chamber elements.
According to an aspect of the invention the movement of a substrate is followed by a movement of some of the chamber elements while maintaining the predefined conditions within the internal chamber.
According to an aspect of the invention the internal chamber is isolated from other components of the chamber, thus reducing internal chamber contamination.
According to another aspect of the invention at least some of the chamber structures employ one or more dynamic seals to establish one or more seals between relatively moving chamber structures. The seals can preserve pressure levels within the internal chamber.
According to an aspect of the invention the internal chamber is defined by a static upper plate, an outer floating ring, an inner floating ring, a flexible connector and a first portion of a movement system, such as an output shaft. A first dynamic seal is formed between a surface of the static upper plate and an upper surface of outer floating ring. The flexible connector is pivotally connected to the outer floating ring and inner floating ring, thus maintaining a desired pressure level, including various degrees of vacuum within the internal chamber. A second dynamic seal is formed between the output shaft to another end of the inner floating ring. The output shaft introduces motion to the substrate that is located within the internal chamber.
As discussed above, the movement system is mounted outside of the internal chamber. This feature decreases the potential for contamination of the interior of the chamber. This contamination potential exists because various contaminants, for example, different kinds of polymers, may be formed in the chamber by a process of carbonization when hydrocarbon molecules from grease, adhesive, or insulation of wires or connectors are dissociated during either processing or inspection of a substrate inside the chamber.
The connector feature, enabling tilt while operating at a maintained pressure within the chamber (such as a given level of vacuum), is desirable not only in the inspection of semiconductor devices at various stages of manufacture, as in the particular embodiment depicted in the drawings, but also in the process of manufacturing these semiconductor devices.
According to an aspect of the invention, a movement system for moving the substrate within the internal chamber is mounted outside of the internal chamber. This feature decreases the potential for contamination of the interior of the chamber. This contamination potential exists because various contaminants, for example, different kinds of polymers, may be formed in the chamber by a process of carbonization when hydrocarbon molecules from grease, adhesive, or insulation of wires or connectors are dissociated during either processing or inspection of a substrate inside the chamber.
According to another aspect of the invention the ability of the flexible connector to pivot may be used to compensate for any non-perpendicularity of the output shaft, thus allowing to tilt the substrate while maintaining predefined consitions within the internal chamber. Furthermore, the manufacturing criteria of the outer floating ring and the inner floating ring may be simplified because the flexible connector permits greater geometric and dimensional tolerance between the chamber components.
In one embodiment, one or more of the dynamic seals described herein may be similar to an air bearing vacuum seal disclosed in commonly assigned U.S. Pat. No. 6,163,033, entitled “Method and Apparatus for Controlling a Workpiece in a Vacuum Chamber.” This U.S. patent is incorporated by reference herein.
In one embodiment, one or more dynamic seals may be achieved by using one or more gas bearings. Air pressure differentials may be maintained across the bearing interfaces such that ambient atmospheric pressure (or higher) may be present on one side of the interfaces while lower pressures, including various levels of vacuum, may be maintained on the opposite side of the interfaces. The air pressure differentials may be maintained without leakage of gas across the bearing interfaces in either direction. The dynamic seals described herein provide low-contact or even contactless interfaces between relatively moving elements, with a film of gas flowing between the elements, in some cases physically separating the elements. The gas film provides a force that opposes the weight of the relatively moving elements as well as any other forces that tend to cause mechanical or frictional resistance at the interfaces between the relatively moving elements. As a result, the gas bearings yield low friction, and in some cases, virtually frictionless interfaces between elements that are in relative movement with respect to one another.
In one embodiment, the internal chamber is defined by a first element having a first surface, and a second element having a second surface about the periphery of the internal chamber. The first surface and the second surface are positioned in proximity with each other to form an interface. The internal chamber further comprises a substrate support, mounted inside the internal chamber, to enable mounting of a substrate, and a first moving system producing relative movement between the first and second elements. The internal chamber employs one or more dynamic seals to allow the two elements to move relative to one another, while maintaining a desired pressure level, including various levels of vacuum, inside the internal chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other features of the invention will be understood better by reference to a detailed description of some embodiments in conjunction with the accompanying drawings, in which:
FIG. 1 a shows a top view of one embodiment of a cluster tool, which includes a load lock, a transfer chamber, process chambers, and an inspection chamber, in which the present invention may be implemented.
FIG. 1 b shows a top view of one embodiment of a stand-alone tool, which includes a inspection chamber, wafer cassettes, and a transfer robot, in which the present invention may be implemented.
FIG. 2 shows a cross-sectional view of a internal chamber, in a closed position, according to one embodiment of the present invention.
FIG. 3 shows a cross-sectional view of the internal chamber, in an open position, according to one embodiment of the present invention.
FIG. 4 shows a close-up of a cross-sectional view of the chamber illustrating the interfaces that employ dynamic seals between the relatively moving elements according to one embodiment of the present invention.
FIG. 5 shows an inboard sweeper plenum according to one embodiment of the present invention.
FIG. 6 shows another cross-sectional view of the internal chamber according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring to FIG. 1 a , in cluster tool 100 , substrates 117 are transported in a wafer cassette 101 . The wafer cassette 101 is loaded into a load lock 103 , which then is sealed from outside pressure. One or more vacuum pumps (not shown) connected to the load lock 103 pump down the load lock 103 to a desired pressure level that may approximate the pressure level in transfer chamber 109 . Transfer robot 105 picks up a substrate 117 from the wafer cassette 101 and loads the substrate 117 into any of the process chambers 107 in the cluster tool 100 . Depending on the process chamber 107 into which the substrate 117 is inserted, material may be deposited on, or patterned on, or removed from the substrate 117 .
Illustrated in FIG. 1 a , an inspection chamber 110 having an internal chamber (not shown) is integrated into a cluster tool 100 . Inspection chamber 110 includes a scanning electron microscope (SEM) 207 ( FIG. 2 ) and an optical microscope 211 ( FIG. 2 ) that may be positioned such as to inspect substrates the are located within the internal chamber. As discussed above, once the load lock doors are closed, the cluster tool 100 including the load lock 103 , the transfer chamber 109 , the process chambers 107 , and the inspection chamber 110 may be sealed from the ambient environment. The substrate 117 may be transferred from the load lock 103 to any process chamber 107 , and from one process chamber 107 to another process chamber 107 under a controlled pressure level, including various levels of vacuum. The pressure levels within the load lock 103 , the transfer chamber 109 , each of the process chambers 107 and the inspection chamber 110 may be maintained at substantially the same or different pressure levels, as desired, depending on the needs of the particular process in a given chamber 107 .
FIG. 1 b illustrates a stand—alone inspection chamber 111 having an internal chamber (not shown). Inspection chamber 111 includes a SEM 207 ( FIG. 2 ) and optical microscope 211 (FIG. 2 ), both may be mounted on the inspection chamber 120 such as to inspect substrates 117 located within the internal chamber. Transfer robot 105 picks up a substrate 117 from the wafer cassette 101 and loads the substrate 117 into the inspection chamber 120 .
FIG. 2 illustrates one embodiment of an inspection chamber 120 having an internal chamber 200 . The inspection chamber 120 may be integrated into a cluster tool 100 (such as inspection chamber 110 of FIG. 1 a ) or may be in stand-alone configuration (such as inspection chamber 111 of FIG. 1 b ).
In one embodiment, inspection chamber 120 may be utilized for electron beam inspection or other type of charged particle beam inspection and/or milling. Accordingly such a chamber shall include electron beam imaging units, such as Scanning Electron Microscope, Focused Ion Beam generators and the like. In another embodiment, the internal chamber may be located within a process chamber, such as ion implant process chamber, etch process chamber, and the like.
Referring again to FIG. 2 , the internal chamber may be defined by chamber elements that include dynamic seals. However, as will be appreciated from the following discussion, the dynamic seals help to maintain whatever pressure level is desired within the internal chamber, while the internal chamber is being moved, for example, horizontally in a first direction and a second direction that is perpendicular to the first direction.
According to an aspect of the invention the internal chamber 200 is defined by static upper plate 201 , outer floating ring 239 inner floating ring 241 , flexible connector 243 and an output shaft 233 . A dynamic seal is formed between a surface of the static upper plate 201 and an upper surface of outer floating ring 239 . The flexible connector 243 is pivotally connected to the outer floating ring 239 and inner floating ring 241 , thus maintaining a desired pressure level, including various degrees of vacuum within the internal chamber 200 . A dynamic seal is formed between the output shaft 233 to another end of the inner floating ring 239 . The 233 output shaft is connected to an electrostatic chuck 235 such as to move the electrostatic chuck and accordingly to move a substrate that is supported by the electrostatic chuck 235 .
The pivotable connection of the flexible connector 243 to the outer floating ring 239 and the inner floating ring 241 may be achieved by welding the ends of the flexible connector 243 to the outer and inner floating rings 239 and 241 , respectively. The pivotable connection also may be achieved by securing the ends of the flexible connector 243 to the outer floating ring 239 and the inner floating ring 241 by clamps, screws, or bolts.
In one embodiment, as shown in FIG. 4 , an upper flange 401 and a lower flange 403 are secured to the outer floating ring 239 and inner floating ring 241 , respectively. The upper flange 401 and lower flange 403 are secured by any suitable method that permits easy installation and removal. Examples of such a method include, but are not to screws or bolts. The flange contact interfaces with the outer floating ring 239 and inner floating ring 241 may be made air-tight by contact seals such as metallic or elastomeric seals. In one embodiment, these seals may be O-ring seals 405 and 407 . The ends of the flexible connector 243 are respectively welded to the upper flange 401 and the lower flange 403 , such that the welded assembly may be easily installed or removed as a unit. As can be appreciated, once secured, the flexible connector 243 may pivot about its longitudinal axis, meaning that it can enable the outer floating ring 239 to tilt, or the inner floating ring 241 to tilt.
The flexible connector 243 may be a bellows and may be constructed from a variety of materials, including but not limited to stainless steel (such as Types 316, 316L, 321, and 347), phosphor bronze, brass or Monel. Other materials or alloys with similar relevant properties also may be used for the flexible connector 243 ; such materials or alloys are well known to the ordinarily skilled artisan. In addition, the connector flexible 243 may have any shape that allows it to pivot, expand, and/or contract. The material used to construct the flexible connector 243 may be selected based on its property to resist fatigue caused by repeated pivoting, expansion, and contraction. The flexible connector 243 , such as a bellows, may be a commonly available commercial product, which may be readily obtained from a parts manufacturer, such as NiCoForm, Inc., Mat-Vac Technology, Inc., Servometer Corporation, or another.
In one embodiment, at the interface 206 between the first and second elements, the first surface 203 and the second surface 205 are curved. Either or both of the first surface 203 and the second surface 205 may be substantially planar or curved. In general, at the interface 206 , the first surface 203 and the second surface 205 may have respective contours as necessary to enable formation of a suitable dynamic seal between those surfaces. Alternatively, the first surface 203 and the second surface 205 may be treated by coating or hardening to increase smoothness, prevent scratches and the like.
The electrostatic chuck 235 may be installed in the internal chamber 200 . The chuck 235 supports a substrate 117 , such as a semiconductor wafer. The electrostatic chuck 235 may be coupled to an electrical power supply (not shown) that provides the necessary power to operate the chuck 235 . A chuck controller (not shown) controls the electrical power supply. The chuck controller may be a separate element, or may be part of a system controller (not shown). When in operation, the chuck 235 provides an electrostatic clamping force to hold the substrate 237 in place during processing or inspection operations.
The outer floating ring 239 , flexible connector 243 , and inner floating ring 241 may be made relatively small so that the assembled chamber has a relatively small volume. Having a small volume, the internal chamber 200 may be pumped down in a relatively short time, and a low pressure, including various degrees of vacuum, may be easily maintained.
The upper plate 201 is mounted on a base 215 by a vibro-isolation system 213 . The vibro-isolation system 213 substantially dampens any vibration transmitted from the base 215 to the upper plate 201 . A lower plate 217 is attached to the upper plate 201 via a system of substantially rigid bars 219 . The lower plate 217 may be a granite table or any support structure that provides substantial stability and inertia to further prevent movement of the structure comprising the upper plate 201 , the system of substantially rigid bars 219 , and the lower plate 217 .
In one embodiment, the lower plate 217 provides a substantially stable platform to support a first movement stage 221 that provides movement in a first direction and a second movement stage 223 that provides movement in a second direction that is perpendicular to the first direction. As can be seen in FIG. 2 , the first movement stage 221 and the second movement stage 223 are mounted on the lower plate 217 .
Looking again at FIG. 2 , in one embodiment a tilt movement stage 261 also may be mounted over the combination of the first movement stage 221 and the second movement stage 223 . The tilt movement stage 261 provides angular tilt movement about a central axis of the chamber, or about some other suitable axis. A vertical movement stage 227 , providing vertical movement, also may be mounted over the tilt movement stage 261 . A rotational movement stage 229 may be mounted over the vertical movement stage 227 , to provide rotational movement in polar coordinates about the central axis of the chamber, or any suitable axis.
While FIG. 2 shows the first movement stage 221 , the second movement stage 223 , the tilt movement stage 261 , the vertical movement stage 227 , and the rotational movement stage 229 all within the same embodiment, it should be understood that the number of these stages, or their order of mounting, is not critical, and may be varied as desired, depending on the object to be accomplished.
In one embodiment a first end of an output shaft 233 is mounted to an output of the rotational movement stage 229 . A second end of the output shaft 233 is connected to the electrostatic chuck 235 through the inner floating ring 241 . As seen more readily in FIG. 4 , inner surface 245 of the inner floating ring 241 and surface 247 of the output shaft 233 form an interface 248 . In one embodiment, the surfaces 245 and 247 may be treated to enhance smoothness of the surfaces. In another embodiment the surfaces 245 and 247 may be hardened to prevent scratches. In a different embodiment, the first end of the output shaft 233 may be mounted to an output of the vertical movement stage 227 . In a further embodiment, the first end of the output shaft 233 may be mounted to an output of the tilt movement stage 261 . The movement stage to which the output shaft 233 is connected is not critical.
As shown in FIG. 2 and FIG. 3 , an internal chamber opening mechanism 225 is installed over the combination of the first movement stage 221 and the second movement stage 223 . To load or unload the substrate 117 , the internal chamber opening mechanism 225 lowers the outer floating ring 239 to open a gap between the interface of the upper plate 201 and outer floating ring 239 (FIG. 3 ). To close the internal chamber 200 after the substrate 117 is loaded or unloaded, the internal chamber opening mechanism 225 raises the outer floating ring 239 and closes the gap between the interface of the upper plate 201 and the outer floating ring 239 (FIG. 2 ). In one embodiment, the internal chamber opening mechanism 225 is composed of three actuators (for example, pneumatic cylinders) and three kinematic couplings 231 , which have three gimbaled mountings (not shown) that allow for substantial tolerance between mating parts. In one embodiment, the ends of each actuator (not shown) may be threaded ball studs (not shown), which facilitate alignment of the actuators. The described kinematic coupling arrangement provides a sealed actuation system with no requirement for adjustment. Finally, the chamber opening mechanism 225 may be operated by a separate control unit, or may be operated by the above-mentioned system controller.
As discussed above, the movement system is mounted outside of the internal chamber. This feature decreases the potential for contamination of the interior of the chamber. This contamination potential exists because various contaminants, for example, different kinds of polymers, may be formed in the chamber by a process of carbonization when hydrocarbon molecules from grease, adhesive, or insulation of wires or connectors are dissociated during either processing or inspection of a substrate inside the chamber.
As described, then, FIGS. 2 and 3 show an internal chamber 200 employing dynamic seals to provide a low friction, and in some cases a virtually frictionless interface between moving elements. The dynamic seals are employed to maintain a pressure level, including various degrees of vacuum, in the internal chamber 200 , while the electrostatic chuck 235 is moved by the various movement stages. The internal chamber 200 tracks the horizontal and angular tilt movements of the electrostatic chuck 235 .
The chamber structures including the outer floating ring 239 , the flexible connector 243 and the inner floating ring 241 are assembled primarily to maintain a pressure level, including various degrees of vacuum. The chamber structures track the movements of the electrostatic chuck 235 as the output shaft 233 moves the chuck in various movements, such as horizontal and angular tilt movements. Therefore, the chamber structures are not used to move the electrostatic chuck 235 . Accordingly, the chamber structures do not necessarily need to be made of rigid materials.
Looking at FIG. 4 , the outer floating ring 239 employs a dynamic seal system including an air bearing annular groove 505 and an isolating land (adjacent to the groove) to provide a relatively contactless seal between the upper plate 201 and the outer floating ring 239 with a film of gas. One or more gas pumps (not shown) provide compressed gas to the air bearing annular groove 505 via one or more gas supply conduits (not shown). In one embodiment, the gas supply conduits may be an array of gas nozzles and flow restrictors similar to the gas supply system disclosed in the commonly assigned U.S. Pat. No. 6,163,033. The one or more gas pumps may be operated separately, or under control of the above-mentioned system controller. The bottom surface of the upper plate 201 may be smooth, and in one embodiment, the bottom surface is planar to enhance the low-friction characteristic of the interface.
FIG. 5 shows one embodiment of an inboard sweeper plenum as applied to the dynamic seals according to the present invention. In one implementation, the outer floating ring 239 has an air bearing annular groove 505 , a first pressure (in one embodiment, atmospheric pressure) annular groove 507 , a second pressure (in one embodiment, relatively low vacuum) annular groove 509 , and a third pressure (in one embodiment, relatively high vacuum) annular groove 511 . These elements provide an integral dynamic seal.
In one embodiment, the grooves are arranged so that they provide seals for increasing levels of vacuum going from outside the chamber to inside the chamber, so that the chamber in this embodiment is at a relatively high vacuum. However, it will be appreciated by those skilled in the art that the arrangement of the grooves, and their order, will depend on the application, the relative pressure differential inside and outside the chamber, and the like. It also will be appreciated that the number of grooves is not critical, but may be varied as desired.
Each plenum, annular grooves 507 , 509 , and 511 , and its isolating land act to remove residual gas from the air bearing annular groove 505 until the required level of isolation is achieved at the seal interface. One or more exhaust conduits (not shown), which may be similar to the exhaust ports in the gas exhaust system disclosed in the commonly assigned U.S. Pat. No. 6,163,033, are coupled to each plenum to remove the residual gas. The conduits are connected to one or more vacuum pumps (not shown). The vacuum pumps may be operated separately, or under the control of the system controller. The necessary number of plenum stages depends upon the level of vacuum required and the pumping rate of the vacuum pumps in conjunction with the precision of the air bearing gap.
In another implementation, the groove structure 505 - 511 is provided on the upper plate 201 , rather than on the outer floating ring 239 . As discussed above, each plenum, vacuum annular grooves 507 , 509 , and 511 , and its isolating land act to remove residual gas from the air bearing annular groove 505 until the required level of isolation is achieved at the seal interface. The presence of the groove and land structure on the outer floating ring 239 , as opposed to the upper plate 201 , is not important; it is the achievement of the seal that is important.
Referring back to FIG. 4 , in one embodiment of the present invention, the inner floating ring 241 has an air bearing annular groove 513 , a first pressure (in one embodiment, atmospheric pressure) annular groove 515 , a second pressure (in one embodiment, relatively low vacuum) annular groove 517 , and a third pressure (in one embodiment, relatively high vacuum) annular groove 519 , to provide an integral dynamic seal between the inner floating ring 241 and the output shaft 233 . The purpose, arrangement, and number of the grooves 513 - 519 is similar to those provided in the foregoing discussion of the groove and land structure 505 - 511 , and the considerations going into the ultimate configuration of grooves 513 - 519 likewise is similar.
One or more gas pumps (not shown) provide compressed gas to the air bearing annular groove 513 via one of more gas supply conduits (not shown). In one embodiment, the gas supply conduits may be an array of gas nozzles and flow restrictors similar to the gas supply system disclosed in the commonly assigned U.S. Pat. No. 6,163,033. The description of the gas supply system in that U.S. Patent is incorporated by reference herein. The gas pumps may be operated separately, or under control of the system controller.
Each plenum, annular grooves 515 , 517 , and 519 , and its isolating land act to remove residual gas from the air bearing annular groove 513 until the required level of isolation is achieved at the seal interface. The residual gas is removed by way of one or more exhaust conduits (not shown), which may be similar to the exhaust ports in the exhaust system disclosed in the commonly assigned U.S. Pat. No. 6,163,033, coupled to each plenum. The description of the exhaust ports in that U.S. Patent is incorporated by reference herein. The exhaust conduits are connected to one or more vacuum pumps (not shown). The vacuum pumps may be operated separately, or under the control of the system controller. The necessary number of such plenum stages depends upon the level of vacuum required and the pumping rate of the vacuum environment in conjunction with the precision of the air bearing gap.
As illustrated in FIGS. 2 , 3 , 4 , and 6 , the flexible connector 243 connects the outer floating ring 239 to the inner floating ring 241 . The flexible connector 243 extends generally along an axis defined by the centerline of the output shaft 233 , the central axis of the chamber, or any suitable axis. The flexible connector 243 may pivot, expand or contract along this axis. The flexible connector 243 is capable of maintaining vacuum or other suitable pressure levels within the internal chamber 200 . The ability of the flexible connector 243 to pivot may be used to compensate for any non-perpendicularity of the output shaft 233 , as provided by the tilt movement stage 261 , with respect to the bottom surface of the upper plate 201 . Additionally, the manufacturing criteria of the outer floating ring 239 and the inner floating ring 241 may be simplified because the flexible connector 243 permits greater geometric and dimensional tolerance between the chamber components. Geometric tolerance includes controlling perpendicularity and parallelism between surfaces. For example, because the outer and inner floating rings, 239 and 241 are connected by the flexible connector 243 , the surfaces of the rings 239 and 241 do not necessarily need to be manufactured precisely parallel to the surfaces of the upper plate 201 and the output shaft 233 to achieve proper interfaces.
FIG. 6 illustrates the output shaft 233 being tilted by the tilt movement stage 261 at an angle α from the central axis of the output shaft 233 . The output shaft 233 may be also tilted about any suitable axis, such as the central axis of the outer floating ring 239 , the inner floating ring 241 , or the chamber assembly. The internal chamber 200 remains sealed and maintains a desired pressure level by means of the dynamic seals as the electrostatic chuck 235 and the substrate 117 are moved, rotated, and/or tilted by the various movement stages.
The connector feature, enabling tilt while operating at a maintained pressure within the chamber (such as a given level of vacuum), is desirable not only in the inspection of semiconductor devices at various stages of manufacture, as in the particular embodiment depicted in the drawings, but also in the process of manufacturing these semiconductor devices.
Ion implantation is one example of a semiconductor manufacturing process in which tilting of the wafer in the ion implantation internal chamber may be useful. Typically, the surface of the wafer will be oriented generally to be perpendicular to the axis of the shortest beamline used, so that the ion beam strikes in a direction that is normal to the planar surface of the substrate. However, in certain implantation processes or steps, it is desirable, or even necessary for the ion beam to strike the substrate at an orientation that is some angle from normal. The internal chamber according to the present invention, with the tilt movement stage 261 and the pivotably mounted flexible connector 243 , permits tilting and/or pivoting of the substrate about the axis of the beam path, the central axis of the internal chamber, or any suitable axis.
Another advantage of the internal chamber employing dynamic seals is the ability to achieve greater positional accuracy. Conventional movement systems employing frictional bearings are prone to positional errors caused by velocity spikes, wheel or gear creepage, spring preload, and the like. However, because the present invention employs dynamic seals and the moving elements have little or no actual physical contact at the interface, positional errors are reduced. Therefore, the internal chamber according to the present invention provides greater flexibility and efficiency for many semiconductor manufacturing processes.
As will be understood by those of skill in the art, the present invention may be embodied in other specific forms or configurations without departing from the essential characteristics thereof. Accordingly, the foregoing description is intended to be illustrative, but not limiting, of the scope of the invention which is set forth in the following claims.
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A process chamber for processing or inspecting a substrate such as a semiconductor wafer and the like includes a internal chamber employing dynamic seals at the interface of relatively moving elements. In one embodiment, the internal chamber has a first element, such as a lid or cover, and a second element, such as the body of the chamber. The first element and the second element meet at the interface. The internal chamber may further include a substrate support, mounted inside the internal chamber, supporting a substrate. A first movement system may produce at least one type of relative movement between the first element and the second element. A second movement system may produce second relative movement between the second element and the substrate support. The resulting structure allows movement of the chamber, while maintaining pressure inside the chamber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of international patent application serial number PCT/EP2009/000323, filed Jan. 20, 2009, which claims benefit of German patent application serial number 10 2008 405 466.6, filed Jan. 21, 2008. The entire contents of international patent application serial number PCT/EP2009/000323 are hereby incorporated by reference.
FIELD
[0002] This disclosure pertains to a nonwoven material with nonwoven fibers exhibiting a special polymer mixture, as well as the nonwoven fiber itself as well as a polymer mixture and applications thereof.
BACKGROUND
[0003] In the manufacture of nonwoven fabrics, particular attention is typically paid to the source material in order to achieve the desired parameters. For this reason it is often desirable to determine by way of tests if a material is appropriate for use at all. Material data sheets of various manufacturers provide certain criteria, however, they are not suitable to provide the desired information desired for specific applications. Since the manufacture of polymers is accordingly expensive, manufacturers only provide a limited selection of polymers.
[0004] It is therefore often left to the user or the manufacture of nonwovens to determine the properties, the manufacturing method as well as the polymer composition of a suitable nonwoven material.
[0005] For cost reasons, nonwovens are often made of polyolefins. When polyethylene is used as source material, we have the known state of the art. U.S. Pat. No. 6,391,443 as well as U.S. Pat. No. 7,223,818 respectively disclose different mixtures and fields of application of the introduced polymers for nonwoven fibers. U.S. Pat. No. 6,391,443 discloses a polymer mixture exhibiting two different polyethylene components with different melting (fusion) points. While one type of polyethylene shall exhibit a density of 0.85 to 0.93 g/cm 3 with a low melting point, the other polyethylene shall exhibit a density of 0.94 g/cm 3 or more, and should have a high melting point. Furthermore, a specific thermal response shall occur, as represented by the DSC measurement. Nonwovens manufactured with this method shall preferably be used for medical materials and, in particular, shall be able to be sterilized with gamma radiation. U.S. Pat. No. 7,223,818 on the other hand describes polymer mixtures where a mixture of two different polyethylene is being used. Both polyethylenes shall have a specific dependency in relation to their densitites as well as in relation to their MFIs.
[0006] From the area of film (foil), WO 01/98409 A1 discloses a mixture of polyethylenes wherein one polyethylene is manufactured based on a metallocene catalyst and shall exhibit a density of less than 0.916 g/cm 3 .
[0007] This polyethylene is often linear without long chain scissions. The other polyethylene shall have a density of 0.94 g/cm 3 or more. The polymer mixture, on the other hand, shall be especially appropriate for the manufacture of foil, in particular for the manufacture of bubble foil and cast foil. If these polymer mixtures are used to manufacture nonwovens cannot be obtained from WO 01/98409. Rather, only foil applications and methods of manufacture of different foil and foil laminates are described.
SUMMARY
[0008] The disclosure provides a nonwoven, a nonwoven fiber and a polymer mixture for the manufacture of nonwoven fibers, which are in particular suitable for a heat-activated laminating process.
[0009] Proposed is a nonwoven with a nonwoven fiber exhibiting a polymer mixture, which as base polymer exhibits a polyethylene with an MFI between 15 and 35, preferably between 15 and 20 20 g/10 min. pursuant to ISO 1133 and a density of 0.935 to 0.965 g/cm 3 according to ASTM D-792, and which exhibits as an at least second polymer an LLDPE with a density of 0.85 to 0.90 g/cm 3 according to ASTM D-762.
[0010] The nonwoven material is preferably made from a nonwoven fiber of this type. Preferably, the nonwoven fiber of the nonwoven material is of the type of a so-called spunbond nonwoven. This type of fiber can be manufactured on a REICOFIL-3 or REICOFIL-4 system. Other manufacturing methods may be used as well. For example, the nonwoven may be a carded nonwoven or a nonwoven manufactured with the melt-blown process.
[0011] The nonwoven fiber preferably exclusively exhibits the base polymer and the second polymer as polymer components. The polymer mixture may furthermore contain additives like antioxidants, like flame-retardants and color pigments, UV stabilizers or other additives for the adjustment of a characteristic of the nonwoven material and the nonwoven fiber created from the polymer mixture.
[0012] Pursuant to an advanced embodiment it is provided that the base polymer is at a minimum 80 weight percent of the polymer mixture, with the second polymer contributing a weight of up to 20 weight percent of the polymer mixture. Another embodiment provides that the second polymer is a polyolefin with an MFI of 3 to 7 g/10 min per ISO 1133, and preferably a melting point in a range of 50° C. to 100° C., preferably from 50° C. to 70° C. pursuant to the DSC measurement. The DSC is measured per DIN IN ISO 11/357-1.
[0013] Furthermore preferred is a design, in which the second polymer is an ethylene/alpha-olefin copolymer. Utilized as alpha-olefin may in particular: 1-propene, 1-butene, 1-pentene, 1 hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, 1-hexadecene, 4-methyl-1-pentene, 3-methyl-1-pentene, 3-methyl-1-butene and/or 3-ethyl-1-pentene; vinylcyclohexane and terpolymers can also be used.
[0014] Further preferred is a polymer mixture composed of homo-homo- and/or copolymers-copolymers. Here as well, terpolymers can also be used.
[0015] One embodiment of a proposed polymer mixture, for example, provides the use of a polyethylene manufactured by the Dow Company under the trade name of “ASPUN 6834” as base polymer. This polymer has an MFI of 17 g/10 min per ISO 1133 at a density of 0.95 g/cm 3 per ASTM D-792 and a melting point of 130° C. pursuant to the measured DSC value. This material is sold by the manufacturer as suitable for the manufacture of nonwoven fibers. Another polyethylene usable as base polymer is the polyethylene sold by the Dow Company under the trade name “ASPUN 6834A”. It has a density of 0.955 g/cm 3 per ASTM D.792, an MFI of 30 per ASTM D-1238 and a DSC melting point of 131° C.
[0016] Used as the second polymer for the creation of the polymer mixture is “Affinity EH 8200”, which is marketed by the same manufacturer, DOW. According to a statement by the manufacturer, it is a polyolefin plastomer manufactured by means of an INSITE catalyst, which shall be used for the manufacture of filled floor coverings and as viscosity modifier in calandered foam layers. However, uses of this material for nonwoven fibers are not known. The polymer sold under the brand name “Affinity EG 8200” has an MFI of 5 g/10 min per ISO 1133, a density of 0.870 g/cm 3 per ASTM D-792, a melting point of 60° C. per the measured DSC value, and a Vicat softening point von 45° C. per ISO 306 (Methodology A).
[0017] The effect of the second polymer on the polymer mixture to increase the capacity to expand is illustrated in Table 1 below. In this case, two different nonwoven material weights, namely 35 g/m 2 and 60 g/m 2 , were analyzed with different added quantities of the second polymer to the base polymer in regard to the changes of the characteristics. We point out that the respective values resulting from these tables shall not be deemed limiting but rather be deemed to be samples. They can be used as limits to formulate different ranges. The values determined for these nonwovens indicated as samples, however, are also verifiable for other nonwoven weights as well as for interim values when adding the second polymer to the base polymer.
[0000]
TABLE 1
Properties of polyethylene nonwovens from different mixtures
Vg
Vg
Vg
Vg
Vh
2.
2.
2.
l.-
l.-
l.-
l.-
l.-
Basis
PE 5%
PE 10%
PE 15%
PE 5%
PE 10%
PE 15%
PE 4%
PE 15%
35 g/m 2
07-StB016-1
07-StB016-3
07-StB016-5
07-StB016-7
07-StB016-9
07-StB016-
07-StB016-
07-StB016-
07-StB016-
11
13
17
23
60 g/m 2
07-StB016-2
07-StB016-4
07-StB016-6
07-StB016-8
07-StB016-
07-StB016-
07-StB016-
07-StB016-
07-StB016-
10
12
14
18
24
Basis weight (g/m 2 )
35 g/m 2
34.2
34.7
35.0
35.5
34.5
34.5
34.8
34.2
34.2
60 g/m 2
59.9
60.3
61.4
60.7
59.5
59.9
60.2
59.2
59.1
Filament titer (dtex)
35 g/m 2
2.7
2.7
2.8
2.8
2.9
2.8
3.1
3.4
2.8
60 g/m 2
2.7
3.0
2.8
2.8
2.9
2.8
2.9
3.4
2.8
Thickness (microns)
35 g/m 2
401
395
395
376
384
387
376
388
394
60 g/m 2
530
540
554
526
522
536
538
566
550
Tensile strength MD (N)
35 g/m 2
22.8
20.7
21.5
24.8
22.2
21.3
26.0
17.6
12.2
60 g/m 2
43.0
37.0
37.3
50.9
39.3
35.5
44.6
33.2
26.2
Tensile strength CD (N)
35 g/m 2
10.8
10.8
12.9
17.3
10.6
11.3
11.1
7.5
7.8
60 g/m 2
20.1
19.8
22.9
26.8
19.3
19.4
21.2
13.8
14.5
Peak elongation MD (%)
35 g/m 2
48.3
52.8
74.2
110.3
50.2
54.5
70.4
33.6
33.2
60 g/m 2
50.4
48.1
59.0
100.2
49.7
46.8
62.0
34.9
36.2
Peak elongation CD (%)
35 g/m 2
58.3
61.7
74.0
119.9
58.9
64.2
79.4
51.4
49.1
60 g/m 2
59.2
57.6
71.8
107.1
57.3
57.7
77.4
55.1
47.0
Bending length MD (cm)
35 g/m 2
2.49
2.22
1.98
1.81
2.40
2.23
2.18
2.26
2.04
60 g/m 2
3.62
3.13
2.90
2.65
3.37
3.28
3.01
3.28
2.88
Bending length CD (cm)
35 g/m 2
1.64
1.53
1.42
1.37
1.53
1.49
1.37
1.47
1.43
60 g/m 2
2.48
2.29
2.21
1.92
2.36
2.26
2.04
2.12
2.11
Flexural rigidity MD (mN * cm)
35 g/m 2
0.56
0.39
0.28
0.22
0.49
0.39
0.37
0.39
0.30
60 g/m 2
2.90
1.91
1.55
1.18
2.35
2.14
1.67
1.85
1.44
Flexural rigidity CD (mN*cm)
35 g/m 2
0.16
0.13
0.10
0.10
0.13
0.12
0.09
0.11
0.10
60 g/m 2
0.93
0.78
0.71
0.44
0.79
0.70
0.53
0.51
0.55
Fuzz (mg/cm 2 )
35 g/m 2
0.718
0.931
0.753
0.567
0.855
0.819
0.812
0.765
0.803
Air permeability (l/m 2 s)
35 g/m 2
3322
3604
3623
3656
3593
3690
3580
4473
3748
60 g/m 2
1826
1874
1938
1937
1873
1904
1930
2473
2049
[0018] The first column of Table 1 indicates the used nonwoven weight grammage, the second column characterizes the values measured on a nonwoven material manufactured exclusively from a base polymer, the second column the addition of 5 weight percent, the third column the addition of 10 weight percent, and the fourth column the addition of 15 weight percent of the second polyethylene to the base polyethylene. The first four columns on the left side therefore provide an overview of the response of the proposed polymer mixture when used for the manufacture of a nonwoven material in comparison to the base polymer. The nonwoven material is furthermore a spundbond nonwoven and was thermally bonded with a calander unit. On the right side of Table 1, additional different comparative mixtures were analyzed after they were also processed into spunbond nonwovens under the same manufacturing conditions. The sixth column indicates that another polyethylene was added, in particular with 5 weight percent to the same base polymer. The seventh and the eighth column reflect the results for the addition of 10 and 15 weight percent to the base polymer. Notable is in particular the increase of a value for the peak elongation in MD and CD direction and which is important for expansion, which value occurs when the proposed polymer mixture is used. Such value can also not be obtained by adding the other two polymers, once at 4 weight percent and once at 15 weight percent respectively to the base polymer. The values indicated in Table 1 were, by the way, measured with the usual measuring methods for nonwovens as suggested by Edana, for example.
[0019] The effect of the addition of the second polymer to the base polymer when creating the polymer mixture is also illustrated by the following representation of FIG. 10 from temperature measurements pursuant to DSC curves.
[0020] Based on this representation 1 in FIG. 10 , the first heating has been mapped in the upper left area, and the cooling curve on the right. The lower range was mapped in the same way. While the upper two representations reflect the base polymer only, the lower part of the diagram reflects the base polymer plus an added 10% of the second polymer.
[0021] The different significant thermal characteristics of the different filaments with different second polymers are shown in Table 2:
[0000]
TABLE 2
Thermal Properties of polyethylene filaments from different mixtures
1st Heat
Cooling
2nd Heat
Peak
Onset
Delta H
Peak
Onset
Delta H
Peak
Onset
Delta H
° C.
° C.
J/g
° C.
° C.
J/g
° C.
° C.
J/g
Base Polymer
128.2
124.4
163.8
109.6
113.5
−168.8
127.9
123.0
182.1
BP + 10% Affinity EG8200
126.5
122.7
143.5
110.9
113.5
−158.4
126.9
123.2
161.5
BP + 10% VGL-P2
127.3
123.5
152.0
109.3
113.3
−166.9
128.0
122.5
163.8
Comparative Polymer 1
122.7
112.2
109.8
103.3
107.2
−113.2
120.4
115.8
123.2
Affinity EG 8200
67.7
54.8
5.8
no peak
68.0
54.8
6.2
Comparative Polymer 2
96.2
83.6
49.5
68.3
72.2
−55.5
95.2
84.4
57.0
[0022] As can be obtained from FIG. 1 and Table 2, the second polymer can be added without significant changes to the thermal characteristics of the base polymer. This means in particular that the application temperatures currently known for the base polymer—for example in the extruder or in the spinplates—do not need to be changed significantly, and a currently stable manufacturing process with the base polymer remains stable despite the addition. If, however, a change of a thermal characteristic of the base polymer like the melting point, for example, the softening temperature or crystallization temperature is desired, this can be achieved by further addition of other additives or polymers.
[0023] On the other hand, the addition of the second polymer to the base polymer can be used to change a crystallinity. This crystallinity can be decreased by adding the second polymer. The crystallinity can be calculated based on the heat transfer in the form of the enthalpy Delta H (melting or consolidating enthalpy). By adding 10 weight percent Affinity EG8200 as second polymer to the base polymer, the crystallinity was reduced by about 10%, for example. It follows that less melting enthalpy is involved to laminate the nonwoven to another layer in a thermobonding step, for example.
[0024] One especially preferred application results for a nonwoven material or a nonwoven fiber manufactured from such polymer mixture, if the nonwoven material or the nonwoven fiber is configured between two layers and creates a bond with the two layers through application of heat. This nonwoven material or this nonwoven fiber created from a polymer mixture will be preferably used as bonding agent between two layers.
[0025] A nonwoven material or a nonwoven fiber from such a polymer mixture has the additional advantage of increasing an elongation (expansion) characteristic of the nonwoven material or the nonwoven fiber. Pursuant to one embodiment it is provided, for example, that an LLDPE, in particular to increase the elongation characteristics of a nonwoven fiber as described above, is preferably used as base polymer in an above-described polyethylene.
[0026] An advanced embodiment provides that a bond with a first, a second and a third layer is created. The second layer is configured between the first and the third layer. The layers are expanded and exposed to heat. Preferably, the layers are simultaneously also exposed to pressure. The second layer develops in this case a bonding characteristic towards the first and towards the second layer.
[0027] This allows a bond to be created between the first and the third layer. With this method, several layers could be placed into a mold, be expanded together under application of pressure and heat and thus being molded and fused together. In particular, this method offers the possibility that the geometry of a nonwoven fiber and/or such nonwoven material based on this type of polymer mixture dissolves in the presence of heat. If nonwoven of this type or a nonwoven fiber of this type is used as a substitute of a hot-melt material, the application of pressure and heat can lead to the fact that after the application of pressure and heat only the resulting polymer mixture of the nonwoven material or of the fiber remains but the geometry of the nonwoven material or the nonwoven fiber has been dissolved.
[0028] Another field of application of the nonwoven material or a nonwoven fiber from this type of polymer mixture is a thermoforming process. In this process, the nonwoven is inserted into a thermoforming mold. A stamp pushes the layered material into the thermoforming mold and creates a bond from the layer material in the mold. The purpose of the nonwoven or the nonwoven fibers being used is one hand to create an adhesive layer, which creates a strong bond between adjacent layers, so that such bond can be broken only under application of strong tearing forces. On the other hand, the above described increase of the expansion characteristic by way of the second polymer on the polymer is being leveraged. The nonwoven material or the nonwoven fiber can be used for the manufacture of carpets, in particular vehicle carpeting, covers or other items, for example.
[0029] One embodiment provides, for example, that the nonwoven material is placed between a first layer of a first polymer material and a second layer of a second polymer material. The first polymer material and the second polymer material are both different and preferably exhibit different softening and melting temperature characteristics, which generally prevents a bond between the two polymer materials or only provides an insufficient mutual bond. It may be provided, for example, for the first layer to be of an EVA or exhibits EVA at the surface, while the second layer exhibits PET or is made of PET. The second layer may be a velour carpet, for example, while the first layer may be a heavy layer. By bonding under pressure and heat, the nonwoven material or the nonwoven fiber will at least become sticky, may after especially long application of pressure and heat dissolve, and thus create either a full-service bond or a discontinuous bond between the both layers.
[0030] Another sample application for the nonwoven material or the nonwoven fiber is the manufacture of acoustics components as may be used in vehicles, for example. However, they can also be used in other areas, like for acoustic insulation or for targeted sound shaping of spaces like opera auditoriums, theater auditoriums, cinema auditoriums and similar event auditoriums (halls). Living rooms or other rooms with desired acoustic properties may also be treated with this type of material. In these cases, a type of needle felt would be used, preferably a needle felt with a weight between 40 and 150 g/m 2 . The backside of the needle felt is used to bond the needle felt to an acoustic foam or any other insulating material, for example. This may also be a so-called rip-nonwoven, which is made of shredded old clothes.
[0031] A nonwoven material manufactured with the proposed polymer mixture is thermally bonded by application of pressure and heat. This may be done with a calandering process. A sample for this is disclosed in U.S. Pat. No. 3,855,046. Instead of thermobonding there is the possibility that the nonwoven material achieves stability (sturdiness) also through spunlacing (hydroentanglement). In this context we refer to U.S. Pat. Nos. 4,021,284 as well as 4,024,612. In order to be able to pre-stretch the nonwoven, the nonwoven may also be stretched in MD direction as well as in CD direction. The MD direction is the machine direction and the CD direction is the traverse direction. The material can be stretched simultaneously or time-sequentially into both directions. Embodiments for the respective devices for this purpose are obtainable from U.S. Pat. No. 4,110,892, U.S. Pat. No. 4,834,741, U.S. Pat. No. 5,143,679, U.S. Pat. No. 5,156,793, U.S. Pat. No. 5,167,897, U.S. Pat. No. 5,422,172 as well as U.S. Pat. No. 5,518,801.
[0032] The nonwoven is preferably manufactured as a single layer and sold to other customers. There is, however, the other possibility that the nonwoven will be manufactured as a laminate with at least one additional layer. This layer may also be a nonwoven. It can also be utilized as foil. The layers can be thermally bonded, glued or connected to each other by other appropriate means. Spray adhesives, for example, so-called hot-melt glues, latexbased glues or other glues may be used. The bonding process may furthermore occur with ultrasound waves or water jets. This can be obtained from WO 02/055778 A1, for example. There is also the option of needling the layers together. Different layers can also placed on top of each other and bonded to each other, while at least one of the layers is still in bondable condition. Different methods as well as systems for laminating are disclosed in U.S. Pat. No. 6,013,151 as well as U.S. Pat. No. 5,932,497, for example.
[0033] The polymer can initially be created inside an extruder, whereby for this purpose the extruder exhibits a first and a second feed for one polymer each. Other additives and extras can be added to the polymer mixture. Twin worm extruders can be used, for example, to manufacture the polymer mixture when it is desired for the manufacture of nonwoven fibers. Another embodiment provided that the polymer mixture is pre-manufactured in batches and supplied (fed) into the extruder in this form.
[0034] There is furthermore the option to use the proposed polymer mixture to manufacture an especially soft nonwoven material. For example, for this purpose a manufacturing process can be used as disclosed in WO 02/312 45 A2. Furthermore, the nonwoven can also be manufactured to exhibit thermally reversible and thermally non-reversible bonds as disclosed in US 20050037 194 A.
[0035] There is the other option to use the polymer mixture to manufacture an SM or SMS material as proposed in U.S. Pat. No. 5,178,931 or U.S. Pat. No. 5,188,885, wherein a so-called melt-blown material according to U.S. Pat. No. 3,704,198 and U.S. Pat. No. 3,849,241 can be made.
[0036] There is the further option to manufacture a bi-component fiber, which exhibits the primary mixture. The bi-component fiber may exhibit a core-sheath structure or any other structure with clearly defined areas of different polymers or polymer mixtures.
[0037] The nonwoven material or the nonwoven fiber can also be used as nonwoven foil laminate. The foil may, for example, have one or more layers, wherein the side of the foil facing the nonwoven exhibits a polyethylene. This creates an especially secure bond between the two outer surfaces of the foil and the nonwoven.
[0038] From DE 10 2005 048 443 follow different applications and samples of such laminates as well as information about possible methods of fabrication. Various additives that can be used advantageously are also referenced. A bond between foil and nonwoven can also be supported with electrostatic charges.
[0039] A system for the manufacture of a spundbond nonwoven is proposed in WO 05/040474 A1, for example. In this system, the nonwoven deposit is supported by the fact that an electrostatic charge is used in addition to the effect of a diffuser. Another manufacturing method for the manufacture of spunbond filaments, from which the nonwoven is created, can be obtained from WO 04/020722 A2.
[0040] Due to its properties, nonwovens can be utilized in various applications, which shall be listed here as samples only without claiming to be exhaustive: in the medical field, for example for stoma-bags, covers, white coats and smocks, face masks, feminine and baby hygiene items, for example as “back sheet” or as “top sheet”, which may also exhibit a coating, for diapers, feminine pads, adult incontinence items, as printing support, protective surface, as packaging material, as separator, as vapor-permeable or watertight material, as adhesive material for use in micro loop and hook-type closures, for example through provision of regions with loops by shaping the nonwoven accordingly, as fastener material for locking systems, as contact surface for adhesives, as contact agent between two surfaces between a bed and an overlay, for example, as part of a wall cover or wall paper or floor material, as cleaning or polishing items, in protective closing like for an overall, for applications close to the skin. As oil and/or grease absorbents and/or cleaning agents, in athletic clothing, athletic accessories and/or athletic gear and shoes, in clothing like gloves, jackets or similar items; as packaging for bottles, for example; in jewel cases for CD's; as sheathing; as decoration; in the automotive industry, for instruments, as lining material for the covering of items; as coating, in roofing materials; as roof lining sheets or part thereof; as house wrap, as building material, as roofing membrane or lower deck lining; as wall cover, for new construction, for restorations, roof recovering, roof extensions; as water, vapor or air barrier and/or facade sheeting; usable in single or multiple layers, as strips in order to achieve specific coverings in the area of the roof, for example; as carrier substrate; as part of carpets or other floor coverings, as noise and/or heat insulation; as filtering agent; as sedimentation agent; as identification, e.g. for the application of lotion; for the storage of substances, which will be released slowly or at once during use, for example through diffusion release; as cleaning cloth for eyeglasses; as loading material for seeds and/or powders; as intermediate layer in an article of personal hygiene, sanitary items, e.g. in a towel, in bathing caps; drainage means; as color marking, as signal marking, as slip cover, as wound cover material, in elastic bandages; as cigarette filters; as surface material for throw-away or single-use items; as cover material for painting, coating and other processes; for the cultivation of cell cultures; for elastic materials, items of personal hygiene as sidebands, waistbands, and/or elastic closures; for suction pads, and other applications.
[0041] The different applications involve different additives to ensure that the nonwoven and/or the laminate containing the nonwoven provides the properties desired for the respective application. For example, additional UV stabilizers can be mixed in. Preferably added is a weight portion of at least 1 weight percent to 5 weight percent of UV stabilizers. Preferred is a UV stabilizer with CAS # 193098-40-7 and/or 067845-93-6. For example, a UV absorber, HALS stabilizer and/or a so-called quencher can be used as UV stabilizers. A UV absorber filters the ultraviolet wave spectrum from the light. The energy of the absorbed light is converted into heat. The degree of UV absorption depends on the concentration of an active substance and the wall thickness of the final product. Benzophenes, triazoles and trazines can be used as UV absorbers. Used as HALS stabilizers (hindered amine light stabilizers) are additives, which prevent the reaction of aggressive photo-oxidation products, in particular of radicals and peroxides. Adjustments to the active substance concentration can be used to determine the product lifecycle of the nonwoven and/or the laminate. HALS stabilizers can be polymeric HALS, oligomeric HALS, NOR-HALS and/or HALS substitutes. A quencher deactivates radicals and finally dissipates energy in the form of heat. It is known, for example, that nickel can be used as such a quencher. In addition to these UV stabilizers, the nonwoven can preferably be equipped with additional thermal stabilizers. Thermal stabilizers are preferably antioxidants which are able to protect the polyethylene being already used during processing. The thermal stabilizers and the UV stabilizers are added to the polymer in the form of a master batch. Samples of thermal stabilizers are phenols or phosphites.
[0042] The disclosure further refers to UV stabilizers as described in U.S. Pat. No. 6,100,208, as well as to the polymer mixtures described there with the accordingly adjusted UV stabilizers and the respective weights and pigments for nonwoven fibers. This disclosure is being included into this description.
[0043] UV stabilization is increased further by increasing the titanium dioxidan part in a polymer. As a sample, provided may be a titanium dioxidan content of more than 5 weight percent of a nonwoven. Preferably, the first layer exhibits a nonwoven fiber with such a titanium dioxide content. A further increase of UV stability results from the use of a reflectant in at least one of the layers of the laminates. For this purpose, a metal coating and/or a metal layer may be provided, in particular in the form of a foil worked into the laminate. Another embodiment provides that metal particles with strong reflective properties are provided on at least one surface. UV stability is increased further by the use of soot particles, in particular in conjunction with polyethylene. The soot particles in the polyethylene material make the polyethylene less vulnerable to UV rays.
[0044] There is the other option of electrostatically charging the nonwoven using additiviation, for example. The nonwoven can also be utilized as electrical insulator but also as an electrical conductor by adding an electrically conductive substance. The nonwoven can also be used as a filter, especially as an inside filter, for example as one layer of many for the filtering out of coarse particles and/or the bonding of different layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] Additional advantageous embodiments and characteristics will be explained respectively in greater detail based on the following figures. The samples shown in the figures shall not be interpreted to be limited but to be samples-only. The characteristics described below can also be linked to characteristics of the other figures as well as to characteristics of the other figures as well as to characteristics of the disclosures described above. In the figures:
[0046] FIG. 1 shows a first spinning system operating according to a first process for the manufacture of a spunbond nonwoven;
[0047] FIG. 2 shows a second system for the manufacture of a spunbond nonwoven;
[0048] FIG. 3 shows a thermoforming process using the nonwoven as composite adhesive sheet;
[0049] FIG. 4 shows a sectional view of the first product;
[0050] FIG. 5 shows another sectional view of a second first product;
[0051] FIG. 6 shows a cross-sectional view of a nonwoven fiber;
[0052] FIGS. 7-9 show cross-sectional views of a bicomponent fiber; and
[0053] FIG. 10 shows a diagram 1 mit temperature reading pursuant to DSC curves.
DETAILED DESCRIPTION
[0054] FIG. 1 shows a first system 1 for the manufacture of proposed nonwoven fibers 2 . A batch of polymer mixture is fed into the system via an extruder 3 , melted and fed into a spin pack 5 through the extrusion head 4 . The extrusion head 4 and the spin pack 5 can be heated separately. Located inside the spin pack 5 is a spinneret plate 6 . The polymer 7 coming from the extruder is pressed through the spinneret plate 6 . After exiting the spinneret plate 6 the polymer 7 continues in the form of individual strings or filaments and is cooled down by a quencher 8 and drawn out.
[0055] The quencher provides that a quenching medium 9 (suggested by the arrows) cools the polymer filaments 10 drawn from the spinneret plate 6 . After moving through this single-part quenching section 11 , the polymer filaments 10 are routed into a gap 12 . In the gap 12 , a driving medium 13 is introduced first. This medium may, in particular, be propellant air. At a distance, a spreader medium 14 is introduced which is used to force the polymer filaments 10 apart in a subsequent diffusor section 15 . The spreading can in addition be supported by an electric charge. The drawn and spread nonwoven fibers 16 can then be placed onto an interim storage surface, which is here not explained in greater detail, and continued to be processed. The shown system and the selected parameters allow the manufacture of the nonwoven described above. For this purpose, a bonding device is added after the first device 1 , in particular a calander device, so that the nonwoven can be produced in one process from the melting of the polymer and further processing of the nonwoven fibers all the way to the hardening through the calendar device without additional steps.
[0056] FIG. 2 shows a second device 17 exhibiting an extruder 18 . The extruder 18 has a first section 19 , a second section 20 , a third section 21 , a fourth section 22 , and a fifth section 23 . Sections 19 to 23 can be heated to different temperatures. The extruder 18 furthermore exhibits a heated extrusion head 24 . The extrusion head supplies the melted polymer under appropriate conditions to the spin pack 25 . Via the spin pack 25 and the via the spinneret plate 26 contained inside the spin pack 25 the pressurized polymer 27 is fed into a chamber 28 . The chamber 28 exhibits an exit opposite of the spin pack 25 .
[0057] The exit may be designed in the shape of gap as shown in the figure. In particular an adjustable width 29 of the gap can be set. The exit 28 end in an enclosure 30 which preferably exhibits a diffusor section 31 . The diffusor section 31 forces the nonwoven fibers 32 apart when placed on the interim staging device. Provided upstream or downstream from the diffusor section 31 may be an electrostatic charge. This charge can also be integrated into the diffusor and support the spreading. Adjacent to the diffusor section and in particular preferably also sealing are a first roller section 33 and a second roller section 34 . Roller sections 33 , 34 are preferable designed such that improved suctioning of the quenching medium through the staging section 35 is possible. The suction 37 can in particular be located underneath a screening belt 36 of the staging section 35 . The suction 37 can preferably adjusted to different exhaust volumes by changing a suction device 38 . The staged nonwovens 32 are then compressed by a calander 39 , in particular, thermobonded. For this purpose, the calander 39 exhibits an embossing roll 40 and a smooth roll 41 . The embossing roll 40 and the smooth roll 41 form an embossing gap 42 , wherein the line pressure inside the gap is adjustable. The nonwoven material is reeled by a subsequent reeling device 43 and stored or further processed in the form of drums. On the screen belt 36 , an unwinder (not shown) or another layer manufacturing device may be located upstream from the second section 17 . In an in-line process, this would allow a support surface 44 to be introduced, on which the spunbound nonwoven can be placed and then bonded. This might be a foil, another nonwoven or even another layer.
[0058] FIG. 3 shows a sample embodiment of a pressing apparatus 45 , in which is 46 composed of a polymer mixture is inserted between a first layer 47 and a third layer 48 as second layer 49 . These layers may preferably be laminated to each other. They may, however, also be fed into the apparatus individually with the pressing process creating a tear-resistant bond. By applying heat and pressure via a pressure stamp 50 , whose travel path is suggested by arrows, changes in temperature and pressure can be used to control if the nonwoven material 46 or the nonwoven fibers remain partially intact or if the nonwoven completely dissolves, thereby creating an adhesive bond between the first and the third layer.
[0059] This suggested schematically by the dissolution of the second layer, which is removed from the pressing apparatus in the form of the schematically suggested thermoforming apparatus.
[0060] Advantageous for the use of the nonwoven is the fact that in a thermoforming process as the one schematically shown, the nonwoven 46 is able to follow the two outer layers while they are being stretched. This prevents the creation of low-adhesion points which result when the nonwoven is torn. Instead, the good stretching characteristics of the nonwoven allow the creation of an adhesive bond across the entire surface. The product manufactured with the nonwoven 46 can be used for automotive applications like coverings, thermal insulator as well as damping material. The nonwoven can, of course, also be used in sanitary items, for example as the layer which may come in contact with the skin.
[0061] FIG. 4 shows a section of a first product 51 . Product 51 exhibits a proposed polyethylene nonwoven 52 at its surface 53 . The product may be a dual-layer material, as shown. This laminate can be foil/nonwoven laminate, for example.
[0062] FIG. 5 shows a section of a second product 54 . The second product 54 is an SMS material, for example, who layers have been thermobonded. Preferably, the layers were bonded not only with each other but also individually embossed. At least one of the spunbond layers is a nonwoven with a polyethylene surface.
[0063] FIG. 6 shows a cross-sectional view of a nonwoven fiber 55 . It exhibits a core 56 , preferably 20 containing another polymer like polypropylene, for example. A surface 57 of the nonwoven fiber at least partially exhibits the polyethylene mixture. The polyethylene can covet the entire core 56 as a coating 58 or intermittently, especially in the case of a changing Surface geometry. If interruptions are present, they may be advantageously provided with an oxidation layer for thermobonding, for example.
[0064] FIGS. 7-9 each shows different cross-sectional views of bicomponent fibers. In addition to the full-surface fiber of the proposed polyethylene material, the bicomponent fiber offers the advantage of allowing desired characteristics of the nonwoven, like the tensile strength, to be controlled by targeted selection of the other polymers. In the shown fiber, the polyethylene mixture creates at least a partial, in particular, a full surface.
[0065] FIG. 10 shows a representation 1 of temperature measurements pursuant to DSC curves. Representation 1: DSC Chromatogram of filaments made exclusively from the base polyethylene (top), and from the base polyethylene 10 weight percent of Affinity EG8200 (bottom). First heating (left) and cooling curve (right).
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A nonwoven and a nonwoven fiber are disclosed. The fleece or fleece fiber include a polymer mixture. The polymer mixture includes a polyethyelene and a LLDPE. Various applications for the fleece are proposed.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is related to Korean Patent Application No. 1999-23382 filed Jun. 22, 1999, and takes priority from that date.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an organic anti-reflective coating (“ARC”) material which allows the stable formation of ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAM semiconductor devices. More particularly, the present invention relates to an organic anti-reflective coating material which contains a chromophore with high absorbance at the wavelengths useful for submicrolithography. A layer of said anti-reflective material can prevent the back reflection of light from lower layers of the semiconductor chip, as well as eliminate the standing waves caused by light and thickness changes of the photoresist layer itself, while conducting a submicrolithographic process using a 248 nm KrF, 193 nm ArF or 157 nm F 2 laser. Also, the present invention is concerned with an anti-reflective coating composition comprising such a material, an anti-reflective coating made therefrom and a preparation method thereof.
[0004] 2. Description of the Prior Art
[0005] During a submicrolithographic process, one of the most important processes for fabricating highly integrated semiconductor devices, there inevitably occur standing waves and reflective notching due to the optical properties of lower layers on the wafer and to changes in the thickness of the photosensitive film applied thereon. In addition, the submicrolithographic process generally suffers from a problem of the CD (critical dimension) being altered by the diffracted light and reflected light from the lower layers.
[0006] To overcome these problems, it has been proposed to introduce a film, called an anti-reflective coating, between the substrate and the photosensitive film to prevent light reflection from the lower layer. Generally, anti-reflective coatings are classified into “organic” and “inorganic” by the materials used and into “absorption” and “interference” by the mechanisms involved. In microlithographic processes using an I-line light source (365 nm in wavelength), inorganic anti-reflective coatings are usually used, for example TiN or amorphous carbon coatings are applied when advantage is taken of an absorption mechanism, and SiON coatings are applied when an interference mechanism is desired. The SiON anti-reflective coatings are also adapted for submicrolithographic processes which uses KrF light sources.
[0007] Recently, extensive and intensive research has been and continues to be directed to the application of organic anti-reflective coatings for such submicrolithography. In view of the present development status, organic anti-reflective coatings, to be useful, must satisfy the following fundamental requirements:
[0008] First, peeling of the photoresist layer due to dissolution in solvents should not take place when conducting a lithographic process with an organic anti-reflective coating. In this regard, the organic anti-reflective coating materials have to be designed so that their cured films have a cross-linked structure without producing by-products.
[0009] Second, there should be no migration of chemical materials, such as amines or acids, into and from the anti-reflective coatings. If acids are migrated from the coatings, the photosensitive patterns are undercut while the egress of bases, such as amines, causes a “footing” phenomena.
[0010] Third, faster etch rates should be realized in the anti-reflective coatings than in the upper photosensitive film, allowing an etching process to be conducted smoothly with the photosensitive film serving as a mask.
[0011] Finally, the organic anti-reflective coatings should be as thin as possible while playing an excellent role in preventing light reflection.
[0012] As varied as anti-reflective coatings are, those which are satisfactorily applied to submicrolithographic processes using ArF light have not been found, thus far. As for inorganic anti-reflective coatings, there have been reported no materials which can control interference at the wavelength of ArF light, that is, 193 nm. As a result, active research has been conducted to develop organic materials which can form superb anti-reflective coatings. In fact, in most cases of submicrolithography, the coating of photosensitive layers is necessarily accompanied by the coating of organic anti-reflective layers which prevent the standing waves and reflective notching occurring upon light exposure and eliminate the influence of back diffraction and reflective light from lower layers. Accordingly, the development of such anti-reflective coating materials showing high absorption properties at specific wavelengths is one of the hottest and most urgent issues in the art.
SUMMARY OF THE INVENTION
[0013] The present invention overcomes the problems encountered in the prior art and provides a novel organic compound which can be used in an anti-reflective coating for submicrolithography processes using 193 nm ArF and 248 nm KrF lasers.
[0014] The present invention provides a method for preparing an organic compound which prevents the diffusion and reflection caused by light exposure in submicrolithography process.
[0015] The present invention further provides an anti-reflective coating composition containing such a diffusion/reflection-preventive compound and a preparation method therefor.
[0016] The present invention also provides an anti-reflective coating formed from such a composition and a preparation method therefor.
[0017] The present invention pertains to acrylate polymer resins (also referred to herein as “polymers” or “resins”) which can be used as an anti-reflective coating. The polymer resins contain a chromophore which shows high absorbance of light having wavelengths of 198 nm and 248 nm. In addition, a cross-linking mechanism between alcohol groups and other functional groups is introduced into the polymer resins, so that a cross-linking reaction takes place when the coatings of the polymer resins are “hard baked,” i.e., heated at a temperature of 100-300° C. for 10-1,000 seconds. As a result, a great improvement can be effected in the formation, tightness and dissolution properties of the anti-reflective coatings. Particularly, maximal cross-linking reaction efficiency and storage stability are realized in the practice of the present invention.
[0018] The anti-reflective coating resins of the present invention have superior solubility in all hydrocarbon solvents, in order to form a coating composition, yet are of such high solvent resistance after hard baking that they are not dissolved in any solvent at all. These advantages allow the resins to be coated without any problem to form an anti-reflective coating which prevents undercutting and footing problems when images are formed on the overlying photosensitive layer. Furthermore, coatings made of the acrylate polymers of the invention are higher in etch rate than the photosensitive film coatings, thereby improving the etch selection ratio therebetween.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The acrylate polymer resins according to the present invention are represented by the following chemical formulas 1 and 2:
[0020] wherein,
[0021] R a , R b , R c R d each is hydrogen or a methyl group;
[0022] R 1 to R 9 , which are the same or different, each represents hydrogen, hydroxy, methoxycarbonyl, carboxyl, hydroxymethyl or a substituted or unsubstituted, linear or branched C 1 -C 5 alkyl or alkoxyalkyl;
[0023] w, x, y and z each is a mole fraction in the range from 0.01 to 0.99; and
[0024] m and n each is an integer of 1 to 5.
[0025] The polymers of the present invention are designed to show high absorbance at 193 nm and 248 nm wavelengths. To accomplish this result, a chromophore substituent which is able to absorb light at a wavelength of 193 nm as well as 248 nm is grafted to the backbone of the polymer.
[0026] The polymer of chemical formula 1 can be prepared by polymerizing a 9-anthraldehydeoximacrylate-type monomer, a hydroxy alkyl acrylate-type monomer, and a glycidyl acrylate-type monomer with the aid of an initiator in a solvent. Each of the monomers has a mole fraction ranging from 0.01 to 0.99, preferably 0.1 to 0.9.
[0027] The polymer of chemical formula 2 can be prepared by polymerizing a 9-anthraldehydeoximacrylate-type monomer, a hydroxy alkyl acrylate-type monomer, a glycidyl acrylate-type monomer and a methyl methacrylate-type monomer at a mole fraction of 0.01 to 0.99 for each monomer, preferably 0.1 to 0.9.
[0028] For initiating the polymerization reaction to prepare the polymers of the chemical formulas 1 and 2, ordinary radical initiators may be used, preferably one selected from the group consisting of 2,2-azobisisobutyronitrile (AIBN), acetylperoxide, laurylperoxide and t-butylperoxide. Also, ordinary solvents may be used for the polymerization, preferably a solvent selected from the group consisting of tetrahydrofuran, toluene, benzene, methylethyl ketone and dioxane.
[0029] Preferably, the polymerization of the polymers of chemical formulas 1 and 2 is carried out at 50°-90° C.
[0030] The present invention also pertains to an anti-reflective coating composition which comprises a polymer of chemical formula 1 or 2 in combination with at least one additive selected from the group consisting of the anthracene derivatives shown in Table 1, below:
TABLE 1 Chemical Formula 3 Chemical Formula 4 Chemical Formula 5 Chemical Formula 6 Chemical Formula 7 Chemical Formula 8 Chemical Formula 9 Chemical Formula 10 Chemical Formula 11 Chemical Formula 12 Chemical Formula 13 Chemical Formula 14 Chemical Formula 15 Chemical Formula 16 Chemical Formula 17 Chemical Formula 18 Chemical Formula 19 Chemical Formula 20
[0031] In Table 1, R 11 , R 12 , R 13 , R 14 and R 15 independently represent hydrogen, hydroxy, hydroxymethyl, or substituted or unsubstituted linear or branched C 1 -C 5 alkyl or alkoxyalkyl.
[0032] An anti-reflective coating composition according to the present invention may be prepared by adding a compound selected from Table 1, at an amount of 0.1 to 30% by weight, to a solution of a polymer of the chemical formula 1 or 2 in a solvent, and then filtering the resultant solution. This coating composition is applied on a wafer that is then hard-baked to form a cross-linked anti-reflective coating. Semiconductor devices can then be fabricated therefrom.
[0033] Ordinary organic solvents may be used in preparing the composition, with preference given to one selected from the group consisting of ethyl 3-ethoxy propionate, methyl 3-methoxy propionate, cyclohexanone and propyleneglycol methyletheracetate. The solvent is preferably used at an amount of 200 to 5000% by weight based on the weight of the anti-reflective coating polymer resin used.
[0034] It has been found that anti-reflective coatings of the present invention exhibit high performance in submicrolithographic processes using 248 nm KrF, 193 nm ArF and 157 nm F 2 lasers as light sources. The same is also true when electron beams, EUV (extremely ultraviolet) and ion beams are used as light sources.
[0035] The following examples are set forth to illustrate more clearly the principles and practice of this invention to one skilled in the art. As such, they are not intended to limit the invention, but are illustrative of certain preferred embodiments.
EXAMPLE 1
Synthesis of poly[9-anthraldehydeoximacrylate-(2-hydroxy ethylacrylate)-glycidylmethacrylate] copolymer
Synthesis of 9-anthraldehydeoximacrylate
[0036] 0.5 moles of 9-anthracenealdehydeoxim and 0.5 moles of pyridine are dissolved in tetrahydrofuran(THF) and then, 0.5 moles of acryloylchloride are added. After the completion of the reaction, the reaction solution is filtered, and extraction is conducted with ethyl acetate. The extract is washed many times with distilled water and dried by distillation under vacuum, to give 9-anthraldehydeoximacrylate, represented by the following chemical formula 21. The yield is 80%.
Synthesis of poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate] copolymer
[0037] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximacrylate synthesized above, 0.3 moles of 2-hydroxyethylacrylate, and 0.2 moles of glycidylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of 2,2′-azobisisobutyronitrile (AIBN), the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 22. The yield is 81%.
EXAMPLE II
Synthesis of poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate] copolymer
[0038] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximacrylate synthesized in Example I, 0.3 moles of 3-hydroxypropylacrylate, and 0.2 moles of glycidylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 23. The yield is 78%.
EXAMPLE III
Synthesis of poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylacrylate] copolymer
[0039] In a 500-ml round-bottom flask are placed 0.5 moles of 9-anthraldehydeoxim acrylate, 0.3 moles of 2-hydroxyethylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitates is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 24. The yield is 80%.
EXAMPLE IV
Synthesis of poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylacrylate] copolymer
[0040] In a 500-ml round-bottom flask are placed 0.5 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 3-hydroxypropylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 25. The yield is 80%.
EXAMPLE V
Synthesis of poly[9-anthraldehydeoximacrylate-(4-hydroxybutylacrylate)-glycidylacrylate] copolymer
[0041] In a 500-ml round-bottom flask are placed 0.5 moles of 9-anthraldehydeoxim acrylate, 0.3 moles of 4-hydroxybutylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(4-hydroxybutylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 26. The yield is 81%.
EXAMPLE VI
Synthesis of poly[9-anthraldehydeoxim methacrylate-(2-hydroxyethyl acrylate)-glycidylmethacrylate] copolymer
Synthesis of 9-anthraldehydeoximmethacrylate
[0042] 0.5 moles of 9-anthracene aldehydeoxim and 0.5 moles of pyridine are dissolved in THF and then, 0.5 moles of methacryloyl chloride are added. After completion of the reaction, this reaction solution is filtered, and extraction is conducted with ethyl acetate. The extract is washed many times with distilled water and dried by distillation under vacuum, to give 9-anthraldehydeoximmethacrylate, represented by the following chemical formula 27. The yield is 82%.
Synthesis of poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate] copolymer
[0043] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximmethacrylate synthesized above, 0.3 moles of 2-hydroxyethylacrylate, and 0.2 moles of glycidylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of 2,2′-azobisisobutyronitrile (AIBN), the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 28. The yield is 78%.
EXAMPLE VII
Synthesis of poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropyl acrylate)-glycidylmethacrylate] copolymer
[0044] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximmethacrylate synthesized in Example VI, 0.3 moles of 3-hydroxypropylacrylate, and 0.2 moles of glycidylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 29. The yield is 81%.
EXAMPLE VIII
Synthesis of poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutyl acrylate)-glycidylmethacrylate] copolymer
[0045] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximmethacrylate, 0.3 moles of 4-hydroxybutylacrylate and, 0.2 moles of glycidylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutylacrylate)-glycidylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 30. The yield is 80%.
EXAMPLE IX
Synthesis of poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethyl acrylate)-glycidylacrylate] copolymer
[0046] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehyde oximmethacrylate, 0.3 moles of 2-hydroxyethylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 31. The yield is 78%.
EXAMPLE X
Synthesis of poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropyl acrylate)-glycidylacrylate] copolymer
[0047] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehyde oximmethacrylate, 0.3 moles of 3-hydroxypropylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 32. The yield is 80%.
EXAMPLE XI
Synthesis of poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutyl acrylate)-glycidylacrylate] copolymer
[0048] In a 500-ml round-bottom flask are placed 0.5 moles of the 9-anthraldehydeoximmethacrylate, 0.3 moles of 4-hydroxybutylacrylate, and 0.2 moles of glycidylacrylate. This mixture is added to 300 g of separately prepared THF with stirring, after which, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutylacrylate)-glycidylacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 33. The yield is 80%.
EXAMPLE XII
Synthesis of poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer
[0049] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 2-hydroxyethylacrylate, 0.2 moles of glycidylmethacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 34. The yield is 80%.
EXAMPLE XIII
Synthesis of poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer
[0050] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 3-hydroxypropylacrylate, 0.2 moles of glycidylmethacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 35. The yield is 79%.
EXAMPLE XIV
Synthesis of poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylacrylate-methylmethacrylate] copolymer
[0051] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 2-hydroxyethylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(2-hydroxyethylacrylate)-glycidylacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 36. The yield is 81%.
EXAMPLE XV
Synthesis of poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylacrylate-methylmethacrylate] copolymer
[0052] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 3-hydroxypropylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(3-hydroxypropylacrylate)-glycidylacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 37. The yield is 79%.
EXAMPLE XVI
Synthesis of poly[-9-anthraldehydeoximacrylate-(4-hydroxvbutylacrylate)-glycidylacrylate-methylmethacrylate] copolymer
[0053] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximacrylate, 0.3 moles of 4-hydroxybutylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximacrylate-(4-hydroxybutylacrylate)-glycidylacrylate methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 38. The yield is 80%.
EXAMPLE XVII
Synthesis of poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer
[0054] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 2-hydroxyethylacrylate, 0.2 moles of glycidylmethacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 39. The yield is 80%.
EXAMPLE XVIII
Synthesis of poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer
[0055] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 3-hydroxypropylacrylate, 0.2 moles of glycidylmethacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 40. The yield is 78%.
EXAMPLE XIX
Synthesis of poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer
[0056] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 4-hydroxybutylacrylate, 0.2 moles of glycidylmethacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutylacrylate)-glycidylmethacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 41. The yield is 81%.
EXAMPLE XX
Synthesis of poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylacrylate-methylmethacrylate] copolymer
[0057] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 2-hydroxyethylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(2-hydroxyethylacrylate)-glycidylacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 42. The yield is 79%.
EXAMPLE XXI
Synthesis of poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropylacrylate)-glycidylacrlyate-methylmethacrylate] copolymer
[0058] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 3-hydroxypropylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(3-hydroxypropyllacrylate)-glycidylacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 43. The yield is 81%.
EXAMPLE XXII
Synthesis of poly[9-anthraldehydeoximmethacrylate-(4-hydroxvbutylacrylate)-glycidylacrylate-methylmethacrylate] copolymer
[0059] In a 500-ml round-bottom flask are placed 0.3 moles of 9-anthraldehydeoximmethacrylate, 0.3 moles of 4-hydroxybutylacrylate, 0.2 moles of glycidylacrylate, and 0.2 moles of methylmethacrylate. This mixture is added to 300 g of separately prepared THF with stirring. Thereafter, in the presence of 0.1-3 g of AIBN, the reaction solution is subjected to polymerization at 60°-75° C. for 5-20 hours in a nitrogen atmosphere. After completion of the polymerization, the solution is precipitated in ethyl ether or normal-hexane and the precipitate is filtered and dried to produce a poly[9-anthraldehydeoximmethacrylate-(4-hydroxybutylacrylate)-glycidylacrylate-methylmethacrylate] copolymer, a polymer according to the present invention, represented by the following chemical formula 44. The yield is 80%.
EXAMPLE XXIII
Preparation of Anti-Reflective Coating
[0060] In 200-5,000% by weight of propyleneglycol methylether acetate (PGMEA) are dissolved a resin having a chemical structure of chemical formula 1 or 2, obtained in any of Examples I to XMI. This solution, alone or in combination with 0.1-30% by weight of at least one additive selected from the compounds of chemical formulas 3 to 20 in Table 1, is filtered, coated on a wafer, and hard-baked at 100°-300° C. for 10-1,000 sec. On the anti-reflective coating thus formed, a photosensitive material may be applied and imaged to form ultrafine patterns in the conventional manner.
[0061] As described hereinbefore, the anti-reflective coatings of the present invention, which are obtained from a polymer resin of chemical formula 1 or 2, alone or in combination with an additive of one of the chemical formulas 3 to 20, contains chromophore substituents sufficient to exhibit absorbance at the wavelengths useful for submicrolithography. Thus, the anti-reflective coatings of the present invention can play an excellent role in forming ultrafine patterns. For example, these ARCs can prevent the back reflection from lower layers of the semiconductor element, as well as eliminate standing waves caused by light and thickness changes of the photoresist itself during a submicrolithographic process using a 248 nm KrF, 193 nm ArF or 157 nm F 2 laser. This results in the stable formation of ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAM semiconductor devices and a great improvement in the production yield.
[0062] Although the invention has been described in detail by referring to certain preferred embodiments, it will be understood that various modifications can be made within the spirit and scope of the invention. The invention is not to be limited except as set forth in the following claims.
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Polymers are disclosed having the following formula 1 or 2:
Polymers of the present invention can be used as an ARC material useful for submicrolithography processes using 248 nm KrF, 193 nm ArF and 157 nm F 2 lasers. The polymers contain a chromophore substituent that exhibits sufficient absorbance at the wavelengths useful for the submicrolithography process. The ARC prevents back reflection of light from lower layers and the alteration of the CD by diffracted and reflected light from the lower layers. The ARC also eliminates standing waves and reflective notching due to the optical properties of lower layers on the wafer and to changes in the thickness of the photosensitive film applied thereon, thereby resulting in the stable formation of ultrafine patterns suitable for 64M, 256M, 1 G, 4 G and 16 G DRAMs and a great improvement in the production yield.
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FEDERALLY SPONSORED RESEARCH
[0001] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0002] Not Applicable
BACKGROUND
[0003] 1. Field of Invention
[0004] This invention relates to the technical and aesthetic storage, preservation, and display of perishable items.
[0005] 2. Discussion of Prior Art
[0006] Historically, the storage, proper preservation, and creative display of perishable and consumable items, such as beverages like wine and beer, have been limited by the technology and creativity applied to the industry. Regarding proper preservation, the maintenance of temperature as well as ambient humidity has long been known to have favorable or deleterious effects upon stored substances, including these bottled beverages. With respect to aesthetic display of consumer items such as bottled beer and wine, it is important to note that the container contours and labels containing images, colors, texture, and text that offer extraordinary human aesthetic appeal, based upon visual recognition and generation of an emotional response, are part of the culture and eventual economics that surround these industries.
[0007] Systems for proper, industry-recognized, temperature storage have, for centuries, taken advantage of the ambient earth temperatures found in caves, cellars or various other underground vaults. Various types of racks and crates have been utilized for the organization of the perishable items within the rooms that are somewhat temperature-regulated by the relatively constant ground temperature well below the exposed surface. Generally, this system is inconvenient in that it requires a trip to a space far removed from the general living space of home occupants or storage areas of purveyors in the industry such as wineries or wine stores. Additionally, bottled beverages and other items so stored are not presented in a fashion for public display for the various purposes for which that would be desirable, not the least of which is human interest and the sharing of such interest. That is, the storage system may not be accessible, viewable, or provide for the presentation of the item in an appealing manner, due to dust, cobwebs, poor stairways, insects, or inadequate lighting, or simply the inconvenience of the excursion to a separate space within the building, to name but a few.
[0008] In the current era it is most common to find vast quantities of beverages, such as wine, stored and displayed in ambient room conditions. Thus, the accessibility and view ability are often excellent. But, these conditions can, and usually do, include elevated and fluctuating temperatures, both of which are known to be detrimental to the quality of an item such as wine or beer. Some wines, for example, are known to connoisseurs as being more desirable and more economically valuable after several years of proper aging within the container. The process can be impaired to the point of spoilage if, to continue the example, the beverage is subjected to improper conditions, including elevated temperature over a period of time. Thus, most of the non-temperature-regulated shelving and racking systems, simply designed to store and display, fail in their capability to properly preserve and enhance many perishable items.
[0009] More modern refrigeration technology has allowed temperature regulation to be utilized in aboveground, ambient room-temperature applications. One current option is a refrigerator box; some having see-through fronts for visual contact with the inner contents without the need for opening the door. Though this option does solve the issue of convenience of access and the proper temperature storage of various perishable items, it offers little with respect to the aesthetic display of containers, labels or contents. The boxes have few aesthetically appealing creative characteristics from their own intrinsic appearance or sound and do little to show-off those aspects of the item that appeal to the consumer. In some ways, this approach is thought to have removed an element of “charm” that was associated with the stone walls of caves or the arched ceilings of other underground storage systems with the possible sounds of trickling water in these underground areas. Stores have indeed adopted open-faced refrigerated display cases that allow ease of visual contact with some types of perishable items such as produce and cheeses. Still, there is a general lack of aesthetic appeal to the storage system itself, leaving the marketing of the product solely to the manufacturer of that product and offering little to augment or present the product in a more titillating and aesthetic fashion.
[0010] With this “charm” and the notions of proper storage and preservation in mind, a modern approach has been taken to recreate the storage cellar by building an entire room within a larger living or commercial space that is temperature and humidity regulated to best suit the needs of the perishable item. The temperatures so desired, commonly between fifty-five and sixty degrees Fahrenheit for wines, for example, are great for the stored item but uncomfortable for most humans over any extended period. Thus, the room is generally isolated by walls from the more inhabitable areas of the human-occupied spaces. Additionally, to adequately isolate this space from the other warmer, less humidified spaces requires a significant expenditure of resources for special construction and maintenance.
[0011] Furthermore, many racking and shelving systems do not properly position corked beverage bottles. The constant contact of bottle contents with a cork closure is essential for prevention of cork shrinkage. In turn, this prevents exchange of outside air and evaporated fluid from within. It is this process that causes one type of premature breakdown of beverage quality. Secondly, the improper positioning of bottles of some beverages prevents the settling of sediments to the lower portion of the bottle where, in the case of wine bottles, a trough is designed into the bottle for the collection of such sediments.
[0012] Space utilization is another area of concern where many items are being stored. Some storage systems stack items for maximum use of space. Items in the lower portions of the system cannot be removed without the difficulty and disturbance of removing items resting upon them. Other systems use so much shelving material that the total consumption of space is, unfortunately, utilized by the shelving rather than the desired product that it was designed to store and display. Various compact systems do not provide for the visual inspection of a representative item and its label without the removal of an item from the system. This then introduces the possibility of breakage and limits the inspection of many alternative choices within a given period of time.
[0013] There has been a veritable explosion of creative designs surrounding the display and storage of bottled beverages such as wine. The remarkable creativity, however, is hampered by the inability of the designs to include ample storage capacity or the capability of proper conditions for preservation of perishable substances.
[0014] The use of fluid dynamics for the purpose of combining the capability of thermal regulation and aesthetic presentation is lacking in the prior art. A category of creative systems that utilizes the aesthetic qualities, but not the storage and display capabilities exists within the framework of waterfalls, water fountains, water sculpture, fountain furniture, etc. None of these available, that could be found, combines the creative water features with the practical notion of storage, preservation, and display of perishable items.
[0015] The most directly relevant items of manufacture in the public domain that could be found are the display cases designed to maintain the humidity of stored and displayed produce such as lettuce or carrots. These systems are generally equipped with shelving and spray nozzles for showering the shelf-displayed produce with a mist of water on some intermittent frequency. They have even incorporated sounds of nature, like thunder, to give warning to those in proximity that the impending “rains” are soon to begin. What these systems have not attained, nor in my estimation even attempted, is to utilize the practical elements and procedures in a manner that is an aesthetic feature. In other words, the water spray has a practical purpose and the structure that is associated does not utilize the movement of water across a surface for the production of natural flowing water aesthetics as is found in the above mentioned waterfalls and water fountains. Put bluntly, this prior art does not exhibit the engineered or innate capability of naturally producing the visual and audio aesthetic qualities of ambient-exposed, modified falling water in combination with its storage and display capabilities. A further shortcoming of this storage mechanism is the necessity of direct contact of the water with the stored items to accomplish the objective of humidity and/or temperature regulation. Many perishable items do not preserve well with direct contact of aqueous media. Additionally, intricate labeling and advertising means such as paper labels do not generally react favorably to direct contact with fluids. There are, apparently, no systems that allow indirect physical contact with a substantially direct thermal contact with stored items of a visibly dynamic fluid flowing in a manner that offers some aesthetic attraction. The inventor believes such a module would offer significant advantages in many cases.
OBJECTS AND ADVANTAGES
[0016] Accordingly, the objects and advantages of this invention arise from the successful combination of the attributes that other systems have not succeeded in assembling together. They are:
(a) to regulate temperature of the stored object or substance, and (b) to provide humidity enhancement in the region of the stored material, and (c) to offer the convenience of locating the storage device within habitable ambient room conditions, and (d) to provide a highly accessible and viewable product, and (e) to allow for an excellent display of a representative item while maintaining proper storage conditions for that item, and (f) to avail for the utilization of raw and naturally appealing elements for construction such as wood, copper, glass, stone, or other options to add natural and charming appeal, and (g) to create visual interest using cascading fluid motion and the associated intrinsic reflective, refractive, and diffractive light behavior, and (h) to provide an option of the natural sound of cascading water for aesthetic interest, and (j) to give versatility by providing for the proper and/or creative arrangement of stored items—example: proper angle for the storage of corked beverage bottles, including the display bottles, and (k) to make easy the removal of any particular stored item, and (l) to offer flexibility for a variety of storage designs for space utilization—example: organizable and customizable to “case’ quantities such as twelve, and (m) to provide variable flow regulation to the viewable fluid free-flow surface for changing the affect of the fluid, and (n) to engineer for an endless variety of potential artistic designs and enhancements to the invention, and (o) to provide for temperature regulation and humidity enhancement of a stored item without direct contact with a fluid media.
[0031] The described objects and advantages do not define a particular shape, size, or configuration, but will be represented in this document by one example that has been built and tested. Other representations will be suggested in order to demonstrate configuration and design options based upon the same objects and advantages. These options are adapted to other specific uses and/or exhibiting other aesthetic expressions.
[0032] Other objects and advantages will become apparent from the specification and drawings.
SUMMARY
[0033] The invention is a temperature-regulated storage and/or display module of various shapes, sizes and configurations for the storage, preservation and display of perishable items. It has the essential inventive elements of a support structure capable of housing a conduit for transporting temperature-regulated fluid through a course that includes thermal contact with item support members such as rods or other holders that are supported by the rigid support structure. The item support members are capable of transporting heat such that the items of interest will be temperature-regulated without direct contact with the fluid. The presented embodiment takes advantage of modern refrigeration with the utilization of a chiller, but differs from refrigerated cases and boxes in that a temperature-regulated fluid is allowed to flow external to the support structure to create visible and audible affects for aesthetic purposes.
[0034] The temperature-regulated storage and/or display module, is represented in the main embodiment presented, housed within a wood cabinet (see FIG. 7 ) that supports a rectangular configuration of the module. The configuration includes a racking arrangement designed specifically for most common 750 milliliter wine bottles. The organization of the rack is such that four cases, of twelve bottles each, can be stored conveniently. Each case occupies two vertical columns. Each of the four cases is provided a display rack where the bottle label can be easily read without removing the bottle. There are four additional spaces for random bottles not necessarily associated with the four cases of twelve. Two copper rods securely cradle each bottle. Removal of any of the bottles does not disturb those remaining. Other embodiments of the invention are represented in FIGS. 8 and 9 , having all of the elements of the main, independent claims.
DRAWINGS
[0000] Drawing Figures
[0035] In the drawings, closely related figures have the same number but different alphabetic suffixes.
[0036] FIG. 1A shows a face perspective view of a basic form of a rigid support structure (RSS). The figure shows milled holes, grooves, slots, cutouts and other millings in the RSS.
[0037] FIG. 1B is a backside perspective drawing of the RSS showing channels, ports for fittings, and cutouts for housing a fluid-supply-conduit.
[0038] FIG. 1C shows the RSS cover that seals the interior flow channels.
[0039] FIG. 2 is the configuration of the fluid-supply-conduit.
[0040] FIG. 3 shows a gated sliding valve with a handle and cut notches.
[0041] FIGS. 4A to 4 C show different types of item support members (ISMs) utilized in this particular rendition of the invention. FIG. 4A shows a standard ISM (SISM), FIG. 4B a ported ISM (PISM), and FIG. 4C a manifold ISM (MISM).
[0042] FIG. 5 shows a free-flow surface (FFS) with a back and basin portion with a sink drain assembly in the basin.
[0043] FIGS. 6A and 6B show the assembly of the preferred embodiment of the module.
[0044] FIG. 7 shows the entire module of the preferred embodiment, without the parts detail, housed within a free-standing floor cabinet unit (optional) with the additional (not part of the module), necessary components for making this embodiment fully functional represented in the drawing as a container and itemized in the text box.
[0045] FIG. 8 shows an alternative embodiment of the module.
[0046] FIG. 9 shows another alternative embodiment of the module.
REFERENCE NUMERALS IN DRAWINGS
[0047]
20 rigid support structure (RSS)
22 and 22′cutouts for tubing fittings
23 and 23′access holes
24 incoming-fluid manifold slot
25 and 25′ incoming-fluid manifold fitting ports
26 sliding gated-valve groove
27 gated-valve handle byway
28 ported item support member (PISM) holes
30 standard item support member (SISM) holes
32 manifold item support member (MISM) holes
34 PISM channels
36 SISM to MISM channels
37 rigid support structure (RSS) cover
38 sliding gated-valve handle cutout
40 ISM RSS cover holes
45 and 45′ fluid-supply conduit channels
46 L-shaped, threaded tubing fitting
47 L-shaped tubing fitting
48 fluid-supply conduit
49 plastic tubing
50 splitter tubing fitting
52 sliding gated-valve bar
53 PISM cutout notches
54 SISM to MISM cutout notches
56 gated-valve lever
58 stainless steel screw
59 holes in PISM tubes
60 ported item support member (PISM)
61 PISM port
62 glass sphere
64 standard item support member (SISM)
66 foamed-plastic plug
68 manifold item support member (MISM)
69 copper manifold tubes
70 holes in base of MISM
72 MISM outlet port
73 free-flow surface (FFS)
74 back copper sheeting
76 base copper sheeting
77 hole for drain assembly
78 ISM holes
84 common sink drain assembly
86 rigid support structure
88 item support members
90 fluid conduit
92 free-flow surface
DETAILED DESCRIPTION
[0000] Description— FIGS. 1A and 1C
[0048] FIG. 1A shows a front perspective view of a rigid support structure (RSS) 20 for a basic version of the module. In this version, or embodiment, RSS 20 is a 61 cm×91.5 cm×2.5 cm piece of high density polyethylene (HDPE). RSS cover 37 , in FIG. 1C , is a thinner sheet of HDPE measuring 61 cm wide×91.5 cm long×4.76 mm thick.
[0049] Cutouts
[0050] There are two cutouts 22 and 22 ′, both 4 cm×7.5 cm making space for L-shaped threaded tubing fittings 46 at each top corner of RSS 20 . Top left cutout 22 is located 3.5 cm from each edge RSS 20 . Top right cutout 22 ′ is located 2.5 cm from the right edge and 0.5 cm from the top of the RSS. Both cutouts remove the entire section of the RSS.
[0051] Another cutout, a sliding gated-valve handle cutout 38 , is positioned on RSS cover 37 beginning 4.5 cm from the right edge of RSS cover 37 . Cutout 38 is 1.8 cm from right to left and 1.0 cm from top to bottom beginning at 10.8 cm from the top edge of RSS cover 37 .
[0000] Slot
[0052] An incoming-fluid manifold slot 24 is milled to a depth of 2.5 cm×1.5 cm wide×48 cm in length. Manifold slot 24 is located parallel with the top edge of RSS 20 with slot 24 beginning 6.0 cm from the top edge and 2.0 cm from the right edge of the RSS.
[0053] Groove and Byway
[0054] A sliding gated-valve groove 26 is milled to a depth of 1.9 cm×3.18 cm wide from top to bottom of RSS 20×48 cm in length from right to left on the RSS. Groove 26 is located parallel with the top edge of the RSS with groove 26 beginning 8.5 cm from the top edge and 2.0 cm from the right edge of RSS 20 .
[0055] A gated-valve handle byway 27 is milled to connect with groove 26 . The byway is positioned to begin from right to left, 4.3 cm from the right edge of RSS 20 and is 2.0 cm wide from right to left×3.2 cm long from the bottom edge of groove 26 downward at a depth of 1.6 cm.
[0056] Holes
[0057] A top horizontal row of holes across the face plane of RSS 20 , PISM holes 28 , begin with the right-most hole centered at 3.6 cm from the right edge and 10 cm from the top edge of RSS 20 . PISM holes 28 alternate distances between hole-centers beginning with 3.5 cm, then 10.6 cm, to include a total of 8 PISM holes 28 . The PISM holes are parallel with top edge of RSS 20 . The PISM holes are 1.5875 cm in diameter and are drilled to a depth of 1.9 cm at the deepest point, angled at 100° from a downward vector line that is parallel with the surface plane and parallel with the side edges of RSS 20 . Thus, PISM holes 28 will be at an angle 10° greater than perpendicular to the RSS when it is in the upright, vertical operating position as shown in FIG. 6 and FIG. 7 . A second horizontal row of holes, the first of 12 rows of SISM holes 30 , begins across the face plane of RSS 20 with the right-most hole centered at 10.6 cm from the right edge and 5.3 cm from horizontal line established by the center of PISM holes 28 . SISM holes 30 alternate distances between hole-centers beginning with 3.5 cm then 10.6 cm to include a total of 8 SISM holes 28 across the second horizontal row. The SISM holes are parallel with the top edge of RSS 20 . SISM holes 30 are drilled to a depth of 1.9 cm at the deepest point and are angled at 100° from a downward vector that is parallel with the surface plane and parallel with the side edges of the RSS 20 . Thus, SISM holes 30 will be at an angle 10° greater than perpendicular to the RSS when it is in the upright, vertical operating position as in FIG. 6 and FIG. 7 . A 3 rd horizontal row of holes, the 2 nd row of SISM holes 30 , begins with the right-most hole centered at 3.6 cm from the right edge and 5.3 cm from the horizontal line established by the center of the 1 st row of SISM holes 30 . This row of SISM holes alternate distances between hole-centers beginning with 3.5 cm then 10.6 cm to include a total of 8 SISM holes 28 across the 3 rd total, horizontal row of holes. SISM holes 30 are parallel with the top edge of RSS 20 . SISM holes 30 are drilled to a depth of 1.9 cm at the deepest point and are angled at 100° from a downward vector that is parallel with the surface plane and parallel with the side edges of RSS 20 . The pattern of alternating start positions for the 1 st hole in the subsequent horizontal rows of the SISM holes is repeated until there is a total of 12 rows of SISM holes 30 in the face of RSS 20 . All SISM holes are 1.5875 cm in diameter at a depth of 1.9 cm, and all at the aforementioned angle of 100°. A final, 14 th total, horizontal row of holes is a 1 st row of MISM holes 32 . MISM holes 32 begin with the right-most hole centered at 10.6 cm from the right edge of RSS 20 and 8.5 cm from the horizontal line established by the centers of the last, or 12 th , row of SISM holes 30 . MISM holes 32 alternate distances between hole-centers beginning with 3.5 cm then 10.6 cm to include a total of 8 SISM holes 32 across the 14 th total, horizontal row of holes. The MISM holes are drilled at a diameter of 1.5875 cm to a depth of 1.9 cm at the deepest point and are angled at 80° from a downward vector that is parallel with the surface plane and parallel with the side edges of the RSS 20 .
[0058] A second set of ISM holes 28 , 30 , 32 matching the pattern of holes in RSS 20 are drilled completely through RSS cover 37 .
[0059] There are two access holes 23 and 23 ′ drilled through the edges of RSS 20 into the cutouts 22 and 22 ′. These access holes are positioned to access the center of their respective cutouts 22 and 22 ′ from the left edge and the top edge of RSS 20 , respectively. The diameter of each access hole 23 and 23 ′ is 1.9 cm.
[0060] Ports
[0061] Incoming-fluid manifold fitting ports 25 and 25 ′ are drilled and tapped through RSS 20 at the left end and the right top of incoming-fluid manifold 24 . A 15 mm hole is drilled through the HDPE material separating cutouts 22 and 22 ′ from manifold 24 . Access holes 23 and 23 ′ are utilized to center ports 25 and 25 ′ with the bores of the holes parallel to the face plane of RSS 20 . The ports are then tapped with a standard 1.5875 mm (⅝ inch) pipe thread tap. L-shaped, threaded tubing fittings 46 are screwed into position in each of the ports. Once seated firmly, fitting 46 in port 25 is directed downward whereas fitting 46 in port 25 ′ is directed to the left toward cutout 22 .
[0062] Channels
[0063] There are two distinct sets of channels milled into the face of RSS 20 . A set of PISM channels 34 , having dimensions of 6.35 nm×6.35 mm, are milled directly from the bottom of incoming-fluid manifold slot 24 to the top center of each of PISM holes 28 . The two right-side PISM holes will have byway 27 located between them. The two PISM channels associated with these holes should clearly avoid contact with byway 27 by angling the channels slightly to maintain at least 3 mm of HDPE material between the two right-most channels and the byway.
[0064] A second distinct set of channels, SISM to MISM channels 36 also originate from the lower boundary of incoming-fluid manifold slot 24 . These channels should be milled after the channels on the backside of the RSS 20 shown in FIG. 2 . SISM to MISM channels 36 are milled to a depth of 6.35 mm and originate as 4 distinct channels of 12.7 mm wide beginning from slot 24 directly above each paired set of 1 st row SISM holes 30 . Approximately 4 cm above 1 st row of SISM holes 30 , each channel 36 splits into two distinct channels of 6.35 mm deep×6.35 mm wide. In essence, 8 channels 36 then proceed in a downward zigzag fashion intersecting through each SISM hole 30 , ending at each MISM hole 32 as shown in FIG. 1A . Channels 36 are milled around both sides of each SISM hole 30 such that there is not HDPE material of RSS 20 between the channels and the holes. Channels 36 terminate and intersect with MISM holes 32 . No additional milling is performed around the MISM holes.
[0065] Screw Holes and Taps
[0066] Screw holes of diameter 7 mm are drilled through RSS cover 37 at the following coordinates measured from top and left. The units are centimeters.
T 4.5 4.5 4.5 5.0 46 87 5 46 87 25 43 58 L 12 31 49 1.0 1.0 1.0 60 60 60 27 34 27
[0067] Holes are countersunk such that a bevel head 6.35 mm (¼ inches)×2.54 cm (1 inch) nylon screw, having 20 threads per inch, will be flush with the surface of RSS cover 37 when fully inserted.
[0068] Screw pilot holes are drilled in the same corresponding locations of RSS 20 with a #7 drill bit to a depth of 2.2 cm. Screw pilot holes are then tapped with a 6.35 mm (¼ inch) 20 thread per inch tap.
[0069] Adhesive Transfer Tape
[0070] An adhesive transfer tape is applied to the perimeter of RSS 20 , inside of cutouts 22 and 22 ′. The adhesive utilized is 3M™ 300 LSE, one inch wide.
[0000] Description— FIG. 1B and FIG. 2
[0071] FIG. 1B is a back perspective drawing of RSS 20 . Generally, the back of the RSS is channeled and houses an incoming-fluid-supply-conduit 48 . FIG. 2 shows the conduit.
[0072] Channels and Incoming-Fluid Conduit
[0073] A set of fluid-supply-conduit channels 45 and 45 ′ are milled from the backside of RSS 20 at a depth of 1.6 cm. The location of channels 45 and 45 ′ are best drawn on the back of RSS 20 by first locating the position of the holes coming from the front side. This can be accomplished most easily by using a light source on the front side that will illuminate the hole-regions on the backside. Draw the channels in an angle between holes as indicated in FIG. 2 . The width of the channels is enough to accommodate a pair of 1.27 cm (½ inches) o.d. plastic tubes 49 and 49 ′ ( FIG. 2 ), or approximately 3.0-3.5 cm. Measuring from the bottom, back, right edge of the RSS, the channel is milled between 4 cm and 10 cm for a length of approximately 5 cm to accommodate a splitter tubing fitting 50 . Fitting 50 is a 1.27 cm (½ inch) push-in splitter that has been drilled out on the single-input side to a diameter of 15 mm. It remains 1.27 cm (½ inch) push-in for both output holes of the fitting. Tubes 49 and 49 ′ are routed side by side in a single channel for approximately 57 cm at which point the right-most tube 49 ′ is routed along the intersecting diagonal space created within the pattern of holes 30 leading toward cutout 22 . The other of the paired tubes continues until intersecting the next highest diagonal path leading to the same cutout. At each of the turning points for tubes 49 and 49 ′, an L-shaped push-in type tubing fitting 47 is utilized to make the direction change. Each of these fittings is shaved or filed so that the dimension of the fittings parallel to the face plane of RSS 20 is 1.9 cm. At the exact location of fittings 47 the HDPE material of RSS 20 is milled to a total depth of 1.9 cm. This area is then outlined with black marker at the outer-most barrier of the 1.9 cm cuts. Then, on the front side of the RSS, marks are made corresponding to those on the back by visualizing the dark line projected through the remaining HDPE material. Aforementioned SISM to MISM channels 36 that cross these areas are milled to a total depth of 4.5 mm rather than the 6.35 for the remainder of channels 36 .
[0074] Once fluid-supply-conduit channels 45 are parted from one another the width is reduced to 1.5 cm. Lower right-most channel 45 ′ proceeds to curve after passing the right-most hole of the third horizontal row of holes 30 viewing from the backside of RSS 20 . The curving channel 45 ′ transitions such that it smoothly goes to a vertical line of travel passing directly between the final two holes of the second horizontal row viewed from the backside of RSS 20 . Channel 45 ′ continues its vertical course through cutout 22 to within 2 cm of the top of RSS 20 . Space is milled to a depth of 1.9 cm to accommodate a third shaved or filed, L-shaped push-in type tubing fitting 47 directed toward cutout 22 ′. Finally, channel 45 ′ takes a course parallel with the top edge of RSS 20 to intersect with cutout 22 ′ such that tubing 49 ′ aligns with fitting 46 in port 25 ′. Channel 45 curves gently, avoiding any holes 30 , to transition smoothly as it approaches to within several centimeters of cutout 22 such that tubing 49 aligns with fitting 46 in port 25 . The tubing is cut to proper lengths between fittings and the entire fluid-supply-conduit is assembled and secured into the channels with duct tape.
[0000] Description— FIG. 3
[0075] FIG. 3 is a perspective drawing of a sliding gated-valve bar 52 . Beginning with an aluminum bar 3.175 mm thick×1.9 cm wide×46 cm long, the bar is positioned into sliding gated-valve groove 26 as far to the right as allowed. Then, eight PISM cutout notches 53 are made to correspond with the width and depth of PISM channels 34 with bar 52 in this position. An L-shaped brass rod with a female threaded screw hole in one end makes gated-valve lever 56 . The lever is attached to the bar with a stainless steel machine screw 58 . The lever is located such that its right side is against the right side of sliding gated-valve handle cutout 38 while bar 52 is in the far-right position. With the bar positioned to the far left, four SISM to MISM cutout notches 54 are made in bar 52 to align with SISM to MISM channels 36 . The bar is polished of all burrs and sharp edges, greased with high quality waterproof grease, and placed into the sliding gated-valve groove.
[0076] Joining of RSS and RSS Cover
[0077] RSS cover 37 is placed on the face of RSS 20 aligning all holes. Bevel headed, 6.35 mm (¼ inches)×2.54 cm (1 inch) nylon screws, having 20 threads per inch, are inserted through the screw holes and tightened.
[0000] Description— FIG. 4
[0078] FIGS. 4 A-C are perspective drawings of the various types of item support members (ISMs) utilized in this embodiment. All of the ISMs in this embodiment are constructed of 1.27 cm (½ inch) I.D. copper tubing.
[0079] FIG. 4A shows a standard item support member (SISM) 64 and FIG. 4B a ported item support member (PISM) 60 , both square-cut on both ends to a length of 18.5 cm. In one end a 14 mm glass sphere 62 is forced into the opening and seated approximately halfway into the end of the tubing. From the other end, polyurethane glue is dropped in to fall and contact the marble and the tubing held in a down position. A foamed plastic plug 66 is forced into the open end to contact the glue and marble.
[0080] PISM 60 in FIG. 4A has a PISM port 61 formed by making a square cut across approximately one-third of the diameter of the tube at 3 cm from the open end. The short end of the PISM tubing, at the cut, is creased inward to form the PISM port. At the base of each PISM tube 60 , on the opposite side of the tube from port 61 , a 7 mm hole is drilled to correspond with each PISM channel 34 entering each PISM hole 28 .
[0081] FIG. 4C shows a manifold item support member (MISM) 68 . The MISM is constructed of eight copper manifold tubes 69 square-cut to lengths of 36 cm. The individual tubes are joined at one end by a combination of standard copper L-fittings and T-fittings as shown in FIG. 4C . The distance between tubes corresponds to the distance between MISM holes 32 . At the base of each manifold tube 69 , a 7 mm hole, MISM hole 70 , is drilled to correspond with each SISM to MISM channel 36 entering the MISM holes. At the right outer corner of the MISM an open-ended copper L-fitting, forming a MISM outlet port 72 , angles back toward the open end of MISM 68 .
[0000] Description— FIG. 5
[0082] FIG. 5 shows a perspective drawing of a free-flow surface (FFS) 73 . In this embodiment of the module, the FFS is built from 16 gauge copper sheet metal. It is comprised of two distinct parts including a back copper sheeting 74 and a base copper sheeting 76 . The back sheet has holes made in the same size and pattern as those in RSS cover 37 . The size of the back sheet is 75 cm across and 91.5 cm long. The sides are bent forward at a 90° angle along lines 7.5 cm from each edge. Base sheet 76 is 66 cm wide×40 cm long. The sides and front are bent upward (assuming the finished orientation) at 90° along lines 3 cm from each of the three corresponding edges and are solder joined and sealed at the corners. Base sheet 76 has a 90° downward bend along a line 2 cm from the corresponding edge. The folded-down back of base sheet 76 is soldered in position against back sheet 74 along a line beginning at 4 cm above the right bottom edge to 3 cm above the left bottom edge of the back sheet. All seams where copper sheets 74 and 76 meet are solder joined and sealed. A hole 77 is drilled to accommodate a common sink drain assembly 84 in the outer corner, corresponding to the same side as outlet port 72 of the MISM, of the base sheet of free-flow surface 73 .
[0000] Description— FIGS. 6A and 6B
[0083] Final Assembly
[0084] Free-flow surface (FFS) 73 is placed upon RSS cover 37 such that all holes align. Then, 18-20 stainless steel pan head screws, evenly dispersed along each inside edge and outside bottom of FFS 73 , are used to attach the FFS to RSS 20 and RSS cover 37 . All item support members (ISMs) 60 , 64 , 69 are inserted into their respective holes 28 , 30 , 32 . The holes drilled into the bases of PISM 60 and MISM 68 must align with channels 34 and 36 that terminate in their respective holes 28 and 32 . Aluminized silicon caulking is used to seal around the base of each ISM 60 , 64 , and 69 at the surface of FFS 73 .
[0000] Description— FIG. 7
[0085] This embodiment of the invention is designed and included in a cabinet, portable or built-in but could be joined with multiple units along a wall or walls, or other structure to which the module could attach. Within a cabinet or housed in a remote location, the necessary equipment such as a pump, a fluid reservoir or and a chiller are required to operate the temperature regulating module.
[0000] Operation— FIGS. 1-7
[0086] The manner of use of the described embodiment of the temperature regulating storage and display module is to attach splitter tubing fitting 50 to an incoming source of temperature-regulated fluid, such as water that is pumped through a thermostatically regulated chiller. By the nature of the design of the module, the fluid is directed through fluid-supply-conduit 48 to reach incoming-fluid manifold slot 24 . By applying hand pressure to gated-valve lever 56 to the left or right, the fluid will be directed to either interior SISM to MISM channels 36 of RSS 20 or to the exterior of FFS 37 . Lever 56 can be positioned anywhere between the far left or far right to regulate the amount of fluid flowing externally. The internal flow is designed to affect the temperature of the ISMs 60 , 64 , and 69 by contact and thermal conduction of the fluid across the base of each of the ISMs 60 , 64 , and 69 . Provided that the fluid is supplied in sufficient quantity with sufficient pressure, the net combination of internal and/or external flow will continuously maintain the temperature of ISMs 60 , 64 , and 69 . SISMs 64 and MISMs 69 , of this embodiment, are positioned and designed to have bottles of various shapes and diameters placed upon them. The contiguous contact of the combination of thermal conductive materials, including, but not limited to, glass bottles of stored items, copper ISMs 60 , 64 , and 69 and flowing-fluid, result in the temperature regulatiion of the contents of the bottles resting upon ISMs 60 , 64 , and 69 . By providing for the routing of the flowing fluid as internal or external to the temperature-regulating module, several aspects are under influence. The amount of fluid that splatters about the perimeter of the invention can be regulated. The sight and sound of the flowing fluid can be altered. The rate of evaporation of the temperature regulating fluid can be influenced.
[0087] The fluid is returned to the sink drain assembly by both internal and external flow mechanisms depending upon the position of gated-valve lever 56 . The internal flow returns the fluid by way of MISM 68 through MISM outlet port 72 . The external flow returns the fluid by way of collection from back copper sheet 74 to base copper sheet 76 . The temperature regulating fluid in this embodiment is directed back to a reservoir and pump from sink drain assembly 84 .
[0000] Description and Operation of Alternative Embodiments— FIGS. 8 and 9
[0088] FIGS. 8 and 9 depict alternative embodiments of the claimed module. In FIG. 8 , the rigid support structure is a rather free-form array of curving, yet substantially upright ribbons of material such as aluminum, stainless steel, brass, copper, glass or a polymer. The ribbons are cross-linked frequently enough to provide rigidity and strength to handle the weight of heavier items such as full wine bottles. The item support members are welded or brazed or otherwise physically and thermally connected, thus making a substantially direct thermal contact connection with the rigid support structure. The conduit for transfer of the fluid is the interior of the near triangular cross-section ribbon comprising the RSS. The face flow surface is any outside surface of the ribbon. Naturally, the ribbon acting as both the rigid support structure and the fluid-supply-conduit could be designed in an endless number of cross-sections and upright arrangements. The alternative embodiment shown in FIG. 7 utilizes the ambient earth temperature as the means for temperature regulation. A pump appropriately sized to handle the pressure and volume required to supply the adequate quantity of water is selected depending upon those site-specific parameters.
[0089] FIG. 9 shows a glass or concrete orb as the RSS with glass or concrete shelves as item support members attached in a manner that will transfer thermal energy to or from them as the fluid, supplied in a conduit through the center of the orb, flows and descends, substantially freely, along the outside surface of the orb contacting the item support members. Here, the thermal hot springs supply both the temperature-regulated fluid as well as the pressure required to transfer the fluid to the substantial height of the RSS. In this embodiment of the invention, some possibilities of perishable items that may be stored and/or displayed are; wrapped candies or pastries, or hot drinks, for clients soaking in the surrounding hot pool. In this embodiment, the hot pool is the diversion for the fluid after it has run its course for the temperature-regulated storage and/or display module.
CONCLUSION, RAMIFICATIONS, AND SCOPE OF INVENTION
[0090] Thus the reader will see that the temperature-regulated storage and/or display module of the invention successfully combines many attributes that work in concert with one another to meet many simultaneous needs and provide a model for a wealth of creative embodiments to carry out the more technical functions. There is not found an equivalent in the public domain that can meet the high demands of the market for high-impact, titillating, aesthetic storage and display of perishable items that can simultaneously meet the technical demands for creating a favorable environment for the proper maintenance of the qualities for which these perishable goods are known and desired. The competitive nature of the grand marketplace in which we operate, coupled with the monetary value associated with the goods and related services demand that the systems of storage and presentation keep pace with the quality of the perishable products themselves. The variety and quality of the embodiments that arise from the claims of this invention are an exemplary step in that direction.
[0091] While the above descriptions contain much specificity, this should not be construed as limitations on the scope of the invention. Though significant alternative embodiments have been presented as examples in the previous section, these too are not to be construed as definitions of the invention rather as exemplifications of preferred and alternative embodiments. With the employment of more artistic designers than the inventor and the use of materials yet to be considered, the variations of the invention itself are legion. Accordingly, with due respect to the legal process(es) to which this document will be subjected, I duly remind the readers hereof that the scope of the invention be determined by the appended claims and their legal equivalents rather than by the embodiments illustrated.
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A system that utilizes a rigid support structure of various configurations and materials, with attached item support members designed to hold perishable items to which the module is adapted. A further system of temperature-regulated fluid is employed to flow across the exterior of the support structure upon a free-flow surface in thermal conduction contact with the item support members. The resultant desirable outcome and intention of the system is to thus regulate the temperature of the stored and/or displayed perishable items while simultaneously producing the visual dynamics and potential audible aesthetic qualities of fluid in modified descending motion. The invention lends itself to artistic expressions for design features, within the limits of the claims, while maintaining the technical goals of perishable item preservation, convenience of location within normal living or merchandising space, and display of representative items.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Ser. No. 60/809,113, which was filed on May 26, 2006.
BACKGROUND
[0002] This application relates to fishing equipment, and in particular to suspending weights used to position a lure or bait at a desired depth in the water. In many instances when fishing it is often necessary to position the lure or bait at a predetermined depth beneath the surface of the water. In many cases this depth can be far below the surface. If trolling a great deal of weight can be required.
[0003] The downrigger is typically a winch like apparatus that includes a line or cable wound on a spool and that can be fed out to a desired length. The cable terminates at a fixture that includes a first attachment point for a weight and a second attachment point for a fishing line. A weight is attached to the terminal fixture. The fishing line that includes the lure or bait is also attached to the terminal fixture by way of a releasable clip. The releasable clip is designed so that the pressure applied to the fishing line when a fish strikes the lure releases the fishing line from the terminal fixture. The fisherman is then left to play and land the fish without the significant added weight of the downrigger weight.
[0004] It is normal practice to attach the downrigger weight to the terminal fixture by what is referred to as a snubber. When fishing in the ocean or other large bodies of water waves often cause sudden movement of the boat and the attached arm that suspends the downrigger. If the downrigger weight is “rigidly” attached to the terminal fixture the sudden movement of the boat can transmit sharp shocks to the fishing line and cause it to break or to release from the terminal device. A snubber is used to prevent those shocks from breaking the relatively light fishing line or prematurely releasing the fishing line from the terminal device. Snubbers also serve as a severable link between the weight and the downrigger in case the weight becomes entangled and can't be freed. In addition the snubber will electrically isolate the weight from the remainder of the downrigger and fishing equipment.
[0005] Prior art snubbers consist of a single strand of elastic material fitted with a connector on each end. The connectors are used to attach the snubber to the terminal device on one end and the downrigger weight on the other end. Prior art snubbers are problematic for several reasons. First, they stretch too much, especially when heavy downrigger weights are used. As the weights are lifted from the water prior art snubbers stretch to the point where either the weight is not clear of the water. Even if the weight is clear of the water, in rough water it is prone to violent swings that can result in the weight hitting and damaging the boat. This poses a significant risk to the boat and its occupants, especially when fishing far from shore.
[0006] Prior art snubbers are also deficient in that while they are elastic and spread out the sharp energy spikes associated with sudden shocks, they don't effectively reduce the total energy delivered to the downrigger. The energy is delivered in a series of lower energy spikes, i.e. bounces, as the elastic snubber stretches and contracts. While it is better that the weight bounces several times and transmits less shock to the downrigger with each bounce, it would be preferable if the shock energy could be dissipated.
[0007] A need therefore exists for an improved snubber that provides shock and electrical isolation between the weight and downrigger, and which overcomes the shortcomings of the prior art.
SUMMARY OF THE INVENTION
[0008] This invention overcomes the shortcomings of the prior art by providing an improved snubber that is economical to manufacture, that is easily attached to the terminal fixture of the downrigger and to the weight without the need for connectors attached to the snubber during manufacture, and that more effectively isolates the terminal fixture from shocks resulting from sudden relative movement between terminal fixture and the weight.
[0009] The invention is embodied in a continuous loop of polymeric material that is elastic and which in addition is dissipates significant amounts of energy as it deforms and returns to its normal shape under the forces associated with the sudden relative movement between the boat and the weight. In this way a snubber according to the invention does not merely reduce the magnitude of energy spikes transmitted to the downrigger, but in addition reduces the total energy transmitted to the downrigger. A snubber according to the invention embodies an additional advantage in that a single snubber can be used with different weights by being configured to suspend the weight with 2 strands of material or 4 strands of material.
[0010] These and other aspects of the invention will be described by reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic view of a downrigger assembly mounted on a boat wherein the downrigger weight is attached using a prior art snubber.
[0012] FIG. 2 is a side elevational view of a downrigger terminal fixture illustrated in FIG. 1 and showing the attachment of the fishing line, and the attachment of the downrigger weight using a prior art snubber.
[0013] FIG. 3 is a top plan view of a snubber according to a preferred embodiment of the invention.
[0014] FIG. 4 is a side elevational view of a downrigger incorporating a snubber according to the invention in a 2 strand configuration.
[0015] FIG. 5 is a side elevational view of a downrigger incorporating a snubber according to the invention in a 4 strand configuration.
DETAILED DESCRIPTION
[0016] Turning now to FIG. 1 , a downrigger is shown generally at 10 , and includes an arm 12 , a winch 14 , a cable 16 , and a terminal fixture 18 . Arm 12 is mounted on the gunwhale of a boat 22 . FIG. 2 shows a typical terminal fixture 18 that includes a connector 24 to attach terminal fixture 18 to cable 16 , a release mechanism 26 that attaches the fishing line 28 to terminal fixture 18 , and a connector 30 to which a prior art snubber 32 is attached. Snubber 32 includes a body 34 and top and bottom connectors 36 and 38 . Weight 39 is attached to snubber 32 by connector 38 .
[0017] Turning now to FIGS. 3-6 a snubber according to the invention is shown at 40 . Snubber 40 is a continuous loop of a flexible, viscoelastic material. Snubber 40 can be configured to suspend weight 39 by two strands of material ( FIG. 4 ), or in a 4-strand configuration ( FIG. 5 ). In the two strand configuration one end of snubber 40 is passed through a connector 42 on weight 39 and back through itself to form cinch connector 42 in a loop 44 . The free end 41 of snubber 40 is then connected to connector 38 to attach weight 39 to terminal fixture 18 .
[0018] Referring to FIG. 5 , when configured in a 4-strand configuration snubber 40 is inserted through connector 42 on weight 39 and then both ends 41 and 43 of snubber 40 are connected to lower connector 38 of terminal fixture 18 .
[0019] In preferred embodiment of the invention snubber 40 is made from a viscoelastic material known as EPDM, ethylene-propylene-diene monomer, that is widely available. EPDM has been widely used in automotive weather-stripping and seals, glass-run channel, radiator, garden and appliance hose, tubing, belts, electrical insulation, roofing membrane, rubber mechanical goods, plastic impact modification, thermoplastic vulcanisates and motor oil additive applications. However, the combination of elasticity and energy dissipation described above with reference to the invention have not previously been recognized in these materials, and have not been recognized as advantageous in this application.
[0020] The snubber can be of any diameter or length. In one preferred embodiment the diameter is 0.23″ and the total length is 11″, although the invention is not limited to any particular dimension. While the preferred embodiment makes use of EDPM having a durometer hardness of 70 durometer, other viscoelastic materials of similar elastic and viscoelastic properties could be substituted without departing from the scope of the invention.
[0021] In the preferred embodiment of the invention the loop has a circular cross sectional shape, although the invention is not limited to any particular cross-sectional shape. In addition in preferred embodiments of the invention the loop is solid and not hollow, although once again the invention encompasses a loop of hollow material as well.
[0022] The snubber of the present invention provides significant advantages over the prior art. The combination of configuration and material provides greater dampening while also providing significant energy dissipation. It achieves these advantages while undergoing less stretching and thereby avoids the stretching-related problems associated with prior art snubbers.
[0023] While the invention has been described by reference to preferred embodiments, those of skill in the art will appreciate that the invention can be modified in various aspects without departing from the scope of the invention.
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An energy absorbing member for use in suspending a weight to a downrigger assembly for fishing. The member is formed of a viscoelastic material.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/294,997, filed on Jun. 3, 2014, entitled “ESTABLISHING ENTROPY ON A SYSTEM,” the disclosure of which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] The security of computing resources and associated data is of high importance in many contexts. As virtualized computing environments are becoming a new mainstream method for providing users with virtual computer systems, such as virtual machines and containers, which are quickly taking the place of hard devices. However, security in a virtualized environment is quite different with the previous computer security control problems. Current methods for providing security in a computing environment using differing cryptographic techniques require constant maintenance and human-interaction to carefully monitor for possible attacks. Cryptosystems depend on the source of randomness being truly random; as pseudorandom number generators work by taking a seed value and computing a sequence of pseudorandom numbers using an algorithm, knowing the random seed can lead to an attacker to be able to predict the entire sequence. Therefore, it is important that the seed be truly random and the seed be private from potential attackers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which:
[0004] FIG. 1 shows an illustrative example of an environment in which various embodiments may be practiced;
[0005] FIG. 2 shows an illustrative example of an environment in accordance with at least one embodiment;
[0006] FIG. 3 shows an illustrative example of an environment, in accordance with at least one embodiment;
[0007] FIG. 4 shows an illustrative example of a computing resource service provider in accordance with at least one embodiment;
[0008] FIG. 5 shows an illustrative example of a process for processing a request for a random number seed via a proxy server in accordance with at least one embodiment;
[0009] FIG. 6 shows an illustrative example of a process for processing a request for a random number seed via a proxy server in accordance with at least one embodiment;
[0010] FIG. 7 shows an illustrative example of a process for processing a request for a random number seed at an entropy service in accordance with at least one embodiment; and
[0011] FIG. 8 illustrates an environment in which various embodiments can be implemented.
DETAILED DESCRIPTION
[0012] In the following description, various embodiments will be described. For purposes of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the embodiments. However, it will also be apparent to one skilled in the art that the embodiments may be practiced without the specific details. Furthermore, well-known features may be omitted or simplified in order not to obscure the embodiment being described.
[0013] Techniques described and suggested herein include methods and systems for generating a secure connection using multiple seeds in a tiered cryptographic operation for computing environments. Techniques described herein further include methods and systems for providing virtual computer systems in a computing environment with additional entropy.
[0014] Various embodiments of the present disclosure include distributed computing environments that include cryptography services that are implemented using appropriate computing resources. A cryptography service may be implemented as a computer system that receives and responds to electronic requests to perform cryptographic operations to improve the amount of available entropy in a virtual computing environment. Example embodiments presented herein may apply in both physical (hardware) machines as well as virtual computer systems, such as virtual machines. While many of the below examples refer to the virtual computer systems, it will be known to those of ordinary skill in the art that physical computing environments may similarly benefit from examples presented herein.
[0015] In computing environments, entropy generally refers to the amount of randomness or uniqueness available. In some example embodiments presented herein, lower amounts of entropy means there is less uniqueness for creating cryptographic random number seeds for initiating secure connections. As the random seed is an important component of cryptographic security to defend against attacks on data communicated in networks, the quality of the random number seed is very important. A random number seed, also referred to as a “random seed” or “seed” or “random code” or “code” is a number used by a number generator, such as a pseudorandom number generator (PRNG) used to create a stream of random numbers to initiate a secure connection. Random seeds are frequently generated by a hardware (true) random number generator (TRNG); however, in virtual environments, TRNG are not always available.
[0016] Generally, in computing environments, a PRNG is used to generate a random seed based on a state of a computing system in the environment, such as a time clock for a specific machine. TRNG, in some embodiments, are hardware-based apparatuses capable of generating a perfect or nearly perfectly strong random seed because the number stream generated by the TRNG is usually non-predictable. In computing networks, without access to a TRNG, a machine must use a PRNG, which may be a software program used to approximately generate random numbers. The purpose of the PRNG, also known as a deterministic random bit generator, is to use an algorithm to transform the random seed into a numerical stream, where the numerical stream may be a longer code or number, in order to improve the amount of randomness or entropy available for that seed. As the PRNG is generally capable of approximating random number streams, the connections based on those numerical streams may remain vulnerable to attacks. While the present disclosure utilizes TRNGs and PRNGs, the techniques of the present disclosure are usable with any suitable random number generators (RNGs) (e.g., truly random or pseudo-random number generators) where different RNGs may have different levels of trust within a system where the levels of trust may or may not correspond to actual performance characteristics of the RNGs. For example, the techniques of the present disclosure may utilize a tiered approach with different of the same type of number generator (e.g., PRNGs).
[0017] However, as a PRNG uses deterministic algorithms, which are predictable, to generate numerical streams, if the condition used to initialize the PRNG, such as the random number seed, are known, the numerical stream may be vulnerable to attack or prediction, thereby causing any connection made with the stream or seed possibly unsecure.
[0018] In alternative example embodiments, a cryptographically secure pseudorandom number generator (CSPRNG) may be used. For example, a CSPRNG may be a pseudorandom number generator with properties that make it suitable for cryptography, including, for example, using entropy obtained from a hardware random number generator or other high-quality entropy source, such as cryptographically secure pseudorandom number generators as published by the National Institute of Standards and Technology, NIST SP 800-90A, for example. Further example embodiments may include having a cryptographically strong random number or random number seed, where one random number was generated from a high-quality entropy source, or from a process with higher entropy.
[0019] In some examples, the random number seed is used by the PRNG to generate the longer or “spread” numerical stream, which is used to initiate a secure connection. Such a connection could be made with a Transport Layer Security (TLS) or Secure Sockets Layer (SSL) cryptographic protocol designed to provide high levels of security for communications over trusted and untrusted networks, such as the Internet. The TLS protocol, for example, provides security for communications across a network or networks in a manner configured to prevent eavesdropping or attacks, such as a man-in-the-middle attack, which is one example of a cryptographic technique for active eavesdropping over a network. For example, a secure network connection or secure connection may include a connection over which communications are encrypted while in transit.
[0020] A fundamental problem that exists in virtualized computing environments includes the amount of available entropy. When new virtual computer systems are instantiated, the amount of available entropy is generally small, which means there is very little uniqueness in the virtualized environment. One result of this problem is that two or more virtual computer systems, such as virtual machines being instantiated at or around a same time may not have enough randomness to generate strong cryptography.
[0021] In one example embodiment, an entropy service is made available for newly instantiated virtual computer systems, such as virtual machines, containers and the like. The new virtual machines generate a best possible random number seed on the local virtual machine, and using that best random number seed, the virtual machine can encrypt a secure connection with the entropy service.
[0022] In some example embodiments, the entropy service may be configured to generate a stronger cryptographic random number seed that can be used to replace the cryptographically weaker seed initially generated by the virtual computer system, thereby providing each newly instantiated virtual computer system with a cryptographically strong seed to use to re-initiate a secure connection and use in all future communications. As used herein, as it relates to random number generation, cryptographic strength refers to the entropy of RNG, which is a measure of uncertainty in a random variable. The measure may be the Shannon entropy or another suitable way of measuring uncertainty in a random variable. Thus, a first random number is cryptographically stronger than a second random number if the first random number is the output of a process with higher uncertainty than another process used to obtain the second random number. A random number may be said to be cryptographically strong (without relation to another random number) if it satisfies one or more specified criteria on entropy. In some embodiments, a random number is cryptographically strong if it satisfies the requirements of the National Institute of Standards and Technology (NIST) Special Publication 800-90B which, along with NIST Special Publications 800-90A and 800-90B, are incorporated herein by reference. Other criteria may be used to determine whether a random number is cryptographically strong. Further, a first number may be said to be cryptographically stronger than a second number if the first number was generated by a process with higher entropy than a process used to generate the second number.
[0023] Alternative example embodiments provide for a method and system for co-locating a client, such as the virtual computer system, within a trusted environment that provides the initial connection between the client and the entropy service with more protection based at least in part on the trusted or mostly-trusted environment. For example, a client connected with an entropy service within a virtual private network or a virtualized private software as a service network is configured to receive the initial generated random number seed. In such an example embodiment, after receiving the stronger cryptographic seed, a client is able to reinitialize the cryptographic system with a truly randomly distributed number sequence, thus allowing the client to traverse a trusted or untrusted environment with a high level of safety because the cryptography for that virtual computer system is strong.
[0024] For example, a newly instantiated virtual machine, or any existing virtual machine, may attempt to create an encrypted connection, using an encryption protocol such as TLS or SSL, with an entropy service in order to obtain a stronger cryptography to be used for later connections in untrusted networks. In one example embodiment, an entropy service includes multiple components including, for example, an entropy server and a hardware-based random number generator, such as a True Random Number Generator (TING), or a random number seed produced by a hardware security module (HSM), where the random number seed produced by the HSM may be used to seed a software-based random number generator, such as a pseudo-random number generator and provide a cryptographically strong random number sequence to be provided or transmitted to the client. In some example embodiments, a hardware random number generator may generate a random number or a table or database of random numbers to be stored in a memory operably interconnected with the hardware. In such an example embodiment, when a request for a random number is transmitted, the hardware random number generator may provide a previously determined random number stored in the memory, in response to the request. A user may use the cryptographically strong random number seed as an input into a local software-based random number generator located on the client device or operably interconnected thereto. The client may use the cryptographically strong seed to reinitialize a cryptography protocol connection that the client may then use for future communications over all networks. Where in some example embodiments, a cryptographically strong seed or strong cryptography is a term applied to cryptographic systems and/or components considered to be highly resistant to cryptanalysis.
[0025] In some example embodiments, when an initial cryptographically weak or less secure connection between the client and the entropy service is engaged, which was initiated using a locally generated seed on the client device the less secure connection is maintained for a minimal amount of time necessary for the client to receive a cryptographically stronger seed from the entropy service. In some example embodiments, in an attempt to provide an initial best effort encrypted session while a second seed is being provided to the client, the connection may terminate if, for example, there is a possibility of an attacker or other risk factor. If such a
[0026] termination is executed, a new session between the client and the entropy service should be made in order to protect the client device.
[0027] In some circumstances, virtual machines may be instantiated concurrently, which leaves the possibility that two separate systems may receive the same random number seed. Conventional techniques for ensuring data security typically provide high security even when two virtual machines utilize the same random number seed. However, in some circumstances, even greater security is desired. Accordingly, example embodiments of the present disclosure enhance conventional data security techniques by enabling higher entropy random number seeds in contexts where virtual machines and other computer systems do not have access to hardware-based random number generators. When a service's random number seed generator encounters a fault or failure event, the service may use the entropy service as a back-up system for their own service that would maintain strong cryptography for the clients of the service so the service does not have to rely on local random generators of the operating system's random number generator. Alternative example embodiments include vulnerabilities that exist for some population of mobile phones, which do not have high levels of entropy available to the mobile device, causing weak cryptography.
[0028] In some example embodiments, a strong cryptographic random number seed may be made more secure when included in a repetitious monitoring system. An entropy service may include a searching module to be run in the background at all times, periodically, aperiodically or upon request that would search for virtual computer systems of lowering entropy and provide for additional or progressive levels of trust. For example, if additional virtual machines are being instantiated and lowering the entropy available in the virtualized computing environment or on the host machine, the multiple newly instantiated virtual machines may be directed to use different servers in the entropy service. By delivering additional trusted connections that may provide a layered architecture where, for example, if a stronger cryptographic random number generator is detected, the virtual machine may be instructed to re-initialize the crypto-connection with the stronger generator in order to receive a cryptographically stronger seed.
[0029] Alternative example embodiments provide for a rotating source of entropy where a new connection is suggested to the virtual machine by the entropy service, a system administrator or other network component if, for example, a random number generator with better quality is detected. Alternative example embodiments provide for a system for providing a virtual machine with a stronger random number seed on a periodic, aperiodic or request-based basis in order to improve the cryptographic strength of the seed and then instructing the virtual machine to re-initialize a secure connection with the new, stronger seed.
[0030] As randomness is one of the fundamental components of cryptography, the lack of entropy can make the computer systems and the computing environment generally, vulnerable to attacks. One of the principle benefits of cryptography in general is the ability to provide very high levels of security because cryptographic security deals with large number spaces, for example 2 128 or 2 256 . The use of such large number spaces makes it very difficult and nearly impossible for an attacker to search such a massive number space when those numbers are truly randomly distributed. However, if there is not enough entropy in the computing environment, such as the case when new computer systems are instantiated, it causes the number space to vastly decrease and become less capable of being randomly distributed. One problematic effect of this lack of entropy includes a reduction in the massive number space to only a subset of the number space, which can provide an attacker a narrower field of search, and, ultimately, a simpler way of potentially breaking the cryptography associated with those computer systems.
[0031] FIG. 1 illustrates an example of a computing environment 100 according to embodiments presented herein. In the environment illustrated in FIG. 1 , interconnected components of a computing network are provided. A client node 103 , which may be a virtual machine or hardware platform used by a customer, is operably interconnected to an entropy service 130 via a local or trusted connection 150 that is initiated in order to provide a secure connection. The entropy service 130 may be a computer system configured to receive requests for random number seeds and provide random number seeds in response to the request. The entropy service may be implemented as a server computer system or a fleet of server computer systems, in which case the entropy service may be considered a distributed computer system. The entropy service may provide a web service front end to which application programming interface (API) requests may be made to receive responses that include the random number seeds. Requests made to the entropy service may be representational state transfer (RESTful) requests, simple object access protocol (SOAP) requests, and/or other remote procedure calls (RPCs). In some embodiments, the entropy service processes requests synchronously where responses to the requests include the random number seeds. In other embodiments, the entropy service 130 processes requests asynchronously where a requests for a random number seed may be provided a response with an identifier of a workflow performed to generate a random number seed. A client of the entropy service 130 may, at a later time, submit a second request to the entropy service with an identifier of a workflow to obtain the random number seed. Multiple second requests may be made until the random number seed is available. To process requests asynchronously, the entropy service may write a received request to a database layer and one or more servers of the entropy service may read the database layer to locate requests to process and, upon processing a request, writing a random number seed to the database layer in association with an identifier of the workflow performed to obtain the random number seed to enable a frontend server of the entropy service to locate responses to requests to provide random number seeds (e.g., in response to a second request mentioned above.)
[0032] The client node 103 is configured to generate a random number seed 121 that may be the best possible seed (e.g., most secure) when generated on the local client device. Using the generated first seed, a connection is formed with an entropy service via the local network. In one example embodiment, the local connection is initiated so that a subsequent communication, including a second seed does not traverse a public or untrusted network, which would expose the second seed to vulnerabilities, such as man-in-the-middle attacks. At the entropy server 135 , a component is enabled to generate a second, more secure seed. The entropy server may generate the second seed using a truly secure generator, such as a hardware random number generator (TRNG). In an example embodiment, the entropy server 135 may generate the second seed according to a pseudorandom number generator (PRNG) when the TRNG is busy or unavailable. For example, in some embodiments, such as when a fleet of entropy servers with TRNGs is unavailable, a TRNG can only generate a finite amount of entropy per second which, at a given time, is insufficient.
[0033] At or near the time the second seed 141 is generated, the entropy service 130 transmits the second seed back to the client devices via the local trusted network or secured channel. In some embodiments, such as some RESTful implementations, the misted connection would close after the request is made. The client node 103 may periodically or otherwise poll another API (e.g., by identifying a workflow for generating the second seed 141 ) to determine the status of obtaining the seed. Such polling may require another SSL or other secure connection. Once the second seed is created, the client may receive the second seed 141 from the entropy service 130 and use the second seed 141 to make subsequent SSL or other secure connections. The second seed is considered a strong seed, according to cryptographic standards generally, a seed generated by a TRNG is a cryptographically strong random number seed. The client device receives the second seed from the entropy service and re-initializes its cryptosy stem using the more secure second seed for all subsequent cryptographic operations.
[0034] For example, the client node 103 , or a component thereof, generates a first seed using a PRNG 105 on the client node's local machine, such as a PRNG application on the operating system of the virtual machine or located on a host machine to which the virtual machine as access. The PRNG generates a stream of random numbers based on the first seed and uses that stream of numbers to initialize a secure cryptographic protocol module 111 , such as Secure Sockets Layer (SSL) connection with the entropy service 130 . The entropy service 130 uses a TRNG to generate a secure second seed for the client. The entropy service 130 may transmit the second seed via the same SSL connection, or the entropy service could negotiate a second SSL connection using more secure random numbers generated by the entropy service, When the client device receives the second seed, it re-initializes its crypto-system using the second seed, which is then used for any future communication over any public, untrusted or other type of network, such as communication over the network 110 with user device 106 .
[0035] Alternative example embodiments include co-locating an entropy service and a client server such that the client connection with the entropy service is a trusted network connection through which the client server may forward a request for a second, more secure random seed. Alternate example embodiments may include additional tiers of security, such as two or more rounds of seed generation. In some embodiments, a host machine implementing a virtualization platform may implement a metadata service for virtual machines implemented by the host machine. The metadata service may be a service callable by virtual machines implemented on the host to obtain various information (metadata) about the virtual machines. The metadata service may be implemented as, for example, a process executing in a privileged domain (referred to as dom0 in some platforms). After a client node (a virtual machine implemented by the host machine) makes an initial request for a random number seed, the entropy service may push a random number seed to the host machine via an SSL or other secure connection with the host machine. The host machine may make the received seed available to the client node via the metadata service. In this manner, the client node is able to obtain the seed from the entropy service without the seed being passed over an insecure network.
[0036] The client node 103 may be any type of device that is configured to request that a code be issued, either in accordance with an automated process executing independent of user input to the client node or in accordance with an automated process executing in accordance with input received from a user. In some examples, the client node requests a random number seed as part of a launch process initiated by a control plane computer system used to manage virtual machines in a distributed computing environment. In some examples, fulfillment of an API request to launch a virtual machine may include processing a request to provision a cryptographic seed. The seed may be pushed to the virtual machine via the metadata service. In this regard, the virtual machine may not require making an SSL connection using a weaker cryptographic seed. Further, the client node 103 may be configured to receive a system-generated or submit the code for validation. For example, the client node 103 may be any type of consumer electronics device including a laptop or desktop computer, a tablet, a mobile phone or a smartphone. The client node 103 may be configured to communicate using any type of communication protocol including a cellular wireless communications protocol, such as fourth generation (4G) communications or long term evolution (LTE™), a wireless local area network (WLAN) communications protocol, such as an Institute for Electrical and Electronics Engineers (IEEE) 802.11, 802.16 or 802.21 communication protocol, or short range communications protocol, among others. The client node 103 may further be equipped with an operating system and may be configured to execute software applications and programs compatible with the operating systems.
[0037] FIG. 2 illustrates an example of a computing environment 200 showing the connections between an entropy service 230 , a host machine 219 , and a proxy server 245 . In an example embodiment of a virtual computer system 220 , which may be a guest on the host machine 219 , the virtual computer system is operably interconnected with the entropy service via a public network 210 , such as the Internet. The virtual computer system, such as a virtual machine, being newly instantiated on the host machine in which a low amount of entropy was available, is configured to request a strong random number seed from the entropy service 230 . However, as noted above, providing a secure seed over an untrusted or unsecured network, such as the Internet, may submit the seed to unnecessary vulnerabilities, as such, the instant example embodiment includes a proxy server configured to connect to both the entropy service and to the host machine via two independent trusted network connections.
[0038] In the example embodiment, while the virtual computer system is connected with the entropy service over the network 210 via a connection 209 , in place of connecting directly with the entropy service 230 , the virtual computer system 220 transmits a request 216 to a proxy server 245 to be forwarded to an entropy server 235 located on or interconnected with the entropy service 230 . In the context of computer networks, a proxy server is generally a computer system server or an application server that acts as an intermediary for requests transmitted from a first location to a second location. The proxy server generally is configured to intercept the request for a specified reason, such as determining a next hop for the connection, determining the availability of the requested content, controlling the request path and to provide many other services. The proxy server is operably interconnected to the host machine via connection 250 b ; the proxy server 245 may be co-located in the same trusted network as the host machine 219 , it may use a preexisting trusted connection or other secure manner of connecting with the host machine if it were otherwise not in communication.
[0039] Unlike some of the example embodiments in FIG. 1 , the virtual computer system in the instant embodiment does not need to generate a local random number seed in order to initiate a connection with the entropy service, as the proxy server provides for the necessary connection between the two computing entities. Alternative example embodiments may provide for the virtual computer system to initiate connections with multiple computing devices in addition to or in place of connecting with the entropy service.
[0040] Returning to the example embodiment of FIG. 2 , the virtual computer system 220 transmits a request to the proxy server 245 requesting a strong or truly random number seed be provided by the entropy service in order to provide for a lack of available entropy on the host machine. The proxy server and the entropy server 230 may be operably interconnected via a secure, trusted network connection 250 a. The secured connection may be a preexisting connection; the entities may be co-located or otherwise connected in a trusted network. In the instant example embodiment, an out-of-band network 212 is configured to provide a cryptographically strong random number seed 214 to both the entropy service 230 and the proxy server 245 , where the seed 214 is used to initiate the secure connection 250 a. An out-of-band mechanism is generally configured to provide data from an independent channel that is separated from the in-band data of the network. In alternative example embodiments, a trusted platform module (TPM), which is an international standard (ISO/IEC 11889) for a secure crypto-processor, may be used as a number generator.
[0041] In alternative example embodiments, the out-of-band network 212 may provide the seed 214 to only one of the computing entities either to the proxy server or to the entropy server, and that entity would initiate a trusted connection. Once the secured, trusted connection 250 a is completed, the proxy server may transmit or forward the request 216 , originally from the virtual computer system, to the entropy service 230 . Upon receipt of the request, the entropy service, via the entropy server 235 or other service component or infrastructure, is configured to generate a strong random number seed 241 to return to the virtual computer system for use in forming secure network connections. The entropy service may transmit the generated seed 241 to the proxy server, which would in turn forward the seed 241 to the virtual computer system. After receiving the seed 241 and initiating a cryptography protocol connection, such as an SSL or TLS protocol, the virtual computer system may then connect with the entropy server over the connection 209 via the untrusted network 210 using the cryptographically strong random number seed provided by the entropy service.
[0042] In alternative example embodiments, the entropy service may return an error or notification to the virtual computer system, via the proxy or via the unsecure connection 209 , that the entropy service could not generate the requested seed. In further alternative example embodiments, there may be more than one proxy server and/or more than one secured, trusted connections between any or all of the computing entities in the computing environment.
[0043] FIG. 3 illustrates an example of a computing environment 300 showing a secured connection between a host machine 319 and an entropy service 330 in a co-located network 310 . In the example embodiment of FIG. 3 , the virtual computer system 320 , which may be a virtual machine, transmits a request 316 to the entropy service requesting a strong random number seed for use in secured connections over untrusted and trusted networks. The connection between the virtual computer system and the entropy server 335 , which is located on the entropy service 330 or otherwise operably interconnected thereto, is a secure/trusted connection. Therefore, the virtual computer system does not need to generate a first, local random number seed to use to form a connection with the entropy service, as is done in the example embodiment of FIG. 1 . However, alternative example embodiments may include the virtual computer system generating a seed to form a connection if desired for any purpose.
[0044] The entropy service 330 may receive the request 316 from the virtual computer system and provide it to the entropy server 335 for processing of the request and generating the strong seed. The entropy server 335 may be operably interconnected with a hardware (true) random number generator (TRNG), such as the TRNG 315 . The TRNG 315 may reside within the entropy service 330 or otherwise be an interconnected component thereof The TRNG may generate a secure random number seed 341 to provide to the entropy server to transmit to the virtual computer system over the secure connection 350 . In alternative example embodiments, the TRNG may be configured to transmit the generated seed 341 directly to the virtual computer system.
[0045] In alternative example embodiments, more than one secure, trusted connection (similar to connection 350 ) may connect the host machine and entropy service. Where one connection or tunnel may be used, for example, to receive requests and the other used, for example, to transmit responses. Alternative example embodiments may provide for multiple host machines or other network components for maintaining virtual computer systems in the same co-located network using the same or different connections. In addition, some such example embodiments may include the computing entities of network 310 being operably interconnected with other computing systems and networks via additional secure and/or unsecure connections.
[0046] FIG. 4 shows an example of a customer connected to a computing resource service provider in accordance with at least one embodiment. The computing resource service provider 402 may provide a variety of services to the customer 404 , wherein the customer may be the owner or user of the client device as illustrated in FIGS. 1-3 , and the customer 404 may communicate with the computing resource service provider 402 via an interface 426 , which may be a web services interface or any other type of customer interface. While FIG. 4 shows one interface 426 for the services of the computing resource service provider 402 , each service may have its own interface and, generally, subsets of the services may have corresponding interfaces in addition to or as an alternative to the interface 426 . The customer 404 may be an organization that may utilize one or more of the services provided by the computing resource service provider 402 to maintain and deliver information to its employees, which may be located in various geographical locations. Additionally, the customer 404 may be an individual that utilizes the services of the computing resource service provider 402 to deliver content to a working group located remotely. As shown in FIG. 4 , the customer 404 may communicate with the computing resource service provider 402 through a network 406 , whereby the network 406 may be a communication network, such the Internet, an intranet or an Internet service provider (ISP) network. Some communications from the customer 404 to the computing resource service provider 402 may cause the computing resource service provider 402 to operate in accordance with one or more embodiment described herein or a variation thereof.
[0047] The computing resource service provider 402 may provide various computing resource services to its customers. The services provided by the computing resource service provider 402 , in this example, include a virtual computer system service 408 , a block-level data storage service 410 , a cryptography service 412 , an on-demand data storage service 414 , a notification service 416 , an authentication system 418 , a policy management service 420 , a task service 422 and one or more other services 424 . It is noted that not all embodiments described herein include the services 408 - 424 described with reference to FIG. 4 and additional services may be provided in addition to or as an alternative to services explicitly described herein. As described herein, each of the services 408 - 424 may include one or more web service interfaces that enable the customer 404 to submit appropriately configured API calls to the various services through web service requests. In addition, each of the services may include one or more service interfaces that enable the services to access each other (e.g., to enable a virtual computer system of the virtual computer system service 408 to store data in or retrieve data from the on-demand data storage service 414 and/or to access one or more block-level data storage devices provided by the block level data storage service 410 ).
[0048] The virtual computer system service 408 may be a collection of computing resources configured to instantiate virtual machines on behalf of the customer 404 . The customer 404 may interact with the virtual computer system service 408 (via appropriately configured and authenticated API calls) to provision and operate virtual computer systems that are instantiated on physical computing devices hosted and operated by the computing resource service provider 402 . The virtual computer systems may be used for various purposes, such as to operate as servers supporting a website, to operate business applications or, generally, to serve as computing power for the customer. Other applications for the virtual computer systems may be to support database applications, electronic commerce applications, business applications and/or other applications. Although the virtual computer system service 408 is shown in FIG. 4 , any other computer system or computer system service may be utilized in the computing resource service provider 402 , such as a computer system or computer system service that does not employ virtualization or instantiation and instead provisions computing resources on dedicated or shared computers/servers and/or other physical devices.
[0049] The block-level data storage service 410 may comprise one or more computing resources that collectively operate to store data for a customer 404 using block-level storage devices (and/or virtualizations thereof). The block-level storage devices of the block-level data storage service 410 may, for instance, be operationally attached to virtual computer systems provided by the virtual computer system service 408 to serve as logical units (e.g., virtual drives) for the computer systems. A block-level storage device may enable the persistent storage of data used/generated by a corresponding virtual computer system where the virtual computer system service 408 may only provide ephemeral data storage.
[0050] The computing resource service provider 402 also includes a cryptography service 412 . The cryptography service 412 may utilize one or more storage services of the computing resource service provider 402 to store keys of the customers in encrypted form, whereby the keys may be usable to decrypt customer 412 keys accessible only to particular devices of the cryptography service 412 .
[0051] The computing resource service provider 402 further includes an on-demand data storage service 414 . The on-demand data storage service 414 may be a collection of computing resources configured to synchronously process requests to store and/or access data. The on-demand data storage service 414 may operate using computing resources (e.g., databases) that enable the on-demand data storage service 414 to locate and retrieve data quickly, to allow data to be provided in responses to requests for the data.
[0052] In the environment illustrated in FIG. 4 , a notification service 416 is included. The notification service 416 may provide notifications to clients using a “push” mechanism without the need to periodically check or “poll” for new information and updates. The notification service 416 may further be used for various purposes such as monitoring applications executing in the virtual computer system service 408 , workflow systems, time-sensitive information updates, mobile applications and many others.
[0053] As illustrated in FIG. 4 , the computing resource service provider 402 , in various embodiments, includes an authentication system 418 and a policy management service 420 . The authentication system 418 , in an embodiment, is a computer system (i.e., collection of computing resources) configured to perform operations involved in authentication of users of the customer. For instance, one of the services 408 - 416 and 420 - 424 may provide information from a user to the authentication service 418 to receive information in return that indicates whether or not the user requests are authentic.
[0054] The policy management service 420 , in an embodiment, is a computer system configured to manage policies on behalf of customers (such as customer 404 ) of the computing resource service provider 402 . The policy management service 420 may include an interface that enables customers to submit requests related to the management of policy. Such requests may, for instance, be requests to add, delete, change or otherwise modify policy for a customer or for other administrative actions, such as providing an inventory of existing policies and the like.
[0055] The computing resource service provider 402 , in various embodiments, is also equipped with a task service 422 . The task service 422 is configured to receive a task package from the customer 404 and enable executing tasks as dictated by the task package. The task service 422 may be configured to use any resource of the computing resource service provider 402 , such as one or more instantiated virtual machines or virtual hosts, for executing the task. The task service 424 may configure the one or more instantiated virtual machines or virtual hosts to operate using a selected operating system and/or a selected execution application in accordance with a requirement of the customer 404 .
[0056] The computing resource service provider 402 additionally maintains one or more other services 424 based at least in part on the needs of its customers 404 . For instance, the computing resource service provider 402 may maintain a database service for its customers 404 . A database service may be a collection of computing resources that collectively operate to run one or more databases for one or more customers 404 . The customer 404 may operate and manage a database from the database service by utilizing appropriately configured API calls. This, in turn, may allow a customer 404 to maintain and potentially scale the operations in the database. Other services include, but are not limited to, object-level archival data storage services, services that manage and/or monitor other services and/or other services.
[0057] FIG. 5 illustrates an example process 500 disclosing a method of connecting a client device to an entropy service via a proxy server. The example embodiment of process 500 may be performed by an administrator or program controlling a proxy server, such as the proxy server 245 described and illustrated in connection with FIG. 2 .
[0058] The process 500 begins with a controller configuring a proxy server in the same area of a local network as a client device ( 502 ) or otherwise co-locates the proxy server and the client device such that there is a secure and/or trusted connection between the two entities. The controller configures or programs the proxy server to be a relay server between the client device and an entropy service ( 504 ), where the entropy service is located in an untrusted network, such as the Internet. The process 500 continues. the controller is configured to enable a secure connection between the proxy server and the co-located client device ( 506 ) and obtain a cryptographically strong random number seed ( 508 ). The cryptographically strong seed may be supplied by an out-of-band network, such as the out-of-band network 212 described and illustrated in connection with FIG. 2 . In some embodiments, the proxy server has its own local TRNG or at least a RNG that operates with higher entropy than that of the client. In such embodiments, the proxy server may obtain 508 the cryptographically strong seed from its local RNG.
[0059] Returning to FIG. 5 , the controller provides the seed to the proxy server ( 510 ). By providing the cryptographically strong seed directly to the proxy server, no intermediary or untrusted networks would have access to the seed causing possible vulnerabilities. Returning to the process 500 , after providing the seed to the proxy server, the proxy server is configured to use the seed to create a secure connection between the proxy server and the entropy service, located on an untrusted network ( 512 ). Upon confirming a secure connection has been formed between the proxy server and the entropy service, the controller enables the client to communicate with the entropy service over the secured connection via the proxy server ( 514 ).
[0060] A proxy service may be used to relay a request from a client on a private network to the entropy service, which resides on an untrusted network, such as the internet. The proxy service relays the client request to the entropy service via a secure connection using a second (strong) seed that can be provided by an out-of-band source or via a Trusted Platform Module (TPM). Such an example embodiment enables an administrator to inject a random number seed into the proxy server so it may connect securely to the entropy service. This method of providing a random number seed avoids the need to inject the random number seed into any other local servers; thereby providing a secure random number seed protecting communications, from the client device via untrusted or unsecured networks, from attacks, such as man-in-the-middle attacks or the like.
[0061] FIG. 6 illustrates an example process 600 disclosing a method of requesting a cryptographically strong random number seed from an entropy service. The example embodiment of process 600 may be performed by a client device or appropriate component thereof, such as client node 103 described and illustrated in connection with FIG. 1 .
[0062] The process 600 begins with a virtual machine, running on a client device or host machine, generating a random number seed on the local virtual machine ( 602 ). As the local machine may not have enough available entropy to allow for a secure cryptography seed to be provided to all new virtual machines, the virtual machine is instructed to generate the best (most secure) seed possible. In many instances, a seed will be generated by a pseudorandom number generator, which may be a software application running on the virtual machine or on the host machine and accessible by the virtual machine.
[0063] Returning to the process 600 , the virtual machine provides the generated random number seed to a software-based random number generator ( 604 ). The random number generator is configured to stretch the seed according to, for example, a deterministic algorithm, in order to add randomness and/or uniqueness to the seed. The virtual machine receives the numerical stream from the random number generator ( 606 ) and causes a secure connection to be initiated using the numerical stream generated by the random number generator ( 608 ). The process 600 continues by the virtual machine transmitting a request to an entropy service ( 610 ), whether the request is a request for a cryptographically strong random number seed that is generated by the entropy service or a component thereof, such as the true rand number generator (TRNG) 315 described and illustrated in connection with FIG. 3 .
[0064] Retuning to FIG. 6 , the process 600 continues by the virtual machine receiving the requested strong seed ( 612 ) and utilizing the strong seed to re-initialize the cryptographic system ( 614 ) in order to have all future connections be protected using the strong seed. The virtual machine then provides the strong random number seed to the software-based random number generator ( 616 ) to be “stretched” into a more unique configuration and to be used by a cryptographic protocol to initiate a secure connection.
[0065] FIG. 7 illustrates an example process 700 disclosing a method of providing a strong random number seed to a client in response to a request. The example embodiment of process 700 may be performed by any service configured to provide random number generation, such as the entropy service 130 described and illustrated in connection with FIG. 1 .
[0066] The process 700 begins with an entropy service receiving a notification of a connection initiated by a virtual machine ( 702 ). The entropy service receives a request for a strong seed sent from the virtual machine ( 704 ) and forwards the request to a true random number generator (TRNG) apparatus for generating a cryptographically strong random number seed ( 706 ). The entropy service receives the strong seed from the TRNG ( 708 ), which may be a component of the entropy service or a hardware apparatus operably interconnected with the entropy service or accessible thereto. Returning to the process 700 , the entropy service transmits the strong seed to the virtual machine in response to the request ( 710 ) and, upon the strong seed being transmitted successfully, the entropy service terminates the connection with the virtual machine ( 712 ).
[0067] FIG. 8 illustrates aspects of an example environment 800 for implementing aspects in accordance with various embodiments. As will be appreciated, although a web-based environment is used for purposes of explanation, different environments may be used, as appropriate, to implement various embodiments. The environment includes an electronic client device 802 , which can include any appropriate device operable to send and/or receive requests, messages or information over an appropriate network 804 and, in some embodiments, convey information back to a user of the device. Examples of such client devices include personal computers, cell phones, handheld messaging devices, laptop computers, tablet computers, set-top boxes, personal data assistants, embedded computer systems, electronic book readers and the like. The network can include any appropriate network, including an intranet, the Internet, a cellular network, a local area network, a satellite network or any other such network and/or combination thereof. Components used for such a system can depend at least in part upon the type of network and/or environment selected. Protocols and components for communicating via such a network are well known and will not be discussed herein in detail. Communication over the network can be enabled by wired or wireless connections and combinations thereof. In this example, the network includes the Internet, as the environment includes a web server 806 for receiving requests and serving content in response thereto, although for other networks an alternative device serving a similar purpose could be used as would be apparent to one of ordinary skill in the art.
[0068] The illustrative environment includes at least one application server 808 and a data store 810 . It should be understood that there can be several application servers, layers or other elements, processes or components, which may be chained or otherwise configured, which can interact to perform tasks such as obtaining data from an appropriate data store. Servers, as used herein, may be implemented in various ways, such as hardware devices or virtual computer systems. In some contexts, servers may refer to a programming module being executed on a computer system. As used herein, unless otherwise stated or clear from context, the term “data store” refers to any device or combination of devices capable of storing, accessing and retrieving data, which may include any combination and number of data servers, databases, data storage devices and data storage media, in any standard, distributed, virtual or clustered environment. The application server can include any appropriate hardware, software and firmware for integrating with the data store as needed to execute aspects of one or more applications for the client device, handling some or all of the data access and business logic for an application. The application server may provide access control services in cooperation with the data store and is able to generate content including, but not limited to, text, graphics, audio, video and/or other content usable to be provided to the user, which may be served to the user by the web server in the form of HyperText Markup Language (“HTML”), Extensible Markup Language (“XML”), JavaScript, Cascading Style Sheets (“CSS”) or another appropriate client-side structured language. Content transferred to a client device may be processed by the client device to provide the content in one or more forms including, but not limited to, forms that are perceptible to the user audibly, visually and/or through other senses including touch, taste, and/or smell. The handling of all requests and responses, as well as the delivery of content between the client device 802 and the application server 808 , can be handled by the web server using PHP: Hypertext Preprocessor (“PHP”), Python, Ruby, Perl, Java, HTML, XML or another appropriate server-side structured language in this example. It should be understood that the web and application servers are not required and are merely example components, as structured code discussed herein can be executed on any appropriate device or host machine as discussed elsewhere herein. Further, operations described herein as being performed by a single device may, unless otherwise clear from context, be performed collectively by multiple devices, which may form a distributed and/or virtual system.
[0069] The data store 810 can include several separate data tables, databases, data documents, dynamic data storage schemes and/or other data storage mechanisms and media for storing data relating to a particular aspect of the present disclosure. For example, the data store illustrated may include mechanisms for storing production data 812 and user information 816 , which can be used to serve content for the production side. The data store also is shown to include a mechanism for storing log data 814 , which can be used for reporting, analysis or other such purposes. It should be understood that there can be many other aspects that may need to be stored in the data store, such as page image information and access rights information, which can be stored in any of the above listed mechanisms as appropriate or in additional mechanisms in the data store 810 . The data store 810 is operable, through logic associated therewith, to receive instructions from the application server 808 and obtain, update or otherwise process data in response thereto. The application server 808 may provide static, dynamic or a combination of static and dynamic data in response to the received instructions. Dynamic data, such as data used in web logs (blogs), shopping applications, news services and other such applications may be generated by server-side structured languages as described herein or may be provided by a content management system (“CMS”) operating on, or under the control of, the application server. In one example, a user, through a device operated by the user, might submit a search request for a certain type of item. In this case, the data store might access the user information to verify the identity of the user and can access the catalog detail information to obtain information about items of that type. The information then can be returned to the user, such as in a results listing on a web page that the user is able to view via a browser on the user device 802 . Information for a particular item of interest can be viewed in a dedicated page or window of the browser. It should be noted, however, that embodiments of the present disclosure are not necessarily limited to the context of web pages, but may be more generally applicable to processing requests in general, where the requests are not necessarily requests for content.
[0070] Each server typically will include an operating system that provides executable program instructions for the general administration and operation of that server and typically will include a computer-readable storage medium (e.g., a hard disk, random access memory, read only memory, etc.) storing instructions that, when executed by a processor of the server, allow the server to perform its intended functions. Suitable implementations for the operating system and general functionality of the servers are known or commercially available and are readily implemented by persons having ordinary skill in the art, particularly in light of the disclosure herein.
[0071] The environment, in one embodiment, is a distributed and/or virtual computing environment utilizing several computer systems and components that are interconnected via communication links, using one or more computer networks or direct connections. However, it will be appreciated by those of ordinary skill in the art that such a system could operate equally well in a system having fewer or a greater number of components than are illustrated in FIG. 8 . Thus, the depiction of the system 800 in FIG. 8 should be taken as being illustrative in nature and not limiting to the scope of the disclosure.
[0072] The various embodiments further can be implemented in a wide variety of operating environments, which in some cases can include one or more user computers, computing devices or processing devices which can be used to operate any of a number of applications. User or client devices can include any of a number of general purpose personal computers, such as desktop, laptop or tablet computers running a standard operating system, as well as cellular, wireless and handheld devices running mobile software and capable of supporting a number of networking and messaging protocols. Such a system also can include a number of workstations running any of a variety of commercially-available operating systems and other known applications for purposes such as development and database management. These devices also can include other electronic devices, such as dummy terminals, thin-clients, gaming systems and other devices capable of communicating via a network. These devices also can include virtual devices such as virtual machines, hypervisors and other virtual devices capable of communicating via a network.
[0073] Various embodiments of the present disclosure utilize at least one network that would be familiar to those skilled in the art for supporting communications using any of a variety of commercially-available protocols, such as Transmission Control Protocol/Internet Protocol (“TCP/IP”), User Datagram Protocol (“UDP”), protocols operating in various layers of the Open System Interconnection (“OSI”) model, File Transfer Protocol (“FTP”), Universal Plug and Play (“UpnP”), Network File System (“NFS”), Common Internet File System (“CIFS”) and AppleTalk. The network can be, for example, a local area network, a wide-area network, a virtual private network, the Internet, an intranet, an extranet, a public switched telephone network, an infrared network, a wireless network, a satellite network and any combination thereof.
[0074] In embodiments utilizing a web server, the web server can run any of a variety of server or mid-tier applications, including Hypertext Transfer Protocol (“HTTP”) servers, FTP servers, Common Gateway Interface (“CGP”) servers, data servers, Java servers, Apache servers and business application servers. The server(s) also may be capable of executing programs or scripts in response to requests from user devices, such as by executing one or more web applications that may be implemented as one or more scripts or programs written in any programming language, such as Java®, C, C# or C++, or any scripting language, such as Ruby, PHP, Perl, Python or TCL, as well as combinations thereof. The server(s) may also include database servers, including without limitation those commercially available from Oracle®, Microsoft®, Sybase® and IBM® as well as open-source servers such as MySQL, Postgres, SQLite, MongoDB, and any other server capable of storing, retrieving and accessing structured or unstructured data. Database servers may include table-based servers, document-based servers, unstructured servers, relational servers, non-relational servers or combinations of these and/or other database servers.
[0075] The environment can include a variety of data stores and other memory and storage media as discussed above. These can reside in a variety of locations, such as on a storage medium local to (and/or resident in) one or more of the computers or remote from any or all of the computers across the network. In a particular set of embodiments, the information may reside in a storage-area network (“SAN”) familiar to those skilled in the art. Similarly, any necessary files for performing the functions attributed to the computers, servers or other network devices may be stored locally and/or remotely, as appropriate. Where a system includes computerized devices, each such device can include hardware elements that may be electrically coupled via a bus, the elements including, for example, at least one central processing unit (“CPU” or “processor”), at least one input device (e.g., a mouse, keyboard, controller, touch screen or keypad) and at least one output device (e.g., a display device, printer or speaker). Such a system may also include one or more storage devices, such as disk drives, optical storage devices and solid-state storage devices such as random access memory (“RAM”) or read-only memory (“ROM”), as well as removable media devices, memory cards, flash cards, etc.
[0076] Such devices also can include a computer-readable storage media reader, a communications device (e.g., a modem, a network card (wireless or wired), an infrared communication device, etc.) and working memory as described above. The computer-readable storage media reader can be connected with, or configured to receive, a computer-readable storage medium, representing remote, local, fixed and/or removable storage devices as well as storage media for temporarily and/or more permanently containing, storing, transmitting and retrieving computer-readable information. The system and various devices also typically will include a number of software applications, modules, services or other elements located within at least one working memory device, including an operating system and application programs, such as a client application or web browser. It should be appreciated that alternate embodiments may have numerous variations from that described above. For example, customized hardware might also be used and/or particular elements might be implemented in hardware, software (including portable software, such as applets) or both. Further, connection to other computing devices such as network input/output devices may be employed.
[0077] Storage media and computer readable media for containing code, or portions of code, can include any appropriate media known or used in the art, including storage media and communication media, such as, but not limited to, volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage and/or transmission of information such as computer readable instructions, data structures, program modules or other data, including RAM, ROM, Electrically Erasable Programmable Read-Only Memory (“EEPROM”), flash memory or other memory technology, Compact Disc Read-Only Memory (“CD-ROM”), digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices or any other medium which can be used to store the desired information and which can be accessed by the system device. Based on the disclosure and teachings provided herein, a person of ordinary skill in the art will appreciate other ways and/or methods to implement the various embodiments.
[0078] The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims.
[0079] Other variations are within the spirit of the present disclosure. Thus, while the disclosed techniques are susceptible to various modifications and alternative constructions, certain illustrated embodiments thereof are shown in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
[0080] The use of the terms “a” and “an” and “the” and similar referents in the context of describing the disclosed embodiments (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected,” when unmodified and referring to physical connections, is to be construed as partly or wholly contained within, attached to or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein and each separate value is incorporated into the specification as if it were individually recited herein. The use of the term “set” (e.g., “a set of items”) or “subset” unless otherwise noted or contradicted by context, is to be construed as a nonempty collection comprising one or more members. Further, unless otherwise noted or contradicted by context, the term “subset” of a corresponding set does not necessarily denote a proper subset of the corresponding set, but the subset and the corresponding set may be equal.
[0081] Conjunctive language, such as phrases of the form “at least one of A, B, and C,” or “at least one of A, B and C,” unless specifically stated otherwise or otherwise clearly contradicted by context, is otherwise understood with the context as used in general to present that an item, term, etc., may be either A or B or C, or any nonempty subset of the set of A and B and C. For instance, in the illustrative example of a set having three members, the conjunctive phrases “at least one of A, B, and C” and “at least one of A, B and C” refer to any of the following sets: {A}, {B}, {C}, {A, B}, {A, C}, {B, C}, {A, B, C}. Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of A, at least one of B and at least one of C each to be present.
[0082] Operations of processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. Processes described herein (or variations and/or combinations thereof) may be performed under the control of one or more computer systems configured with executable instructions and may be implemented as code (e.g., executable instructions, one or more computer programs or one or more applications) executing collectively on one or more processors, by hardware or combinations thereof. The code may be stored on a computer-readable storage medium, for example, in the form of a computer program comprising a plurality of instructions executable by one or more processors. The computer-readable storage medium may be non-transitory.
[0083] The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0084] Embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate and the inventors intend for embodiments of the present disclosure to be practiced otherwise than as specifically described herein. Accordingly, the scope of the present disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the scope of the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.
[0085] All references, including publications, patent applications and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
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Servers in datacenters, mobile devices and virtualized servers without human interaction may experience difficulties in establishing entropy in a virtualized computing environment. Entropy is an important foundation for cryptography and a lack of entropy has led to weaknesses that can be used to break cryptographic systems in the past.
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[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/298,559, filed Jun. 15, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to phthalate polyester-based compositions and high dimensional stability all water-blown spray polyurethane foams derived from such compositions. More particularly, it relates to phthalate polyester-based compositions comprising a polyester polyol, a cell opening agent, a catalyst, and water. The invention also relates to methods for preparing the phthalate polyester-based compositions and methods of producing spray foams therefrom. Further, the invention relates to the use of such foams as insulation materials, especially roof insulation materials.
[0004] 2. Description of the Related Art
[0005] In the manufacture of refrigeration cabinets, picnic coolers, doors, and other insulated containers, polyurethane foam is poured in place between two substrates defining a cavity. In the production of roofing insulation, polyurethane foam is typically sprayed into place.
[0006] There are several desirable criteria that a polyurethane foam should possess. One requirement is that the polyurethane foam should flow well and/or spread evenly on a surface so that the entire cavity is filled with the foam or the entire surface area is evenly coated with the foam. If the foam prematurely gels, voids will form behind the prematurely gelled foam where the foaming mass could not reach or as in a spray foam application, the foam will not produce uniform coverage over a substrate. A second requirement is to use the least amount of raw foaming material to fill a particular cavity or cover a surface to save on raw material costs. To adequately fill all portions of the cavity and prevent the presence of voids, it is often necessary to over pack the cavity or over cover the surface. The less overpacking that is necessary to completely fill the mold, however, the greater the savings in raw material costs. Thus, it is desired to form a polyurethane-filled container having the lowest density possible. A third criteria is that an alternative blowing agent to ozone depleting CFCs and HCFCs is needed. Several fully halogenated hydrocarbons (chlorofluorocarbons, commonly referred to as CFC's) normally used as blowing agents for the preparation of rigid foams are believed to cause environmental problems. For instance, CFC-11 (trichlorofluoromethane) and CFC-12 (dichlorodifluoromethane) have been implicated in the deterioration of the stratospheric ozone layer and are no longer used in the preparation of polyurethanes. Many partly halogenated hydrocarbons currently in use will no longer be available for polyurethane foam use beyond 2003.
[0007] Water is clearly viewed as the safest, most economically and ecologically attractive alternative blowing agent for the spray foam industry and many polyurethane foam manufacturers are now turning to water as the sole source of blowing agent instead of CFCs or HCFCs. However, to this point no water blown spray foam has proven practical or effective due to a variety of significant limitations. For example, in the field of cooling containers where the foam is poured in place, water-blown rigid polyurethane foams present a unique problem. Rigid polyurethane foams blown with water tend to be closed-celled foams which shrink and pucker over a period of time after foaming and during cure. This is partly due to the migration of carbon dioxide gas, produced by the reaction of water with polyisocyanate, out of the closed cells and leaving behind a vacuum which then tightens and shrinks the foamed mass over time. Foam that shrinks in foamed-in-place applications will either pull away from a substrate, or continue to adhere to the inner surface of the substrates causing waviness and surface deformities on the substrate. The problem of foam shrinkage in CFC-blown and HCFC-blown foams has not been as acute since CFC gases tend to migrate out of the closed cells very slowly over a period of months or years, if at all, resulting in a minimized pressure gradient within the foam. The problem of foam shrinkage or dimensional stability is more severe in applications such as picnic coolers where the coolers are often subject to wide temperature variations, from indoor 70-80° F. temperatures to beach temperatures in direct sun which may climb to 110-120° F., causing the gas in the cells to further expand and diffuse out.
[0008] In general, water-blown foams have suffered from poor dimensional stability, narrow processing window, high reaction exotherm, poor inter-laminar and substrate adhesion, and an inability to be processed on conventional spray foam equipment. The difficulty in processing on routine equipment has been the result of higher formulation viscosity; due to the absence of HCFC-141b blowing agent, no thinning of the resin occurs as is normally the case when such a blowing agent is present. Additionally, the requirement for increased isocyanate usage (due to the presence of significant water levels) has precluded use on conventional equipment which frequently require processing at 1:1 isocyanate/resin volume ratios. Poor adhesion characteristics are the result of increased foam friability associated with poor mixing (due to the higher resin viscosity) as well as extensive use of high functional polyether and/or Mannich-type polyols. These high functional polyols are normally required in order to provide the foamed polymer with adequate crosslink density to resist shrinkage. The high reaction exotherm, a direct result of the water-isocyanate reaction and the absence of cooling from a physical blowing agent such as HCFC-141b, contributes to foam cracking and surface blisters. The extensive heat also makes it difficult to control the reaction profile thereby limiting the range of environmental conditions under which the spray foam can be applied.
[0009] It is, therefore, desirable to produce a foam having a lower density yet which fully fills the cavity or spreads on a surface and is dimensionally stable in order to lower raw material costs. Lowering the density, however, especially in water-blown foam already having a tendency to shrink has the attendant disadvantage of further exacerbating the dimensional instability of the foam. Examples of open celled foams have been described in U.S. Pat. Nos. 5,214,076; 5,219,893; 5,250,579; 5,262,447; 5,318,997; 5,346,928; 5,350,777; 6,066,681; and 6,211,257, each of which is incorporated herein in its entirety.
SUMMARY OF THE INVENTION
[0010] The invention avoids many or all of the limitations which have excluded water-blown spray foams from commercial viability. The invention provides a solution to the dimensional stability issue. By smoothly and homogeneously opening the cells of the sprayed foam, a rapid pressure equalization is permitted after carbon dioxide departure, thereby limiting or eliminating vacuum-induced shrinkage. Through incorporation of the unique cell opening technology of the invention formulation component modifications can readily be made without impacting foam dimensional stability. In particular, the invention makes it possible to adjust the polyol composition to lessen polymer reliance on high functional polyether or Mannich-type polyols. This results in lower formulation viscosity and improved adhesion characteristics. In one aspect of the invention, a significant proportion of low functional, i.e., 1-2 functional groups, polyester polyol is incorporated into the polyol formulation.
[0011] The invention also relies on the use of diluents in the formulation. These diluents (which are typically plasticizers) perform several functions including viscosity reduction, enhanced flammability performance, reduction in reaction exotherm, and the ability to process the resin on conventional spray foam equipment. In particular, the use of diluents as provided herein allows the foam to be processed at 1:1 A/B volume ratio without adversely affecting the qualitative or physical properties of the polymer, wherein the “A-side” means materials comprising an isocyanate and/or isocyanurate and the “B-side” means materials comprising a polyol, as those terms are used by those skilled in the art.
[0012] In summary, the invention provides spray foam technology and spray foams that meet the physical and processing requirements stipulated by the industry; the invention provides the first and only commercially viable all water-blown spray foam available. Thus, in one aspect, the invention provides spray foams that are the product of a reaction mixture comprising a polyol blend and a polymeric isocyanate, preferably at a blend/isocyanate volume ratio of about 1:1. These blends comprise a polyol formulation, diluent, cell opening agent, and blowing agent. The blends optionally include other components as necessary to adjust, e.g., the viscosity and stability of the blend. The polyol formulation, as discussed below comprises any of a variety of polyols, i.e., polyester polyol, polyether polyol, and/or Mannich-type polyol
[0013] The invention provides dimensionally stable, low density, all water blown polyurethane foams that are prepared predominantly with low functional polyester polyols. These foams have an open cell content sufficient to prevent shrinkage of the foam. Further, the inventive foams are of a strength sufficient to prevent shrinkage of the foam.
[0014] Accordingly, in one aspect of the invention, there is provided a method for preparing a polymeric foam comprising urethane units and having an open-cell content sufficient to resist shrinkage. This method comprises reacting an aromatic polymeric isocyanate with a dispersed polyol blend, where the polyol blend comprises:
(a) from about 20%, preferably 25%, to about 90% based on the weight of the polyol blend of a polyol formulation; (b) a blowing agent; (c) a cell opening agent which is a divalent metal salt of a fatty acid; and (d) from about 0.05 to about 50% by weight of the polyol blend of a diluent.
[0019] Another aspect the invention provides polyol blends, i.e., a polyol resins, suitable for preparing a polymeric foam comprising urethane units and having an open-cell content sufficient to resist shrinkage. These blends comprise:
(a) a polyol formulation comprising from about 25-90% by weight of the blend of a polyester polyol, a polyether polyol and/or a Mannich-type polyol; (b) a blowing agent; (c) a cell opening agent which is a divalent metal salt of a fatty acid; and (d) from about 0.05% to about 50% by weight of the blend of a diluent.
[0024] In one aspect, the the polyol blends are dispersed polyol blends.
[0025] The inventive foams are produced using cell opening agents having melting points or softening points between about 100 and 180° C. When formulated according to the invention, these cell opening agents form part of a dispersed polyol blend having a dispersion droplet or particle size of less than about 50%. Without being bound by a particular theory, it is believed that during the polymerization reaction, the dispersion containing the cell opener breaks down releasing the cell opener thus allowing controlled cell opening. Without being bound by a particular theory, it is believed that cell opening takes place immediately prior to polymer gelation.
[0026] The resulting low density, water blown foam is primarily an open celled foam and exhibits dimensional stability in both the sprayed free rise state as well as within a packed cavity. By “primarily open celled” is meant a foam that has a sufficient amount or percentage of open cells to resist shrinkage.
[0027] Thus, the invention encompasses methods and compositions for preparing polyurethane foams having strength and an open-cell content sufficient to prevent or resist shrinkage comprising reacting an aromatic polymeric isocyanate with a dispersed polyol blend. The dispersed polyol blend of the invention comprises a polyol formulation, a blowing agent, a cell opening agent; and a diluent.
[0028] The polyol formulation of the invention may optionally contain an acid. It has been unexpectedly discovered that the addition of an acid to a combination of a polyol, a blowing agent such as water, and a specific cell opening agent provides a dispersed polyol blend that has surprising stability. The dispersed polyol blends, when reacted with aromatic isocyanates, form open-celled, spray and pour-in-place urethane foams having excellent dimensional stability at low densities.
[0029] The invention also provides polyol blends comprising a polyol formulation, preferably containing high levels, i.e., up to about 100% by weight of the formulation, of a polyester polyol, together with a blowing agent and a cell opening agent. Optionally, the polyol blends of the invention may comprise an emulsifier.
DETAILED DESCRIPTION OF THE INVENTION
[0030] In this document, all temperatures are stated in degrees Celsius unless otherwise indicated. All amounts, ratios, concentrations, proportions and the like are stated in weight units, unless otherwise stated, except for ratios of solvents, which are in volume units. Percentages are by weight unless otherwise indicated.
[0031] By OH value is meant hydroxyl value, a quantitative measure of the concentration of hydroxyl groups, usually stated as mg KOH/g, i.e., the number of milligrams of potassium hydroxide equivalent to the hydroxyl groups in 1 g of substance.
[0032] By NCO/OH index is meant the molar ratio, multiplied by 100, of isocyanate groups to hydroxyl groups (including those contributed by water) in the reaction between the polyol blend and the polyisocyanate.
[0033] By functionality is meant the number of reactive groups, e.g., hydroxyl groups, in a chemical molecule.
[0034] By uniform open cell content is meant a polyurethane foam having an average open cell content that does not vary substantially between two or more samples removed from the same foam material and separated in the foam material by a distance of at least about 2 cm.
[0035] The polyol blends of the invention are preferably “dispersed polyol blends.” By the term “dispersed polyol blend” is meant a polyol blend or polyol resin, i.e., a mixture comprising a polyol formulation, cell opening agent, diluent and blowing agent, together with any optional components, where the cell opening agent, preferably as particles, and more preferably as particles having a mean diameter of less than about 50μ, is stably suspended in the polyol blend. Such a dispersion is stable for a period of time sufficient to allow reaction with the polyisocyanate to form an open-celled foam having an open-cell content sufficient to prevent or resist shrinkage. Preferably, the dispersed polyol blends are stable at a temperature of about 25° C. for at least about 1 week, more preferably, the blends are stable at 25° C. for at least about 3 months.
[0036] By softening point as used herein is meant a temperature at which a material becomes more liquid, less rigid, softer, or more elastic; i.e., a temperature at or above its glass transition temperature.
[0037] As used herein, resistance to shrinkage means less than about 5% shrinkage of a polyurethane foam material.
[0038] The polyol blends of the invention preferably have particles having mean diameters of less than about 50μ, more preferably less than about 25, even more preferably less than about 10μ, and most preferably less than about 1μ. Smaller particles are believed to result in improved stability of the polyol blends which in turn results in improved uniformity of the open celled content of the final polyurethane foams.
[0039] The invention provides polyurethane foams suitable for use as insulating materials disposed on or between a variety of substrates. Suitable substrate materials comprise metal such as aluminum or sheet metal; wood, including composite wood, acrylonitrile-butadiene-styrene (ABS) triblock of rubber, optionally modified with styrene-butadiene diblock, styrene-ethylene/butylene-styrene triblock, optionally functionalized with maleic anhydride and/or maleic acid; polyethylene terephthalate, polycarbonate, polyacetals, rubber modified high impact polystyrene (HIPS), blends of HIPS with polyphenylene oxide; copolymers of ethylene and vinyl acetate, ethylene and acrylic acid, ethylene and vinyl alcohol; homopolymers or copolymers of ethylene and propylene such as polypropylene, high density polyethylene, high molecular weight high density polyethylene, polyvinyl chloride, nylon 66, or amorphous thermoplastic polyesters, fiberglass or fiberglass composites; roof decking materials such as gypsum board, Dens-Deck, Iso-board, Cementitious Wood Fiber (Tectum Deck), Light Weight Concrete, Modified Bitumen, and a variety of rubber based membranes.
[0040] The foams of the invention have in-place densities of from about 2 to 5.0 and, in one embodiment, the foams of the invention have in-place densities of from about 2.3 to 3.5, lbs./ft 3 (pcf). The sprayed foams of the invention have sprayed in-place densities of from about 2.0 to 3.5 and, preferably, from about 2.3 to 3.3, pcf.
[0041] As explained in more detail below, the foams of the invention may be water blown foams. The water blown foams according to the invention have K-factors of at least about 0.16 to 0.24.
[0042] The polyurethane foam of the invention comprises the product of the reaction of the aromatic polyisocyanate with at least one polyol component in a polyol blend. The polyurethane foam is rigid, meaning that the ratio of tensile strength to compressive strength is high, on the order of 0.5 to 1 or greater, and has less than 10 percent elongation.
[0043] The blends disclosed herein are generally free of CFC and/or hydrocarbon blowing agents and are highly suited for use in spray foam applications, i.e., insulative roof spray foams.
[0044] Although not critical to the invention, the blends of the invention may optionally contain from about 0.01-50.0 percent by weight of a cross linking agent. Suitable cross linking agents are, for example, higher functionality alcohols such as triols or pentaerythritol.
[0045] In a preferred aspect, the invention provides polyol blends suitable for preparing a urethane foam, comprising:
(a) from about 28% to about 85%, more preferably 80%, by weight, based on the weight of the composition, of a polyol formulation; (b) from about 0.05% to about 3, preferably 2.0%, by weight, based on the weight of the composition, of a cell opening agent; (c) from about 3.5%, preferably about 5%, to about 50, preferably about 45%, by weight, based on the weight of the composition, of a diluent; and (d) from about 0.5% to about 5% by weight, based on the weight of the composition, of water.
[0050] More preferred polyols formulations of the invention comprise from about 1% to about 100% by weight of a polyester polyol or mixtures of such polyols. More preferably, the polyol formulation or mixtures thereof comprise polyester polyols having an OH value of from about 150 to 350 and a molecular weight of from about 350 to 700.
[0051] Even more preferred polyol formulations comprise from about 30-48% of polyester polyol by weight of the polyol blend, and most preferably from about 30-45% of polyester polyol by weight of the polyol blend.
[0052] The blends of the invention can further comprise:
(e) from about 0.25% to about 5% by weight, based on the weight of the composition, of a urethane catalyst; and/or (f) from about 0% to about 1% by weight, based on the weight of the composition, of an acid; and/or (g) from about 0% to about 3% by weight, based on the weight of the composition, of a surfactant.
[0056] In a preferred embodiment, the polyol formulation comprises from about 1% to 100%, more preferably about 75-100%, by weight, based on the weight of the polyol formulation, of a diethylene glycol phthalate polyester polyol having an OH value of from about 150 to 350 and comprising
(a) the reaction product of mixture comprising a phthalic acid compound and a low molecular weight aliphatic diol and (b) an optional nonionic surfactant, and where the diethylene glycol phthalate polyester polyol has a molecular weight of from about 350 to 700.
[0059] In a particularly preferred embodiment, the polyol blend comprises from about 50-85% by weight of a polyol formulation comprising a modified diethylene glycol phthalate polyester polyol having an OH value of about 290-325, an Mannich type polyol having an OH value of 415-435, and diethylene glycol.
[0060] In another particularly preferred embodiment, the polyol blend comprises from about 50-85% by weight of a polyol formulation comprising a modified diethylene glycol phthalate polyester polyol having an OH value of about 23-350, an Mannich type polyol having an OH value of 415-435, and diethylene glycol.
[0061] In another particularly preferred embodiment, the polyol blend of the invention comprises about
(a) 30-35% by weight of a modified diethylene glycol phthalate polyester polyol having an OH value of about 290-325 or a modified diethylene glycol phthalate polyester polyol having an OH value of about 230-250; (b) 20-30% by weight of an Mannich type polyol having an OH value of 415-435; (c) 5.5-9% by weight of diethylene glycol (d) 1-3% by weight of water; (e) 0.1-1% by weight of the cell opener; and (f) about 18-34% by weight of the diluent.
[0068] In another preferred embodiment, the polyol blend comprises, based on the weight of the blend,
about 30-35% by weight of the modified diethylene glycol phthalate polyester polyol having an OH value of about 290-325 or the modified diethylene glycol phthalate polyester polyol having an OH value of about 230-250, from about 20-30 by weight of the Mannich type polyol having an OH value of 415-435, from about 6-8% by weight of diethylene glycol, from about 1-3% by weight of water, from about 0.15-2.5% by weight of the cell opener, and from about 20-34% by weight of the diluent.
[0075] In one aspect, the invention relates to a urethane foam made from a reaction mixture comprising (a) a polyol blend of the invention, and (b) an isocyanate, a polyisocyanate, or a mixture thereof. In this embodiment, the isocyanate preferably is 2,4- and/or 2,4/2,6-toluene diisocyanate, diphenyl methane 4,4′-diisocyanate, hexamethylene diisocyanate, isophorone diisocyanate, or a mixture thereof. Also in this embodiment, the polyisocyanate is alternatively a polyphenyl polymethylene polyisocyanate.
[0076] The invention further relates to a method for preparing polyol compositions which is suitable for preparing a urethane foam. This method comprises combining:
(a) from about 38% to about 90% by weight, based on the weight of the composition, of a polyol formulation; (b) from about 0.05% to about 2.0% by weight, based on the weight of the composition, of a cell opening agent; (c) from about 5% to about 45% by weight, based on the weight of the composition, of a diluent; and (d) from about 0.5% to about 5% by weight, based on the weight of the composition, of water.
[0081] The methods of the invention can further include adding the following optional components:
(e) from about 0.25% to about 5% by weight, based on the weight of the composition, of a urethane catalyst; and/or (f) from about 0% to about 1% by weight, based on the weight of the composition, of an acid; and/or (g) from about 0% to about 3% by weight, based on the weight of the composition, of a surfactant.
[0085] In anther embodiment, the invention provides a polyurethane foam comprising from about 0.01 to 1% by weight of a cell opening agent which is a divalent metal salt of a fatty acid, where the foam has an open-cell content sufficient to resist shrinkage and exhibits less than about 5% shrinkage when stored at about 158° F. and about 100% relative humidity for about 28 days. These foams comprise the reaction product of an aromatic polymeric isocyanate with a polyol blend of the invention.
[0086] Preferably, the polyurethane foam exhibits less than about 3% shrinkage when stored at −20° F. for 28 days.
[0087] In yet another embodiment, the invention relates to a method for preparing a urethane foam comprising reacting the polyol composition with an isocyanate, a polyisocyanate, or a mixture thereof, to produce the foam. In accordance with this embodiment, the NCO/OH index of the foam is 85-125. The foam produced in accordance with the embodiments disclosed herein is pourable, and/or is sprayable. Accordingly, the invention also relates to methods of applying spray foams, which are derived from the blends described herein, to various substrates, particularly roofs.
[0088] Polyols
[0089] The polyols suitable for use in the invention are polyester polyols, polyether polyols and Mannich-type polyols. Preferred polyol blends are those that comprise a polyester polyol. In these preferred blends, the polyester polyol can be up to about 100% of the polyol formulation. In other preferred polyol blends, the polyol formulation is a mixture of polyols, e.g., (a) polyester polyol and polyether polyol, (b) polyester polyol and polyether polyol, (c) polyether polyol and Mannich-type polyol, or (d) polyether polyol, polyester polyol, and Mannich-type polyol. Thus, the polyol formulation may be up to about 100% by weight of polyether polyol, i.e., it may be polyester polyol free, or may contain a mixture of polyether and polyester polyols.
[0090] Starting polyol components suitable for use in the polyol blends or mixtures according to the invention include polyesters containing at least two hydroxyl groups, as a rule having a molecular weight of from 300 to 10,000, in particular polyesters containing from 2 to 8 hydroxyl groups, and, in some embodiments of the invention, having a molecular weight of from 350 to 700, in other embodiments having a molecular weight of from 350 to 600, wherein the acid component of these polyesters comprise at least 50% by weight in one embodiment, and at least 70% by weight in another embodiment, of phthalic acid residues.
[0091] These polyesters containing hydroxyl groups include for example, reaction products of polyhydric, such as dihydric and trihydric, alcohols with phthalic acids and other polybasic, such as dibasic, carboxylic acids. Instead of using the free phthalic acids or polycarboxylic acids, the corresponding acid anhydrides or corresponding acid esters of lower alcohols or mixtures thereof may be used for preparing the polyesters. Orthophthalic acids, isophthalic acids and/or terephthalic acids may be used as the phthalic acid. The optional polybasic-carboxylic acids may be aliphatic, cycloaliphatic, aromatic and/or heterocyclic and may be substituted, for example, with halogen atoms and/or may be unsaturated. The following are mentioned as examples; succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, trimellitic acid, trimellitic anhydride, tetrahydrophthalic acid anhydride, hexahydrophthalic acid anhydride, endomethylene tetrahydro phthalic acid anhydride, glutaric acid anhydride, maleic acid, maleic acid anhydride, fumaric acid, dimeric and trimeric fatty acids, such as oleic acid, optionally mixed with monomeric fatty acids. Suitable polyhydric alcohols include, for example, ethylene glycol, propylene glycol-(1,2) and -(1,3), diol-(1,8), neopentyl glycol, cyclohexane dimethanol (1,4-bis-hydroxymethylcyclohexane), 2-methyl-1,3-propane diol, glycerol, trimethylolpropane, hexanetriol-(1,2,6)butane triol-(1,2,4), trimethylolethane, pentaerythritol, quinitol, mannitol and sorbitol, methylglycoside, also diethylene glycol, triethylene glycol, tetrathylene glycol, polyethylene glycols, dibutylene glycol, and polybutylene glycols. The polyesters may also contain carboxyl end groups. Polyesters of lactones, such as ε-caprolactone, or hydroxycarboxylic acids, such as β-hydroxycaproic acid, may also be used.
[0092] In one embodiment, polyester polyols for use in the invention comprise the reaction products of (a) phthalic acid compounds, (b) low molecular weight aliphatic diol compounds, (c) and nonionic surfactant compounds. Such polyester polyols are described in U.S. Pat. Nos. 4,644,047 and 4,644,048, each of which is incorporated herein in its entirety.
[0093] Suitable polyols for the invention also include Mannich-type polyols. Mannich-type polyols are prepared by reacting, for example, nonylphenol, formaldehyde, and mono or dialkanolamines or mixtures thereof. This intermediate is then typically reacted with alkylene oxide to produce the final “Mannich Polyol.” The preparation of Mannich-types polyols is also described in U.S. Pat. Nos. 3,297,597; 4,137,265; 4,383,102; 4,247,655; 4,654,376, each of which is incorporated herein in its entirety.
[0094] According to the invention, polyethers containing at least one, generally from 2 to 8, and, in one embodiment of the invention, 3 to 6 hydroxyl groups and having a molecular weight of from 100 to 10,000 may be used in the polyol blend. These are prepared, for example, by the polymerization of epoxides, such as ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide, or epichlorohydrin, either on its own for example in the presence of BF 3 , or by chemical addition of these epoxides, optionally as mixtures or successively, to starting components having reactive hydrogen atoms, such as alcohols or amines, for example water, ethylene glycol, propylene glycol-(1,3) or -(1,2), trimethylol propane, 4,4-dihydroxy diphenylpropane aniline, ammonia ethanolamine or ethylene diamine. Sucrose polyethers which have been described, for example in German Auslgeschrift Nos. 1,176,358 and 1,064,938 may also be used according to the invention.
[0095] Among the corresponding polythioethers which may also be used are the condensation products obtained from thiodiglycol on its own and/or with other glycols, dicarboxylic acids, formaldehyde, aminocarboxylic acids or aminoalcohols should be particularly mentioned. The products obtained are polythio mixed ethers, polythio ether esters or polythio ether ester amides, depending on the co-components.
[0096] Polyhydroxyl compounds already containing urethane or urea groups and modified or unmodified natural polyols, such as castor oil, carbohydrates or starch may also be used. Addition products of alkylene oxides and phenyl/formaldehyde resins or of alkylene oxides and urea/formaldehyde resins are also suitable according to the invention.
[0097] Representatives of these compounds which may be used according to the invention have been described, for example, in High Polymers, Volume XVI, “Polyurethanes, Chemistry and Technology”, by Saunders and Frisch, Interscience Publishers, New York; London, Volume 1,1962, pages 32-42 and pages 44 to 54 and Volume II, 1964, pages 5 and 6 and 198-199, and in Kunststoff-Handbuch, Volume VII, Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, for example, on pages 45 to 71.
[0098] In certain embodiments, the polyol formulation comprises a phthalate polyester-ether polyol. These polyester-ether polyols are the reaction product of a phthalate polyester polyol (“intermediate polyester polyol” and a polyhydridic polyol. The intermediate phthalate polyester polyol is the reaction product of
(1) about 2-60% by weight, based on the weight of the polyester polyol, of phthalic anhydride or phthalic acid; and (2) about 40-98% by weight, based on the weight of the polyester polyol, of at least one polyol of the formula:
HO—R 1 —OH
wherein R 1 represents:
(a) alkylene groups of about 2 to 10 carbon atoms; or (b) —CH 2 —R 2 —CH 2
where R 2 represents:
(c) a mixture thereof.
[0106] The R 1 alkylene group may be branched or straight chain, saturated or unsaturated, and when R 2 contains a hydroxyl moiety, such hydroxyl group may be optionally alkoxylated.
[0107] Preferably, the phthalate polyester polyol is of the general formula:
wherein R represents:
(a) alkylene groups of about 2 to 10 carbon atoms; or (b) —CH 2 —R 2 —CH 2 where R 2 represents:
or
(c) a mixture thereof.
[0114] Suitable polyhydridic polyols include (i) alkoxylated glycerine, such as propoxylated glycerine, (ii) alkoxylated sucrose, and (iii) alkoxylated glycols, such as diethylene glycol, ethylene glycol, propylene glycol, butylene glycol, and the like, or mixtures of any of these polyhydric alcohols. Typical alkoxylating agents for any of these polyhydric alcohols are ethylene, propylene and/or butylene oxide.
[0115] In a preferred aspect, the polyester and polyhydric alcohol are combined together in the polyol blend and before reacting the blend with the isocyantate “A-side”. In these blends, the polyester polyol and polyhydric alcohols may be present at a variety of suitable ratios. Suitable ratios of polyester polyol to polyhydric alcohol are from about 25:1 to 1:1. More preferred ranges are from higher ratios of about 20:1 or 15:1 to lower ratios of about 1.5:1. Even more higher ratios are about 8:1. More preferred lower ratios are 3:1 or 2:1.
[0116] The polyester-ether polyols of the invention may be the reaction product of phthalic anhydride (PA), a polyhydroxyl compound, and an alkoxylating agent, e.g., propylene oxide, as shown below:
wherein R is branched or linear, saturated or unsaturated C 2-10 alkyl, cycloalkyl, alkenyl, alkynyl, aromatic, polyoxyethylenic, polyoxypropylenic; wherein R may contain pendant secondary functionality such as hydroxyl, aldehyde, ketone, ether, ester, amide, nitrile, amine, nitro, thiol, sulfonate, sulfate, and/or carboxylic groups. Where pendant secondary hydroxyl functionality is present, such hydroxyl groups may optionally be alkoxylated. In some embodiments of the invention, phthalic anhydride is reacted with a polyol, i.e., a diol such as diethylene glycol to form a polyester polyol.
[0118] Preferred polyester polyols may be made as follows
wherein n=2-10, x=1-500. In accordance with this embodiment, PA polyester polyol intermediates for use in the invention are derived from the condensation of phthalic anhydride and ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, neopentyl glycol, 1,4-butanediol, 1,6-hexanediol, polyethylene glycol, polypropylene glycol triethylene glycol, and tetramethylene glycol and mixtures thereof.
[0120] Specific polyester polyols suitable for use in the compositions of the invention include for example phthalic acid diethylene glycol polyester polyols. Suitable phthalic acid diethylene glycol polyester polyols are commercially available from Stepan Company, Northfield, Ill. Representative auxiliary polyols are StepanPol® PS-2002 (a phthalic anhydride diethylene glycol polyester polyol having an OHv of 195 and a functionality of 2), StepanPol® PS-3152 (a phthalic anhydride diethylene glycol polyester polyol having an OHv of 315 and a functionality of 2), StepanPol® PS-4002 (a phthalic anhydride diethylene glycol polyester polyol having an OHv of 400 and a functionality of 2), and StepanPol PS-2502A (an aromatic polyester polyol having an OHv of 245) and mixtures thereof. In the invention, by OH value (OHv) is meant hydroxyl value, a quantitative measure of the concentration of hydroxyl groups, usually stated as mg KOH/g, i.e., the number of milligrams of potassium hydroxide equivalent to the hydroxyl groups in 1 g of substance. By functionality is meant the number of reactive groups, e.g., hydroxyl groups, in a chemical molecule.
[0121] Other auxiliary polyester polyols, i.e. non-phthalic anhydride-based polyester polyols, include for example, polyester polyols derived from the condensation of caprolactone and a poly alcohol, and terate polyester polyols (e.g. Terate-203; a diethylene glycol terephthalate polyester polyol having an OHv of 315 and a functionality of 2.3; commercially available from Kosa). Specific auxiliary polyether polyols suitable for use in the methods and compositions of the invention include for example the condensation products of propylene glycol/propylene oxide, trimethylolpropane/ethylene oxide/propylene oxide, trimethylolpropane/propylene oxide, sucrose/propylene glycol/propylene oxide, alkylamine/propylene oxide, and glycerin/propylene oxide, and mixtures thereof.
[0122] Polyisocyanate
[0123] The polyisocyanate starting components used according to the invention include aliphatic, cycloaliphatic, araliphatic, aromatic and heterocyclic polyisocyanates, such as those described, for example, by W. Siefken in Justus Liebigs Annalen der Chemie 562: 75-136. Examples include ethylene diisocyanate; tetramethylene-1,4-diisoyanate, hexamethylene-1,6-diisocyanate; dodecane-1,12-diisocyanate; cyclobutane-1,3-diisocyanate; cyclohexane-1,3- and 1,4-diisocyanate and mixtures of these isomers 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (German Auslegeschrift No. 1,202,785, U.S. Pat. No. 3,401,190); hexahydrotolylene-2,4- and 2,6-diisocyanate and mixtures of these isomers; hexahydrophenylene-1,3- and/or -1,4-diisocyanate; perhydrodiphenylmethane-2,4′- and/or 4,4′-diisocyanate; phenylene-1,3- and -1,4-diisocyanate; tolylene-2,4- and -2,6-diisocyanate and mixtures of these isomers; diphenylmethane-2,4′- and/or -4,4′-diisocyanate; naphthylene-1,5-diisocyanate; triphenylmethane-4,4′1,4″-triisocyanate; polyphenylpolymethylene polyisocyanate which may be obtained by aniline/formaldehyde condensation followed by phosgenation and which have been described, for example, in British Pat. Nos. 874,430 and 848,671; m- and p-isocyanatophenyl sulphonyl isocyanate according to U.S. Pat. No. 3,454,606; perchlorinated aryl polyisocyanate as described, for example, in U.S. Pat. No. 3,277,138; polyisocyanate; containing carbodiimide groups as described in U.S. Pat. No. 3,152,162; the diisocyanates described in U.S. Pat. No. 3,492,330; polyisocyanates containing allophanate groups as described, for example, in British Pat. No. 994,890, Belgian Pat. No. 761,626 and Published Dutch Patent application No. 7,102,524; polyisocyanates containing isocyanurate groups as described, for example, in U.S. Pat. No. 3,001,973, in German Pat. Nos. 1,022,789; 1,222,067 and 1,027,394 and in German Offenlegungsschriften Nos. 1,929,034 and 2,004,048; polyisocyanates containing urethane groups as described, for example, in Belgian Pat. No. 752,261 or in U.S. Pat. No. 3,394,164; polyisocyanates containing acrylated urea groups according to German Pat. No. 1,230,778; polyisocyanates containing biuret groups as described, for example, in U.S. Pat. Nos. 3,124,605 and 3,201,372; and in British Pat. No. 889,050; polyisocyanates prepared by telomerization reactions as described, for example in U.S. Pat. No. 3,654,016; polyisocyanates containing ester groups as mentioned, for example, in British Pat. Nos. 965,474 and 1,072,956, in U.S. Pat. No. 3,567,763 and in German Pat. No. 1,231,688; reaction product of the above-mentioned isocyanates with acetals according to German Pat. No. 1,072,385; and, polyisocyanates containing polymeric fatty acid groups as described in U.S. Pat. No. 3,455,883. Also suitable for use in the present invention are isocyanate terminated pre-polymers using hydroxy containing reactants of any of the foregoing.
[0124] The distillation residues obtained from the commercial production of isocyanates and which still contain isocyanate groups may also be used, optionally dissolved in one or more of the above-mentioned polyisocyanates. Mixtures of the above-mentioned polyisocyanates may also be used.
[0125] In some embodiments of the invention, the polyisocyanates which are readily available are used, for example, toluene-2,4- and -2,6-diisocyanate and mixtures of these isomers (“TDI”); polyphenyl polymethylene polyisocyanates which may be obtained by aniline/formaldehyde condensation followed by phosgenation crude MDI”); and, polyisocyanates containing carbodiimide groups, urethane groups, allophanate groups, isocyanurate groups, urea groups or biuret groups (“modified polyisocyanates”), and mixtures thereof.
[0126] In some embodiments of the invention, polyisocyanates are 2,4- and/or 2,4/2,6-toluene diisocyanate, diphenyl methane 4,4′-diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate, and mixtures thereof.
[0127] In one embodiment of the invention, the polyisocyanate is methylene bis(phenyl isocyanate).
[0128] Suitable polyisocyanurates useful in the invention also include, as is well known to those skilled in the art, the cyclotrimerization product of any of the aforementioned polyisocyanates.
[0129] In a typical rigid spray-in-place application the polyisocyanate mixture is reacted with a polyol blend at a ratio of 0.9-1.1:1 (v/v) ratio. The reaction can be achieved using a spray gun apparatus or other suitable mixing devices. Alternatively, the reaction can be achieved using a high pressure impingement machine provided with a nozzle capable of filling a void volume. As another alternative, the reaction may be achieved using a low pressure static mixing machine equipped with a nozzle to fill a void volume.
[0130] Acid Component
[0131] Some embodiments of the polyol formulation used in the invention comprises a polyester polyol and an acid. The acid is used in an amount capable of maintaining the dispersed polyol blend as a dispersion for a period of time sufficient to allow for the production of a polyurethane foam and preferably a foam having a uniform open celled content. The foam is made by reacting the polyol blend with an aromatic polyisocyanate.
[0132] The amount of acid optionally present is generally up to about 5% by weight of the polyol blend. In one embodiment, the amount of the acid is from about 0.05 to 5% by weight of the polyol blend. In another embodiment, the amount of acid is from about 0.1 to 1%.
[0133] Suitable acids are generally Bronsted acids, i.e., substances that can donate protons. In one embodiment of the invention, the acids are organic acids. In another embodiment, the acids are various alkanoic or alkenoic acids of the formula RCO 2 H, where R is hydrogen, a straight or branched chain alkyl group having from about 1 to 12 carbon atoms, or a straight or branched chain alkenyl group having from about 2 to 12 carbon atoms. Representative acids include, for example, formic, acetic, isobutryic, and 2-ethylhexanoic acids. In a preferred embodiment, the acid is 2-ethylhexanoic acid.
[0134] Blowing Agent
[0135] According to the invention, the reaction of the dispersed polyol blend as set forth above with a polyisocyanate provides an open cell rigid polyurethane foam as desired. In a preferred embodiment of the invention, water is used as a primary blowing agent in the dispersed polyol blend. In this embodiment, the amount of water as a blowing agent is about 0.5-5%, and can be about 1-4%, and further can be 1.5-2.5%, based on the weight of the composition. When the amount of water is insufficient, a low density foam may not be produced.
[0136] Although the preparation of the foam is typcially carried out using a dispersed polyol blend having water as a blowing agent, in another embodiment, the blowing agent comprises a secondary blowing agent, either alone, or preferably in combination with the primary blowing agent, water. Suitable secondary blowing agents include both CFC and non-CFC blowing agents. Secondary blowing agents are typically liquids having low boiling points.
[0137] Suitable secondary blowing agents include, but are not limited to, halogenated hydrocarbons such as, for example, 2,2-dichloro-2-fluoroethane (HCFC-141b), water, and hydrocarbons such as pentane, hydrofluorocarbons (HFCs) and perfluorocarbons for example. Other suitable organic blowing agents include, for example, acetone, ethyl acetate, halogenated alkanes, such as methylene chloride, chloroform, ethylidene chloride, vinylidene chloride, and also butane, pentane, hexane, heptane or diethylether. The effect of a blowing agent may also be obtained by adding compounds which decompose at temperatures above room temperature to liberate gases, such as nitrogen, for example, azo compounds, such as azoisobutyric acid nitrile. Other examples of blowing agents and details about the use of blowing agents may be found in Kunststoff-Handbuch, Volume VII, published by Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, for example, on pages 108 and 109, 453 to 455 and 507-510.
[0138] Further examples of suitable optional blowing agents are described in U.S. Pat. No. 5,346,928, which is incorporated herein in its entirety.
[0139] Cell Opening Agent
[0140] Cell opening agents suitable for use in the invention include known powdered divalent metal salts of long chain fatty acids having from about 1-22 carbon atoms. Examples of such agents are divalent metal salts of stearic or myristic acid, such as calcium stearate, magnesium stearate, strontium stearate, zinc stearate or calcium myristate, as disclosed in Japanese Patent Application Laid-open No. 61-153480. The cell opening agent is used in an amount of about 0.01-2.0% based on the weight of the composition. The cell opening agent is typically capable of forming a stable dispersion with the polyester polyol.
[0141] In preferred embodiments of the invention, cell opening agents having melting or softening points of from about 100 to 180° C. are used. In one embodiment, dispersed polyol blends comprise from about 0.05 to 1.5% cell opening agent based on the weight of the composition. In another embodiment, dispersed polyol blends comprise from about 0.1 to 0.8% cell opening agent based on the weight of the composition.
[0142] Isocyanate Polymerization Catalyst
[0143] Compounds which readily initiate a polymerization reaction of the NCO-groups at temperatures as low as room temperature are used as the catalyst system for polymerization. Compounds of this type are described, for example, in French Pat. No. 1,441,565, Belgian Pat. Nos. 723,153 and 723,152 and German Pat. No. 1,112,285.
[0144] Such catalyst systems are, in particular, mononuclear or polynuclear Mannich bases of condensable phenols, oxo-compounds and secondary amines which are optionally substituted with alkyl groups, aryl groups or aralkyl groups, and, in one embodiment of the invention, those in which formaldehyde is used as the oxo-compound and dimethylamine as the secondary amine.
[0145] According to the invention, the catalysts that may be used as the catalyst for the polyurethane reaction include, for example, tertiary amines, such as triethylamine, tributylamine, N-methyl morpholine, N-ethyl-morpholine, N-cocomorpholine, N,N,N′,N′-tetramethylethylenediamine, 1,4-diaza-bicyclo-(2,2,2)-octane, N-methyl-N′-dimethyl aminoethyl-piperazine, N,N-dimethylbenzylamine, bis-(N,N-diethylaminoethyl)-adipate, N,N-diethylbenzylamine, pentamethyldiethylenetriamine, N,N-dimethylcyclohexylamine, N,N,N′,N′-tetramethyl-1,3-butane-diamine, N,N-dimethyl-.beta.-phenylethylamine, 1,2-dimethylimidazole and 2-methylimidazole and Curithane 52 (available from Air Products).
[0146] Tertiary amines containing isocyanate-reactive hydrogen atoms used as catalysts include, for example, triethanolamine, triisopropanolamine, N-methyl-diethanolamine, N-ethyl-diethanolamine, N,N-dimethylethanolamine and the reaction products thereof with alkylene oxides, such as propylene oxide and/or ethylene oxide.
[0147] Silaamines having carbon-silicon bonds as described, for example, in German Pat. No. 1,229,290 (corresponding to U.S. Pat. No. 3,620,984) may also be used as catalysts, for example, 2,2,4-trimethyl-2-silamorpholine and 1,3-diethylaminomethyl-tetramethyl-disiloxane.
[0148] The catalysts used may also be basic nitrogen compounds, such as tetralkylammonium hydroxides, alkali metal hydroxides, such as sodium hydroxide, alkali metal phenolates, such as sodium phenolate, or alkali metal alcoholates, such as sodium methylate. Hexahydrotriazines may also be used as catalysts. Typically, the amine catalyst is employed in excess of the required acid. However, any of the catalysts derived from amines may be used in the invention as the corresponding ammonium salts or quaternary ammonium salts. Thus, in the practice of the invention, catalysts derived from amines may be present in the polyol blends as their corresponding acid blocked form. Accordingly, in certain embodiments, such a catalyst and the requisite acid may be simultaneously added conveniently as the amine salt of the acid.
[0149] According to the invention, organic metal compounds, in particular organic tin compounds, may also be used as catalysts.
[0150] Suitable organic tin compounds are, in some embodiments of the invention, tin (II)-salts of carboxylic acids, such as tin (II)-acetate, tin (II)-octoate, tin (II)-ethylhexoate and tin (II)-laurate, and the tin (IV)-compounds, for example dibutyl tin oxide, dibutyl tin dichloride, dibutyl tin diacetate, dibutyl tin dilaurate, dibutyl tin maleate or dioctyl tin diacetate.
[0151] Suitable organo lead compounds for use as primary catalysts include lead naphthanate and lead octoate.
[0152] All of the above-mentioned catalysts may be used as mixtures.
[0153] Further representatives of catalysts which may be used according to the invention, as well as details on the mode of operation of the catalyst are described in Kunststoff-Handbuch, Volume III, published by Vieweg-Hochtlen, Carl-Hanser-Verlag, Munich, 1966, for example, on pages 96 to 102.
[0154] Other catalysts include N,N-dimethyl-cyclohexylamine, lead naphthanate, tin octanoate and tin dilaurate.
[0155] Still other catalysts suitable for use in the invention include amino acid salt catalysts, e.g., those derived from sarcosine. Suitable amino salts derived from sarcosine include various N-(2-hydroxy or 2-alkoxy-5-alkylphenyl)alkyl sarcosinates. The alkyl groups are independently C 1 -C 18 alkyl groups and the alkoxy groups are C 1 -C 6 alkoxy groups. Of course, each of the sarcosinate derivatives includes a suitable counterion, such as, for example, sodium, potassium, magnesium, lithium, etc. In one embodiment of the invention, the amino acid salt is sodium N-(2-hydroxy-5-nonylphenyl)methyl sarcosinate. Each of the amino acid derivatives may be prepared according to the procedures set forth in U.S. Pat. No. 3,903,018. Representative amino acid salt catalysts are, for example, sodium N-(2-hydroxy-5-methylphenyl)methyl sarcosinate; sodium N-(2-hydroxy-5-ethylphenyl)methyl sarcosinate; sodium N-(2-hydroxy-5-butylphenyl)methyl sarcosinate; sodium N-(2-hydroxy-5-heptylphenyl)methyl sarcosinate; sodium N-(2-hydroxy-5-nonylphenyl)methyl sarcosinate; sodium N-(2-hydroxy-5-dodecylphenyl)methyl sarcosinate; potassium N-(2-hydroxy-5-nonylphenyl)methyl sarcosinate; lithium N-(2-hydroxy-5-nonylphenyl)methyl sarcosinate; and mixtures thereof. Other suitable catalysts include, for example, the disodium salt of 2,6-bis-(N-carboxymethyl-N-methylaminomethyl)-p-ethylphenol and the disodium salt of 2,6-bis-(N-carboxymethyl-N-methlaminomethyl)-p-nonylphenol; and mixtures thereof.
[0156] The catalysts are generally used in a quantity of from about 0.001 to 10%, by weight, based on the quantity of the polyesters used according to this invention.
[0157] Diluents
[0158] As used herein, the terms diluent or diluents include within their scope plasticizer materials. Diluents suitable for use in the invention include those described in U.S. Pat. Nos. 3,773,697, 5,929,153, 3,929,700 and 3,936,410, the disclosures of each of which are incorporated herein by reference in their entirety. Suitable diluents include
(a) phthalic plasticizers such as di-n-butyl phthalate, di-2-ethylhexyl phthalate, di-n-octyl phthalate, diisononyl phthalate, diisodecyl phthalate, diisooctyl phthalate, octyldecyl phthalate, butylbenzyl phthalate and di-2-ethylhexyl isophthalate, aliphatic ester plasticizers such as di-2-ethylhexyl adipate, di-n-decyl adipate, diisodecyl adipate, dibutyl sebacate and di-2-ethylhexyl sebacate, trimellitic plasticizers such as trioctyl trimellitate and tridecyl trimellitate, phosphoric ester plasticizers such as tributyl phosphate, tri-2-ethylhexyl phosphate, 2-ethylhexyldiphenyl phosphate and tricresyl phosphate, epoxy plasticizers such as epoxy soybean oil, polyester-based high-molecular plasticizers, and the like. Other diluents suitable for use in the invention include, for example, (b) propylene carbonate, (c) alkyl esters of monobasic acids where the alkyl group is straight or branched chain alkyl having from 1-20 carbon atoms, such as 2-ethylhexylbenzoate, methyl 2-ethylhexanoate and the like (hereinafter “monobasic esters”), (d) dialkyl esters of dibasic acids where each alkyl group is independently a straight or branched chain alkyl having from 1-20 carbon atoms (hereinafter “dibasic esters”), (e) diacid esters of α, ω-diols where the acid is a straight or branched chain alkanoic acid having from 1-6 carbon atoms and the diol is a straight of branched chain aliphatic diol (hereinafter “diol esters”, (f) mono- and di(C 1 -C 6 )alkyl ethers of alkylene and polyalkylene glycols (hereinafter “glycol ethers”), (g) nonyl phenols alkoxylated with from 1 to about 50 moles of an alkoxylating agent or mixture of alkoxylating agents having from 1-6 carbon atoms, preferably about 7-12 moles of an alkoxylating agent having from 2-4 carbon atoms (hereinafter “alkoxylated nonyl phenols”), e.g., Makon 10 (available from Stepan Company), (h) tris-isopropylchlorophosphate, and (i) mixtures of any of (a)-(h).
[0168] Representative glycol ethers include monomethyl diethylene glycol, monoethyl dipropylene glycol, and monomethyltripropylene glycol.
[0169] Suitable diesters of dibasic acids for use in the invention include, for example, dimethyl adipate, dialkyl adipate, dimethyl glutarate, dimethyl succinate, H 3 CO(CO)(CH 2 ) n (CO)OCH 3 , wherein n is an integer between 1 and 10, and di(2-ethylhexyl) adipate. A preferred aspect of the invention employs mixture of dibasic esters. A particularly preferred mixture contains about 20% by weight of dimethyl succinate, 21% by weight of dimethyl adipate and about 59% by weight of dimethyl glutarate.
[0170] A representative diacid ester of an α, ω-diol is 2,2,4-trimethyl-1,3-pentanediol diisobutyrate.
[0171] Preferred diluents include propylene carbonate, a dibasic ester mixture, alkoxylated nonyl phenols, more preferably Makon 10, tris-isopropylchlorophosphate, and glycol ethers, more preferably monomethyl dipropylene glycol and monomethyl tripropylene glycol.
[0172] In preferred embodiments of the invention, the diluents are of low viscosity (less than approximately 50 centipoise at 25° C.) and act as plasticizers within the polymer.
[0173] Surfactants and Additives
[0174] Surfactants suitable for use in the invention include non-ionic surfactants and amphoteric surfactants such as those disclosed in U.S. Pat. No. 6,017,860 the disclosure of which is incorporated herein by reference in its entirety. Suitable nonionic surfactants in accordance with the invention are also generally disclosed at column, 13 line 14 through column 16, line 6 of U.S. Pat. No. 3,929,678, the disclosure of which is incorporated herein by reference in its entirety. Generally, the nonionic surfactant is selected from the group comprising polyoxyethyleneated alkylphenols, polyoxyethyleneated straight chain alcohols, polyoxyethyleneated branched chain alcohols, polyoxyethyleneated polyoxypropylene glycols, polyoxyethyleneated mercaptans, fatty acid esters, glyceryl fatty acid esters, polyglyceryl fatty acid esters, propylene glycol esters, sorbitol esters, polyoxyethyleneated sorbitol esters, polyoxyethylene glycol esters, polyoxyethyleneated fatty acid esters, primary alkanolamides, ethoxylated primary alkanolamides, secondary alkanolamides, ethoxylated secondary alkanolamides, tertiary acetylenic glycols, polyoxyethyleneated silicones, N-alkylpyrrolidones, alkylpolyglycosides, alkylpolylsaccharides, EO-PO blockpolymers, polyhydroxy fatty acid amides, amine oxides and mixtures thereof.
[0175] Suitable amphoteric surfactants are selected from the group comprising alkyl glycinates, propionates, imidazolines, amphoalkylsulfonates sold as “Miranol” by Rhone Poulenc, N-alkylaminopropionic acids, N-alkyliminodipropionic acids, imidazoline carboxylates, N-alkylbetaines, amido propyl betaines, sarcosinates, cocoamphocarboxyglycinates, amine oxides, sulfobetaines, sultaines and mixtures thereof. Additional suitable amphoteric surfactants include cocoamphoglycinate, cocoamphocarboxyglycinate, lauramphocarboxyglycinate, cocoamphopropionate, lauramphopropionate, stearamphoglycinate, cocoamphocarboxypropionate, tallowamphopropionate, tallowamphoglycinate, oleoamphoglycinate, caproamphoglycinate, caprylamphopropionate, caprylamphocarboxyglycinate, cocoyl imidazoline, lauryl imidazoline, stearyl imidazoline, behenyl imidazoline, behenylhydroxyethyl imidazoline, caprylamphopropylsulfonate, cocamphopropylsulfonate, stearamphopropylsolfonate, oleoamphopropylsulfonate and the like.
[0176] Other surfactants suitable for use in the invention include, but are not limited to, polyether siloxanes or alkoxylated polysiloxanes such as Niax L-5440 (available from OSI Specialties, Crompton), Tegostab B-8404 (available from Goldschmidt), Dabco DC-5357 (available from Air Products), and mixtures thereof.
[0177] Surface-active additives and foam stabilizers, may also be used in the invention. Suitable materials include, for example, the sodium salts of ricinoleic sulphonates, or salts of fatty acids and amines, such as oleic acid diethylamine or stearic acid diethanolamine. Alkali metal or ammonium salts of sulphonic acids, such as dodecyl benzene sulphonic acid or dinaphthylmethane, disulphonic acid or of fatty acids, such as ricinoleic acid, or of polymeric fatty acids may also be used as surface-active additives.
[0178] The foam stabilizers used are preferably polyether siloxanes, especially those which are water-soluble. These compounds generally have a polydimethyl siloxane group attached to a copolymer of ethylene oxide and propylene oxide. Foam stabilizers of this type have been described, for example, in U.S. Pat. Nos. 2,834,748; 2,917,480 and 3,629,308.
[0179] According to the invention, it is also possible to use known cell regulators such as paraffins or fatty alcohols or dimethyl polysiloxanes, as well as pigments or dyes and known flame-proofing agents, for example, trischloroethylphosphate, tricresylphosphate or ammonium phosphate or polyphosphate, also stabilizers against ageing and weathering, plasticizers, fungistatic and bacteriostatic substances and fillers, such as barium sulphate, kieslguhr, carbon black or whiting.
[0180] Other examples of surface-active additives, foam stabilizers, cell regulators, reaction retarders, stabilizers, flame-proofing substances, plasticizers, dyes, fillers and fungistatic and bacteriostatic substances which may also be used according to the invention and details concerning the use and action of these additives may be found in Kunststoff-Handbuch, Volume VII, published by Vieweg and Hochtlen, Carl-Hanser-Verlag, Munich 1966, for example on pages 103 and 113.
[0181] Emulsifiers
[0182] The polyol blends may optionally include emulsifiers to prolong the stability and shelf-life of the dispersed polyol blends. Examples of suitable emulsifiers include sodium N-(2-hydroxy-5-nonylphenyl)methyl sarcosinate and soybean oil.
[0183] All documents, e.g., patents and journal articles, cited above or below are hereby incorporated by reference in their entirety.
[0184] One skilled in the art will recognize that modifications may be made in the invention without deviating from the spirit or scope of the invention. The invention is illustrated further by the following examples which are not to be construed as limiting the invention or scope of the specific procedures described herein.
[0185] The following is a description of certain materials used in the following examples:
Stepanpol PS-2352: a low functional (functionality of 2) modified diethylene glycol phthalate polyester polyol having an OH value of about 220-250, sold by Stepan Company, Northfield, Ill. Stepanpol PS-3152: a low functional (functionality of 2) diethylene glycol phthalate polyester polyol having an OH value of about 290-325, sold by Stepan Company, Northfield, Ill. Stepanpol ®PS-2502-A: a low functional (functionality of 2) modified diethylene glycol phthalate polyester polyol having an OH value of about 230-250, sold by Stepan Company, Northfield, Ill. Dabco ®DC5357: a polysiloxane surfactant composed of dimethyl, methyl (polyethylene oxide) siloxane copolymer, sold by Air Products Corporation of Allentown, Pa. Tegostab B8404: a polysiloxane surfactant composed of dimethyl, methyl (polyethylene oxide) siloxane copolymer, sold by Godlschmidt. Niax ®A-1: a catalyst which contains about 70% bis(2-dimethylaminoethyl)ether in 30% dipropylene glycol, sold by OSI Specialty Chemical. Mondur MR®: polymethylene polyphenyl isocyanate having an isocyanate content of about 31.5%, commercially available from Bayer, Pittsburgh, Pa. Thanol R-360: an alkoxylated sucrose glycerin polyether polyol having an OH value of about 345-375, sold by Eastman. Polycat 8: Dimethylcyclohexylamine catalyst, sold by Air Products. Jeffcat ZR-70: a catalyst containing 2-(2-(dimethylamino)ethoxy]ethanol, sold by Huntsman. Pluracol P-975: a high functional alkoxylated sucrose diol having an OH value of approximately 380-420, sold by BASF. Voranol-270: a low functional alkoxylated glycerin having an OH value of 230-250, sold by Dow Chemical. Voranol-470×: an Mannich type polyol having an OH value of 460-480, sold by Dow Chemical. Markol RB 216: an Mannich type polyol having an OH value of 470-490, sold by Quimica Pumex. Silpol SIP-425LV: an Mannich type polyol having an OH value of 415-435, sold by Siltech Corp. Carbowax 400: polyethylene glycol of approximately 400 MW sold by Union Carbide. Makon 10: nonyl phenol ethoxylated with an average of 10 ethylene oxide units sold by Stepan Company. Terate-203: a diethylene glycol terephthalate polyester polyol having an OH value of 300-330, sold by Kosa. Surfactant L-5440: an alkoxylated polysiloxane surfactant sold by Crompton OSI. Curithane 52: an isocyanate polymerization catalyst available from Air Products.
General Experimental
[0207] Amounts of components in the below examples are percentages by weight of the polyol (resin) blend unless indicated otherwise. The individual resin components are added and mixed until a stable homogeneous polyol dispersion is obtained.
[0208] The polyol blends set forth below are prepared according to the invention and reacted by hand mixing and/or spraying with a polyisocyanate (Mondur MR®). The hand mixed foams are reacted in an amount of 150 g of total material at an isocyanate/resin weight ratio of 52/48 (approximately 1:1 isocyanate/resin ratio by volume). Unless otherwise indicated, the isocyanate and resin components are conditioned to 77 deg. F prior to mixing. The isocyanate is pre-weighted in a 32 ounce No. 2 cup. The desired quantity of resin component is then added to the isocyanate and the two are mixed vigorously for 3 seconds using a double Conn mix blade rotating at approximately 3500 rpm. The foam is allowed to rise and cure in the cup used for mixing. The properties of the hand mix foams are indicated below. Machine sprayed foams utilize either a Gusmer machine or GlasCraft machine with parameters as indicated by the particular examples.
EXAMPLE 1
[0209]
Phthalate Polyester (Stepanpol PS-3152)
37.26%
Terate Polyester (Terate-203)
14.90%
Propoxylated Glycerine (Voranol-270)
22.35%
Surfactant (L-5440)
1.49%
Cell Opener (Calcium Stearate)
0.33%
Amine Catalysts*
5.23%
Lead Catalyst (30% Pb Naphthanate)
0.22%
2-Ethylhexanoic Acid
0.37%
Diluents**
14.90%
Water
2.94%
*Amine catalysts: Polycat 8 = 2.24%; Dimethylethanolamine = 2.24%; Curithane 52 = 0.75%.
**Diluents: tris-isopropylchlorophosphate.
[0210] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 4 sec. Tack Free Time 11 sec. Cup Density 2.49 pcf Resin Viscosity (77° F.) 580 cps
[0211] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Dim. Stability (100°F./95% R.H., 27 day, ASTM D-2126) −0.82% Water Absorption (28 day weight gain) 1.75% Water Vapor Permeability (with surface skin, ASTM E-96) 2.69 perm in. (permeability X inch) Water Vapor Permeability (without surface skin, ASTM E-96) 4.59 perm in.
EXAMPLE 2
[0212]
Phthalate Polyester (Stepanpol PS-3152)
37.02%
Terate Polyester (Terate-203)
14.81%
Propoxylated Glycerine (Voranol-270)
22.21%
Surfactant (L-5440)
2.04%
Cell Opener (Calcium Stearate)
0.30%
Amine Catalysts*
5.18%
Lead Catalyst (30% Pb Naphthanate)
0.22%
2-Ethylhexanoic Acid
0.37%
Diluents**
14.81%
Water
3.04%
*Amine catalysts: Polycat 8 = 2.22%; Dimethylethanolamine = 2.22%; Curithane 52 = 0.74%.
**Diluents: tris-isopropylchlorophosphate.
[0213] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 5 sec. Tack Free Time 12 sec. Cup Density 2.53 pcf Resin Viscosity (77° F.) 550 cps
[0214] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Density (with passline, ASTM D-1622) 2.76 pcf Density (no passline, ASTM D-1622) 2.19 pcf Compressive Strength (with passline, ASTM D-1621) 26.9 psi Compressive Strength (no passline, ASTM D-1621) 22.8 psi Shear Strength (with passline, ASTM C-273) 30.2 psi Shear Strength (no passline, ASTM C-273) 26.6 psi Tensile Strength (with passline, ASTM D-1623) 38.8 psi Tensile Strength (no passline, ASTM D-1623) 54.6 psi Friability (with passline, % wt. loss, ASTM C-421) 0.21% Friability (no passline, % wt. loss, ASTM C-421) 0.45% Dim. Stab. (with passline, −20° F., 28 day, ASTM D-2126) −0.01% Dim. Stab. (with passline, 158° F., 28 day, ASTM D-2126) −0.36% Dim. Stab. (w/passline, 100° F./95% R.H., ASTM D-2126) 0.91%
EXAMPLE 3
[0215]
Phthalate Polyester (Stepanpol PS-3152)
46.11%
Propoxylated Sucrose (Pluracol P-975)
23.05%
Surfactant (L-5440)
2.11%
Cell Opener (Calcium Stearate)
0.21%
Amine Catalysts*
5.77%
Lead Catalyst (30% Pb Naphthanate)
0.15%
2-Ethylhexanoic Acid
0.38%
Diluents**
19.21%
Water
3.01%
*Amine catalysts: Polycat 8 = 2.50%; Dimethylethanolamine = 2.50%; Curithane 52 = 0.77%.
**Diluents: tris-isopropylchlorophosphate = 11.53%; Makon 10 = 7.68%.
[0216] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 5 sec. Tack Free Time 12 sec. Cup Density 2.56 pcf Resin Viscosity (77° F.) 680 cps
[0217] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Density (with passline, ASTM D-1622) 2.64 pcf Density (no passline, ASTM D-1622) 2.25 pcf Compressive Strength (with passline, ASTM D-1621) 30.3 psi Compressive Strength (no passline, ASTM D-1621) 17.2 psi Shear Strength (with passline, ASTM C-273) 22.3 psi Shear Strength (no passline, ASTM C-273) 20.8 psi Tensile Strength (with passline, ASTM D-1623) 42.7 psi Tensile Strength (no passline, ASTM D-1623) 36.6 psi
EXAMPLE 4
[0218]
Phthalate Polyester (Stepanpol PS-3152)
45.27%
Mannich Polyol (Voranol 470X)
20.89%
Diethylene Glycol
3.48%
Surfactant (L-5440)
2.09%
Cell Opener (Calcium Stearate)
0.35%
Amine Catalysts*
3.55%
Diluents**
21.58%
Water
2.79%
*Amine catalysts: Polycat 8 = 1.25%; Dimethylethanolamine = 1.95%; Curithane 52 = 0.35%.
**Diluents: tris-isopropylchlorophosphate = 14.62%; Makon 10 = 6.96%.
[0219] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 6 sec. Tack Free Time 13 sec. Cup Density 2.81 pcf Resin Viscosity (77° F.) 600 cps
[0220] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Shear Strength (with passline, ASTM C-273) 32.7 psi Shear Strength (no passline, ASTM C-273) 46.6 psi Tensile Strength (with passline, ASTM D-1623) 64.7 psi Tensile Strength (no passline, ASTM D-1623) 99.2 psi Friability (with passline, % wt. loss, ASTM C-421) 0.61% Friability (no passline, % wt. loss, ASTM C-421) 1.35% Dim. Stab. (with passline, −20° F., 28 day, ASTM D-2126) 0.20% Dim. Stab. (no passline, −20° F., 28 day, ASTM D-2126) 0.20% Dim. Stab. (with passline, 158° F., 28 day, ASTM D-2126) 1.12% Dim. Stab. (no passline, 158° F., 28 day, ASTM D-2126) −0.91% Dim. Stab. (w/passline, 100° F./95% R.H., ASTM D-2126) 3.37% Dim. Stab. (no passline, 100° F./95% R.H., ASTM D-2126) −0.05% Dim. Stab. (w/passline, 158° F./95% R.H., ASTM D-2126) 0.45% Dim. Stab. (no passline, 158° F./95% R.H., ASTM D-2126) −2.60% Water Absorption (Gusmer H-2, GX-7, 800 psi, D-2842) 2.56% Water Absorption (Gus. H-2000, GX-7, 1500 psi, D-2842) 0.08%
EXAMPLE 5
[0221]
Phthalate Polyester (Stepanpol PS-3152)
36.93%
Mannich Polyol (Voranol 470X)
26.87%
Diethylene Glycol
6.72%
Surfactant (L-5440)
2.02%
Cell Opener (Calcium Stearate)
0.32%
Amine Catalysts*
3.77%
Diluents**
20.83%
Water
2.54%
*Amine catalysts: Polycat 8 = 1.21%; Dimethylethanolamine = 1.88%; Curithane 52 = 0.34%; Niax A-1 = 0.34%.
**Diluents: tris-isopropylchlorophosphate = 14.11%; Makon 10 = 6.72%.
[0222] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 5 sec. Tack Free Time 12 sec. Cup Density 2.94 pcf Resin Viscosity (77° F.) 550 cps
[0223] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Density (with passline, ASTM D-1622) 2.74 pcf Compressive Strength (with passline, ASTM D-1621) 34.7 psi Shear Strength (with passline, ASTM C-273) 38.1 psi Tensile Strength (with passline, ASTM D-1623) 65.6 psi Friability (with passline, % wt. loss, ASTM C-421) 0.33% Dim. Stab. (with passline, −20° F., 28 day, −0.44% ASTM D-2126) Dim. Stab. (with passline, 158° F., 28 day, −1.49% ASTM D-2126) Dim. Stab. (w/passline, 158° F./95% R.H., −3.13% ASTM D-2126) Water Vapor Permeability (with passline, 2.01 perm in. ASTM E-96)
[0224] Machine Sprayed Prop. (Gusmer H-2000; GX-7 Gun; 130° F. Temps.; 1500 psi Pressures)
Density (with passline, ASTM D-1622) 3.18 pcf Density (no passline, ASTM D-1622) 2.93 pcf Compressive Strength (with passline, ASTM D-1621) 41.3 psi Compressive Strength (no passline, ASTM D-1621) 40.0 psi Water Vapor Permeability (with passline, ASTM E-96) 1.23 perm in.
EXAMPLE 6
[0225]
Phthalate Polyester (Stepanpol PS-3152)
42.54%
Mannich Polyol (Markol RB 216)
15.47%
Diethylene Glycol
5.80%
Surfactant (L-5440)
1.90%
Cell Opener (Calcium Stearate)
0.48%
Amine Catalysts*
3.46%
Diluents**
27.85%
Water
2.49%
*Amine catalysts: Polycat 8 = 1.06%; Dimethylethanolamine = 1.66%; Curithane 52 = 0.39%; Niax A-1 = 0.35%.
**Diluents: tris-isopropylchlorophosphate = 16.25%; Makon 10 = 11.60%.
[0226] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 5 sec. Tack Free Time 11 sec. Cup Density 2.99 pcf Resin Viscosity (77° F.) 520 cps
[0227] Machine Sprayed Properties (Gusmer H-2; GX-7 Gun; 120° F. Temps.; 800 psi Pressures)
Density (with passline, ASTM D-1622) 3.82 pcf Density (no passline, ASTM D-1622) 3.22 pcf Compressive Strength (with passline, ASTM D-1621) 61.8 psi Compressive Strength (no passline, ASTM D-1621) 52.1 psi Shear Strength (with passline, ASTM C-273) 42.4 psi Shear Strength (no passline, ASTM C-273) 52.3 psi Tensile Strength (with passline, ASTM D-1623) 68.9 psi Tensile Strength (no passline, ASTM D-1623) 72.8 psi Friability (with passline, % wt. loss, ASTM C-421) 0.31% Friability (no passline, % wt. loss, ASTM C-421) 0.34% Water Absorption (no passline, ASTM D-2842) 0.58%
EXAMPLE 7
[0228]
Phthalate Polyester (Stepanpol PS-3152)
32.47%
Mannich Polyol (Silpol SIP-425LV)
21.65%
Diethylene Glycol
7.22%
Surfactant (L-5440)
1.77%
Cell Opener (Calcium Stearate)
0.39%
Amine Catalysts*
3.36%
Diluents**
30.97%
Water
2.16%
*Amine catalysts: Polycat 8 = 1.04%; Dimethylethanolamine = 1.63%; Curithane 52 = 0.36%; Niax A-1 = 0.33%.
**Diluents: tris-isopropylchlorophosphate = 15.15%; Makon 10 = 10.82%;Propylene Carbonate = 5.00%.
[0229] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 5 sec. Tack Free Time 13 sec. Cup Density 3.08 pcf Resin Viscosity (77° F.) 320 cps
[0230] Machine Sprayed Properties (GlasCraft; Probler Gun; 120° F. Temps.; 1500 psi Pressures)
Density (with passline, ASTM D-1622) 3.14 pcf Compressive Strength (with passline, ASTM D-1621) 43.0 psi Shear Strength (with passline, ASTM C-273) 46.8 psi Tensile Strength (with passline, ASTM D-1623) 76.4 psi Friability (with passline, % wt. loss, ASTM C-421) 0.71% Dim. Stab. (with passline, 158° F., 28 day, 0.58% ASTM D-2126) Dim. Stab. (w/passline, 100° F./95% R.H., −0.32% ASTM D-2126) Dim. Stab. (w/passline, 158° F./95% R.H., −2.44% ASTM D-2126) Water Vapor Permeability (with passline, ASTM E-96) 2.09 perm in. Water Absorption (no passline, ASTM D-2842) 0.79%
[0231] Machine Sprayed Prop. (Gusmer H-2000; GX-7 Gun; 130° F. Temps.; 1500 psi Pressures)
Density (with passline, ASTM D-1622) 3.18 pcf Compressive Strength (with passline, ASTM D-1621) 41.9 psi
EXAMPLE 8
[0232]
Polyethylene Glycol (Carbowax 400)
32.70%
Mannich Polyol (Silpol SIP-425LV)
21.80%
Diethylene Glycol
7.27%
Surfactant (L-5440)
0.75%
Cell Opener (Calcium Stearate)
0.40%
Amine Catalysts*
3.36%
Diluents**
31.17%
Water
2.55%
*Amine catalysts: Polycat 8 = 1.04%; Dimethylethanolamine = 1.63%; Curithane 52 = 0.36%; Niax A-1 = 0.33%.
**Diluents: tris-isopropylchlorophosphate = 15.26%; Makon 10 = 10.90%; Dibasic Esters = 5.00%.
[0233] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 Component Temperatures 77° F. Initiation Time 4 sec. Tack Free Time 12 sec. Cup Density 2.97 pcf Resin Viscosity (77° F.) 130 cps Cup Open Cell Content 95.7% Hand Mix Dimensional Stability <2.0% (158° F./95% R.H., 7 Days)
EXAMPLE 9
[0234]
Polyethylene Glycol (Carbowax 400)
39.79%
Mannich Polyol (Silpol SIP-425LV)
26.53%
Surfactant (L-5440)
0.75%
Cell Opener (Calcium Stearate)
0.40%
Amine Catalysts*
3.36%
Diluents**
26.62%
Water
2.55%
*Amine catalysts: Polycat 8 = 1.04%; Dimethylethanolamine = 1.63%; Curithane 52 = 0.36%; Niax A-1 = 0.33%.
**Diluents: tris-isopropylchlorophosphate = 15.56%; Makon 10 = 11.05%.
[0235] Hand Mix Properties
Mix Ratio (A/B by Volume) 1:1 (by volume) Component Temperatures 77° F. Initiation Time 4 sec. Tack Free Time 12 sec. Cup Density 3.02 pcf Resin Viscosity (77° F.) 180 cps Cup Open Cell Content 92.4% Hand Mix Dimensional Stability <2.0% (158° F./95% R.H., 7 Days)
[0236] The invention and the manner and process of making and using it, are now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make and use the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the present invention as set forth in the claims. To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification.
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The invention relates to methods and compositions for preparing all water blown spray polyurethane foams by reacting a polyisocyanate with a polyol blend. The polyol methods and compositions of the invention comprises a polyol component, water, a cell opening agent and a diluent. Polyurethane foams prepared according to the invention meet the physical and processing requirements stipulated by the industry.
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TECHNICAL FIELD
[0001] The present invention relates to a process for producing 2-chloro-3,3,3-trifluoropropene.
BACKGROUND ART
[0002] 2-Chloro-3,3,3-trifluoropropene (HCFO-1233xf) represented by the chemical formula: CF 3 CCl═CH 2 is a useful compound as an intermediate for producing various fluorocarbons, and also as a monomer component for various kinds of polymers.
[0003] A known process for producing 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) comprises reacting anhydrous hydrogen fluoride (HF) in a gas phase in the presence of a catalyst. For example, Patent Literature 1 listed below discloses a process comprising fluorination of 1,1,2,3-tetrachloropropene (HCO-1230xa) in a gas phase in the presence of a chromium-based catalyst. Patent Literature 2 listed below also reports a process in which HCO-1230xa is fluorinated in a gas phase, using a chromium-based catalyst.
[0004] However, the processes disclosed in the above literature are problematic in that since catalytic activity tends to deteriorate as a reaction proceeds, if the reaction is continued for a long period of time, catalytic activity decreases, resulting in decline in the selectivity of 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf).
[0005] For example, Patent Literature 3 listed below discloses a process for preparing 2,3,3,3-tetrafluoropropene (HFO-1234yf) by using 1,1,2,3-tetrachloropropene (HCO-1230xa), 1,1,1,2,3-pentachloropropane (HCC-240db), or the like as a starting material, fluorinating the starting material with HF to produce 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), and then adding HF to the thus-obtained HCFO-1233xf to produce 2-chloro-1,1,1,2-tetrafluoropropane (HCFC-244bb), followed by a dehydrochlorination reaction. In this process, decline in catalytic activity as the reaction proceeds is also unavoidable in a first step, which comprises fluorinating HCO-1230xa, HCC-240db, or the like with HF in the presence of a fluorination catalyst such as a fluorinated chromium oxide to produce HCFO-1233xf. For example, Example 1 of Patent Literature 3, which describes a step of preparing HCFO-1233xf by reacting HCO-1230xa as a starting material with HF in the presence of fluorinated Cr 2 O 3 , discloses that the selectivity of HCFO-1233xf was decreased to about 83% after 650 hours of reaction time, and that the reaction was stopped due to loss of catalytic activity.
[0006] Patent Literature 4 listed below discloses a process comprising fluorination of 1,1,2,3-tetrachloropropene (HCO-1230xa), 1,1,1,2,3-pentachloropropane (HCC-240db), 2,3,3,3-tetrachloropropene (HCO-1230xf), or the like in the presence of a fluorination catalyst, in which catalyst deterioration is suppressed by adding an amine-based stabilizer, hydroquinone-based stabilizer, or other stabilizers.
[0007] However, according to this process, selectivity is decreased, and a satisfactory effect of suppressing decrease in catalytic activity cannot be attained. Thus, a periodic catalyst activation treatment is inevitable.
[0008] Patent Literature 5 listed below discloses a process in which 1,1,2,3-tetrachloropropene (HCO-1230xa) is reacted with HF in a liquid phase in the presence of an antimony halide catalyst. However, in addition to the difficulty in handling the catalyst, this process is not economical due to the occurrence of reactor corrosion, the necessity of waste treatment, and the like. Thus, the process is not suitable as an industrial production process. Furthermore, Patent Literature 6 listed below reports that 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) can be produced by reacting HCO-1230xa with HF in a liquid phase under catalyst-free conditions. However, because it requires a long reaction time due to a slow reaction rate; a large excess of HF; severe reaction conditions under high pressure; etc., this process is not suitable as an industrial scale production process.
[0009] As described above, a process for continuously producing 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) at a high yield in a simple and economical manner has not yet been established.
CITATION LIST
Patent Literature
[0010] PTL 1: WO 2007/079431
[0011] PTL 2: WO 2008/054781
[0012] PTL 3: Japanese Unexamined Patent Publication No. 2009-227675
[0013] PTL 4: U.S. Pat. No. 7,795,480
[0014] PTL 5: US 2009/0030247 A1
[0015] PTL 6: WO 2009/003084 A1
SUMMARY OF INVENTION
Technical Problem
[0016] The present invention has been accomplished in view of the foregoing state of the art, and its primary object is to provide a process for efficiently producing 2-chloro-3,3,3-trifluoropropene in a simple and economically advantageous manner even on an industrial scale.
Solution to Problem
[0017] The present inventors conducted extensive research to achieve the above object. As a result, the inventors found that in a process for producing 2-chloro-3,3,3-trifluoropropene by using a chloropropane compound or a chloropropene compound represented by a specific formula as a starting material and reacting the starting material with hydrogen fluoride in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating, decrease in catalytic activity can be suppressed when the reaction is conducted in the presence of molecular chlorine or when the water content in the reaction system is controlled at a very low concentration. In particular, the inventors found that when the reaction is conducted in the presence of molecular chlorine and the water content in the reaction system is controlled at a low concentration, decrease in catalytic activity can be suppressed over a long period of time, and 2-chloro-3,3,3-trifluoropropene can be continuously produced at a high yield for a long period of time. The present invention has been accomplished based on these findings.
[0018] More specifically, the present invention provides the following process for producing 2-chloro-3,3,3-trifluoropropene.
[0000] Item 1. A process for producing 2-chloro-3,3,3-trifluoropropene, comprising:
[0019] reacting anhydrous hydrogen fluoride with at least one chlorine-containing compound in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating,
[0020] the at least one chlorine-containing compound being selected from the group consisting of chloropropanes represented by Formula (1): CXYZCHClCH 2 A, wherein X, Y, and Z are the same or different and each is F or Cl, and A is a halogen atom, chloropropenes represented by Formula (2): CXYZCCl═CH 2 , wherein X, Y, and Z are the same or different and each is F or Cl, and chloropropenes represented by Formula (3): CXY═CClCH 2 A, wherein X and Y are the same or different and each is F or Cl, and A is a halogen atom, and
[0021] the reaction being carried out in the presence of molecular chlorine.
[0000] Item 2. A process for producing 2-chloro-3,3,3-trifluoropropene, comprising:
[0022] reacting anhydrous hydrogen fluoride with at least one chlorine-containing compound in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating,
[0023] the at least one chlorine-containing compound being selected from the group consisting of chloropropanes represented by Formula (1): CXYZCHClCH 2 A, wherein X, Y, and Z are the same or different and each is F or Cl, and A is a halogen atom, chloropropenes represented by Formula (2): CXYZCCl═CH 2 , wherein X, Y, and Z are the same or different and each is F or Cl, and chloropropenes represented by Formula (3): CXY═CClCH 2 A, wherein X and Y are the same or different and each is F or Cl, and A is a halogen atom, and
[0024] the reaction being carried out with a water content in the reaction system of 300 ppm or less based on the total weight of the at least one chlorine-containing compound used as a starting material.
[0000] Item 3. A process for producing 2-chloro-3,3,3-trifluoropropene, comprising:
[0025] reacting anhydrous hydrogen fluoride with at least one chlorine-containing compound in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating,
[0026] the at least one chlorine-containing compound being selected from the group consisting of chloropropanes represented by Formula (1): CXYZCHClCH 2 A, wherein X, Y, and Z are the same or different and each is F or Cl, and A is a halogen atom, chloropropenes represented by Formula (2): CXYZCCl═CH 2 , wherein X, Y, and Z are the same or different and each is F or Cl, and chloropropenes represented by Formula (3): CXY═CClCH 2 A, wherein X and Y are the same or different and each is F or Cl, and A is a halogen atom, and
[0027] the reaction being carried out in the presence of molecular chlorine and with a water content in the reaction system of 300 ppm or less based on the total weight of the at least one chlorine-containing compound used as a starting material.
[0000] Item 4. The process according to Item 1 or 3, wherein the amount of molecular chlorine supplied is 0.001 to 0.3 moles per mole of the at least one chlorine-containing compound used as a starting material.
Item 5. The process according to Item 4, wherein the at least one chlorine-containing compound used as a starting material is selected from the group consisting of chloropropenes represented by Formula (2): CXYZCCl═CH 2 , wherein X, Y, and Z are the same as above, and chloropropenes represented by Formula (3): CXY═CClCH 2 A, wherein X, Y, and A are the same as above, and the amount of molecular chlorine supplied is 0.001 to 0.2 moles per mole of the at least one chlorine-containing compound.
Item 6. The process according to Item 2 or 3, wherein the reaction is carried out with a water content in the reaction system of 100 ppm or less based on the total weight of the at least one chlorine-containing compound used as a starting material.
Item 7. The process according to any one of Items 1 to 6, wherein the chromium atom-containing fluorination catalyst is at least one catalyst selected from the group consisting of chromium oxides and fluorinated chromium oxides.
Item 8. The process according to Item 7, wherein the fluorination catalyst is at least one catalyst selected from the group consisting of chromium oxides represented by the composition formula: CrO m (1.5<m<3) and fluorinated chromium oxides obtained by fluorinating the chromium oxides.
Item 9. The process according to any one of Items 1 to 8, wherein the reaction is carried out at a temperature in the range of 200 to 380° C.
Item 10. The process according to any one of Items 1 to 9, wherein the reaction is carried out using 3 moles or more of anhydrous hydrogen fluoride per mole of the at least one chlorine-containing compound used as a starting material.
Item 11. The process according to any one of Items 1 to 10, wherein the at least one chlorine-containing compound used as a starting material is selected from the group consisting of 1,1,1,2,3-pentachloropropane and 1,1,2,3-tetrachloropropene.
[0028] Hereinafter, the process for producing 2-chloro-3,3,3-trifluoropropene of the present invention is specifically described.
(I) Starting Compound
[0029] In the present invention, used as a starting material is at least one chlorine-containing compound selected from the group consisting of chloropropanes represented by Formula (1): CXYZCHClCH 2 A, wherein X, Y, and Z are the same or different and each is F or Cl, and A is a halogen atom, chloropropenes represented by Formula (2): CXYZCCl═CH 2 , wherein X, Y, and Z are the same or different and each is F or Cl, and chloropropenes represented by Formula (3): CXY═CClCH 2 A, wherein X and Y are the same or different and each is F or Cl, and A is a halogen atom. Examples of the halogen atom represented by A in Formulas (1) and (3) above include F, Cl, Br, and I.
[0030] When these chlorine-containing compounds are used as a starting material and reacted with anhydrous hydrogen fluoride according to the below-described conditions, the desired 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) can be continuously produced for a long period of time at a high yield in a single-step reaction.
[0031] Among the starting compounds, specific examples of the chloropropanes represented by Formula (1): CXYZCHClCH 2 A include 1,1,1,2,3-pentachloropropane (CCl═CHClCH 2 Cl) (HCC-240db), 1-fluoro-1,1,2,3-tetrachloropropane (CFCl 2 CHClCH 2 Cl) (HCFC241db), 1,1-difluoro-1,2,3-trichloropropane (CF 2 ClCHClCH 2 Cl) (HCFC-242dc), and 2,3-dichloro-1,1,1-trifluoropropane (CF 3 CHClCH 2 Cl) (HCFC-243db). Specific examples of the chloropropenes represented by Formula (2): CXYZCCl═CH 2 include 2,3,3,3-tetrachloropropene(CCl 3 CCl═CH 2 ) (HCO-1230xf) and 2,3-dichloro-3,3-difluoropropene (CF 2 ClCCl═CH 2 ) (HCFO-1232xf). Specific examples of the chloropropenes represented by Formula (3): CXY═CClCH 2 A include 1,1,2,3-tetrachloropropene (CCl 2 ═CClCH 2 Cl) (HCO-1230xa).
[0032] All of these starting compounds are known compounds that can be easily obtained.
[0033] In the present invention, the starting compounds can be used singly, or in a combination of two or more.
(II) Reaction Process
[0034] The production process of the present invention is a process that comprises reacting at least one of the above-described starting compounds with anhydrous hydrogen fluoride in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating, the reaction being conducted in the presence of molecular chlorine or with a water content in the reaction system of 300 ppm or less based on the total weight of the at least one chlorine-containing compound used as a starting material.
[0035] When the starting compound is reacted with anhydrous hydrogen fluoride under such conditions, the desired 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) can be obtained with high selectivity in a single-step reaction. Further, decrease in catalytic activity is suppressed, and HCFO-1233xf can be continuously produced for a long period of time with high selectivity and a high yield. Accordingly, the production process of the present invention is very useful as a process for producing HCFO-1233xf on an industrial scale.
[0036] Hereinafter, the process in which the reaction is conducted in the presence of molecular chlorine, and the process in which the water content is controlled are specifically described.
[0000] (1) Process in which the Reaction is Conducted in the Presence of Molecular Chlorine:
[0037] A first aspect of the present invention is a process in which the reaction is conducted in the presence of molecular chlorine. In this process, when the aforementioned starting compound is reacted with hydrogen fluoride in a gas phase, using a chromium atom-containing fluorination catalyst as a catalyst, the reaction is conducted in the presence of molecular chlorine.
[0038] In this case, in the process in which the reaction is conducted in a gas phase, the starting compound may be in a liquid form when supplied as long as the starting compound is in a gaseous form when it comes into contact with anhydrous hydrogen. fluoride within the reaction temperature range described below. For example, when the starting compound is liquid at an ordinary temperature and ordinary pressure, the starting compound is vaporized using a vaporizer (vaporization region), passed through a preheating region, and then supplied to a mixing region wherein the starting compound is contacted with anhydrous hydrogen fluoride, whereby the reaction can be conducted in a gas phase. The reaction may also be carried out by supplying the starting compound in a liquid form to a reactor, heating a catalyst layer placed in the reactor to the vaporization temperature or higher of the starting compound, and vaporizing the starting compound when the compound enters a reaction range to react with hydrogen fluoride.
[0039] The reaction may be generally conducted by supplying anhydrous hydrogen fluoride to a reactor in a gas phase together with the starting compound. The amount of anhydrous hydrogen fluoride to be used is not particularly limited. To achieve high selectivity of 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf), the amount of anhydrous hydrogen fluoride is preferably about 3 moles or more, and more preferably about 8 moles or more, per mole of the chlorine-containing compound used as a starting material. When the amount of anhydrous hydrogen fluoride is less than this range, the selectivity of HCFO-1233xf and catalytic activity tend to decrease. Thus, an amount of anhydrous hydrogen fluoride less than the above range is unfavorable.
[0040] The upper limit of the amount of anhydrous hydrogen fluoride is not particularly limited. Even if the amount of hydrogen fluoride is excessively large, there is less influence on the selectivity and conversion. However, the productivity is decreased because of increase in the amount of hydrogen fluoride to be separated during purification. For this reason, the amount of anhydrous hydrogen fluoride is generally preferably about 100 moles or less and more preferably about 50 moles or less, per mole of the chlorine-containing compound used as a starting material.
[0041] In the production process of the present invention, the chlorine-containing compound used as a starting material is reacted with anhydrous hydrogen fluoride, using a chromium atom-containing fluorination catalyst as a catalyst, in the presence of molecular chlorine according to the below-described conditions. This process enables decrease in catalytic activity to be suppressed, and the selectivity of 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) to be maintained at a high value.
[0042] Examples of usable chromium atom-containing fluorination catalysts include halides and oxides. Of them, as examples of preferred catalysts, CrCl 3 , CrF 3 , Cr 2 O 3 , CrO 2 , CrO 3 , and the like can be mentioned. These catalysts may be supported on a carrier. There is no particular limitation on the carrier, and examples of the carrier include porous alumina silicates typified by zeolites, aluminum oxides, silicon oxides, activated carbons, titanium oxides, zirconia oxides, zinc oxides, and aluminum fluorides.
[0043] In the present invention, it is particularly preferable to use at least one catalyst selected from the group consisting of chromium oxides and fluorinated chromium oxides. Examples of such chromium oxides and fluorinated chromium oxides include crystalline chromium oxides, amorphous chromium oxides, and fluorinated products thereof.
[0044] There is no particular limitation on the composition of the chromium oxides. For example, the chromium oxides are oxides represented by the composition formula: CrO m , wherein m is preferably in the range of 1.5<m<3 and more preferably 2<m<2.75. Chromium oxide catalysts in any form, such as powder form and pellet form may be used, as long as they are suitable for the reaction. Of them, chromium oxide catalysts in the form of pellets are preferable. The above-mentioned chromium oxide catalysts can be produced, for example, by the process disclosed in Japanese Unexamined Patent Publication No. H5-146680.
[0045] The fluorinated chromium oxides can be prepared, for example, by fluorinating the chromium oxides obtained by the above-described process with hydrogen fluoride (HF treatment). The fluorination temperature may be, for example, about 100 to about 460° C. For instance, the fluorination of a chromium oxide may be carried out by supplying anhydrous hydrogen fluoride to a reactor in which the chromium oxide is placed. After the chromium oxide is fluorinated in this manner, the starting material is supplied to the reactor, thereby allowing the reaction for producing the desired product to proceed efficiently.
[0046] Since the reaction is carried out in the presence of hydrogen fluoride in the process of the present invention, even in the case where a chromium oxide is not fluorinated in advance, the fluorination of catalyst will proceed during the reaction.
[0047] The degree of fluorination is not particularly limited. For example, a chromium oxide having a fluorine content of about 5 to about 30 wt % may be suitably used.
[0048] The surface area of the catalyst is varied as a result of the fluorination treatment. In general, the greater the specific surface area, the higher the activity. The specific surface area of chromium oxide after fluorination is preferably about 25 to about 130 m 2 /g, but is not limited to this range.
[0049] Further, the catalyst disclosed in Japanese Unexamined Patent Publication No. H11-171806, which comprises, as a main component, a chromium compound containing at least one metallic element selected from the group consisting of indium, gallium, cobalt, nickel, zinc, and aluminum, may be used as a chromium oxide catalyst or a fluorinated chromium oxide catalyst.
[0050] There is no particular limitation on the method of using the catalyst. The catalyst may be used so that the starting material gases are sufficiently brought into contact with the catalyst. For example, a method of forming a catalyst layer by immobilizing a catalyst in a reactor, a method of dispersing a catalyst in a fluidized bed, or other methods can be employed.
[0051] The production process of the present invention requires the reaction to be conducted in the presence of molecular chlorine when the chlorine-containing compound is reacted with anhydrous hydrogen fluoride, using the above catalyst. Conducting the reaction in the presence of molecular chlorine makes it possible to suppress decrease in catalytic activity and to continuously produce 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) with high selectivity for a long period of time.
[0052] There is no particular limitation on the process in which the reaction is conducted in the presence of molecular chlorine. The reaction may be generally conducted by supplying molecular chlorine to a reactor together with the chlorine-containing compound used as a starting material. Alternatively, molecular chlorine may also be supplied to a reactor after being dissolved in the chlorine-containing compound.
[0053] The amount of molecular chlorine supplied is preferably about 0.001 to about 0.3 moles, more preferably about 0.001 to about 0.05 moles, and particularly preferably about 0.002 to about 0.03 moles, per mole of the chlorine-containing compound used as a starting material. In the case where at least one chlorine-containing compound selected from the group consisting of chloropropenes represented by Formula (2): CXYZCCl═CH 2 and chloropropenes represented by Formula (3): CXY═CClCH 2 A is used as a starting material, in order to more effectively suppress decrease in catalytic activity, the amount of molecular chlorine supplied is preferably about 0.001 to about 0.2 moles, and more preferably about 0.001 to about 0.1 moles, per mole of the chlorine-containing compound used as a starting material.
[0054] If the amount of molecular chlorine supplied is excessively small, the effect of suppressing decrease in catalytic activity cannot be sufficiently attained; whereas if the amount of molecular chlorine supplied is excessively large, polychlorinated products, such as 1,2-dichloro-3,3,3-trifluoropropene, are increased, resulting in decline in the selectivity of 2-chloro-3,3,3-trifluoropropene (HCFC-1233xf). Thus, an excessively small or large amount of molecular chlorine is not desirable.
[0055] As one specific embodiment of the process of the present invention, a process can be mentioned in which a fluorination catalyst is placed into a tubular flow reactor, and the above-mentioned chlorine-containing compound used as a starting material, anhydrous hydrogen fluoride, and molecular chlorine are introduced to the reactor.
[0056] The reactor used is preferably made of a material resistant to the corrosive action of hydrogen fluoride, such as Hastelloy, Inconel, Monel, or the like.
[0057] The starting material may be supplied to the reactor as is; or a gas that is inert to the starting material and catalyst, such as nitrogen, helium, and argon, may coexist. The concentration of the inert gas is about 0 to about 80 mol % based on the amount of the gaseous components introduced into the reactor, i.e., the amount of the chlorine-containing compound, anhydrous hydrogen fluoride, and chlorine gas plus the amount of the inert gas.
[0058] Moreover, in the process of the present invention, oxygen may be supplied at the same time chlorine is supplied. By doing so, decrease in catalytic activity can be further suppressed. The amount of oxygen supplied is not particularly limited and is preferably about 0.001 to about 0.5 moles, per mole of the chlorine-containing compound used as a starting material.
[0059] The lower limit of the reaction temperature is not particularly limited because the lower reaction temperature is advantageous in terms of less decomposition of the starting material and product. However, if the temperature is excessively low, a chlorine-containing compound conversion tends to decrease. For this reason, the reaction temperature is preferably 200° C. or more, and more preferably 220° C. or more.
[0060] Regarding the upper limit of the reaction temperature, an excessively high reaction temperature is not preferable because an excessively high reaction temperature notably decreases catalytic activity due to decomposition of the starting material; and easily causes formation of C 1 , C 2 compounds, CF 3 CH═CHF, and isomers, such as CF 3 CH═CHCl, as by-products. For this reason, the reaction temperature is preferably 380° C. or less, and more preferably 350° C. or less.
[0061] Note that in the case where only oxygen is used for catalytic activation without using chlorine, the activation effect is difficult to obtain at a reaction temperature of less than 300° C., and thus the reaction temperature needs to be increased; additionally, even if the reaction temperature is increased to about 350° C., the amount of oxygen required for the activation becomes large, causing unfavorable effects such as the necessity of dealing with combustible gas.
[0062] The pressure during the reaction is not particularly limited, and the reaction may be conducted under reduced pressure, ordinary pressure, or increased pressure. Although the reaction may be generally carried out at pressure near atmospheric pressure (0.1 MPa), it can also proceed smoothly under reduced pressure of less than 0.1 MPa. Furthermore, the reaction may be conducted under increased pressure within a range in which the starting material does not liquefy.
[0063] There is no limitation on the contact time. For example, the contact time, which is represented by W/F 0 , is preferably adjusted to about 0.5 to about 70 g·sec/mL, and more preferably about 1 to about 50 g·sec/mL. W/F 0 is the ratio of the amount of catalyst used W(g) to the total flow rate F 0 (flow rate at 0° C., 0.1 MPa: mL/sec) of the starting material gases supplied to the reaction system. The total flow rate of the starting material gases in this case refers to the total flow rate of the chlorine-containing compound, anhydrous hydrogen fluoride, and chlorine. In the case where an inert gas, oxygen, or other gases are further used, the total flow rate of the starting material gases refers to the total flow rate of the chlorine-containing compound, anhydrous hydrogen fluoride, and chlorine plus the flow rate of the inert gas, oxygen, or other gases.
[0064] In the production process of the present invention, other compounds may be present in the reaction system within a range that satisfies the above-described conditions, as long as they do not adversely affect the effects of the present invention.
[0065] For example, the known stabilizers disclosed in Patent Literature 4 (U.S. Pat. No. 7,795,480) described above, such as an amine-based stabilizer and hydroquinone-based stabilizer, may be present in the reaction system.
[0000] (ii) Process in which the Water Content in the Reaction System is Controlled:
[0066] A second aspect of the present invention is a process in which the water content in the reaction system is controlled. In this process, when the aforementioned chlorine-containing compound as a starting material is reacted with hydrogen fluoride in a gas phase, using a chromium atom-containing fluorination catalyst as a catalyst, the water content in the reaction system is controlled at a small amount.
[0067] The type of catalyst to be used, specific reaction process, reaction conditions, and the like may be the same as in the above-described case in which the reaction is conducted in the presence of molecular chlorine. Each component, such as oxygen, inert gas and stabilizer, is also usable in the same conditions as in the case in which the reaction is conducted in the presence of molecular chlorine. By controlling the water content in the reaction system at a small amount, decrease in catalytic activity can be suppressed in the same reaction temperature range as in the case in which the reaction is conducted in the presence of molecular chlorine.
[0068] In the process in which the water content in the reaction system is controlled, it is necessary for the water content in the reaction system when the starting compound and hydrogen fluoride are reacted in a gas phase to be 300 ppm or less, preferably 100 ppm or less, based on the weight of the chlorine-containing compound used as a starting material. A water content exceeding this range deactivates the catalyst and increases the intermediate products HCFO-1232xf and HCO-1230xa; thus, it is not preferable in continuous production.
[0069] The water content in the reaction system refers to the water content present when the chlorine-containing compound and anhydrous hydrogen fluoride contact the catalyst and undergo reaction; i.e., the water content of the chlorine-containing compound used as a starting material and anhydrous hydrogen fluoride, plus the water content of components added as necessary, such as oxygen, inert gas, and stabilizer.
[0070] There is no particular limitation on the method of decreasing the water content in the reaction system. The chlorine-containing compound used as a starting material, hydrogen fluoride, and other additional components may be dehydrated by a known method prior to the reaction. A method of supplying the previously dehydrated materials to the reaction; a method of dehydrating the starting material, hydrogen fluoride, and other additional components, and subsequently supplying them to the reaction system; or other methods can be suitably employed.
[0071] As the method of dehydrating the chlorine-containing compound used as a starting material, for example, a distillation method or a method using a dehydrating agent may be employed, and a method of removing water using a dehydrating agent is preferable in terms of efficiency. As the method of removing water using a dehydrating agent, for example, a method of adsorbing water using a zeolite is preferable. The form of zeolite is not particularly limited, and a zeolite in the form of powder, granules, or pellets may be used. Regarding the pore size of zeolite, a zeolite having a pore size of about 2.0 to about 6.0 Å may be used. There is no particularly limitation on the method of bringing the chlorine-containing compound into contact with a zeolite, and it is generally preferable in terms of efficiency that the chlorine-containing compound in a gaseous form or liquid form is flowed into a container in which a zeolite is placed.
[0072] Moreover, the water content in the reaction system can also be decreased by a method in which a dehydrating agent packed bed is provided before a catalyst packed bed in a reactor (reaction tube) without separately providing a container containing a dehydrating agent, and the starting material supplied in the reactor (reaction tube) is passed through the dehydrating agent packed bed and then passed through the catalyst packed bed. The location of the dehydrating agent packed bed is not particularly limited, and the dehydrating agent packed bed is preferably disposed in a portion at 100° C. or less before the catalyst packed bed for the reason that a temperature exceeding 100° C. causes desorption of adsorbed water from the dehydrating agent.
[0073] As the method of dehydrating hydrogen fluoride, for example, a distillation method or other methods may be used.
[0074] Specific dehydration conditions may be determined by, for example, preliminarily conducting an experiment according to the water content of the starting material, additional components, etc., to be used; the type and structure of a device to be used; and other conditions so that the water content in the reaction system is adjusted to a desired value.
[0000] (iii) Process in which the Water Content is Controlled and the Reaction is Conducted in the Presence of Molecular Chlorine:
[0075] In the process for producing 2-chloro-3,3,3-trifluoropropene of the present invention, it is preferable that the reaction is conducted, in particular, in the presence of molecular chlorine and with a water content in the reaction system of 300 ppm or less based on the weight of the chlorine-containing compound used as a starting material. Reaction conditions in this case may be the same as those in (i) and (ii) described above.
[0076] The reaction of the chlorine-containing compound used as a starting material with hydrogen fluoride under these conditions enables, in particular, notable suppression of decrease in catalytic activity, as well as production of HCFO-1233xf with high selectivity and a high yield for a long period of time.
(III) Reaction Product
[0077] According to the above-mentioned processes of the present invention, the desired 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) can be obtained with high selectivity in a single-step reaction from at least one of the chlorine-containing compounds represented by Formulas (1) to (3), used as a starting material; additionally, in the case where the reaction continues, decrease in catalytic activity is slight, and high selectivity can be maintained for a long period of time.
[0078] In the process of the present invention, 2-chloro-3,3,3-trifluoropropene (HCFO-1233xf) can be separated and collected by distillation of the product obtained at the reactor outlet or by other methods.
[0079] 1,1,1,2,2-pentafluoropropane (HFC-245cb), a main component of by-products contained in the product, can be easily converted to 2,3,3,3-tetrafluoropropene (HFO-1234yf) by dehydrofluorination reaction. Accordingly, 1,1,1,2,2-pentafluoropropane (HFC-245cb) and 2,3,3,3-tetrafluoropropene (HFO-1234yf) (which is regarded as a final object product), which are contained in the product, can also be used effectively as useful compounds.
Advantageous Effects of Invention
[0080] According to the process of the present invention, 2-chloro-3,3,3-trifluoropropene (HCFC-1233xf) can be produced at a high yield in a single-step reaction, using a chlorine-containing compound represented by a specific formula as a starting material; additionally, in the case where the reaction continues, decrease in catalytic activity is slight, and high selectivity can be maintained for a long period of time.
[0081] In particular, in the case where the reaction is conducted in the presence of molecular chlorine, and the water content is controlled at a small amount, decrease in catalytic activity can be suppressed, and HCFO-1233xf can be obtained with high selectivity and a high yield over a long period of time.
[0082] Accordingly, the process of the present invention enables 2-chloro-3,3,3-trifluoropropene (HCFC-1233xf) to be continuously produced at a high yield for a long period of time without requiring complicated treatments, such as catalyst replacement and catalyst regeneration treatment.
[0083] Therefore, the process of the present invention is a highly advantageous process as a process for producing 2-chloro-3,3,3-trifluoropropene (HCFC-1233xf) from an industrial standpoint.
DESCRIPTION OF EMBODIMENTS
[0084] Hereinafter, the present invention is described in more detail with reference to Examples.
EXAMPLE 1
[0085] 10 g of a catalyst (fluorine content: about 15.0% by weight) obtained by fluorinating a chromium oxide represented by the composition formula: CrO 2 was placed into a tubular Hastelloy reactor with an inner diameter of 15 mm and a length of 1 m. The reactor was maintained at atmospheric pressure (0.1 MPa) and 250° C., and anhydrous hydrogen fluoride (HF) gas having a water content of 50 ppm was supplied to the reactor at a flow rate of 114 mL/min (flow rate at 0° C., 0.1 MPa) for 1 hour. CCl 3 CHClCH 2 Cl (HCC-240db) having a water content of 40 ppm was then supplied at a flow rate of 5.6 mL/min (gas flow rate at 0° C., 0.1 MPa). The water content in the reaction system at this point based on the weight of HCC-240db was 134 ppm. The molar ratio of HF:HCC-240db was 20:1. The contact time (W/F 0 ) was 5.0 gsec/cc.
[0086] The outlet gas from the reactor after 20 hours, 100 hours, and 200 hours was analyzed using gas chromatography. Table 1 shows the analysis results.
[0087] Under these conditions, the selectivity of HCFO-1233xf was maintained at a high value: 96.7% after 20 hours, and 93.9% after 200 hours. The rate of decline in the total selectivity of useful compounds of HCFO-1233xf, HFC-245cb, and HFO-1234yf was 0.37%/day; thus, the decline in the selectivity was suppressed.
[0000]
TABLE 1
Reaction Time (hr)
20
100
200
Conversion of HCC-240db (%)
99.9
99.4
98.9
Selectivity of HFO-1234yf (%)
0.4
0.2
0.1
Selectivity of HFC-245cb (%)
0.9
0.2
0.0
Selectivity of HCFO-1233xf (%)
96.7
95.8
93.9
Selectivity of HCFO-1232xf (%)
0.3
0.9
1.3
Selectivity of HCO-1230xa (%)
0.2
0.7
1.1
Others (%)
1.5
2.2
3.6
Comparative Example 1
[0088] A reaction was conducted under the same conditions as in Example 1, except that CCl 3 CHClCH 2 Cl (HCC-240db) having a water content of 250 ppm was supplied. The water content in the reaction system at this point based on the weight of HCC-240db was 340 ppm. Table 2 shows the analysis results of the outlet gas.
[0089] Under these conditions, the selectivity of HCFO-1233xf was 95.6% after 20 hours, and decreased to 89.8% after 200 hours. The total selectivity of useful compounds of HCFO-1233xf, HFC-245 cb, and HFO-1234yf was decreased at 0.77%/day.
[0000]
TABLE 2
Reaction time (hr)
20
100
200
Conversion of HCC-240db (%)
99.8
99.2
98.0
Selectivity of HFO-1234yf (%)
0.2
0.1
0.0
Selectivity of HFC-245cb (%)
0.4
0.0
0.0
Selectivity of HCFO-1233xf (%)
95.6
92.9
89.8
Selectivity of HCFO-1232xf (%)
0.5
2.4
4.6
Selectivity of HCO-1230xa (%)
0.5
1.2
1.8
Others (%)
1.5
3.4
3.8
EXAMPLE 2
[0090] A reaction was carried out under the same conditions as in Example 1, except that CCl 3 CHClCH 2 Cl (HCC-240db) in which 0.008 moles of molecular chlorine per mole of HCC-240db was dissolved was supplied. The water content in the reaction system at this point based on the weight of HCC-240db was 134 ppm. Table 3 shows the analysis results of the outlet gas.
[0091] Under these conditions, the selectivity of HCFO-1233xf was maintained at a high value: 96.1% after 20 hours, and 96.3% after 200 hours. The total selectivity of useful compounds of HCFO-1233xf, HFC-245cb, and HFO-1234yf had a decline rate of 0.03%/day, and was maintained at an almost constant value.
[0000]
TABLE 3
Reaction Time (hr)
20
100
200
Conversion of HCC-240db (%)
99.9
100
99.9
Selectivity of HFO-1234yf (%)
0.3
0.3
0.2
Selectivity of HFC-245cb (%)
0.6
0.4
0.3
Selectivity of HCFO-1233xf (%)
96.1
96.2
96.3
Selectivity of HCFO-1232xf (%)
0.2
0.1
0.3
Selectivity of HCO-1230xa (%)
0.2
0.1
0.1
Others (%)
1.6
2.9
5.1
EXAMPLE 3
[0092] CCl 3 CHClCH 2 Cl (HCC-240db) having a water content of 15 ppm was prepared by adding molecular sieves 4A (100 g) to HCC-240db (1 kg) having a water content of 40 ppm, which was used in Example 1, hermetically sealing the resulting mixture, and allowing the mixture to stand for 24 hours.
[0093] In addition, anhydrous hydrogen fluoride (HF) having a water content of 10 ppm was prepared by placing anhydrous hydrogen fluoride (HF) (800 g) having a water content of 50 ppm, which was used in Example 1, in a 1 L polytetrafluoroethylene container equipped with a reflux condenser and a distillation tube, and heating the container to collect HF.
[0094] A reaction was carried out under the same conditions as in Example 1, except that CCl 3 CHClCH 2 Cl (HCC-240db) having a water content of 15 ppm and anhydrous hydrogen fluoride (HF) gas having a water content of 10 ppm obtained in the above manner were supplied. The water content in the reaction system at this point based on the weight of HCC-240db was 34 ppm. Table 4 shows the analysis results of the outlet gas.
[0095] Under these conditions, the selectivity of HCFO-1233xf was maintained at a high value: 96.8% after 20 hours and 95.6% after 200 hours. The rate of decline in total selectivity of useful compounds of HCFO-1233xf, HFC-245cb, and HFO-1234yf was 0.24%/day; thus, the decline in the selectivity was suppressed.
[0000]
TABLE 4
Reaction Time (hr)
20
100
200
Conversion of HCC-240db (%)
100
99.8
99.5
Selectivity of HFO-1234yf (%)
0.5
0.3
0.2
Selectivity of HFC-245cb (%)
0.7
0.6
0.4
Selectivity of HCFO-1233xf (%)
96.8
96.1
95.6
Selectivity of HCFO-1232xf (%)
0.3
0.6
1.0
Selectivity of HCO-1230xa (%)
0.2
0.5
0.8
Others (%)
1.5
1.9
2.0
EXAMPLE 4
[0096] A reaction was carried out under the same conditions as in Comparative Example 1, except that chlorine gas was supplied at 0.14 mL/min (gas flow rate at 0° C., 0.1 MPa) concurrently with supply of CCl 3 CHClCH 2 Cl (HCC-240db). The water content in the reaction system at this point based on the weight of HCC-240db was 340 ppm. Table 5 shows the analysis results of the outlet gas.
[0097] Under these conditions, the selectivity of HCFO-1233xf was maintained at a high value: 96.2% after 20 hours, and 95.3% after 200 hours. The rate of decline in total selectivity of useful compounds of HCFO-1233xf, HFC-245cb, and HFO-1234yf was 0.11%/day; thus, the decline in the selectivity was suppressed.
[0000]
TABLE 5
Reaction Time (hr)
20
100
200
Conversion of HCC-240db (%)
100
100
100
Selectivity of HFO-1234yf (%)
0.2
0.1
0.1
Selectivity of HFC-245cb (%)
0.3
0.2
0.2
Selectivity of HCFO-1233xf (%)
96.2
95.9
95.3
Selectivity of HCFO-1232xf (%)
0.1
0.2
0.3
Selectivity of HCO-1230xa (%)
0.0
0.1
0.2
Others (%)
3.2
3.4
3.9
EXAMPLE 5
[0098] A reaction was carried out under the same conditions as in Example 1, except that chlorine gas was supplied at 0.14 mL/min (gas flow rate at 0° C., 0.1 MPa) concurrently with supply of CCl 3 CHClCH 2 Cl (HCC-240db). At this point, the molar ratio of Cl 2 :HCC-240db was 0.025:1, and the water content in the reaction system based on the weight of HCC-240db was 134 ppm. Table 6 shows the analysis results of the outlet gas.
[0099] Under these conditions, the selectivity of HCFO-1233xf was maintained at a high value: 94.8% after 20 hours and 94.0% after 200 hours. The total selectivity of useful compounds of HCFO-1233xf, HFC-245cb, and HFO-1234yf had a decline rate of 0.09%/day, and was maintained at an almost constant value.
[0000]
TABLE 6
Reaction Time (hr)
20
100
200
Conversion of HCC-240db (%)
100
100
100
Selectivity of HFO-1234yf (%)
0.3
0.2
0.1
Selectivity of HFC-245cb (%)
0.4
0.2
0.0
Selectivity of HCFO-1233xf (%)
94.8
94.5
94.0
Selectivity of HCFO-1232xf (%)
0.1
0.2
0.3
Selectivity of HCO-1230xa (%)
0.0
0.0
0.2
Others (%)
4.4
4.9
5.4
Comparative Example 2
[0100] 20 g of a catalyst (fluorine content: about 15.0% by weight) obtained by fluorinating a chromium oxide represented by the composition formula: CrO 2 was placed into a tubular Hastelloy reactor with an inner diameter of 15 mm and a length of 1 m. The reaction tube was maintained at atmospheric pressure (0.1 MPa) and 250° C., and anhydrous hydrogen fluoride (HF) gas was supplied to the reactor at a flow rate of 114 mL/min (flow rate at 0° C., 0.1 MPa) for 1 hour. After the flow rate of HF was adjusted to 76 mL/min, CCl 2 ═CClCH 2 Cl (HCO-1230xa) having a water content of 240 ppm was supplied at a flow rate of 3.8 mL/min (gas flow rate at 0° C., 0.1 MPa). The water content in the reaction system at this point based on the weight of HCO-1230xa was 330 ppm. The molar ratio of HF:HCO-1230xa was 20:1, and the contact time (W/F 0 ) was 15.0 gsec/cc.
[0101] The outlet gas from the reactor after 40 hours, 70 hours, and 110 hours was analyzed using gas chromatography. Table 7 shows the analysis results.
[0102] Under these conditions, the conversion of HCO-1230xa was 85.2% after 40 hours, and decreased to 50.0% after 110 hours. Additionally, the yield (conversion x selectivity) of HCFO-1233xf was 75.5% after 40 hours, and decreased to 23.0% after 110 hours. Moreover, the total yield of useful compounds of HCFO-1233xf, HFC-2450b, and HFO-1234yf was also decreased at 18.0%/day.
[0000]
TABLE 7
Reaction Time (hr)
40
70
110
Conversion of HCO-1230xa (%)
85.2
68.8
50.0
Selectivity of HFO-1234yf (%)
0.0
0.0
0.0
Selectivity of HFC-245cb (%)
0.0
0.0
0.0
Selectivity of HCFO-1233xf (%)
88.6
76.7
46.0
Selectivity of HCFO-1232xf (%)
8.4
17.3
26.9
Others (%)
3.0
6.0
27.1
EXAMPLE 6
[0103] A reaction was carried out under the same conditions as in Comparative Example 2, except that chlorine gas was supplied at 0.12 mL/min (gas flow rate at 0° C., 0.1 MPa) concurrently with supply of CCl 2 ═CClCH 2 Cl (HCO-1230xa). At this point, the water content in the reaction system based on the weight of HCO-1230xa was 340 ppm, and the molar ratio of Cl 2 :HCO-1230xa was 0.032:1. Table 8 shows the analysis results of the outlet gas.
[0104] Under these conditions, the conversion of HCO-1230xa was maintained at a high value: 92.9% after 25 hours and 84.3% after 100 hours; the yield of HCFO-1233xf was also maintained at a high value: 88.4% after 25 hours, and 78.0% after 100 hours. In addition, the rate of decline in the total yield of useful compounds of HCFO-1233xf, HFC-2450b, and HFO-1234yf was 3.4%/day, and the deterioration of catalytic activity was reduced by the supply of chlorine gas.
[0000]
TABLE 8
Reaction Time (hr)
25
70
100
Conversion of HCO-1230xa (%)
92.9
88.0
84.3
Selectivity of HFO-1234yf (%)
0.2
0.2
0.1
Selectivity of HFC-245cb (%)
0.3
0.2
0.2
Selectivity of HCFO-1233xf (%)
95.2
93.7
92.6
Selectivity of HCFO-1232xf (%)
1.8
3.0
3.8
Others (%)
2.5
2.9
3.3
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This invention provides a process for producing 2-chloro-3,3,3-trifluoropropene, comprising: reacting anhydrous hydrogen fluoride with at least one chlorine-containing compound selected from the group consisting of chloropropanes and chloropropenes represented by specific formulas in a gas phase in the presence of a chromium atom-containing fluorination catalyst while heating, the reaction being carried out in the presence of molecular chlorine or with a water content in the reaction system of 300 ppm or less. This invention enables suppression of catalyst deterioration and efficient production of 2-chloro-3,3,3-trifluoropropene in a simple and economically advantageous manner on an industrial scale.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a national stage application (under 35 USC §371) of PCT/EP2013/072674, filed Oct. 30, 2013, which claims benefit of German application 10 2012 110 361.5, filed Oct. 30, 2012.
BACKGROUND OF THE INVENTION
Technical Field and State of the Art
[0002] The invention relates to a device for sorting, comprising a plurality of helical rollers, each exhibiting at least one helix, wherein each helical roller rotates about a rotary axis of its own, at least two adjacent helical rollers exhibit the same direction of rotation, and the rotary axes of at least three helical rollers are not arranged in a common plane.
[0003] The invention also relates to a digger and a digger's scoop comprising such a device for sorting.
[0004] EP 2 329 891 A1 discloses a device comprising the features cited at the beginning. Although this application focuses substantially on a sorting device which is designed as a disc screen and arranged at an inclination, the discs can however also be designed in accordance with one modification as propeller-like discs which drive the material not only in the circumferential direction of the rotation of the discs but also orthogonally to it, in the direction of the rotary axis of the rotary elements. This, however, makes it more difficult or even completely impossible to transport the oversize grain away in the direction of the rotary axis past the bearing sides of the rotary elements which are mounted at both ends.
[0005] DE 10 2010 030 507 A1 discloses a device for sorting, comprising a plurality of rotary elements which are designed as helical rollers, each exhibiting at least one helix, and each of which rotates about a rotary axis of its own, wherein at least two adjacent helical rollers exhibit the same direction of rotation.
[0006] DE 602 18 668 T2 discloses a sorting device, which is designed in a V shape as a disc screen, for mixed recyclable material. The free ends of the rotary elements of the disc screen are mounted at both ends in a frame.
[0007] EP 1 570 919 B1 discloses a device of the type cited at the beginning, for sorting substantially solid materials. In one specific embodiment of this device, material to be separated is introduced, via a feed belt and at a particular angle, onto a plurality of spiral rollers which are driven in the same rotational direction. The material is conveyed in the longitudinal direction by a runway effect and simultaneously sideways by the spiral helix, wherein any parts which are smaller than the intermediate spaces, which are predetermined by the design, fall down between the spiral helices. Long, thin parts are discharged in the rotational direction and thick, cubical shaped parts are discharged via the freely terminating shaft ends. The so-called fine grain which falls through the intermediate spaces can be directly transported away by suitable conveyor belts below the spiral rollers, as can the two coarse materials.
BRIEF SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to specify a device for sorting which enables the oversize grain to be sorted and in particular also transported away in an improved way.
[0009] This object is solved by a device of the type cited at the beginning, which is characterised in that at least some of the helical rollers are held and rotatably mounted exclusively at one end.
[0010] It has been found that the sorting result can be improved by being able to exert an additional force on the sorting material—in particular by utilising (utilizing) its weight—in particular regions of a sorting surface formed by the helical rollers. The force can for example be directed towards the lowest point on a sorting surface which is designed in the shape of a depression. This achieves an improved sorting result, since the unsorted material is available to the sorting process for longer. This in particular reduces the likelihood of an undersize grain, which should in fact fall down between the helical rollers, inadvertently leaving the device for sorting via the exit path for the oversize grain when it is exposed to the influence of the rotary elements, which are embodied as helical rollers or spiral rollers, by a repelling weight component. In accordance with the invention, at least some of the rotary elements, which are designed as helical rollers or spiral rollers, are held and rotatably mounted exclusively at one end. Consequently, the oversize grain can be expelled via the free ends of these rotary elements, while the undersize grain falls through the rotary elements. In addition, it is also possible to stipulate that the elongated portions of the sorting material are transported past the sorting surface and expelled in a straight direction.
[0011] In one preferred embodiment, the rotary axes of the rotary elements are orientated parallel to each other.
[0012] In one particular device for sorting, it is stipulated that the sorting surface formed by the rotary elements is curved in a partial region. The curve can in particular be designed with a cross-section in the shape of a circular portion or parabola, or also a V shape.
[0013] Alternatively or additionally, it is also advantageously possible for the sorting surface formed by the rotary elements to be curved in one partial region and designed so as to be level in another partial region. It is in particular possible to stipulate that the sorting surface formed by the rotary elements is designed so as to be level in a region onto which the unsorted material is introduced, and is curved and in particular gradually rises in a region for expelling the oversize grain which lies opposite the introducing region. This advantageously means that the sorting material which has traversed the level sorting surface then has an additional force component exerted on it by the curved part of the sorting surface, which repels the sorting material onto the sorting surface. This achieves a particularly good sorting result, since—as already stated—the part of the sorting material which should in fact fall down between the rotary elements, which can for example be embodied as helical rollers or screen star rollers, remains in their region of influence for longer, thus increasing the likelihood of them falling through as desired. This ultimately improves the sorting result significantly. This also in particular enables parts of the sorting material which are stuck together to be separated.
[0014] As already briefly mentioned, it is advantageously possible to stipulate that the sorting surface formed by the rotary elements forms a depression and/or is part of a depression. In addition to the rotary elements, at least one additional limiting wall can be provided in order to form the depression.
[0015] In one embodiment of a device in accordance with the invention which sorts to a very particular level of accuracy, at least two rotary elements exhibit different directions of rotation. It is in particular possible to stipulate that the rotary elements in a first partial region exhibit a first direction of rotation and the rotary elements in a second partial region which is different from the first partial region exhibit a direction of rotation which is opposite to the first direction of rotation. It is for example advantageously possible to stipulate that all the rotary elements exhibit a direction of rotation such that the side of the rotary elements directed towards the material to be sorted always exerts a force on the sorting material which is for example directed towards a centre (center) of the sorting surface and/or a lowest point on a depression.
[0016] In one particular embodiment, it is stipulated that the helices of the spiral rollers in a first partial region of the sorting surface exhibit a different coiling direction to the helices of the spiral rollers in a second partial region of the sorting surface which is different from the first partial region. It is in particular also possible to stipulate that the helices of mutually adjacent spiral rollers in a first partial region of the sorting surface of the device exhibit a different coiling direction to the helices of mutually adjacent spiral rollers in a second partial region of the sorting surface which is different from the first partial region.
[0017] However, an effect of transporting the material to be sorted along the sorting surface due to the runway effect is only achieved when a plurality of consecutive rotary elements (for example in a partial region of the sorting surface or over the entire sorting surface) exhibit the same direction of rotation. This desired transporting effect would not occur if the adjacent rotary elements exhibit alternately opposite directions of rotation. It is therefore stipulated in accordance with the invention that at least two adjacent rotary elements and preferably more than two consecutive rotary elements exhibit the same direction of rotation.
[0018] In one particular embodiment, it is stipulated that the helices of the spiral rollers interlock at least in a partial region and/or that the helices of the spiral rollers of the partial regions of the sorting surface each interlock in the same direction of rotation and/or that the helices of all mutually adjacent spiral rollers interlock.
[0019] In one particular embodiment, a direction for introducing the material to be sorted is defined which is orientated parallel to the rotary axis of at least one rotary element. It is in particular possible to stipulate that a region for introducing the sorting material is defined by adjacent ends of the rotary elements. It is particularly advantageously possible to stipulate that a region for introducing the sorting material is defined in the region of the ends at which the rotary elements are held at one end.
[0020] Alternatively, it is also possible to stipulate that a direction for introducing the material to be sorted is defined which is orientated perpendicular to the rotary axis of at least one rotary element. In this respect, it is in particular possible to stipulate that the sorting material is introduced laterally onto one or more rotary elements and then transported over the sorting surface by the rotary elements due to the runway effect described above.
[0021] In a very particularly advantageous embodiment of the device in accordance with the invention, it is stipulated that the sorting surface formed by the rotary elements can be pivoted as a whole. Pivoting can in particular be used to position individual regions of the sorting surface more steeply and other regions more flatly. For this purpose, it is in particular possible to stipulate that the sorting surface formed by the rotary elements is mounted such that it can be pivoted about a pivot axis which is parallel to the rotary axes. An ability to pivot in this way can also be used to load the device for sorting with sorting material and/or to effect a loading position, for example when the device for sorting is part of a digger's scoop.
[0022] It is also possible, for example in order to make it more difficult to expel the sorting material via the free ends of the spiral rollers by adding an additional weight component, for the sorting surface formed by the rotary elements to be mounted such that it can be pivoted as a whole about a pivot axis arranged in a plane which is perpendicular to the rotary axes. In this way, the force directed onto the sorting material towards the free end of the spiral rollers by the rotation of the spiral rollers which are provided with helices, is opposed by a weight component which causes the sorting material to have a longer dwelling time on the sorting surface. This improves the sorting result as a whole. It is however also possible, for example when a large amount of sorting material is to be processed within a short period of time, to incline the sorting surface in the opposite direction in order to achieve a high throughput, albeit at a reduced sorting quality.
[0023] In accordance with one independent and self-contained concept of the invention, it is stipulated that the helical rollers which are held and/or rotatably mounted at one end comprise a core tube which is preferably fixed and on which an outer tube casing is rotatably mounted which bears the helix and/or spiral. This embodiment, comprising a core tube which is preferably stationary and surrounded by a tube casing which bears the helix and/or spiral, is particularly advisable for larger-designed devices. The core tube and the outer tube casing are mounted at at least two points. The tube casing is effectively mounted at both ends; the tube casing is effectively mounted at both ends. This internal design substantially reduces oscillations and imbalances within the helical rollers and/or spiral rollers.
[0024] The core tube can then extend into the tube casing over only some of the length of the tube casing. The core tube can for example protrude into the tube casing up to at least half the length of the tube casing.
[0025] In accordance with another embodiment of the invention, it is stipulated that the mounting between the core tube and the tube casing is arranged in the region of the drive for the helical roller such that the forces coming from the drive are introduced particularly economically into the helical roller, without causing increased material stress.
[0026] In accordance with one self-contained and independent concept of the invention, it is stipulated that a digger's scoop is fitted with a device for sorting, in particular a device in accordance with the invention.
[0027] Such a digger's scoop can comprise all the features of the device for sorting described above, wherein it need not however necessarily be stipulated that the rotary axes of at least three rotary elements are not arranged in a common plane. The digger's scoop can instead also be designed such that the rotary axes of all the rotary elements are arranged in a common plane.
[0028] The embodiment of the digger's scoop in which the sorting surface formed by the rotary elements is curved at least in a partial region is however particularly advantageous, since the digger's scoop can be designed so as to be curved in the region of its base, which makes it easier to perform a shovelling movement in order to fill the digger's scoop.
[0029] It is then in particular possible to stipulate that the digger's scoop comprises a filling opening and an opening for expelling the oversize grain which is different from the filling opening. In addition, it is possible to stipulate that the digger's scoop comprises another path for expelling the undersize grain, wherein this expelling path generally extends through the intermediate spaces between the rotary elements.
[0030] The digger's scoop is preferably designed for sorting only and not for example for crushing the material received by the digger's scoop.
[0031] In one advantageous embodiment, the digger's scoop comprises at least one partition wall which keeps the fractions produced by the device for sorting separate from each other. Alternatively or additionally, it is also in particular possible to stipulate that the rotary elements terminate freely and that the digger's scoop comprises at least one partition wall which is arranged below the free ends of the rotary elements when the digger's scoop is in its operational position for sorting and/or that the digger's scoop comprises at least one partition wall which is arranged below the opening for expelling the oversize grain when the digger's scoop is in its operational position for sorting.
[0032] This ensures in particular that the fractions do not recombine below the digger's scoop.
[0033] The digger's scoop can comprise a drive device of its own for rotary-driving the rotary elements. It is in particular possible to stipulate that the drive device is designed hydraulically, for example by utilising (utilizing) the hydraulic pumps, fluids and conduits which in most cases are provided on a digger anyway. A construction machine, in particular a digger, comprising a device for sorting in accordance with the invention and/or comprising a digger's scoop which is embodied as has been described is particularly advantageous.
[0034] Other aims, advantages, features and possible applications of the present invention may be gathered from the following description of an example embodiment on the basis of the drawings, wherein any of the described and/or illustrated features, in their own right or in any expedient combination, form the subject-matter of the present invention, including independently of their recapitulation in the claims or the dependency of said claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0035] There is shown:
[0036] FIG. 1 an example embodiment of a device for sorting in accordance with the invention;
[0037] FIG. 2 a detailed view of the device for sorting in accordance with the invention;
[0038] FIG. 3 a cross-sectional representation of a detail of the device for sorting in accordance with the invention;
[0039] FIG. 4 another example embodiment of a device for sorting in accordance with the invention;
[0040] FIG. 5 a detailed view of said other example embodiment;
[0041] FIG. 6 another detailed view of the example embodiment in accordance with the invention;
[0042] FIG. 7 a plan view onto a detail of said other example embodiment;
[0043] FIG. 8 a cross-sectional representation of a detail of said other example embodiment;
[0044] FIG. 9 an example embodiment of a digger's scoop comprising a device for sorting in accordance with the invention, in a perspective view;
[0045] FIG. 10 the example embodiment of a digger's scoop, in a cross-sectional representation;
[0046] FIG. 11 another example embodiment of a digger's scoop comprising a device for sorting;
[0047] FIG. 12 one possible embodiment of a helical roller comprising an interior core tube and an outer tube casing which bears the spiral and/or helix;
[0048] FIG. 13 a representation of the cross-section of the helical roller in accordance with FIG. 12 , in the region of the free end of the helical roller; and
[0049] FIG. 14 the detail “Z” in accordance with FIG. 12 .
DETAILED DESCRIPTION OF THE INVENTION
[0050] FIG. 1 shows an example embodiment of a device 1 for sorting in accordance with the invention, comprising a plurality of rotary elements 2 which are designed as helical rollers 3 comprising interlocking helices 4 or also as spiral rollers. Each of the rotary elements 2 rotates about a rotary axis of its own which respectively corresponds to the longitudinal centre (center) axis of each rotary element. The rotary axes are orientated parallel to each other, wherein the sorting surface formed by the rotary elements 2 is however designed so as to be level in a first partial region 4 and is curved in a second partial region 5 . Sorting material is fed towards the region of the sorting surface opposite the curved second partial region 5 , as indicated by the arrow 6 .
[0051] The helical rollers 3 rotate clockwise, such that the introduced sorting material is transported towards the curved end of the sorting surface by the rotation of the helical rollers 3 , wherein the undersize grain falls down between the helical rollers 3 and through a funnel 7 onto an undersize grain discharge belt 8 and is transported away, as indicated by the directional arrow 9 . The oversize grain leaves the sorting surface via the free ends of the rotating helical rollers 3 , as indicated in the figure by the directional arrow 10 , wherein the oversize grain falls past a deflector 11 into a collecting container which is not shown in the figure.
[0052] FIG. 2 shows a detailed view of the example embodiment shown in FIG. 1 . The detailed view clearly shows how the helical rollers 3 comprise interlocking helices 4 , wherein all the helical rollers rotate in the same clockwise direction.
[0053] The helical rollers 3 are mounted on a drive/gear part 12 at one end.
[0054] FIG. 3 shows a detail of the example embodiment shown in FIG. 1 , in a cross-sectional representation. This representation also shows how the helices 4 of the helical rollers 3 interlock. It can also clearly be seen how the first partial region 13 comprises a level sorting surface, while the second partial region 14 comprises a curved sorting surface.
[0055] As already mentioned, the sorting material is introduced onto the first helical roller of the level first partial region 4 , as indicated by the directional arrow 6 . The device is in particular suitable for separating clumped materials, such as for example rocks which are stuck together by mud, from each other and then making them available to the sorting process. This is ideally achieved by the sorting material being first transported along the first, level part of the sorting surface by the rotating helical rollers 3 , wherein some of the undersize grain already falls down between the helical rollers 3 . The rocks which are clumped together are transferred by the rotating rollers into the second partial region 14 which is curved upwards, causing the sorting material to roll back and tumble, thus breaking open the clumps and enabling the individual constituent parts to then be sorted.
[0056] A wall, or a rigid tube which does not rotate and is not provided with a helix, could be adjoined to the uppermost helical roller 3 , in particular for shielding for safety reasons and/or to prevent sorting material from falling out. Alternatively, it would also be possible to provide a helical roller which exhibits an opposite direction of rotation and prevents material from spilling beyond the last helical roller 3 .
[0057] FIG. 4 shows another example embodiment of a device for sorting in accordance with the invention. In this example embodiment, the rotary elements are formed by helical rollers 3 and arranged such that the sorting surface 17 formed by them is curved in the shape of a depression, with a cross-section in the shape of a parabola. In this device, the helical rollers 3 which are arranged in a first partial region 13 exhibit a different direction of rotation to the rotary elements 2 which are arranged in a second partial region 14 which is different from the first partial region 13 .
[0058] Specifically, the direction of rotation of the helical rollers 3 is chosen such that they always exert a force on the sorting material which is orientated towards the bottom of the depression. The sorting material is introduced via an introducing funnel 15 and a transporting belt 16 onto the sorting surface 17 foamed by the rotary elements 2 , as indicated by the directional arrow 6 . The oversize grain leaves the sorting surface 17 past the free ends of the helical rollers 3 and falls onto an oversize grain outlet belt 18 , as indicated by the directional arrow 10 . The undersize grain falls down between the helical rollers 3 and ultimately leaves the sorting surface 17 via an undersize grain outlet belt 19 , as indicated by the directional arrow 9 . The device for sorting is fitted with a tracked undercarriage 20 which facilitates its use in mobile applications.
[0059] The sorting surface 17 formed by the rotary elements 2 can be pivoted about a pivot axis 21 , thus enabling it to be made more difficult for material to be expelled via the free ends, by adding a weight component, or easier. It is thus possible, by positioning the sorting surface 17 more steeply, to increase the dwelling time of the sorting material on the sorting surface 17 and therefore improve the sorting result with respect to accuracy. Lastly, setting the inclination of the sorting surface 17 influences the ratio of the amount of expelled undersize grain to expelled oversize grain.
[0060] FIG. 5 shows the part of the device for sorting which includes the sorting surface 17 . It can clearly be seen how the helices 4 of the helical rollers 3 of the first region 13 interlock. These helical rollers 3 rotate in the same direction of rotation.
[0061] The helical rollers 3 of the second region 14 likewise comprise interlocking helices 4 and rotate in a direction of rotation which is opposite to that of the helical rollers 3 of the first region 13 . These helical rollers 3 also exhibit a different coiling direction, with respect to their helices 4 , to the helical rollers 3 from the first region 13 .
[0062] The helices 4 of the two mutually adjacent helical rollers 3 which exhibit opposite directions of rotation and opposite coiling directions of their helices 4 interlock in the example embodiment shown. The rotational speeds of all the helical rollers 3 therefore have to be identical so as not to cause jamming. Alternatively, it would also be possible for the two mutually adjacent helical rollers 3 which exhibit opposite directions of rotation to not interlock. In this case, different rotational speeds between the helical rollers 3 of the different regions 13 , 14 are also possible.
[0063] A first drive 22 , which is embodied as a gear motor, is provided for the helical rollers of the first region 13 . A second drive 23 , which is likewise designed as a gear motor, is provided for the helical rollers of the second partial region 14 . A receptacle 24 for pivotally mounting about the pivot axis 21 can also clearly be seen in the figure.
[0064] In order to prevent the sorting material from inadvertently falling over the raised sides of the sorting surface 17 , rigid steel tubes 25 which do not rotate are arranged parallel to the helical rollers 3 and adjoining the peripheral sorting rollers 3 .
[0065] FIG. 6 shows a different, perspective view of the detail of the device for sorting which has already been shown in FIG. 5 . The material is introduced in the direction indicated by the arrow bearing the reference sign 6 . The undersize grain leaves the sorting surface 17 in the direction indicated by the arrow bearing the reference sign 9 . The oversize grain leaves the sorting surface 17 in the direction indicated by the directional arrow 10 .
[0066] FIG. 7 shows the sorting surface 17 in a plan view. The two regions which respectively comprise helical rollers 3 exhibiting different rotary directions and different coiling directions of their helices 4 can in particular be seen.
[0067] FIG. 8 shows a cross-sectional representation of the detail which has already been shown in FIGS. 5 to 7 . It clearly shows how the helices 4 of the helical rollers 3 interlock. The receptacles 24 for pivotally mounting, and also the drives 22 , 23 , are also indicated.
[0068] FIG. 9 shows a digger's scoop 26 comprising a device 1 for sorting in accordance with the invention. The digger's scoop comprises helical rollers 3 which are mounted at one end and each provided with a helix 4 . The sorting material is introduced into the digger's scoop via the filling opening 28 which is provided with teeth 27 .
[0069] The digger's scoop comprises a lateral opening 29 for expelling the oversize grain, which is different from the filling opening. The oversize grain leaves the device for sorting via this lateral expelling opening 29 , as indicated by the directional arrow 10 . The undersize grain leaves the device for sorting downwards through the intermediate spaces of the helical rollers 3 . The digger's scoop comprises a support bracket 30 , adjacent to the helical rollers 3 , for stabilising (stabilizing) the digger's scoop.
[0070] FIG. 10 shows the digger's scoop in a cross-sectional representation which shows how the helices 4 of the helical rollers 3 interlock. This figure also shows the location of the support bracket 30 .
[0071] The oversize grain leaves the digger's scoop 26 through the expelling opening 29 which is provided for this purpose, i.e. in relation to the figure shown, towards the observer. Material to be sorted is fed in the direction of the arrow which is provided with the reference sign 6 .
[0072] FIG. 11 shows an alternative embodiment of a digger's scoop 26 comprising a device 1 for sorting in accordance with the invention. In this embodiment, the oversize grain is likewise expelled through a separate expelling opening 29 along the path indicated by the directional arrow bearing the reference sign 10 . The undersize grain leaves the digger's scoop through the intermediate spaces between the helical rollers 3 along the path indicated by the directional arrow bearing the reference sign 9 .
[0073] FIGS. 12 to 14 show an embodiment of a helical roller 3 which can in particular be used for larger designs, wherein the helical roller 3 comprises a core tube 31 which is stationary in the example embodiment chosen here and which protrudes into the tube casing 32 up to at least half the length of the tube casing 32 . The outer tube casing 32 bears the spirals 33 .
[0074] In the example embodiment in accordance with FIG. 12 , the core tube 31 protrudes almost as far as the free end of the tube casing 32 , wherein the tube casing 32 and the core tube 31 are in contact with each other via two bearings 34 , 35 . This internal design massively reduces oscillations and imbalances within the helical rollers 3 . The tube casing 32 is effectively mounted on a projecting core tube 31 at both ends.
[0075] The detailed image in accordance with FIG. 14 in particular shows how the tube casing 32 is mounted on the core tube 31 , wherein the free end of the tube casing 32 is received, via a journal 36 , in the bearing 35 which is situated at the end of the core tube 31 . On the opposite end, the tube casing 32 comprises a rotational part 37 which is mounted in a second bearing 34 . The drive-end bearing 34 is enclosed by a sprocket 38 which is designed as a rotational part and via which the tube casing 32 is driven. The reference sign 39 denotes the terminal box in which the stationary core tube 31 is received.
[0076] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
LIST OF REFERENCE SIGNS
[0000]
1 device
2 rotary element
3 helical roller
4 partial region/helix
5 second partial region
6 arrow
7 funnel
8 undersize grain discharge belt
9 directional arrow
10 directional arrow
11 deflector
12 drive/gear part
13 partial region
14 second region
15 introducing funnel
16 transporting belt
17 sorting surface
18 outlet belt
19 undersize grain outlet belt
20 tracked undercarriage
21 pivot axis
22 drive
23 drive
24 receptacle
25 steel tube
26 digger's scoop
27 tooth
28 filling opening
29 expelling opening
30 support bracket
31 core tube
32 tube casing
33 spiral, helix
34 bearing
35 bearing
36 journal
37 rotational part
38 sprocket
39 terminal box
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The invention relates to a device for sorting particulate materials of different grain size that can be part of a construction machine or digger's scoop. The device for sorting has a plurality of helical rollers, each exhibiting at least one helix, wherein each helical roller rotates about a rotary axis of its own, at least two adjacent helical rollers exhibit the same direction of rotation, and the rotary axes of at least three helical rollers are not arranged in a common plane. At least some of the helical rollers are held and rotatably mounted exclusively at one end.
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BACKGROUND OF THE INVENTION
The present invention relates to the suspension of the human body in an inverted position and, in particular, to a device into which the feet of the user may be comfortably secured for supporting the human body in an inverted position.
Inclined and inverted suspension of the human body is well known and has been used to treat a variety of physical ailments. Inclined or inverted suspension has been found to relax muscle tension, relieve stress upon bones and muscles, improve circulation of the blood in parts of the body, and reduce or moderate nervous disorders. Physicians and chiropractors employ patient inversion, as well as traction, for the treatment of a number of back problems. Inversion therapy is also employed to develop amd strengthen certain muscles in the body, as by exercising.
A number of machines have been developed for tilting or rotating a patient about a horizontal axis from a normal or upright body position into an inclined or inverted position while maintaining the patient secured to the machine. This may be achieved by holding the patient's thighs, calves, legs, ankles, heels, insteps or shoulders. Examples of such machines are disclosed in U.S. Pat. Nos. 1,085,486; 1,693,810; 2,934,063, 3,081,085; 3,152,802; 3,286,708; 3,380,447; 3,568,669; 3,589,358; 3,707,285; 4,114,613; as well as in my U.S. Pat. No. 4,232,662.
Certain of the prior art machines possess a number of serious disadvantages. Clamping the patient around the leg and above the ankle as by stocks, straps or leg cuffs, even though padded, causes trauma to the patient. To reduce this problem, certain machines have been designed to provide padded clamps fitted behind the ankle and in front of the foot at the instep area. Other machines provide a heel brace with a formed member placed over the top of the foot to retain the foot of the patient within a defined area. The more successful of the prior art machines secure the patient by providing padded ankle and instep cuffs for each foot, designed to fit, if desired, above the shoe worn by the patient in order to minimize and reduce trauma in the leg, ankle, instep and heel areas of the foot. One such version is shown in my pending U.S. patent application Ser. No. 251,484, filed Apr. 6, 1981, now U.S. Pat. No. 4,367,731.
SUMMARY OF THE INVENTION
The present invention departs from the principle of suspending the patient in an inclined or inverted position by the use of stocks, clamps, leg cuffs, ankle pads, instep pads, heel braces or pads over the top of the foot. Instead, the present invention employs a comfortably fitting, high-top shoe into which the foot, heel, ankle and instep area are inserted and secured. A structural re-enforcing member is designed as a part of the arch-heel area of the shoe from which a supporting attachment or linkage member is connected to carry the load or weight of the patient when the patient is inclined or inverted. The re-enforcing member of the shoe, with its attachment or linkage member, is designed for removable coupling to a rigid, supporting structure, such as a horizontal bar or tiltable bed. In the inverted position the patient is suspended from the shoe while the sole, arch and heel area of the shoe is physically retained in a secured position relative to the supporting structure or frame. The weight of the patient is distributed over the top area of the shoe and around the portion of the shoe that surrounds the instep, ankle, heel and lower leg portion.
The preferred embodiment employs a form-fitting, high-top shoe, similar in part to an ice skating or roller skating shoe. A strong re-enforcing plate is designed into or attached to the heel-arch area of the shoe for supporting a pivoted, inverted U-shaped member to which a hook member is securely attached. The hook member, positioned in front of and spaced apart from the ankle area of the foot, is retained in position by means of a strap or clamp attachable around the leg and above the ankle of the user. Both the U-shaped member and the hook member are spaced apart from the top portions of the shoe to prevent the forces acting upon the shoe, when the user is in an inverted position, from bearing upon the under side of the U-shaped and hook members. The hook member is removably attachable to a horizontal supporting bar. When the user is inverted, the forces acting upon the shoe are transmitted to the re-enforcing plate and on to the U-shaped member into the hook member. These forces are then carried by the hook member on to the horizontal supporting bar. The U-shaped member, along with the attached hook, is pivotally attached about a horizontal axis to the re-enforcing plate to enable both hook and U-shaped members to pivot forward of the foot to allow the foot to be easily inserted into the shoe.
Accordingly, a principal object of the invention is to provide a device for comfortably supporting the human body in an inverted position.
Another object is to provide a form-fitting shoe device for suspending the human body in an inverted position from the sole-heel area of the shoe.
Still another object of the invention is to provide a shoe device having a hook pivotally attached to the sole area of the shoe for holding the human body in an inverted position.
Yet another object is to provide an inversion shoe that is safer, easier to use and attractive in appearance.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the side view of the preferred embodiment of the inversion shoe of the invention.
FIG. 2 shows the side view of the inner structural plate of the re-enforcing member of the inversion shoe.
FIG. 3 illustrates the side view of the external sturctural plate of the re-enforcing member.
FIG. 4 is a front view of the preferred inversion shoe of FIG. 1.
FIG. 5 is a front view of the inner structural plate of FIG. 2.
FIG. 6 is a top view of the inner structural plate of FIGS. 2 and 5.
FIG. 7 is a top view of the inversion shoe of FIGS. 1 and 4.
FIG. 8 is a front view of the external structural plate of FIG. 3.
FIG. 9 is a top view of the external structural plate of FIGS. 3 and 8.
FIG. 10 is a side view of an alternative embodiment of the inversion shoe of the invention.
FIG. 11 is a side view of the external plate of the re-enforcing member for the inversion shoe of FIG. 10.
FIG. 12 is a view of the linkage member used with the inversion shoe of FIG. 10 showing the snap sliding latch.
FIGS. 13 and 14 are side views of a further embodiment of the inversion shoe of the invention.
DESCRIPTION OF THE INVENTION
Referring to the preferred embodiment of the invention 11 as illustrated in FIGS. 1, 4 and 7, there is shown a high-top, form-fitting shoe 12 constructed of leather, polymer or other suitable material for comfortably securing the instep, ankle, heel, leg and top portion of the foot of the user. As shown, the upper area 13 of shoe 12, along with the heel area 14, is shaped to conform to the leg and heel of the user. Similarly, the arch area 15 is likewise shaped to comfortably fit the arch of the foot. Shoe 12 includes a flexible sole 16, thereby enabling the user to walk in the shoe 12 in the normal fashion.
The top portion or area 17 of shoe 12 is designed to be securely attached over the top portion of the foot in the usual manner, as by lacing or other suitable means, and holes 18 are provided for shoe laces (not shown) for lacing the shoe.
The sole, arch and heel portions of the shoe are securely attached to the top or upper areas of the shoe, as by stitching, glueing or other suitable means. A preferred construction of shoe 12 is by molding whereby the entire shoe is composed of the same material. Shoes of this construction are well known, and one such form-fitting shoe is molded of resilient polymer material for use as a roller skating shoe. A sock 19 or other suitable liner may be worn by the user, if desired.
Shoe 12 is provided with re-enforcing member means consisting of an external or first shaped plate 21 and an inner or second shaped plate 22, as shown in FIGS. 2, 3, 5, 6, 8 and 9. Inner plate 22 is located within shoe 12 in the heel-arch area, as shown, and is provided with a group of eight holes 23, as seen in FIG. 6, for securing inner plate 22 to the shoe, as by glueing or by means of rivets. External plate 21 is attached below shoe 12 in the heel-arch area, as shown. Plate 21 is provided with a matching set of eight holes 24, as shown in FIG. 9, for securing plate 21 to shoe 12. Plate 21 is, preferably, secured to the heel-arch area by adhesive as well as by rivets coupled between plates 21 and 22 and passing through the matching holes 23 and 24 and the heel-arch area of shoe 12. Both re-enforcing plates 21 and 22 are shaped, as shown, and formed of steel or other material of suitable strength.
External re-enforcing plate 21 is provided with a pair of upwardly extending tabs 25 and 26 formed as by bending. Each tap 25 and 26 includes, respectively, holes 27 and 28, as seen in FIG. 3, for receiving a bushing or bolt. The upwardly extending tabs are located, respectively, on opposite sides of shoe 12 in the forward portion of the arch area of the shoe, as shown in FIG. 4.
An inverted U-shaped member 30, similar in part to a stirrup, is located in front of shoe 12. The lower ends 31 and 32 of U-shaped member 30 are pivotally attached to tabs 25 and 26 by means of bolts or screws passing through the holes 27 and 28, as shown in FIGS. 1, 4 and 7. If desired, the lower ends 31 and 32 may be forked, as shown, so as to straddle the tabs 25 and 26.
The manner by which the inverted U-shaped member 30 is pivotally attached to the external re-enforcing plate 21 may be similar to that used in conventional prosthetic devices to provide for a strong, pivotal support for U-shaped member 30 on re-enforcing plate 21. This form of attachment employs an internally threaded bushing extending through the lower end 31, 32 of U-shaped member 30 and through the holes 27 or 28 of tab 25 or 26. An oval-head type machine screw engages the internal threads of the bushing to securely retain inverted U-shaped member 30 pivotally attached to the tabs 25 and 26 of the external re-enforcing plate 21.
Securely attached to the top or apex of inverted U-shaped member 30 is a hook member 40 shaped, as shown, for detachable engagement to a horizontal, cylindrical support bar 41, shown by dotted lines in FIGS. 1, 4 and 7. The inner surface portion 42 of hook member 40 adjacent shoe 12 is further shaped to fit partially around the front area of shoe 12 and, accordingly, around the lower leg portion of the user, as shown in FIGS. 4 and 7. A leather strap 43 or other suitable means is attached to the inside surface portion 42 of hook member 40 to enable the user to secure hook member 40 to the leg of the user as by surrounding the upper portion of shoe 12. Leather strap 43 may be secured to the inner surface of portion 42 by adhesive or by rivets 44, as shown in FIG. 1. Strap 43 surrounds the upper portion of shoe 12 and, accordingly, the leg of the user above the ankle area and may be retained by means of a buckle (not shown) or other suitable means. in FIG. 7 the leather strap is secured behind shoe 12 and above the heel area 14 by a safety snap 45. Upon release of leather strap 43, hook member 40, along with inverted U-shaped member 30, may be pivoted forward of shoe 12 about the pivot axis a--a, as shown by the broken lines in FIGS. 4 and 7. This enables the user to easily insert the foot into shoe 12 and to lace shoe 12 to firmly grip and support the instep, ankle and heel areas of the foot.
The amount by which inverted U-shaped member 30 and hook member 40 may be pivoted forward of shoe 12 may be determined by the triangular shape of the upper tip 46 of taps 25 and 26 of external plate 21. This triangular-shaped tip 46 serves as a limit stop in cooperation with the inner surface of the lower forked ends 31, 32 of U-shaped member 30 to limit both the forward, as well as the rearward, pivoting of members 30 and 40.
While the inversion shoe 12 of FIGS. 1, 4 and 7 is shown in the upright position for ease of illustration, it will be appreciated that when the user is suspended in the inverted position he will be held in this position by the horizontal support bar 41. In this inverted position, shoe 12 will be inverted from the position shown in FIGS. 1 and 4.
The location of the pivot axis a--a in the forward area of the arch of shoe 12 causes the weight of the user, when inverted, to fall along an imaginary line 1--1 which passes through the center of hook member 40 and through the pivot axis a--a. The imaginary line 1--1 extends in the direction of and passes substantially through the center of gravity of the body of the user. This design feature substantially reduces the lateral forces acting upon hook member 40 in the direction of the leg of the user and minimizes the forces pressing against the upper portion 13 of shoe 12. Accordingly, the strength of leather strap 43 need not be great to safely secure hook member 40 to the upper area 13 of shoe 12 and to the leg of the user.
The embodiment of the invention illustrated in FIG. 10 employs a shoe 52, similar in most respects to shoe 12 of the preferred embodiment. The re-enforcing means, however, includes an external shaped plate 53 provided with two sets of upwardly extending tabs 54,55 and 56,57, as shown in FIG. 11. The first set of tabs 54,55 is located in the front or forward area of the arch, one being positioned on each side of shoe 52, while the second set 56,57 is positioned near the rear and on each side of the heel. The inner shaped plate located within shoe 52 may be the same as employed in the preferred embodiment. The inner shaped plate and the external shaped plate 53 are firmly secured to shoe 52 by adhesive and by rivets (not shown).
An inverted U-shaped member and hook member 60 integrally formed of the same material, as by stamping or shaping, is pivotally attached, at its lower ends 61,62, to the forward, upwardly extending tabs 54,55 in any suitable manner. The integrally formed U-shaped member and hook member 60 provides the same function as hook member 40 of the preferred embodiment, and is adapted for removable attachment to a cylindrical, horizontal support bar.
The integral U-shaped member and hook member 60 may be secured and locked in the position shown in FIG. 10 by a pair of linkage members 63, 64 located, respectively, on each side of shoe 52. The lower ends 65, 66 of each linkage member are pivotally attached, respectively, to the second set of upwardly extending tabs 56, 57. The upper ends 67, 68 of each linkage member are provided, respectively, with holes 69, 70 cooperating with a conventional sliding latch means 71, 72, as seen in FIG. 12.
A pair of detented studs 73, 74 extend, respectively, from each side of member 60 at a position above the ankle area. Studs 73, 74 are rigidly attached to member 60 and are adapted for receiving the upper ends 67, 68, respectively, by passing through the holes 69, 70 when the sliding latch is in its down or unlocked position. When linkage members 63, 64 are in the engaged position, the jaws of the sliding latch means 71, 72 engage and snap around the detented studs 73, 74, respectively, to secure the U-shaped and hook member 60 in a rigid and locked position.
A strip of leather or other suitable material 81 is placed on the inside of the upper portion of member 60 that partially surrounds the upper portion of shoe 52 to prevent or reduce wear upon this region of shoe 52. A pair of holes 82, 83 extending through member 60 are located at the upper rear end 84 of member 60 near the detented studs 73, 74. A similar pair of holes are located on the opposite side of member 60. These holes are adapted for receiving lacing cords (not shown) drawn around the rear of shoe 52 and above the heel to retain shoe 52, and, accordingly, the leg of the user into the position as shown.
Disengagement or release of the sliding latch means 71, 72 and removal of the upper ends 67 and 68 of the linkage member 63, 64 from the detented studs 73, 74 allows the U-shaped and hook member 60 to be pivoted forward of shoe 52 so that the foot of the user may be easily inserted into shoe 52.
The integral U-shaped and hook member 60 should be formed of strong material and may be cut, stamped and formed of steel, if desired. The re-enforcing means, including the inner plate and the external plate 53, may be similarly formed. Alternatively, U-shaped and hook member 60 may be molded of a strong and rigid plastic or polymer material, if desired.
When the user is inverted, the weight acting upon the U-shaped and hook member 60 falls along an imaginary line 1--1 passing through the center of hook member 60 and the pivot axis of the tabs 54, 55 in the same general manner as described in connection with the preferred embodiment of FIGS. 1, 4 and 7.
The embodiment of the invention illustrated in FIGS. 13 and 14 employs a high-top, form-fitting shoe 92 substantially identical to the shoe employed in the above-described embodiments. The re-enforcing means 100 includes an external shaped plate 101 and an internal plate 102 secured to each other through the heel-arch area of the shoe by any suitable means, such as rivets. External plate 101 includes two pairs of upwardly extending tabs 105, 106 and 107, 108, located, respectively, on opposite sides of shoe 92 below the heel area.
A hook member 110 is pivotally supported in the positions shown in FIGS. 13 and 14 by two pairs of linkage members 113, 114 and 115, 116, located, respectively, on opposite sides of shoe 92 in the heel-ankle area. The lower ends of each pair of linkage members are pivotally attached, respectively, to taps 105, 106 and 107, 108, as shown. The upper ends of each pair of linkage members are pivotally attached, respectively, to each side of hook member 110. A pad of suitable material 120 is attached to the inside surface of the portion of hook member 110 that partially surrounds the upper portion of shoe 92 and the leg of the user. Hook 110 is secured to the leg of the user by any suitable safety latch, buckle or other means attached to the rear portion of hook 110 for surrounding the rear portion of the leg of the user.
Hook member 110 may be moved forward and downward, when not secured, to the position shown in FIG. 14 to enable the user to readily insert the foot into shoe 92.
When the user is inverted, the weight is transmitted from shoe 92 into the re-enforcing means 100 and through the two pairs of linkage members 113, 114 and 115, 116 on to hook member 110. The forces on hook member 110 are carried by a horizontal support bar or other suitable supporting structure, in the same manner as described above.
Each of the embodiments of the inversion shoe of the invention includes a comfortable, form-fitting shoe for securing the foot, heel, ankle, instep and lower leg portions of the user. The re-enforcing means in the sole-heel area of the shoe transfers the load carried by the shoe through a pivotal linkage structure on to a hook member located in front of the shoe and above the ankle area. The hook member is supported so as not to bear down upon the top or instep area of the shoe and, accordingly, the top portion of the foot of the user. When matching pairs of inversion shoes are worn by the user, he may be comfortably and safely secured in an inclined or inverted position without the trauma experiemced with the prior art devices.
Since many changes may be made in the above-described apparatus and many different embodiments of this invention could be made without departing from the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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A high-top, form-fitting shoe is disclosed for suspending the human body in an inverted position. The shoe includes a re-enforcing member located in the heel-arch area of the shoe. An inverted U-shaped member, spanning the top portion of the shoe, is pivotally attached to the re-enforcing plate on each side of the shoe adjacent the arch area. The under side of the U-shaped member is spaced apart from the top portion of the shoe to prevent physical contact therewith. A hook member is rigidly attached at the apex of the inverted U-shaped member. The hook is held in front of the leg of the user by a holding means such as a strap. When inverted, the user is suspended from the shoe, the weight of the user being carried from the shoe into the re-enforcing plate, to the inverted U-shaped member and onto the hook. The hook is removably attachable to a horizontal supporting bar. The location of the pivot axis of the inverted U-shaped member upon the re-enforcing plate is selected to insure that the weight of the human body acting upon the hook extends along a line perpendicular to the pivot axis and through the approximate center of gravity of the human body of the user when the user is in the inverted position.
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This is a division of application Ser. No. 936,578 filed Aug. 22, 1979, now U.S. Pat. No. 4,215,469, issued Aug. 5, 1980.
BACKGROUND OF THE INVENTION
The present invention relates to a method of inserting and fixing or clinching electronic components (hereinafter called component) to a printed circuit board (hereinafter called p-c-b for short) and an apparatus for practically realizing the method.
The general process order of inserting or planting components to a p-c-b is (a) inserting a pair of lead wires of a component into lead wire inserting holes (hereinafter called simply inserting holes) formed, large in number, over the surface of a p-c-b; (b) bending or clinching a portion of the lead wires protruded to the back of the p-c-b, passing through the holes, for preventing the same from coming off; and then soldering the lead wires to the conductive circuit arranged on the p-c-b.
Recently developed automatic planting methods of components and apparatuses therefor have greatly contributed to the rationalization of assemblying lines, not only in the field of household electrical appliances such as television sets, audio apparatuses, etc., but also in the field of industrial instruments and machines. Most of the conventionally utilized means or apparatuses for this purpose have been, however, based on employing of an inserting guide having tapered guide holes or inclined guide grooves. After a component-to-be-inserted having been moved to targeted holes by a separate means such as a chuck or a pusher, the tip of the lead wires of the component-to-be-inserted are guided to the targeted inserting holes by the above-mentioned inserting guide. These inserting guides are mostly usable for only one type of component having a specific lead wire gage (the distance between the two lead wires). In actuality, the lead wire gage is of much variety, such as 1.5, 2.0, 2.5, 5.0, 6.0 mm--(there are many standardized dimensions). In the conventional way of planting the components on the p-c-b, one type of components of a specific gage have to be planted first, scatteringly with much interval, and another type of components of a different gage must be planted with another inserting guide between the already planted components. Such being the case, components-to-be-inserted of different gage dimension require changing inserting guides every time according to the size of the components one by one sporadically over the surface of the p-c-b, seeking enough space available for the planting operation. The more the planting stage advances, i.e., as the planting operation progresses, the harder becomes the planting operation, because the p-c-b surface is filled with the already planted components, requiring seeking space in the scantily left area. In other words, the conventional way of planting is faulty in that it is inefficient in its operation because of the need to change the guide often and seeking an operation space with difficulty, and that consequently the distribution density of planting is comparatively low. For some components of so-called axial type wherein the lead wires are extending axially from either side of a component, a device which is disclosed by the Japanese Published Examined patent application No. 49 (1974)-7936, is known. This device is able to plant or insert the lead wires bent at a right angle, even when the gage or distance of the lead wires are different in several dimensions. This device is composed of two parts for inserting respectively the right side wire and the left side wire, and is obliged to be complicated in its construction, because it aims at planting components of different gage by means of adjusting the distance between the two parts of the device itself. Such a device is a step progress indeed, but it is too expensive because of its sophisticated structure, to be generally utilized, and still leaves something to be desired because of its non-applicability to components of so-called radial type wherein the lead wires are extending parallelly at one side of a component. This invention has been made from such a background.
It is therefore a primary object of this invention to provide a technological art of inserting for fixing a plurality kinds of components, different respectively in the lead wire gage, at as high a distribution density as possible, into the inserting holes in a p-c-b.
It is another object of this invention to provide a technological art of inserting for fixing a plurality of kinds of components, different respectively in the lead wire gage, with a desired order, into the inserting holes in a p-c-b.
This invention, in order to fulfill the above-mentioned objects, is aimed at (a) chucking the two lead wires of a component by means of a chuck, which is open and closable between the two pawls thereof in a perpendicular direction to a plane determined by the two lead wires, with a distance identical to that between a pair of lead wire inserting holes formed in the p-c-b; (b) letting the lead wires protrude from the chuck by means of a separately disposed pusher, or approaching the chuck itself with the lead wires held to the p-c-b; and (c) inserting the lead wires into the inserting holes and clinching the projected portion of the lead wires to the back side of the p-c-b by bending or squashing.
Regarding this chucking operation of the lead wires there are several unprecedented devices applied here. One of which is, in chucking a variety or plurality of kinds of components having respectively different wire gage indiscriminately, to chuck one of the lead wires at a preset base position of the chuck biased to either one edge of the chucking surface thereof (selectable either one edge from both edges). When the inserting is about to take place, the p-c-b is rightly positioned relative to the chuck such that the already planted component just comes to the side of the very edge of the chuck at which edge the lead wires of the component-to-be-inserted are held. In case of chucking and inserting such lead wires by a chuck, which is open-and closable in a direction perpendicular to the plane including the two lead wires, a chuck having a width of the chucking portion wider than the widest lead wire gage of the components, is able to cover all the components-to-be-planted. Such a chuck would be too big in size, when used for planting comparatively small sized components of narrower gage, and consequently requires too much useless space around the components. It would also produce another problem of degrading the distribution density of component planting. This invention has solved this knotty problem by a principle that the chucking of lead wires is always done by holding a pair of lead wires at either one or exclusively one biased edge portion of the chuck, instead of holding at the central portion thereof, and by always letting this biased edge portion approach the already planted component through an appropriate relative positioning of the chuck and the p-c-b. By means of such an arrangement of the chuck, the portion thereof where it does not hold the lead wires is always positioned above a non-planted area of the p-c-b, which provides no disadvantageous conditions with respect to distribution density. Although this invention was made focusing on planting of the components of radial type, it may be applicable to those of axial type, too, so long as the lead wires (or one of the lead wires) are bent in advance to extend parallelly with a preset distance to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic general plan view of an embodiment of an inserting system according to this invention;
FIG. 2 is a schematic general elevation view of the same;
FIG. 3 is a cross-sectional view of the embodiment of FIG. 1 taken along the section line 3--3;
FIG. 4 is an enlarged elevation of an essential portion of the turret loader (9) in FIG. 3;
FIG. 5 is a vertical cross-section showing the engagement of the cam plate (21) and the index table;
FIG. 6 is a vertical cross-section of a part of FIG. 4 taken along the section line 6--6;
FIG. 7 is an enlarged elevation (partly in cross-section) of the chucking-system on the turret loader (9);
FIG. 8 is a cross-section of a part of FIG. 7 taken along the section line 8--8;
FIG. 9 is a projection, seen from the line 9--9, of the chucking-system of FIG. 7;
FIG. 10 is an enlarged transverse cross-section of V-grooves formed on a fixed pawl of the chuck (32) of FIG. 7;
FIG. 11 is an explanatory view showing how a lead wire (L) of a component is held in a V-groove of FIG. 10;
FIG. 12 is an enlarged elevation of an essential portion of the cutter (91) in FIG. 13 on the component supplying means (8) shown in FIG. 3;
FIG. 13 is an elevation of the component supplying means 8 shown in FIG. 3;
FIG. 14 is a side view of the same (FIG. 13);
FIG. 15 is an elevation (partly in section) of the drawing-in mechanism (17) and the clinching means (18) shown in FIG. 3;
FIG. 16 is a cross-section of a part of FIG. 15 taken along the section line 16--16;
FIG. 17 is a cross-section taken along the section line 17--17 of FIG. 15;
FIG. 18 is a cross-section taken along the section line 18--18 of FIG. 15;
FIG. 19 is a cross-section taken along the section line 19--19 of FIG. 15;
FIG. 20 is an enlargement of elevation (partly in section) of the stationary blade (141) and the movable blade (142) of FIG. 15;
FIG. 21 is an enlarged plan view of the upper side of the movable blade (142) shown in FIG. 15;
FIG. 22 is an enlarged explanatory view of the lead wires (L) clinched by the clinching means (18) shown in FIG. 15;
FIG. 23 is an explanatory view to show in what layout and how the components are planted;
FIGS. 24-33 are explanatory views to show the inserting operation in order;
FIG. 34 is another embodiment of the movable blade corresponding to FIG. 21;
FIG. 35 is another embodiment of the clinching means corresponding to FIG. 19;
FIG. 36 is an elevation of still another embodiment of the clinching means;
FIG. 37 is a cross-section of the clinching means of FIG. 36 taken along the section line 37-37;
FIG. 38 is an explanatory view illustrating the operation of the clinching means shown in FIG. 37;
FIG. 39 is an explanatory view of the lead wires (L) clinched by another embodiment of the clinching means (correspond to FIG. 22).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
CONSTRUCTION
The lead wire inserting system as a whole will be described, particularly concerning the layout of each mechanism referring to FIGS. 1-3, followed by a detailed structural explanation of each mechanism one by one. In these FIGS. 1-3, the complicated mechanism of each part is purposely shown only by designating the laid out position thereof by the two-dot-chain lines. Numeral 1 designates a main body of the inserting system, above but back-off of which is positioned a magazine means 2, which is provided with a rotatable frame 4 supported by a supporting rod 3. On the outer periphery of the rotatable frame 4 are attached a plurality of reels 5 (in this embodiment 36 in number) for retaining rolled tapes, on which a number of electronic components are stuck at their lead wire portions. The frame 4 is rotated by a servomotor 7, under command signals from a control panel 6. When a given reel 5 is positioned at a component supplying position, a tape T drawn out of the reel 5 is delivered to a component supplying means 8, wherein components are fed to a turret loader 9 after having been cut at their lead wire portions stuck to the tape T. The tape T left behind is discharged through a chute 11, to the rear of the main body 1. The component supplying means 8 is divided into two principal parts, a stationary part 8a and a movable part 8b, the former being fixed to the main body 1 and the latter being attached to the rotatable frame 4 in the same number as the reels 5.
A p-c-b, on which components are to be planted, is conveyed by an in-conveyer 12 for being fixed to a positioning means 13 by means of a well known loading means (not shown). The positioning means 13 is provided with two feeding servomotors 14 and 15 in X and Y axial directions, and with a third servomotor 16 for rotation, all of which serve to position the p-c-b at a predetermined position under the command signals from the control panel 6. When the tips of the lead wires of a component which has been conveyed, by the turret loader 9 from the component supplying means 8 are inserted into targeted inserting holes in the p-c-b just rightly positioned, a drawing-in mechanism 17 and a clinching means 18 are actuated in succession for pulling in the lead wires to be cut or sheared at a certain appropriate length and bending them to be fixed not to come off until they are nearly parallel to the back side of the p-c-b. A p-c-b planted fully with the predetermined number of components, at a predetermined layout, will be removed therefrom by means of a well-known unloading means (not shown) for being conveyed away by means of an out-conveyor 19.
Essential parts of each means mentioned above will be elaborated hereunder.
As can be seen in FIGS. 4 and 5, (the former being an elevational enlargement of a turret loader 9 and the latter being a vertical cross-section thereof for showing the connection of an index table and a cam plate), an index table 22 is supported, via bearing 24, by a supporting cylinder 23, and a cam plate 21 having a cam surface 21a for retracting a pusher (described later in detail) and is secured to the supporting cylinder 23. The index table 22 may be rotated by any ordinary intermittent rotary mechanism (indexing means) intermittently by 1/8 round (45°) each time. Index table 22 is provided with eight radially projected portions 22a, with an equal circumferential angular distance to each other, having respectively a chuck retainer 25 mounted on it, eight in all. Each chuck retainer 25 is provided with a guide block 26 secured to the projected portion 22a and a plurality of rods 27, 28, 29, and 31 slidably fitted, in an axial direction, in the guide block 26, and supports at the tip thereof a chuck 32.
Referring to FIGS. 7-11 further description on this part of the apparatus will be made.
A pair of rods 28, as shown in FIGS. 7 and 9 are connected at the tip (lower portion in FIG. 7) by a block 33 and at the end thereof (upper portion in FIG. 7) by a connecting block 34; between the latter 34 and the guide block 26 is mounted a compression spring 35 for constantly biasing, via the connecting block 34, the rods 28 toward the end thereof.
On the block 33 is firmly attached a stationary or fixed pawl 36 of the chuck 32, which stationary pawl 36 is preferable as thin and straight in configuration as possible and provide with, on its lead wire chucking surface 36a, V-shaped (in section as shown in FIG. 10) guide grooves A, B, C, D, E, F, G, H, J, and K formed thereon.
These guide grooves, A--K, are all to be formed perpendicularly to the tip surface 36b of the stationary pawl 36 to such a depth that a small part of the circumferential surface of a lead wire L chucked therein can be out of the groove beyond the groove upper level as shown in FIG. 11. The grooves C, D, E, J, and K are respectively formed with a respective distance from the groove A, biased or put aside to one edge, 1.5, 2.0, 2.5, 5.0, and 6.0 mm; on the other hand, the grooves H, G, F, B, and A are all respectively formed similarly, with a respective distance from the groove K, biased to the other edge, 1.5, 2.0, 2.5, 5.0, and 6.0 mm. The above-mentioned arrangement of the grooves is aimed at allowing either edge of the chucking surface 36a of the stationary pawl, i.e., either the rightly biased or leftly biased edge portion, to be employed according to the circumstances of the already planted (or inserted) components W 1 and/or inserting holes. In other words, the chuck 32 can hold the lead wires L at its rightwardly biased edge portion or leftwardly biased edge portion freely selecting the suitable side according to the situation of the already planted components W 1 and the targeted inserting holes. On the block 33 is pivoted a lever 37 with a pin 38, and on one end of this lever 37 is fixed a movable pawl 39 of the chuck 32. The chuck 32 is open-and closable, owing to rotation of the movable pawl 39 together with the lever 37 about the pin 38, for chucking or holding the lead wires L between the grooves, A-K, formed on the stationary pawl 36 and the chucking surface 39a of the movable pawl 39. The opposite end of the lever 37, from one where the movable pawl 39 is fixed, is connected with a pin 41 to a block 42 which is secured to the tip of a pair of rods 27 (lower portion in FIG. 7). The pin 41 passes through an elongated hole 37a formed in the lever 37, and is secured to the block 42. The pair of rods 27 are at their tip portion connected by the block 42 (lower in FIG. 7) and at the end portion connected by a connecting block 43 (upper in FIG. 7). Between the connecting block 43 and the guide block 26 is disposed a compression spring 44 for constantly biasing the rods 27, via the connecting block 43, toward the end portion (upward in FIG. 7).
Between the stationary pawl 36 and the movable pawl 39 is disposed a pusher head 45, which is secured to the tip of a rod 29. By means of urging a connecting block 46, which is connected to the end portion of the rod 29 (upper portion in FIG. 7), the pusher head 45 can be moved downwards, in FIG. 7; it is also, through connection with a clutch means 47, connected to a connecting block 48. The clutch means 47 comprises, as shown in FIG. 8, a clutch body 49 secured to the end portion of a pair of rods 31, which are guided by the guide block 26, a piston 51 slidably fitted in a bore 49a formed in the clutch body 49, and a compression spring 52 mounted between the head 51a of the piston 51 and the clutch body 49. The elastic force of the compression spring 52 serves to connect the rod 29 and a connecting block 48 with the aid of the frictional force generated among the clutch body 49, the piston 51, and the rod 29 passing through these members. The clutch means 47 itself is biased upward (in FIG. 7) by a compression spring 53 disposed between the clutch body 49 and the guide block 26. As a guide rod 54, which is connected to the connecting block 46, is slidably fitted through the clutch body 49, rotation of the connecting block 46 and the rod 29 and that of the pusher head 45 about the axial line are all restricted. On the connecting block 46 is pivoted a cam follower 55.
The operative parts of a chucking mechanism composed of the chuck retainer 25 and the chuck 32 will be described hereunder.
The cam plate 21 is, as shown in FIG. 4, provided with a pinion housing 56 firmly fixed, in which three pinions 57, 58, and 59 are rotatably, independent to each other, mounted. As shown in FIG. 6, on the cogs of the pinion 57 rack portions 61a and 62a of two push rods 61, 62 are engaged; when the push rod 61 is rightwardly moved by a cam (not shown), which is in interlock relation with the rotation mechanism of the index table 22, the push rod 62 is downwardly shifted by the same distance as that in the former. As to the other pinions 58 and 59 the description holds true quite identically; push rods 63 and 64, and the push rods 65 and 66 are respectively moved the same distance, changing the direction of the movement by 90°. In other words, the role of the pinion housing 56 is to transfer or deliver the movement of the push rods 61, 63, and 65, disposed in and parallel to the axis of the supporting cylinder 23, which movement is imparted by a cam (not shown, but disposed to the left of the supporting cylinder 23 in FIG. 5), to the push rods 62, 64, and 66, upon changing the direction of the movement by 90°, which will in turn become the urging force to be imparted to the connecting blocks 43, 34, and 48 through the abutting thereon. On the cam plate 21 are secured other two pinion housings 67 and 68, being of similar construction to the pinion housing 56, in which a similar movement transfer is respectively carried out, from the push rods 71 and 72 to the push rods 73 and 74 and further from the push rod 75 to the push rod 76. The push rods 73 and 74 respectively abuts on the connecting block 34 and 43 to urge the same; on the tip of the push rod 76 is slidably fitted a cylindrical pusher 77 with a bottom, which is constantly biased in the projecting direction by a compression spring 78 and restricted at the same time of a projection beyond a certain limit through the engagement of a pin 79 and an elongated hole 77a. The urging force of the push rod 76 is transferred or delivered, via the compression spring 78 and the cylindrical pusher 77, to the connecting block 46.
On the pinion housing 67 is secured a bracket 81, on which a clutch releasing lever 82 is, at its middle portion, pivoted. One end of the clutch releasing lever 82 is positioned just confronted to the head 51a of the piston 51 fitted in the clutch 47, the other end thereof being pivoted to a push rod 83.
On the cam plate 21 is also attached a clutch releasing plate 84 of sector configuration, just at a position to be interferred with the head 51a of the piston 51. When the piston 51 is rotated caused by the rotation of the index table 22, the contact of the piston head 51a with the clutch releasing plate 84 will cause the release of the clutch means 47. The inner cam surface 21a of the cam plate 21 is so configurated as to contact, at this time, with the cam follower 55 pivoted on the connecting block 46 to cause the cam follower 55, the connecting block 46, the rod 29, and the pusher head 45 to move toward the axial line of the index table 22, i.e., to draw back radially toward the axial line thereof.
The turret loader 9 is further provided with a lead wire pushing back means 85, which is disposed, as shown in FIG. 4, at a south-east position (lower right direction) along the circumferential line of the turret loader 9, and composed of a pushing-in lever 86 and an operation shaft 87, which is actuated by a not-shown mechanism to oscillate the pushing-in lever 86 at a preset time by a preset angle. This lead wire pushing back means 85 functions, when the chuck 32, which is holding the middle portion of the lead wires L, is halted at a obliquely lower right position, to push back the projected portion of the lead wires L out of the tip level of the chuck 32 therewithin.
The work or component supplying means 8 must be described next, which functions to separate electronic components one by one from a tape T which has been taken off the reel 5 of the magazine means 2 for supplying them to the turret loader 9. This supplying means 8 concurrently operates as a position conforming means so as to conform the position of supplying the lead wires L of the component W to the chuck 32 of the turret loader 9 exactly with the position of the commanded pair of guide grooves formed on the chuck 32, among A to K, under the signals from the control panel 6.
Although the magazine means 2 is, under the command of the control panel 6, actuated by the servomotor 7 in order to supply the tapes T, which retain respectively one type of components, according to the order of the components to be planted on the p-c-b P, at an exactly conformed position with the chuck 32, the lead wires L of the components-to-be-planted do not rightly agree with the guide grooves, A to K, on the chuck 32, because the lead wires L are more or less bent in general. It is therefore required to exactly conform the position or posture of the lead wires L with the guide grooves, A to K, formed on the chuck 32 for letting the same firmly hold the lead wires L as they are, before cutting the lead wires L to take the component off the tape T. In this embodiment a lead wire cutter 91 in FIG. 12 is so designed as to work concurrently as the position conforming means, which is composed of two blades, a first 92 and a second 93, for shearing in mutual cooperation the lead wires L. The first blade 92 is provided with a recess 92a for guiding the lead wires L, which recess 92a is further composed of a pair of rectangular positioning recess portion 92b parallelly formed with a distance equal to the distance between one pair of the guide grooves, A to K, on the chuck 32, i.e., 1.5, 2.0, 2.5, 5.0, and 6.0 mm (standardized interlead-wire distance or gage), and a guiding recess portion 92c which is connected to the positioning recess portion 92b and diverging in width toward the opening thereof. The lead wires L are exactly positioned by this guiding recess 92a and then sheared between the bottom portion 92d of the positioning recess 92b and a slightly skewed cutting blade 93a of the second blade 93.
The component supplying means 8, provided with the lead wire cutter 91 having such a function, is shown in its essential part in FIGS. 13 and 14. The first blades 92, provided respectively with the lead wire guiding recess 92a, are attached, same in number to that of the reels 5, to the rotatable frame 4 of the magazine means 2, for being rotated accompanied by the rotation of the rotatable frame 4. The first blade 92 is secured to a mounting block 95, which is secured on the upper end of a pair of rods 94, which rods are, in turn, slidably fitted through a guide block 96 secured to the lower end of the rotatable frame 4. The pair of rods 94 are connected together at their lower end portion with a connecting member 97, and are constantly biased downwardly by a compression spring 98, which urges the connecting member 97. The connecting member 97 concurrently functions as a mounting member for a roller 99. On the rotatable frame 4 are mounted tape feeding means (not shown) composed of a driving sprocket 101 for intermittently shifting the tapes T retaining electronic components W and a driven sprocket 102, same in number as the reels 5. This tape feeding means are rotated with the blade 92 accompanied by the rotation of the rotatable frame 4. The above description will clarify the construction of the movable portion 8b of the component supplying means 8. The movable portion 8b of the component supplying means 8 is actuated by a common actuating means disposed on the main body 1 side, without possessing any specific actuating means for itself. When the movable portion 8b has taken an agreeable position against the stationary part 8a of the component supplying means 8 a bell crank 103, in FIG. 13, pivoted on the main body 1 is clockwise rotated, by an actuating means (not shown) which includes a cam, to push upwards overcoming the elasticity of the compression spring 98 the roller 99, the connecting member 97, the rods 94, the mounting block 95, and the first blade 92. The stationary or fixed portion 8a of the component supplying means 8 is composed of the second blade 93, for shearing lead wires L in cooperation with the first blade 92, and an actuating means therefor attached on the side of the main body 1.
The second blade 93 is secured with a bolt to a mounting block 105 fixed to the lower end of a rod 104, which is slidably retained by a guide block 106 secured to the main body 1. On the upper end of the rod 104 is secured a block 107; a roller 108 pivoted on this block 107 is being fitted in a U-shaped recess 109a formed on one end of a bell crank 109, which is pivoted on the main body 1. When the bell crank 109 is rotated, clockwise or counter-clockwise in FIG. 13, by an actuating means including a cam, the block 107, the rod 104, and the second blade 93 are raised upwards or pushed downwards. The second blade 93 and other members connected thereto are prevented from a rotation about the vertical axial line in FIG. 13, because a rod 111 secured to the block 107 is paralelly fitted through the guide block 106 to the rod 104. As shown in FIG. 14 on the mounting block 95 for the first blade 92 is attached a supporting member 112; and on the mounting block 105 for the second blade 93 is attached a pusher 114, which is constantly biased downwardly by a compression spring 113. These members 112 and 113 serve, when the lead wires L are sheared by the cutter 91, to strengthen the chucking force of the chuck 32 by pinching the same from opposite sides upper and lower in order to prevent the lead wires L from getting out of place.
The drawing-in mechanism 17 will be described next, which is a means for further deeply draw in the lead wires L inserted by the turret loader 9 in the inserting holes in the p-c-b P. This mechanism 17 is, as shown in FIG. 15, positioned in confrontation, holding a p-c-b P inbetween, with the chuck 32 halted at the inserting posture (the lowest position in this embodiment).
The drawing-in mechanism 17 is provided with a movable rod 123 of quadrangular prism form retained axially (up and down in FIG. 15) slidablly by a guide block 122, which is secured to the main body 1. On the tip of the movable rod 123 is attached a pair of drawing-in pinchers 126 composed of a stationary or fixed pawl 124 and a movable pawl 125. The stationary pawl 124 is, at its foot portion 124a, of H-shape in section, as shown in FIG. 16. At a recess formed on the left side of the H-shape, the stationary pawl 124 is threadedly fixed to the movable rod 123, in close engagement with a recessed portion formed on the tip of the movable rod 123. The movable pawl 125 is, on the other hand, secured to an oscillating arm 128 which is pivoted, with a pin 127, on the movable rod 123. The oscillating arm 128 is a yoke-shaped member as shown in FIG. 17, and is pivoted, with its bifurcated portion 128a straddling the movable rod 123, thereto. The movable pawl 125 is, at its foot portion 125a, threadedly fixed on the tip of the bifurcated portion 128a of the oscillating arm 128; it is larger in width at its foot portion 125a than at the end portion 125b and is extending, as shown in FIG. 16, upward, with the end portion 125b passing through the right side recess of the foot portion 124a of the stationary pawl 124. The oscillating arm 128 is, at the opposite end from one end where the movable pawl 125 is secured, connected with a pin 129 to one end (upper end in FIG. 15) of an operation rod 131, in other end of the operation rod 131 being connected, with a pin 132, to a lever 133. The lever 133 is pivoted on a supporting shaft 134 which is secured to the main body 1, and on the other hand connected, through a connecting rod 130, to an oscillating lever which is oscillated by a cam (not shown). The lever 133 is oscillated, according to the rotation of the cam, at a preset time by a preset angle to move the operation rod 131 in a substantially parallel direction to the reciprocal direction of the movable rod 123 (up and down in FIG. 15). When the operation rod 131 is moved upwards, the force directed upwards will be delivered, via the oscillating arm 128, even to the movable rod 123; the latter 123 is, however, restricted from the upward movement, owing to a preset frictional force between the movable rod 123 and the guide block 122 generated by the elasticity of a pair of compression springs 135 abutted on one side of the movable rod 123. So long as the oscillating arm 128 can be rotated about the pin 127, the movable rod 123 will not be raised. Therefore, when the operation rod 131 is moved upwards, the oscillating arm 128 is clockwise (in FIG. 15) rotated first accompanied by the same directional rotation of the movable pawl 125. And the maximum possible rotation angle of the movable pawl 125 is limited by a stopper plate 136 threadedly fixed to the foot portion of the stationary pawl 124a. As soon as the movable pawl 125 abuts on the stopper plate 136, the movable rod 123 begins to move upwards overcoming the above-mentioned frictional force.
Likewise the operation rod 131, when moved downwards, causes the oscillating arm 128 and the movable pawl 125 to counterclockwise rotate; and the movable rod 123 does not begin to move until the movable pawl 125 abuts the stationary pawl 124. A simple up-and down motion of the operation rod 131 makes a cycle of all necessary steps for drawing-in of the lead wires L, i.e., opening, rising, closing, and descending of the drawing-in pinchers 126.
On opposite sides of the above described drawing-in mechanism 17, as shown in FIG. 15, is disposed a clinching mechanism 18 for clipping or shearing the lead wires L, which have been drawn in by the drawing-in mechanism 17, at an appropriate length and bending the same so as to make them substantially parallel to the back surface of the p-c-b P. The clinching mechanism 18, which shears and bends the lead wires L for preventing the same from getting out of place, includes a stationary blade 141 and a movable blade 142.
The stationary blade 141 is secured, with an ordinary fastening means such as bolting, to the tip of a blade retaining bar 143. A first cutter member consisting of the stationary blade 141 and a blade retaining bar 143 is slidably, upwardly slanting with the right end up, retained by a guide block 144 secured to the main body 1. Via a lever 146, which is pivoted on a supporting shaft 145 secured to the main body 1, this first cutter member is lengthwise reciprocated due to an actuation by a not-shown operation means, which means that the stationary blade carries out a shearing action while stationary and, does not necessarily mean that it is a completely fixed blade. A movable blade 142, which cooperates with the stationary blade 141 in shearing the lead wires L, is divided into three small bladelets by dividing planes perpendicular to the cutting edge thereof, as shown in FIGS. 18 and 19, 142L, 142C, and 142R, each of these being secured to the tip of respective blade retaining bars 147L, and 147C, and 147R with an ordinary fastening means such as bolting. These blade retaining bars 147L, 147C, and 147R pass through a guide block 148, or retaining member slantingly with their left end up, which guide block 148 is seucred to the main body 1, and are respectively pivoted, at their end portions (lower), to a movable member 149 for constituting a second cutter member. The movable member 149 is composed, as shown in FIG. 18, of a quadrangle prism portion 149a, a foot portion 149b, and a yoke portion 149c. The quadrangle prism portion 149a is slidably fitted in a guide bore 148a in the guide block 148; the yoke portion 149c is connected to a lever 151. When the lever 151 is rotated about a supporting shaft 152, actuated by a not-shown operating means, the movable member 149 is lengthwise reciprocated. On the foot portion 149b of the movable member 149 blade retaining bars 147L, 147C, and 147R are respectively pivoted with a pins 153L, 153C, and 153R. A guide bore 148b formed in the guide block 148 is slightly larger in width, as shown in FIG. 19, then the width which just allows accommodation of the blade retaining bars 147L, 147C, and 147R, so it is possible for the three blade retaining bars to rotate slightly respectively about the pins 153L, 153C, and 153R.
In the guide block 148 is formed another guide bore 148c, therethrough a substantially quardrangle-prism-shaped operation rod 154 being fitted slidably. At the lower end of the operation rod 154, a yoke portion thereof 154c is connected to a lever 155 for being lengthwise reciprocated, actuated by a not-shown operating means through the lever 155. At the upper end thereof (in FIG. 18), a pair of links 156 and 157 are pivoted by a pin 158. The other end of the links 156 and 157 are respectively connected with a pin 159 and a pin 161 to the blade retaining bars 147L and 147R in the vicinity of the upper end portion thereof (free end).
On the side of the blade retaining bars 147L and 147R confronting to the blade retaining bar 147C, are respectively formed three bores 147a and 147b, each having a bottom, on each side. In each of these bores 147a and 147b is air-tightly fitted a piston 162, 163 respectively, to form an air-cylinder by sliding reciprocation movement therein. These bores 147a and 147b are respectively connected, via passages 147c, 147d and pipings 164, 165, to an electro-magnetic valve 166. By means of switching of the electro-magnetic valve 166 the bores 147a and 147b are selectively supplied from an air source with compressed air.
The stationary blade 141 has, on its upper end portion, a recess 141a, formed at a lower side thereof as shown in FIG. 20, the extreme edge thereof being denoted as a cutting edge 141b; on either depending portion of the recess 141a is respectively formed and slantingly recessed portion 141d for facilitating engagement with the bladelets 142L and 142R.
On the tip portion of the bladelets 142L, 142C, and 142R are formed, as shown in FIG. 21 in enlargement, surfaces 142a, 142b, and 142d parallel to the back (lower) side Pb of the p-c-b P. On these surfaces are formed V-shaped grooves A', B', C', D', E', F', G', H', J', and K', at the position shown in FIG. 21, in the perpendicular direction to the blade edge of the bladelets 142L, 142C, and 142R. These grooves, A' to K', are arranged such that by taking A' on the bladelet 142L as a base C', D', E', J', and K', are respectively located at positions 1.5, 2.0, 2.5, 5.0, and 6.0 mm distant therefrom, and conversely, taking K' on the bladelet 142R as another base, H', G', F', B', and A' are similarly located at a position 1.5, 2.0, 2.5, 5.0, and 6.0 mm distant therefrom. All of these gauges are respectively agreed with the standard gauges (pitches) of the lead wire inserting holes in the p-c-b P. As a result of this, on the blade edge of each bladelet 142L, 142C, and 142R the same number of V-shaped recesses are formed. Such a construction of the movable blade 142 is aimed at bending of the lead wires L in widely divergent directions to each other, as shown in FIG. 22, and at the same time adapting to the construction of the chuck 32, wherein lead wires L can be held selectively at rightwards biased positions or leftwards biased positions, which will be further described with respect to the operation of the machine.
As to how the inserting operation of the lead wires L of components W is carried out, an example in which components W 1 , W 2 , W 3 , W 4 are planted in a layout shown in FIG. 23 will be described, with reference also to FIGS. 24-33.
First of all a component W 1 is inserted at the upper right corner (in FIG. 23) of the p-c-b P, the lead wire distance (gage) being assumed to be 1.5 mm. Under the command of the control panel 6, the rotatable frame 4 of the magazine means 2 is rotated, and the reel 5 which retains the component W 1 is moved to the component supplying position. The first blade 92 disposed on the movable part 8b of the component supplying means 8 is halted at a position where the positioning recess portion 92b of the recess 92a for guiding just agrees with the V-shaped grooves K, H on the chuck 32 of the turret loader 9. When the sprocket 101 is rotated by a preset angle, the lead wires L of the component W 1 come to stop above the first blade 92, followed by lifting of the first blade 92 to guide the lead wires L into the recess 92a for guiding (as shown in FIG. 12 and in FIG. 24) and to exactly position the same in the V-shaped grooves H, K on the chuck 32.
Being caused by the retraction of the rods 72 and 74, the rod 27 is retracted owing to the restoring force of the compression spring 44 (refer to FIGS. 4 and 7). The chuck 32 which has been rested in an immediately neighboring position of the first blade 92 is closed for holding the middle portion of the lead wires L as shown in FIG. 25. The second blade 93 is then lowered to shear the lead wires L with cooperation of the first blade 92, see FIG. 25. At this time the lead wires L receive a rightward drawing force (in FIG. 25), however, the chuck 32 holds strongly enough the lead wires L to prevent the movement thereof, being pressed and reinforced of holding force by the supporting member 112 and the pusher 114, relative to the chuck 32. This mechanism for strengthening the holding force will further serve, in cooperation of the drawing force, to straighten the lead wires L. When the lead wires L have been clipped, the rods 71, 73 are retracted accompanied by the retraction, aided by the restoring force of the compression spring 35, of the rod 28. The chuck 32 is also retracted, with the lead wires L being held intact at the middle portion thereof as shown in FIG. 26.
Then the index table 2 is rotated by 45° to move the chuck 32 to a south-east position shown in FIG. 4, lowered 45° in the right-hand side. The operation shaft 87 will, in turn, be rotated, followed by a clockwise rotation of the lever 86, in FIG. 4, secured to the operation shaft 87, to push back the projected portion of the lead wires L from the tip of the chuck 32 within the tip level thereof, as shown in enlargement in FIG. 27.
Then the clutch releasing lever 82 is rotated by the push rod 83, and the piston 51 of the clutch means 47 is pushed into the clutch body 49 overcoming the spring force of the compression spring 52 to release the clutch means 47. The push rods 75, 76 are operated to urge, via the compression spring 78 and the pusher 77, the connecting block 46, causing advance of the same 46, the rod 29, and the pusher head 45, until the pusher head 45 finally abuts the head H of the component W 1 , see FIG. 28. As a result of this, reaction force acted on the cylindrical pusher 77 from the connecting block 46 is rapidly increased to overcome the set load of the compression spring 78. Contraction of the compression spring 78 triggered in this way restricts the advance of the cylindrical pusher 77, the connecting block 46, the rod 29, and the pusher head 45, irrespective of the advance of the push rod 76. At this state the clutch releasing lever 82 is restored to the original position to connect the clutch means 47, the pusher head 45 consequently being kept connected to the connecting block 48, with the tip thereof abutting the head H of the component W 1 . Afterwards the index table 22 is rotated again by 45° accompanied by the advance of the chuck 32, i.e., the push rod 64 begins to operate soon after the beginning of the rotation of the index table 22 to advance the rod 28, so the chuck 32 advances in the radial direction of the index table 22, while rotating with the index table 22, to approach the p-c-b P which is retained at a preset position by the positioning means 13 (refer to FIGS. 1 and 29). The p-c-b P is placed in a tangential direction to a circle A, concentric with the index table 22; and the chuck 32 is so operated as to halt at the most advanced position immediately before the halting of the index table 22. Thus the chuck 32 actually moves substantially parallel to the surface of the p-c-b P in the vicinity of a targeted position. The chuck 32 is approached, as shown in FIGS. 23 and 29, from a direction marked with arrow R to the targeted lead wire inserting holes Pa and halted exactly above the same holes Pa.
When the chuck 32 has halted exactly above the targeted position, the push rods 65, 66 begin to operate to advance the pusher head 45 by the distance, which equals to the travelling distance of the chuck 32 plus the length the lead wires to be protruded from the tip of the chuck 32, for pushing down the component W 1 , as shown in FIG. 30. The lead wires L are subsequently protruded out of the chuck 32, overcoming the frictional force, to be inserted from their tip portion into the lead wire inserting holes Pa in the p-c-b P, wherein the lead wires L, being guided by the V-shaped grooves K, H formed on the stationary pawl 36, can be protruded straightly.
As shown in FIG. 30, the moment when the tip portion of the lead wires L are protruded, as far as the back side of the p-c-b P, to be between the already opened drawing-in pincers 126, the lever 133 is rotated counterclockwise (in FIG. 15) to pull down the operation rod 131, whereby the oscillating arm 128, in turn, counterclockwise rotates the movable pawl 125 to close the drawing-in pinchers 126 for holding the tip portion of the lead wires. Further downward motion of the operation rod 131 causes a downward motion, overcoming the frictional force, of the movable rod 123, which makes the drawing-in pinchers 126 come down, with the lead wires L held therein, to the sufficient deep position as can be seen in FIG. 31. At this time, the pusher head 45 is already retracted (upwards) and the chuck 32 is open. When the lead wires L are fully drawn in, the lever 146 (in FIG. 15) is rotated by a not-shown operation means including a cam to advance the stationary pawl 141 toward the back (lower in FIG. 15) surface Pb of the p-c-b P to be halted at a preset position. Soon afterwards, the levers 151, 155 are simultaneously rotated by a same angle to advance the movable member 149 and the operation rod 154, accompanied by a simultaneous and parallel advancing of the blade retaining bars 147L, 147C, and 147R, which are respectively pivoted at the end portion (lower portion) thereof to the movable member 149 and connected at the tip portion (upper portion) thereof to the operation rod 154, via the links 156 and 157. The bladelets 142L, 142C, and 142R fixed respectively on the tip of the blade retaining bars 147L, 147C, and 147R approach the back surface Pb of the p-c-b P from a slant direction, in a manner as if they were an integral cutter, to shear the lead wires L, with the aid of the stationary blade 141. The bladelets 142L, 142C, and 142R are, after having sheared the lead wires L, further advanced deep into a triangular space formed between the p-c-b P and the stationary blade 141, to bend the lead wires L along the back surface Pb of the p-c-b P. The operation rod 154 is then moved faster than the movable member 149, owing to the construction mode of the operation means, which will cause a relative movement of the pin 158 to the pins 159 and 161. The distance between the pin 159 and the pin 161 is to be enlarged to consequently rotate the blade retaining bars 147L and 147R respectively about the pin 153L and 153R at a same angle but in opposite directions away from each other. As the lead wire distance of the component W 1 is being assumed to be 1.5 mm, the lead wires L, which have been held and inserted by the grooves K, H of the chuck 32, are to be sheared at the V-groove K' on the bladelet 142R and the V-groove H' on the bladelet 142C (V-grooves K', H' are formed at the confronted position to that of the V-grooves K, H on the chuck 32). The electro-magnetic valve 166 is then already switched to a direction in which air is supplied to the piping 165, which causes the blade retaining bar 147C to be urged, by the pistons 163, to the side of the blade retaining bar 147L. It means that the blade retaining bar 147C is rotated in the same direction as the blade retaining bar 147L, when the blade retaining bars 147L and 147R are rotated in the opposite directions from each other. From the above it is easily understood that blade retaining bars 147R and 147C are split apart, and the bladelets 142C and 142L are moved leftwards and the bladelet 142R is moved rightwards, in FIG. 19, consequently the distance (gage) between the V-shaped grooves H' and K' is increased, and as a result, the lead wires L which are guided by these two grooves will be bent in a fanwise divergent direction by the angle θ, as shown in FIG. 22. And this angle θ is to be determined at will by means of changing the ratio between the advancing speed of the bladelets 142L, 142C, and 142R and the divergent speed (a moving speed in the perpendicular direction against the advancing direction).
The reason why the lead wires L are, in addition to the pushing down by the pusher head 45 on the head H of the component W 1 for inserting into the lead wire inserting holes, drawn in by the drawing-in pinchers 126 lies in, as can be understood in the above description, prevention of buckling of the lead wires L while inserting and exact adaptation of the lead wires' position to that of the V-grooves A' to K' on the movable blade 42. As the lead wires L are, in this embodiment, held by the drawing-in pinchers 126, the moment the tip portion thereof protrude slightly through the lead wire inserting holes Pa, and drawn downwards straightly, i.e., in a perpendicular direction to the p-c-b P, so they are in an upright posture, parallel to each other with the same distance as that between the lead wire inserting holes Pa in the p-c-b P, spanned between the p-c-b P and the drawing-in pinchers 126. The lead wires L are, therefore, sheared exactly at the position of the V-shaped groove H' of the bladelet 142C and that K' of the bladelet 142R, and subsequently pressed to be surely bent in the divergent direction, as the grooves H' and K' diverge in accordance with the diverging of the blade retaining bars driving the bladelets 142R and 142L, as mentioned above.
When the bending or clinching of the lead wires L has been finished, and the stationary and movable blades 141, 142 have been restored to the original position distant from the p-c-b P, the control panel 6 gives a commanding signal to the p-c-b P to be positioned for the next inserting operation.
In the above-mentioned one cycle of the insertion, the component W 1 is finished of planting in the upper-right corner of the p-c-b P, as shown in FIG. 23.
While the component W 1 is inserted in the p-c-b P in such a manner, a second component W 2 is held in the next chuck 32 and a third component W 3 is likewise held in the third chuck 32.
Assume the lead wire distance of the component W 2 is 6 mm, then the first blade 92 having the positioning recess portion 92b of the same distance 6 mm is disposed beneath the reel 5 retaining the component W 2 of the magazine means 2, which positioning recess portion 92b is to be halted at a position just confronting to the V-shaped grooves A, K on the chuck 32 of the turret loader 9. The lead wires L of the component W 2 positioned by the first blade 92 are held by the chuck 32 at the V-shaped grooves of A, K, and cut off the tape T by the descending of the second blade 93 for being inserted, in the same mode as the component W 1 , into the inserting holes Pa of the p-c-b P.
The lead wires L inserted are drawn in deeper by the drawing-in pinchers 126 and sheared or cut at the position of the V-shaped groove A' on the bladelet 142L and at that K' on the bladelet 142R. The lead wires L are, likewise in case of W 1 , bent in divergent direction due to the advance of the bladelets 142R and 142L while being separated from each other. Furthermore, a component W 3 with the gage of 5.0 mm is held by the chuck 32 at the position of the V-shaped grooves A, J for being positioned, from the direction marked with the arrow M, right above the inserting holes Pa, as shown in FIG. 23 (the p-c-b P is positioned in compliance with such a situation).
The lead wires L inserted into the inserting holes Pa and drawn in by the drawing-in pinchers 126 are sheared at the position of the V-shaped groove A' on the bladelet 142L and that J' on the bladelet 142C, for being bent. The electromagnetic valve is then, by a commanding signal from the control panel 6, already switched to supply compressed air through the piping 164. So when the blade retaining bars 147L and 147R are split or separated from each other, the blade retaining bar 147C is urged by the pistons 162 to rotate in the same direction as the blade retaining bar 147R, which separates the bladelet 142L and the bladelet 142C from each other. The lead wires L, which are in captivity of the V-shaped groove A' on the bladelet 142L and that J' on the bladelet 142C, will be, likewise in case of W 1 and W 2 , bent and clinched in the fanwise divergent direction.
The component W 4 with the gage of 2.5 mm is to be held by the chuck 32 at the V-shaped grooves F and K for being inserted at the position shown in FIG. 23. The chuck 32 is then advanced, with the stationary pawl 36 ahead, in the direction marked with the arrow N in FIG. 23 and FIG. 33, so the same 32 is allowed to approach the inserting holes while pushing away the already planted component W 1 on the p-c-b P indicated with a two-dot-chain line in FIG. 33, from the space wherein the component W 4 is to be inserted with the back (outer side) of the stationary pawl 36. It makes the distance between the holes where the component W 1 being inserted and the holes where the component W 4 is to be inserted extremelly small, which allows, in other words, to enhance the component distribution density. The chuck 32 in this embodiment is provided with a stationary pawl 36 so designed as to be as thin and straight as possible. It makes possible to make the distance between the components W 1 and W 4 far smaller than that in the conventional cases; besides the concept that the stationary pawl 36 pushes away the head H of the already planted component W 1 with the outer side thereof, when inserting another component W 4 in the immediate neighboring area, allows the distance between the components W 1 and W 4 to be minimized even to a state wherein W 1 and W 4 are in contact with each other. As can be understood from the above description, the chuck 32 is used, when holding a component W, at a pair of rightwardly biased V-shaped grooves (in case of W 1 , W 4 ) or at a pair of leftwardly biased V-shaped grooves (in case of W 3 ), in accordance with the situation of the p-c-b P. When the lead wire gage is the greatest (W 2 ) the component is held exceptionally at the V-shaped grooves positioned centrally, which should be regarded as a special case of the principle of holding biasedly to either side.
As can be seen in FIG. 23, when the component W 3 is inserted, the p-c-b P shall be positioned in advance such that the already planted component W 1 comes around to the left (upper in FIG. 23) of the left-side extremity of the chuck 32, which is working at the leftwardly (upper in FIG. 23) biased pair of grooves for holding the component W 3 . When the component W 4 is inserted, the p-c-b P is positioned such that the already planted component W 3 comes around to the right of the right-side extremity of the chuck 32 which is working at the rightwardly biased pair of grooves for holding the component W 3 . By means of positioning the p-c-b P such that an already planted component is always confronted to the side of the chuck 32, on which the biasedly used pair of grooves on the chuck 32 are sided for holding a component-to-be-inserted, it has become possible to insert components at a very high distribution density regardless of the size of the chuck 32. In other words, the chuck 32 shown by a two-dot lined rectangular in FIG. 23 holds a component always at a pair of grooves biased to either one side, and the other side (not-holding the component) is always kept directed to the unplanted area of the p-c-b P. Disadvantages of traditional inserting method and apparatus, which had to take a wide space between components-to-be-inserted in accordance with the circumstances around the inserting apparatus or machine, have been completely eliminated.
The above-mentioned embodiment is only an example of this invention. Many variations and modifications are practicable without departing from the spirit and scope of this invention. Some of the examples will be disclosed hereunder.
Contrary to the above embodiment, wherein the chuck 32 is composed of a stationary pawl 36 and a movable pawl 39, the former being comparatively small in size, and the same is usable by, for holding a component, biasing the base to either one side, a chuck of symmetrical form against the chucking surface is also practicable such as one having a pair of pawls openable to either side, wherein holding of the component biased exclusively to one fixed side is possible.
Secondly in the above first embodiment a plurality of chucks 32 are disposed circumferentially around the index table 22, so a series of inserting operations of a component is divided into a plurality of steps for economizing the time required for inserting a component. Besides, the chuck 32 is approached to the p-c-b P, utilizing the rotation movement of the index table 22, it can be substantially parallelly moved to the surface of the p-c-b P when it comes to the nearest position to the p-c-b P, which enables the chuck 32 to push away the already planted components in order to effectively enhance the component distribution density. It is, however, possible to make a laterally movable member, on a horizontal guide rail, hold or grip a component-to-be-inserted.
It is not an absolute requirement to push away already planted components on the p-c-b P by the movement of the chuck 32; after the chuck 32 has been halted at the targeted position, the p-c-b P itself may be moved parallelly to the surface thereof to achieve the same object. As the p-c-b P is, as shown in FIG. 1 and FIG. 2, usually mounted on a member which is movable in any direction in a plane (even a rotation movement when required) for being positioned at a desired position, it is also practicable to push away the already planted components by the chuck 32, by means of utilizing this plannar movement of the p-c-b P for the purpose of positioning. The chuck 32 can also be approached to the targeted inserting holes, from the perpendicular direction against the surface of the p-c-b P, wherein the back (outer side) of the stationary pawl 36 must be made slanted. If the already planted components can be pushed away, by utilizing this slanted back surface of the stationary pawl 36, the object of enhancing the component distribution density is likewise attainable.
Various modifications are possible to be made about the structure of individual members. For example, a magazine means 2, wherein reels are parallelly retained to each other and they are fed by a linear movement one by one to the component supplying position, can be substituted for the first embodiment type in which reels are radially arranged on the circumference of the rotatable frame 4.
The cutter 91 in the component supplying means 8 functions concurrently as a positioning means for accurately positioning the lead wires L against the chuck 32, which enables indeed elimination of a particular actuating means therefor. It is, however, possible to dispose a proper separate positioning means such as a positioning plate having a guide recess.
The chuck 32 is not limited to the above-mentioned structure; any one type which is openable in a perpendicular direction to a plane including the two lead wires L for holding the same will do for the purpose.
In the above embodiment, the lead wires L are accommodated once within the chuck 32, and are, when having arrived at the targeted position, protruded out of it to be inserted into the inserting holes Pa. It indeed has a great advantage of avoiding scratching, or contacting with, other objects by the lead wires L while being moved, but it is not essential to this invention. If a chuck 32 satisfies such conditions that the protruded portion of the lead wires L can be minimized when a component W is held by the chuck 32, and the chuck 32 can be moved without letting the protruded portion of the lead wires L contact the p-c-b P, being retained within a distance from the p-c-b P capable of pushing away the already planted components W with the back side of the stationary pawl 36, it may be moved horizontally, i.e., parallelly to the surface of the p-c-b P until it reaches right above the targeted inserting holes Pa, followed by a perpendicular movement thereof to insert the lead wires L. In this case, disposition of the V-shaped grooves on the chuck 32 is not necessarily required. Rubber lining on the chucking surface of either or both pawls of the chuck 32 is preferable for ensuring the positioning of the lead wires L when being held. As to the open-and closing of the chuck 32, mechanical structure is not the only way, but employing other means such as electromagnetism or compressed air are also practicable.
When the lead wires L are pulled by the drawing-in pinchers 126, a simultaneous descending of the pusher head 45 at an identical speed is also effective to be practiced. Even when the drawing-in pinchers 126 are by chance out of order for holding the lead wires L, they can be inserted deeply enough by the pusher head 45, which is good for enhancing the reliability of the apparatus.
It is also possible to carry out the insertion with only a pusher head 45 or a chuck 32, eliminating the drawing-in pinchers 126.
Regarding the clinching means 18 variations can also be made. The V-shaped grooves A'-K' formed on the bladelets 142L, 142C, and 142R need not necessarily be in a perpendicular direction to the blade edge, but may be formed with a certain angle slanted thereto. In this case, the lead wires L may be effectively prevented from getting out of the V-grooves even when they are being bent substantially parallel to the lower side (back side) of the p-c-b P.
When the width of the bladelets is large enough, or the angle θ formed between the lead wire bending direction and the shearing direction (see FIG. 22) is comparatively small, means for keeping the lead wires L in place or means for increasing the friction coefficiency is not necessarily indispensable.
The mechanism for separating the blade retaining bars 147L, 147C, and 147R from each other is not limited to the above-mentioned combination, as shown in FIGS. 15, 18, and 19, of the operation rod 154, the links 156 and 157, the pistons 162 and 163, the electro-magnetic valve, etc., but may be one shown in FIG. 35, wherein the operation rod 154 is eliminated and the divergent separation of the blase retaining bars 147L, 147C, and 147R are carried out by utilizing the forward movement thereof, although they pass, as in the first embodiment, through the guide bore 148b of the guide block 148 and pivoted respectively at their end portion (lower portion in FIG. 35) to the movable member 149 by the pins 153L, 153C, 153R for being lengthwise movable therewith. Between the end portion of the blade retaining bars 147L and 147R is mounted a tension spring 205 for constantly biasing them closed; between the blade retaining bar 147L and the blade retaining bar 147C, and between the blade retaining bar 147C and the blade retaining bar 147R are respectively formed an accommodating hole 206, 207 for being selectively fitted thereinto by a wedge-shaped member 208, 209 from the rear side, in order to regulate the moving direction of the three blade retaining bars. Three rollers 211L, 211C, and 211R, which are pivoted on the respective blade retaining bars 147L, and 147R, are advanced together with the three blade retaining bars to contact either of the wedge-shaped members 208, 209, which selectively come up into the accommodating holes 206, 207, when the three blade retaining bars are selectively separated between the blade retaining bar 147L and the blade retaining bar 147C or between the blade retaining bar 147C and the blade retaining bar 147R. Then the bladelets 142L, 142C, and 142R are imparted the identical movement as in the first embodiment. For selectively actuating the wedge-shaped members 208, 209, a combination of an air cylinder and an electromagnetic valve or a combination of a spring and an electromagnet, or the like may be preferably employed.
The movement of the blade retaining bars for separating the bladelets is preferably performed by a rotating type for simplifying the structure of the mechanism; but it is possible to achieve the same object by a parallel movement. The direction of the movement of the movable blade when clinching the lead wires is usually preferred to be, as in the above embodiments, a little slant against the back surface of the p-c-b for ensuring the clinching process; it is, however, possible to move it in a parallel direction to the back surface of the p-c-b P. An example thereof is illustrated in FIGS. 36 and 37. A stationary blade 214 is secured to an up-and downwards movable member 216 actuated by an air cylinder 215. Bladelets 217L and 217R (movable blades) are secured to the tip of rotating arms 221L and 221R respectively, which are pivoted on movable members 219L and 219R laterally moved by air cylinders 218L and 218R. On a guide bar 223 for guiding the movable members 219L and 219R is slidably disposed a stopper means 224 for restricting the movement range of the movable members 219L and 219R. This stopper means 224 is selectively moved to a right side position or to a left side position by a feeding thread 226 directly connected to a rotating shaft of a servomotor 225 which is secured to the up-and downwards movable member 216.
The bladelets 217L, 217R shear the lead wires L, in this embodiment, from a substantially parallel direction to the back (lower) side of the p-c-b P, when the rotating arms 221L, 221R are rotated by the air cylinders 222L, 222R; after the bladelets 217L, 217R have sheared the lead wires L they continue to move parallelly to the back side of the p-c-b P for bending the lead wires L as shown in FIG. 38 parallelly to the shearing direction and with a certain small angle α against the back side Pb of the p-c-b P. Afterwards, due to a separation of the movable members 219L, 219R from each other actuated by the air cylinders 218L, 218R, the bladelets 217L, 217R will be consequently separated from each other. The lead wires L, once bent parallelly to the shearing direction, are to be diverged outwardly with a certain angle, just like the arrangement shown in FIG. 22. In order to ensure the angle of the bending direction from the shearing direction in which the lead wires L are bent and diverged, it is also effective in this embodiment to form fine grooves or recesses 217a on the upper surface of the bladelets 217L, 217R, or to stick some material of high friction coefficiency for preventing slipping or sliding of the lead wires L on the upper surface of the bladelets 217L, 217R.
When the lead wires L are inserted by being held at a rightwardly biased position of the chuck 32 the stopper means 224 is moved to a rightwardly biased position, and when vice versa, the stopper means 224 is moved to a leftwardly biased position, thereby adapting the operation position of the bladelets 217L, 217R to the position of the inserting holes of the lead wires L.
Even the clinching means 18 in FIG. 15 can be modified such that by making the guide block 148 movable in a parallel direction to that of the diverging movement of the bladelets the clinching means 18 itself may be adapted to the position change of the lead wires L, thereby reducing the number of bladelets and blade retaining bars to two each. For that it is required to allow a changing of relative position, due to the movement of the guide block 148, between the movable member 149, the operation rod 154 and the levers 151, 155, by means of taking some measures such as enlarging the width of the yoke portions of the movable member 149 and the operation rod 154 larger than the thickness of the levers 151, 155.
Contrary to the earlier described clinching of the lead wires L, wherein the same were bent in divergent directions, bending in convergent or in mutually approaching directions is also possible, where the lead wires L are bent inwardly directed as shown in FIG. 39. In that case the bladelets are made approach to each other, after the shearing has been finished, symmetrically and perpendicularly to the shearing direction.
Furthermore, a clinching means which simply bends and clinches the lead wires L without shearing them, or which simply squashes the tip portion of the lead wires L flat is possible.
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An apparatus for inserting electronic components into a printed circuit board including (a) chucking means for holding a pair of lead wires of an electronic component, which chuck opens and closes in a direction perpendicular to a plane including the axes of the pair of lead wires; with a distance identical to that between the lead wire inserting holes in the printed circuit board; (b) means for inserting thus held lead wires into a corresponding pair of lead wire inserting holes; and (c) means for applying a clinching treatment to the inserted lead wires protruding from the back side of the printed circuited board, whereby an electronic component is, regardless of the size of the inter-lead-wire distance, held by a chuck such that one of the lead wires is located at a certain preset base position biased to either side of the chucking surface of the chuck, and the printed circuit board and the chuck are relatively positioned when the lead wires held by the chuck are about to be inserted, and such that the components, when the lead wires have been inserted, are positioned beside the side edge of the chuck against which the component is biased.
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BACKGROUND OF THE INVENTION
This invention relates to a final drive suspension system for a vehicle.
Final drives have been provided in motor vehicles for transmitting the drive from a cardan shaft to an axle shaft having driving wheels secured thereon. The final drive has a bevel pinion integral with a drive shaft coupled through a cardan joint to the cardan shaft. The bevel pinion meshes with a bevel wheel for turning the drive round through 90° and reducing the speed of the drive shaft. During vehicle driving, the final drive is subject to torques of reaction around the axis of the cardan shaft (cardan shaft moment) and also around the axis of the axle shaft (starting moment). For this reason, the final drive should be suspended elastically at the floor or the vehicle in order to reduce vibrations and noises which would be transmitted to the vehicle if it is mounted rigidity from the floor of the vehicle. However, it is impossible to nullify final drive motions merely by elastically suspending the final drive from the floor of the vehicle.
Various approaches have been proposed to reduce vibrations transmitted from the final drive to the cardan shaft. For example, U.S. Pat. No. 4,699,230 describes an axle gear casing suspension system for elastically flexibly suspending a rear axle gear casing at least two suspension points. One of the suspension points is shifted from a torque support plane determined by the other suspension point so that swivel motions of the same magnitude are produced in opposite directions at a connection point between the cardan shaft and the drive shaft. This is effective to reduce changes in the position of the connection point which is subject to the influence of the starting and cardan shaft moments.
With such a conventional suspension system, however, it is impossible to hold the drive shaft in its original position under the influence of the starting and cardan shaft moments. Particularly when a universal joint, such as a cardan joint, is used to couple the cardan joint to the drive shaft, a secondary moment, which corresponds to the joint angle between the cardan shaft and the drive shaft, will occur to produce vibrations and noises. The vibrations and noises will increase as the angle of the drive shaft with respect to the cardan shaft changes because of changes in the position of the final drive.
SUMMARY OF THE INVENTION
Therefore, it is a main object of the invention to provide an improved final drive suspension system which can minimize the change in the position of the drive shaft drivingly coupled to the cardan shaft.
There is provided, in accordance with the invention, a final drive suspension system for a vehicle comprising an axle shaft having driving wheels secured thereon, the axle shaft having an axis extending transversely of the vehicle, a cardan shaft, a final drive having a drive shaft having an axis extending longitudinally of the vehicle, the drive shaft being drivingly coupled to the cardan shaft and drivingly coupled to the axle shaft for transmitting a drive from the cardan shaft to the driving wheels, the final drive being subject to a rolling action due to reaction torques around the drive shaft axis and to a pitching action due to reaction torques around the axle shaft axis during vehicle driving, and at least three eleastic suspension means provided at respective suspending positions for elastically flexibly suspending the final drive with respect to the vehicle. The at least three suspension means have respective rigidities determined in relation to the suspending positions to cancel the rolling and pitching actions on the drive shaft axis.
In another aspect of the invention, there is provided a final drive suspension system for a vehicle comprising an axle shaft having driving wheels secured thereon, the axle shaft having an axis extending transversely of the vehicle, a cardan shaft, a final drive having a drive shaft having an axis extending longitudinally of the vehicle, the drive shaft being drivingly coupled to the cardan shaft, a bevel pinion integral with the drive shaft, a bevel wheel provided in rear of the bevel pinion, the bevel wheel meshing with the bevel pinion, the bevel wheel being drivingly coupled to the axle shaft for transmitting a drive from the cardan shaft to the driving wheels, and elastic suspension means for elastically flexibly suspending the final drive at first, second and third suspension points with respect to the vehicle. The first suspension point is located in front of the axle shaft axis. The third suspension point is located behind the axle shaft axis. The second suspension point being located on one side of the drive shaft axis, whereas the third suspension point and the bevel wheel is located on the other side of the drive shaft axis. The elastic suspension means has rigidities k1, k2 and k3 at the first, second and third suspension points, respectively, the final drive having a reduction ratio of ζ. The first suspension point is located a transverse distance of e1 from the second suspension point. The drive shaft axis is located a transverse distance of e2 from the second suspension point. The third suspension point is located a transverse distance of e from the second suspension point. The first suspension point is located a longitudinal distance of d from the third suspension point. The first suspension point is located a longitudinal distance of d2 from the second suspension point. The elastic suspension means has rigidities k1, k2 and k3 at the first, second and third suspension points, respectively, the rigidities k1, k2 and k3 being determined by ##EQU1##
In another aspect of the invention, there is provided a final drive suspension system for a vehicle comprising an axle shaft having driving wheels secured thereon, the axle shaft having an axis extending transversely of the vehicle, a cardan shaft, a final drive having a drive shaft having an axis extending longitudinally of the vehicle, the drive shaft being drivingly coupled to the cardan shaft, a bevel pinion integral with the drive shaft, a bevel wheel provided in rear of the bevel pinion, the bevel wheel meshing with the bevel pinion, the bevel wheel being drivingly coupled to the axle shaft for transmitting a drive from the cardan shaft to the driving wheels, and elastic suspension means for elastically flexibly suspending the final drive at first, second and third suspension points with respect to the vehicle. The first suspension point is located in front of the axle shaft axis. The second and third suspension points are located behind the axle shaft axis. The first and second suspension points are located on one side of the drive shaft axis. The third suspension point and the bevel wheel are located on the other side of the drive shaft axis. The elastic suspension means has rigidities k1, k2 and k3 at the first, second and third suspension points, respectively, the rigidity k2 at the second suspension point being less than the rigidities k1 and k3 at the first and third suspension points.
In still another apsect of the invention, there is provided a final drive suspension system for a vehicle comprising an axle shaft having driving wheels secured thereon, the axle shaft having an axis extending transversely of the vehicle, a cardan shaft, a final drive having a drive shaft having an axis extending longitudinally of the vehicle, the drive shaft being drivingly coupled to the cardan shaft, a bevel pinion integral with the drive shaft, a bevel wheel provided in rear of the bevel pinion the bevel wheel meshing with the bevel pinion, the bevel wheel being drivingly coupled to the axle shaft for transmitting a drive from the cardan shaft to the driving wheels, and elastic suspension means for elastically flexibly suspending the final drive at first, second and third suspension points with respect to the vehicle. The first and second suspension points are located in front of the axle shaft axis. The third suspension point is located behind the axle shaft axis. The second suspension point is located on one side of the drive shaft axis. The first and third suspension points and the bevel wheel are located on the other side of the drive shaft axis. The elastic suspension means has rigidities k1, k2 and k3 at the first, second and third suspension points, respectively, the rigidity k1 at the first suspension point is less than the rigidities k2 and k3 at the second and third suspension points.
In still another aspect of the invention, there is provided a final gear suspension system for a vehicle comprising an axle shaft having driving wheels secured thereon, the axle shaft having an axis extending transversely of the vehicle, a cardan shaft, a final drive having a drive shaft having an axis extending longitudinally of the vehicle, the drive shaft being drivingly coupled to the cardan shaft, a bevel pinion integral with the drive shaft, a bevel wheel provided in rear of the bevel pinion, the bevel wheel meshing with the bevel pinion, the bevel wheel being drivingly coupled to the axle shaft for transmitting a drive from the cardan shaft to the driving wheels, and elastic suspension means for elasticially flexibly suspending the final drive at first, second and third suspension points with respect to the vehicle. The first and second suspension points are located in front of the axle shaft axis. The third suspension point is located behind the axle shaft axis. The first and second suspension points are located on one side of the drive shaft axis. The third suspension point and the bevel wheel are located on the other side of the drive shaft axis. The first suspension point is located a transverse distance of zero from the second suspension point. The elastic suspension means has rigidities k1, k2 and k3 at the first, second and third suspension points, respectively, the rigidities k1 and k2 at the first and second suspension points being less than the rigidity k3 at the third suspension point.
BRIEF DESCRIPTION OF THE DRAWINGS
This invention will be described in greater detail by reference to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic diagram used in explaining the principles of the invention;
FIG. 2 is a plan view in section showing one embodiment of a final drive suspension system made in accordance with the principles of the invention;
FIG. 3 is a side view in section of the final drive suspension system of FIG. 2;
FIG. 4 is a schematic diagram used in explaining the positions of the first, second and third suspension points of the final drive suspension system of FIG. 2;
FIG. 5 is a schematic diagram used in explaining alternative positions of the first, second and third suspension points; and
FIG. 6 is a schematic diagram used explaining alternative positions of the first, second and third suspension points.
DETAILED DESCRIPTION OF THE INVENTION
Prior to the description of the preferred embodiments of the present invention, the principles of the invention will be described in order to provide a basis for a better understanding of the invention.
Referring to FIG. 1, there is shown a final drive unit including an axle gear casing 10 which contains a final drive 12 and a differential 22. The final drive 12 is shown as including a bevel pinion 12 meshed with a bevel wheel 16 having a diameter greater than the diameter of the bevel pinion 14. The bevel pinion 14 is integral with a drive shaft 18 which extends outward through the front end of the axle gear casing 10 and terminates at its front end in a disc flange for connection to a cardan or propeller shaft. The drive shaft 18 has an axis 20 extending in the direction of the length of the vehicle. Two axle shafts, which extend from the axle gear casing 10 to the respective driving wheels of the vehicle, have an axis 28 extending in the direction of the width of the vehicle. From the engine the drive is transmitted through a clutch and a gear box to the cardan shaft having a universal joint at each end. It is then taken by the drive shaft 18 to the final drive 12. The final drive 12 turns the drive round through 90° and reduces the speed in a selected ratio. The differential 22 divides it equally between the two axle shafts which convey it to the driving wheels.
It is first assumed that the axle gear casing 10 is suspended elastically flexibly at the floor of the vehicle body through three elastic suspension elements located at suspension points S1, S2 and S3, as shown in FIG. 1. The first suspension point S1 is located in front of the axle shafts axis 28 and the second and third suspension points S2 and S3 are located behind the axle shaft axis 28. The first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20, whereas the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20. In a two-dimensional orthogonal coordinate system, O-xy, with the x coordinate axis extending parallel to the axle shaft axis 28 (or to the lateral central axis of the axle gear casing 10) and through the first suspension point S1 and the y coordinate axis extending parallel to the drive shaft axis 20 (or to the longitudinal central axis of the axle gear casing 10) and through the second suspension point S2, the first suspension point S1 has the coordinates (e1, 0), the second suspension point S2 has the coordinate (0, d2), and the third suspension point S3 has the coordinates (e, d). In FIG. 1, the distance to the right of O along the x coordinate axis is the abscissa and the distance to the downward of O along the y coordinate axis is the ordinate. The drive shaft axis 20 is spaced a transverse distance e2 from the y coordinate axis.
Assuming now that M is the reaction torque created around the drive shaft axis 20 (cardan shaft moment) when the vehicle moves in the forward direction with the final drive 12 having a reduction ratio of ζ, the reaction torque produced around the axle shaft axis 28 (starting moment) is ζM. The reaction forces P1, P2 and P3 produced at the respective suspension points S1, S2 and S3 are obtained as follows:
The sum of the moments around the y coordinate axis is zero.
M-e1 P1-e P3=0 (1)
The sum of the moments around the axis extending parallel to the x coordinate axis and through the third suspension point S3 is zero.
d P1+ζM+(d-d2)P2=0 (2)
It is to be noted that the mass of the final drive unit may be ignored since the cardan shaft moment M and the starting moment ζM are much greater than the torque produced in relation to the mass of the final drive. The sum of the supporting reaction forces P1, P2 and P3 acting at the first, second and third suspension points S1, S2 and S3, respectively, is zero.
P1+P2+P3=0 (3)
Solving Equations (1), (2) and (3) for the supporting reaction forces P1, P2 and P3 yields ##EQU2##
The displacements z1, z2 and z3 of the respective suspension points S1, S2 and S3 in the z-direction perpendicular to the x and y coordinate axes are given as ##EQU3## where k1, k2 and k3 are the rigidities of the suspension elements located at the first, second and third suspension points S1, S2 and S3, respectively.
In the three-dimensional orthogonal coordinate system, O-xyz, with the z coordinate axis extending normal to the x and y coordinate axes and through the origin 0, the first, second and third suspension points S1, S2 and S3 are expressed as S1(e1, 0, z1), S2(0, d2, z2) and S3(e, d, z3). Therefore, the plane in which the suspension points S1, S2 and S2 lie is given by ##EQU4## If no displacement occurs in the z-direction at two given points lying in the axis 20 of the drive shaft 18, it means that the drive shaft 18 is held in its original position. In other words, if two given points SF (e2, 0, 0) and SR (e2, d, 0) satisfy Equation (10) regardless of the z-direction displacements z1, z2 and z3, it means that no change occurs in the angle between the drive shaft 18 and the cardan shaft 32. Substituting the points SF and SR and Equations (7), (8) and (9) into Equation (10) yields the following equations ##EQU5##
Equations (11) and (12) can be modified as ##EQU6##
Equations (13) and (14) can be modified to forms including ratios of k1, k2 and k3. ##EQU7## Solving Equations (15) and (16) for k2/k1 and k2/k3, respectively, yields ##EQU8## where
A={e2d+(e-e2)d2}P1
B=(e2-e1)d2P3
C=-(e2-e1)d P2
D=-(e-e2)(d-d2)P1
E={e1d+(e2-e1)d2}P3
F=(e-e2)d P2
Rearrangement gives the following equations ##EQU9##
It is, therefore, possible to hold the drive shaft 18 in its original position regardless of changes of the position of the final drive unit by selecting the positions (determined by e, e1, e2, d, d2) and the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3 in a manner to satisfy Equations (19) and (20).
Considerations are made to the conditions for which Equation (19) holds. Since the left side (k2/k1) of Equation (19) is positive, the right side of Equation (19) should be positive. Thus, Equation (19) may be considered to hold for the following four cases of conditions: ##EQU10## These conditions can be fulfilled. ##EQU11## These conditions cannot be fulfilled. ##EQU12## These conditions can be fulfilled. ##EQU13## These conditions can be fulfilled.
Considerations are made to the conditions for which Equation (20) holds. Since the left side (k2/k1) of Equation (20) is positive, the right side of Equation (20) should be positive. Thus, Equation (20) may be considered to hold for the following two cases of conditions since ζ e1/e+d2/e are always positive except when the first and second suspension points S1 and S2 are located at the origin O (when e1=0 and d2=0). ##EQU14## If the conditions of the selected one of the first, third and fourth cases (I), (III) and (IV) are not contradictory to the conditions of selected one of the fifth and sixth cases (V) and (VI), both of Equations (19) and (20) will hold for the combination of the conditions of the selected cases. We have thus found two combinations, the first combination being the combination of the conditions of the first case (I) and the conditions of the sixth case (VI). The second combination is the combination of the conditions of the fourth case (IV) and the conditions of the sixth case (VI). The conditions of the first combination are given as ##EQU15##
If these conditions for which both of Equations (19) and (20) hold are fulfilled, the rolling motion which would be produced on the final drive unit due to the cardan shaft moment around the drive shaft axis 20 and the pitching motion which would be produced on the final drive unit due to the starting moment around the axle shaft axis 28 will be canceled with each other on the drive shaft axis 20 so that the drive shaft 18 can be held in its original position. Because of this, no bending force acts on the joint between the drive shaft 18 and the cardan shaft 32 and thus no vibrations and noises occur at the joint between the drive shaft 18 and the cardan shaft 32.
These conditions of the first combination can be fulfilled, for example, when ζ=4, e1/e=1/4, e2/e=1/2, e1/e2=1/2, d/e=5 and d2=d. In this case, k1:k2:k3=4:1:3, as can be derived from Equations (19) and (20).
The conditions of the first combination can also be fulfilled when ζ=4, e1=∘, e2/e=1/2, d/e=5, and d2=d. In this case, k1:k2:k3=4:1:5, as can be derived from Equations (19) and (20).
From the above two examples, the following set of conditions can be derived:
e1<<e(or e1=0), and d2=d
These conditions are fulfilled when the first suspension point S1 is located in front of the axle shaft axis 28, whereas the second and third suspension points S2 and S3 are located behind the axle shaft axis 28, and when the first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20, whereas the third suspension point S3 and the bevel wheel 16 are located on the other side of drive shaft axis 20. In this case, the rigidity at the second suspension point S2 should be smaller than the rigidities at the first and second suspension points S1 and S3 to hold the drive shaft 18 substantially in its original position regardless of changes in the position of the final drive unit or the axle gear casing 10. It is to be understood that such a desirable effect can be achieved as long as the conditions to be set for the positions of the first, second and third suspension points S1, S2 and S3 and the rigidities at the first, second and third suspension points S1, S2 and S3 are close to the conditions for which Equations (19 ) and (20) hold.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the axis 20 of the drive shaft 18, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 become closer to the conditions for which Equations (19) and (20) hold so that the movement of the drive shaft 18 with respect to the cardan shaft 32 can be reduced further.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the final drive unit. In this case, the rigidity at the additional suspension point should be smaller than the rigidities at the first, second and third suspension points S1, S2 and S3 to bring the set conditions closer to the conditions for which Equations (19) and (20) hold and thus to further reduce the change in the angle between the drive shaft 18 and the cardan shaft 32.
The conditions of the first combination can also be fulfilled when ζ=4, e1=0, e2/e=1/2, d2/e=2/3, and d/e=13/3. In this case, k1:k2:k3=1:1:2, as can be derived from Equation (19) and (20).
From this example, the following set of conditions can be derived:
e1=0, and d2<<d
These conditions are fulfilled when the first and second suspension points S1 and S2 are located in front of the axle shaft axis 28, whereas the third suspension point S3 is located behind the axle shaft axis 28, and when the first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20, whereas the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20, and when the transverse distance between the first and second suspension points S1 and S2 is zero. In this case, the rigidities at the first and second suspension points S1 and S2 should be smaller than the rigidity at the third suspension point S3 to hold the drive shaft 18 substantially in its original position regardless of changes in the position of the final drive unit. It is to be understood that such a desirable effect can be achieved as long as the conditions to be set for the positions of the first second and third suspension points S1, S2 and S3 and the rigidities at the first, second and third suspension points S1, S2 and S3 are close to the conditions for which Equations (19) and (20) hold.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the axis 20 of the drive shaft 18, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 become closer to the conditions for which Equations (19) and (20) hold so that the movement of the drive shaft 18 with respect to the cardan shaft 32 can be reduced further.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the final drive unit. In this case, the rigidity at the additional suspension point should be smaller than the rigidities at the first, second and third suspension points S1, S2 and S3 to bring the set conditions closer to the conditions for which Equations (19) and (20) hold and thus to further reduce the movement of the drive shaft 18 with respect to the cardan shaft 32.
The conditions of the second combination are given as ##EQU16##
If these conditions for which both of Equations (19) and (20) hold are fulfilled, the rolling motion which would be produced on the final drive unit due to the cardan shaft torque around the drive shaft axis 20 and the pitching motion which would be produced on the final drive unit due to the starting torque around the axle shaft axis 28 will be canceled with each other on the axis 20 of the drive shaft 18 so that the drive shaft 18 can be held in alignment with the cardan shaft 32. Because of this, no bending force acts on the joint between the drive shaft 18 and the cardan shaft 32 and thus no vibrations and noises occur at the joint between the drive shaft 18 and the cardan shaft 32.
These conditions of the second combination can be fulfilled, for example, when ζ=4, e1/e=1, e2/e=1/2, e1/e2=2, d2/e=1/3 and d/e=5. In this case, k1:k2:k3=2:15:13, as can be derived from Equations (19) and (20).
The conditions of the second combination can also be fulfilled when ζ=4, d2=0, e1/e=1, e2/e=1/2, e1/e2=2 and d/e=5. In this case, k1:k2:k3=1:5:4, as can be derived from Equations (19) and (20).
From the above two examples, the following set of conditions can be derived:
e1=e and d2<<d (or d2=0)
These conditions are fulfilled when the first and second suspension points S1 and S2 are located in front of the axle shaft axis 28, whereas the third suspension point S3 is located behind the axle shaft axis 28, and when the first and third suspension points S1 and S3 are located on one side of the drive shaft axis 20, whereas the second suspension point S2 and the bevel wheel 16 are located on the other side of the drive shaft axis 20. In this case, the rigidity at the first suspension point S1 should be smaller than the rigidities at the second and third suspension points S2 and S3 to hold the drive shaft 18 substantially in its original position regardless of changes in the position of the final drive. It is to be understood that such a desirable effect can be achieved as long as the conditions to be set for the positions of the first, second and third suspension points S1, S2 and S3 and the rigidities at the first, second and third suspension points S1, S2 and S3 are close to the conditions for which Equations (19) and (20) hold.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the axis 20 of the drive shaft 18, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 become closer to the conditions for which Equations (19) and (20) hold so that the movement of the drive shaft 18 with respect to the cardan shaft 32 can be reduced further.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the final gear unit. In this case, the rigidity at the additional suspension point should be smaller than the rigidities at the first, second and third suspension points S1, S2 and S3 to bring the set conditions closer to the conditions for which Equations (19) and (20) hold and thus to further reduce the movement of the drive shaft 18 with respect to the cardan shaft 32.
Referring to FIGS. 2 and 3, there is shown one embodiment of a final drive suspension system made in accordance with the principles of the invention. Like reference numerals have been applied to FIGS. 2 and 3 with respect to the like parts shown in FIG. 1.
The axle gear casing 10 contains the same parts as described in connection with FIG. 1. The drive shaft 18 is coupled through a cardan joint 30 to the cardan shaft 32. Two axle shafts 24 and 26 extends from the axle gear casing 10 to the respective driving wheels (not shown) of the vehicle. From the engine the drive is transmitted through a clutch (not shown) and a gear box (not shown) to the cardan shaft 32 and hence through the drive shaft 18 to the final drive. The final drive 12, which has a bevel pinion 14 meshed with a bevel wheel 16 having a diameter greater than the diameter of the bevel pinion 14, as shown in FIG. 1, turns the drive round through 90° and reduce the speed in a selected ratio. The differential 22 (FIG. 1) divides it equally between the two axle shafts 24 and 26 which convey it to the driving wheels.
The axle gear casing 10 is elastically flexibly suspended from the floor of the vehicle by means of first, second and third elastic suspension elements 40, 42 and 44 located at the respective suspension points S1, S2 and S3. The first, second and third elastic suspension element 40, 42 and 44 may be of the type having an elastic bush made of an elastic material, such as rubber. The first elastic suspension element 40 is secured on a carrier member 50 mounted at the floor of the vehicle to elastically flexibly suspend the axle gear casing 10 at the first suspension point S1. The second and third elastic suspension elements 42 and 44 are secured on another carrier member 52 mounted at the floor of the vehicle to elastically flexibly suspend the axle gear casing 10 at the second and third suspension points S2 and S3. The rigidity at each of the first, second and third suspension points S1, S2 and S3 may be adjusted by adjusting the shape and/or size of the elastic bush, by varying the carbon content of the elastic bush to adjust its hardness, or by adjusting the conditions under which the elastic bush is vulcanized.
In this embodiment, the locations of the first, second and third suspension points S1, S2 and S3 are selected, as shown in FIG. 4, to fulfill the conditions of e1=0 and d2=0 which satisfy both of the first case (I) of conditions and the sixth case (VI) of conditions. That is, the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26. The second suspension point S2 is located behind the axle shaft axis 28. The third suspension point S3 is located behind the axle shaft axis 28. The first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20, whereas the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
Substitution of e1=0 and d2=0 into Equations (19) and (20) gives the following equations for the ratios of the rigidities k1, k2 and k3 at the respective suspension points S1, S2 and S3. ##EQU17##
If the transverse distance e of the third suspension point S3 from the y coordinate axis, the transverse distance e2 of the drive shaft axis 20 from the y coordinate axis, the longitudinal distance d of the second and third suspension points S2 and S3 from the x coordinate axis, and the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3 are selected to satisfy Equations (21) and (22), the rolling motion of the final drive unit caused by the cardan shaft moment (M) around the drive shaft axis 20 and the pitching motion of the final drive unit caused by the starting moment (ζM) around the axle shaft axis 28 will be canceled on the drive shaft axis 20. Because of this, the drive shaft 18 is held in its horizontal position and no change occurs in the angle between the drive shaft 18 and the cardan shaft 32. This minimizes the vibrations and noises which may occur at the cardan joint 30. In this case, Equations (21) and (22) hold, for example, when e2/e=1/2 and d/e=5 and k1:k2:k3=4:1:5.
When the e1≧0, the distances e, e1, e2, d and d2 and the rigidities k1, k2 and k3 may be selected to fulfill the conditions of e1/e=1/4, e2/e=1/2, e1/e2=1/2, d/e=5, d2=d, and k1:k2:k3:=4:1:3. It is to be noted that Equations (21) and (22) hold when e1<0.
Equations (21) and (22) hold approximately and substantially no change occurs in the angle of the drive shaft 18 with respect to the cardan shaft 32 as long as the rigidity k2 at the second suspension point S2 is smaller than the rigidities k1 and k3 at the first and third suspension points S1 and S3 when the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26, when the second suspension point S2 is located in the behind the axle shaft axis 28, when the third suspension point S3 is located behind the axle shaft axis 28, and when the first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20 and the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the drive shaft axis 20, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 will become closer to the conditions for which Equations (21) and (22) hold so as to further reduce the change in the angle of the drive shaft 18 with respect to the cardan shaft 32. It is to be noted, however, that the change in the angle of the drive shaft 18 with respect to the cardan shaft 32 is much smaller than in the conventional suspension structures even though the suspension points S1, S2 and S3 do not lie in a common plane containing the drive shaft axis 20 as long as Equations (21) and (22) hold approximately.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the axle gear casing 10. In this case, Equations (21) and (22) hold approximately when the rigidity at the additional suspension point is smaller than the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3.
Alternatively, the locations of the first, second and third suspension points S1, S2 and S3 are selected, as shown in FIG. 5, to fulfill the conditions of e1=e and d2=0 which satisfy both of the fourth case (IV) of conditions and the sixth case (VI) of conditions. That is, the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26. The second suspension point S2 is located in front of the axle shaft axis 28. The third suspension point S3 is located behind the axle shaft axis 28. The second suspension point S2 is located on one side of the axis 20 of the drive shaft 18, whereas the first and third suspension points S1 and S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
Substitution of e1=e and d2=0 into Equations (19) and (20) gives the following equations for the ratios of the rigidities k1, k2 and k3 at the respective suspension points S1, S2 and S3. ##EQU18##
If the transverse distance e of the third suspension point S3 from the y coordinate axis, the transverse distance e2 of the drive shaft axis 20 from the y coordinate axis, the longitudinal distance d of the second and third suspension points S2 and S3 from the x coordinate axis, and the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3 are selected to satisfy Equations (23) and (24), the rolling motion of the final drive unit caused by the cardan shaft moment (M) around the drive shaft axis 20 and the pitching motion of the final drive unit caused by the starting moment (ζM) around the axle shaft axis 28 will be canceled on the drive shaft axis 20. Because of this, the drive shaft 18 is held in its horizontal position and no change occurs in the angle between the drive shaft 18 and the cardan shaft 32. This minimizes the vibrations and noises which may occur at the cardan joint 30. In this case, Equations (23) and (24) hold, for example, when e1/e=1, e2/e=1/2, e1/e2=2, d/e=5 and k1:k2:k3=1:5:5.
When d2>0, the distances e, e1, e2, d and d2 and the rigidities k1, k2 and k3 may be selected to fulfill the conditions of e1/e=1, e2/e=1/2, e1/e2=1/2, d2/e=1/3, d/e=5, and k1:k2:k3:=2:15:13.
Equations (23) and (24) hold approximately and substantially no change occurs in the angle of the drive shaft 18 with respect to the cardan shaft 32 as long as the rigidity k1 at the first suspension point S1 is smaller than the rigidities k2 and k3 at the second and third suspension points S2 and S3, when the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26, when the second suspension point S2 is located in front of the axle shaft axis 28, when the third suspension point S3 is located behind the axle shaft axis 28, and when the second suspension point S2 is located on one side of the drive shaft axis 20, whereas the first and third suspension points S1 and S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the drive shaft axis 20, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 will become closer to the conditions for which Equations (23) and (24) hold so as to further reduce the change in the angle of the drive shaft 18 with respect to the cardan shaft 32. It is to be noted, however, that the change in the angle of the drive shaft 18 with respect to the cardan shaft 32 is much smaller than in the conventional suspension structures even though the suspension points S1, S2 and S3 do not lie in a common plane containing the drive shaft axis 20 as long as Equations (23) and (24) hold approximately.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the axle gear casing 10. In this case, Equations (23) and (24) hold approximately when the rigidity at the additional suspension point is smaller than the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3.
Alternatively, the locations of the first, second and third suspension points S1, S2 and S3 are selected, as shown in FIG. 6, to fulfill the condition of e1=0 which satisfies both of the first case (I) of conditions and the sixth case (VI) of conditions. That is, the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26. The second suspension point S2 is located in front of the axle shaft axis 28. The third suspension point S3 is located behind the axle shaft axis 28. The first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20 and the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
Substitution of e1=0 into Equations (19) and (20) gives the following equations for the ratios of the rigidities k1, k2 and k3 at the respective suspension points S1, S2 and S3. ##EQU19##
If the transverse distance e of the third suspension point S3 from the y coordinate axis, the transverse distance e2 of the drive shaft axis 20 from the y coordinate axis, the longitudinal distance d of the second and third suspension points S2 and S3 from the x coordinate axis, the longitudinal distance d2 of the second suspension point S2 from the x coordinate axis, and the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3 are selected to satisfy Equations (25) and (26), the rolling motion of the final drive unit caused by the cardan shaft moment (M) around the drive shaft axis 20 and the pitching motion of the final drive unit caused by the starting moment (ζM) around the axle shaft axis 28 will be canceled on the drive shaft axis 20. Because of this, the drive shaft 18 is held in its horizontal position and no change occurs in the angle between the drive shaft 18 and the cardan shaft 32. This minimizes the vibrations and noises which may occur at the cardan joint 30. In this case, Equations (25) and (26) hold, for example, when e2/e=1/2, d2/e=2/3, d/e=13/3 and k1:k2:k3=1:1:2. It is to be noted that Equations (25) and (26) hold when e1<0.
Equations (25) and (26) hold approximately and substantially no change occurs in the angle of the drive shaft 18 with respect to the cardan shaft 32 as long as the rigidities k1 and k2 at the first and second suspension points S1 and S2 are smaller than the rigidity k3 at the third suspension point S3 when the first suspension point S1 is located in front of the axis 28 of the axle shafts 24 and 26, when the second suspension point S2 is located in front of the axle shaft axis 28, when third suspension point S3 is located behind the axle shaft axis 28, and when the first and second suspension points S1 and S2 are located on one side of the drive shaft axis 20 and the third suspension point S3 and the bevel wheel 16 are located on the other side of the drive shaft axis 20.
If the first, second and third suspension points S1, S2 and S3 are located in a common plane including the drive shaft axis 20, the conditions set for the positions of the first, second and third suspension points S1, S2 and S3 will become closer to the conditions for which Equations (25) and (26) hold so as to further reduce the change in the angle of the drive shaft 18 with respect to the cardan shaft 32. It is to be noted, however, that the change in the angle of the drive shaft 18 with respect to the cardan shaft 32 is much smaller than in the conventional suspension structures even though the suspension points S1, S2 and S3 do not lie in a common plane containing the drive shaft axis 20 as long as Equations (25) and (26) hold approximately.
An additional suspension point may be provided along with the first, second and third suspension points S1, S2 and S3 to suspend the axle gear casing 10. In this case, Equations (25) and (26) hold approximately when the rigidity at the additional suspension point is smaller than the rigidities k1, k2 and k3 of the respective suspension points S1, S2 and S3.
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A final drive suspension system for a motor vehicle. The final drive has a drive shaft integral with a bevel pinion meshing with a bevel wheel for turning the drive from a cardan shaft around through 90° and transmitting the drive to an axle shaft having driving wheels secured thereon. The drive shaft has an axis extending longitudinally of the vehicle and the axle shaft has an axis extending transversely of the vehicle. The final drive is subject to a rolling action due to reaction torques around the drive shaft axis and to a pitching action due to reaction torques around the axle shaft axis during vehicle running. The final drive suspension system elastically flexibly suspends the final drive at least three suspension points with respect to the vehicle. The rigidities at the respective suspension points are determined in relation to the positions of the respective suspension points to cancel the rolling and pitching actions on the drive shaft axis.
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[0001] This patent application claims the benefit of priority from U.S. Provisional Application Ser. No. 60/627,609, filed Nov. 12, 2004, teachings of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to improved methods to fluorescently label DNA substrates for use with CEL nuclease and other mismatch cutting DNA endonucleases to determine whether a DNA sequence contains mutations or polymorphic changes. The present invention also relates to a one-step universal fluorescent PCR primer technique to generate fluorescent PCR products for enzymatic mutation detection by CEL nuclease and other mismatch cutting DNA endonucleases. These methodologies provide for highly sensitive, high throughput, economic mismatch detection in all DNA samples.
BACKGROUND OF THE INVENTION
[0003] The accurate and efficient detection of both inherited and induced mutations in genomes is a critical step for the diagnosis of diseases and drug discovery. A highly sensitive, high throughput and economic mutation detection technique is essential for these areas of endeavor. There have been a number of methodologies developed for mutation detection; all have limitations that restrict their uses.
[0004] A novel family of DNA mismatch-specific endonucleases from plants was discovered recently (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602; Yang et al. Biochem. 2000 39:3533-3541). The plant source with the highest apparent concentration of this class of endonucleases is celery (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602), and thus the enzyme was purified from celery and named CEL I (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602; Yang et al. Biochem. 2000 39:3533-3541). CEL I cleaves DNA at the 3′-side of sites of base-substitution mismatch and DNA distortion (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602; Yang et al. Biochem. 2000 39:3533-3541).
[0005] Purified preparations of CEL nuclease identified as CEL I actually contain two different protein species (Yang et al. Biochem. 2000 39:3533-3541; U.S. Pat. No. 5,869,245). One species, called CEL I, has been purified and characterized and its gene has been sequenced and cloned (Yang et al. Biochem. 2000 39:3533-3541; U.S. Pat. No. 5,869,245). CEL I nuclease has been used to accurately detect a variety of mutations and polymorphisms in the human BRCA1 gene (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602; Yang et al. Biochem. 2000 39:3533-3541; Kulinski et al. BioTechniques 2000 29:44-48). The second protein species present in purified preparations of CEL I, called CEL II, has been separated from CEL I, purified and characterized, and its gene has been sequenced and cloned. CEL II has been used to verify the presence of known mutations in a number of genes in human peripheral blood DNA (Scaffino et al. Transgenics 2004 4:157-166), to carry out screening for induced point mutations in barley (Caldwell et al. The Plant Journal 2004 doi:10.111/j.1365-313X.204.02190.x), to screen for error-free clones generated from a plant cDNA library by PCR-based cloning (Qiu et al. Molecular Biotechnology 2005 29:11-18), and to screen for mutations in the mitochondrial DNA of patients with respiratory chain defects (Bannwarth et al. Human Mutation 2005 25:575-582).
[0006] CEL I nuclease and CEL II nuclease have a unique enzymatic property that has been demonstrated advantageous in mutation detection (Oleykowski et al. Nucl. Acid Res. 1998 26:4597-4602; Yang et al. Biochem. 2000 39:3533-3541; Kulinski et al. BioTechniques 2000 29:44-48; Colbert et al. Plant Physiology 2001 126:480-484; Sokurenko et al. Nucl. Acids. Res. 2001 29:e11; U.S. Pat. No. 5,869,245; Qiu et al. BioTechniques 2004 36:702-707). With a DNA duplex containing mismatches such as a substitution, insertion or deletion, CEL nuclease cleaves the mismatched structure to generate DNA fragments which can be identified with gel electrophoresis, HPLC or capillary electrophoresis detection platforms. Compared to primer extension methods, CEL nuclease mutation detection requires no prior knowledge of the position or the nature of the mutation. In heterogeneous DNA samples, such as in somatic mutations and heteroplasmy, a CEL nuclease-based method outperforms direct sequencing where base calling is difficult or impossible. Moreover, the ability to pool DNA samples in CEL nuclease mutation detection significantly increases the throughput for large population samples, while at the same time reduces associated costs.
[0007] Fluorescent labeling of DNA samples offers major benefits to CEL nuclease mutation detection methods including increased signal intensity relative to ultraviolet (UV) absorbance for detection of DNA, reduced sample quantity requirement for application to high throughput polyacrylamide or capillary electrophoretic instruments suited to automated detection and data collection and handling, and multicolor/multichannel capability with selected fluorescent dyes for sample pooling and increased dependability in data analysis.
[0008] One of the enzymatic characteristics of the CEL nuclease family of plant DNA endonucleases is the tendency to remove nucleotides from the 5′ ends of double-stranded DNA molecules. Unfortunately this tendency to remove DNA 5′-end nucleotides reduces the sensitivity of detection of DNA labeled at the 5′ end with a fluorophore. Replacing phosphate-oxygen groups with phosphate-sulfur groups at internucleoside linkages near the DNA 5′ end does not prevent the hydrolysis. Thus, the amount of CEL nuclease relative to 5′-end labeled DNA substrate must be carefully controlled in a reaction so that the amount of residual fluorescent signal remains sufficient for fluorescent capillary electrophoresis detection after CEL nuclease mismatch cutting.
SUMMARY OF THE INVENTION
[0009] In the present invention, a method to determine mutations and/or polymorphic changes in DNA sequences via CEL nuclease is provided wherein a fluorescent label is positioned at a nucleotide internal from the 5′ end of a double-stranded DNA thereby protecting the label from CEL exonuclease removal. It has now been found that by placing a fluorescent dye on a base downstream from the 5′ end of double-stranded DNA, greater than 90% of the label is preserved during CEL nuclease treatment. Based upon this finding, internally labeled fluorescent PCR primers have now been produced to amplify target DNA sequences for subsequent CEL nuclease mutation detection. With these primers and using capillary electrophoresis detection, the signal was dramatically increased and mutations could be detected at a level of 1% in a wild-type DNA population. As demonstrated herein, these primers and methodologies for use are useful not only with CEL nuclease but other mismatch cutting endonucleases such as KAL III.
[0010] Thus, one aspect of the present invention relates to the design and use of internally labeled fluorescent PCR primers for generating fluorescent PCR products in mismatch cutting DNA endonuclease mutation detection.
[0011] Another aspect of the present invention relates to the design and use of internally labeled fluorescent universal nucleotide sequences as universal fluorescent PCR primers and unlabeled primers containing the universal primer sequence in one-step or separate PCR reactions, as a means to generate fluorescent PCR products, for mismatch cutting DNA endonuclease nuclease mutation detection.
[0012] Another aspect of the present invention relates to methods for carrying out PCR amplifications in a one-step PCR reaction or a nested PCR reaction using these PCR primers.
[0013] Another aspect of the present invention relates to methods of incorporating fluorescent labels internally into DNA molecules.
[0014] Another aspect of the present invention relates to methods for placing fluorescent dyes, either identical or distinct, on both ends of a DNA molecule.
[0015] Another aspect of the present invention relates to methods for pooling labeled DNA samples for multiplexed mutation detection to increase detection throughput and reduce assay costs.
[0016] Another aspect of the present invention relates to methods for enzymatic digestion by CEL nuclease or other mismatch cutting nucleases of labeled DNA products for detecting the presence, position and nature, in the nucleotide sequence, of mutations or sequence variations.
[0017] Another aspect of the present invention relates to methods for fluorescence detection of the labeled DNA products by capillary electrophoresis, gel electrophoresis, HPLC, and other fluorometric methods.
[0018] Another aspect of the present invention relates to kits for carrying out the methods of the present invention. In one embodiment, the kit comprises universal fluorescent PCR primers containing the same or different fluorescent dyes and sequence information of the universal priming sites. Kits of the present invention may further comprise rules for designing target sequence specific PCR primers for embedding internal fluorescent dye in PCR products by universal fluorescence priming, PCR DNA polymerase and related PCR reaction components, and/or CEL nuclease and/or related buffers as well as primer sets specific for target sequence(s) of interest.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a thin layer chromatogram showing mono-, di- and trinucleotides released from a 64 basepair DNA duplex terminally labeled at one 5′ end with 32 P by the exonuclease activity of CEL II nuclease at various time points. Lane −E: no CEL II nuclease present.
[0020] FIGS. 2A and 2B depict an agarose gel from experiments demonstrating that an internal fluorescent label is protected from CEL II nuclease removal. Control G PCR products were unlabeled (Lane 1 and 2); were labeled at the 5′ end with 6-FAM (Lane 3 and 4); or were labeled internally near the 5′ end with fluorescein (Lane 5 and 6). The DNAs (200 ng) were treated with 5 units of CEL II nuclease at 42° C. for 20 minutes (Lane 2, 4, and 6) or with buffer alone (Lane 1, 3, 5). The panel in FIG. 2A depicts darkreader fluorescent imaging showing fluorescent end label; the panel in FIG. 2B shows UV imaging of total DNA stained with the intercalating dye ethidium bromide.
[0021] FIGS. 3A and 3B are schematic drawings of internally labeled synthetic universal fluorescent primers FKS (fluorescein labeled universal primer; FIG. 3A ; SEQ ID NO:1) and TSK (TAMPA labeled universal primer; FIG. 3B ; SEQ ID NO:2).
[0022] FIG. 4 is a schematic diagram of exemplary one-step and nested fluorescent PCR amplification techniques performed in accordance with the present invention. In this diagram, (G1) is the gene specific forward priming sequence, (U1) is the universal priming site, (G2) is the gene specific reverse priming sequence, (U2) is the universal priming site, (F1) is the fluorescent universal primer with the same sequence as (U1), and (F2) is the fluorescent universal primer with the same sequence as (U2).
[0023] FIGS. 5A and 5B is an agarose gel depicted PCR incorporation of universal primer labeled with fluorescein and mixed at different ratios with the unlabeled primer KS.CELR. Primer mixtures of labeled to unlabeled primer of 0:1, 1:1, 9:1, 19:1 were used in one-step amplification/labeling PCR reactions. The total concentration of the combined FKS and KS.CELR primers was 0.5 μM. The PCR products were separated by electrophoresis on a 3% agarose gel. The panel depicted in FIG. 5A is from darkreader fluorescent imaging showing fluorescent end labeled DNA. The panel depicted in FIG. 5B shows UV imaging of the total DNA stained with ethidium bromide.
[0024] FIG. 6 shows capillary electrophoresis chromatograms of Control G homoduplex and Control G/C heteroduplexes digested with CEL II nuclease. Control G and C DNAs were labeled by PCR amplification with universal primers FKS downstream and FCELF upstream; labeled Control G and C DNAs were annealed at different ratios; 200 ng of total DNA was digested with 5 units of CEL II nuclease at 42° C. for 20 minutes; and the digestion products were separated by capillary electrophoresis on an ABI PRISM® 3100 Genetic Analyzer. The percentages indicate the amounts of Control C in Control C/G heteroduplex DNA.
[0025] FIG. 7 shows capillary electrophoresis chromatograms of PCR amplified Lac Z mutant DNAs annealed with amplified wild-type DNA and digested with CEL II. The PCR amplification products of 26 different Lac Z mutant plasmid DNAs labeled with primer FKS were annealed separately with amplified wild-type DNA, digested with 5 units of CEL II nuclease at 42° C. for 20 minutes, and separated by capillary electrophoresis on an ABI PRISM® 3100 Genetic Analyzer. The digestion fragment sizes for clones 1-6 are indicated and the sizes agree with those predicted based upon CEL II nuclease cleavage at the location of mutations determined by DNA sequencing (see Appendix 2).
[0026] FIGS. 8A , 8 B and 8 C provide a comparison of DNA sample processing methods after CEL II nuclease digestion. Fluorescent tag-labeled Control C/G heteroduplex DNAs at different ratios of Control C to Control G were digested with CEL II nuclease. The samples were prepared in HiDi loading solution without prior processing (straight loading (FIG. 8 A)), with prior ethanol precipitation to remove salt in the sample ( FIG. 8B ), or with prior desalting on Microspin G-25 columns ( FIG. 8C ). The Control C/G heteroduplex DNA for straight loading and ethanol precipitation was labeled at one end with FKS primer. The Control C/G heteroduplex DNA processed by desalting on Microspin G-25 columns was labeled at both ends by the use of an internal fluorescein modified forward PCR primer, FCELF (5′-ACACCTGATCAAGCC[FdT]GTTCATTTGATTAC-3′ (SEQ ID NO:3), 411-bp fragment) and FKS (232-bp fragment).
[0027] FIG. 9 shows results from experiments detecting a LacZ mutation with mismatch cutting enzyme KAL III. Sample processing was performed in accordance with procedures outlined in FIG. 7 except that DNAs were cleaved with KAL III nuclease.
DETAILED DESCRIPTION OF THE INVENTION
[0028] CEL nuclease specifically cuts DNA mismatches including single-base substitutions, deletions, and insertions in a DNA duplex. Such cleavage produces DNA fragments indicative of mutation(s) between wild-type reference and mutant DNA.
[0029] Fluorescent labeling of the 5′ ends of DNA samples with one or more fluorophores can greatly increase detection sensitivity and sample throughput when coupled with an appropriate fractionation/detection platform. However, because CEL nuclease also possesses exonuclease activity that efficiently removes nucleotides at DNA 5′ ends, fluorescent label at DNA 5′ends added by use of conventionally synthesized PCR primers is rapidly removed by CEL nuclease, thus diminishing detection sensitivity.
[0030] The efficient exonuclease activity that removes nucleotides from the 5′ ends of double-stranded DNA is shown in FIG. 1 . In this experiment, a 64-base synthetic oligonucleotide labeled at the 5′ end with 32 P with polynucleotide kinase and annealed to an unlabeled complementary 64 mer was incubated with 5 units of CEL II nuclease at 42° C. for 0.5, 1, 2, 5, 10, 20, 40 minutes and analyzed by thin layer chromatography. 32 P-Labeled mono- and dinucleotides were immediately released within 0.5 and 2 minutes. At the 20-minute time point, a typical incubation time for CEL II nuclease enzymatic mutation detection, the majority of the 32 P label migrated as mononucleotide and to a lesser extent as dinucleotide. The exonuclease activity of CEL II nuclease and members of this family presents a significant problem for well-established and convenient methods used to fluorescently label DNA molecules at 5′ ends for CEL nuclease mutation detection. In fact, as shown by experiments depicted in FIG. 2 , PCR product with 5′ end 6-FAM label (see FIG. 2 , Lane 3) lost most of its fluorescence after CEL II digestion and became invisible on an agarose gel when fluorescence from the 6-FAM was measured ( FIG. 2 , Lane 4).
[0031] The present invention overcomes this problem by placing a fluorescent label on a nucleotide base of a PCR primer internal to the 5′ end. For example, FIG. 2 provides results from experiments comparing CEL II digestion using a 5′ labeled PCR primer versus a PCR primer with a fluorescein label placed 16 bases internally in a PCR primer. In these experiments, digestion with CEL II was performed at 42° C. for 20 minutes. In contrast to 5′ end fluorescent label ( FIG. 2 , Lanes 3 and 4), the internal label was well preserved ( FIG. 2 , Lane 5 and Lane 6). Densitometry showed that internal labeling resulted in retention of 97% of the label after CEL II nuclease digestion (mean intensity 49.68 vs. 50.18, CEL II digested vs. undigested). These results indicate that CEL II exonuclease activity is confined to removal of a few bases from the 5′ end of double-stranded DNA in the 20 minute incubation. This understanding was utilized to synthesize fluorescently labeled substrates, and in particular PCR primers resistant to removal of label by CEL II nuclease.
[0032] Accordingly, one aspect of the present invention relates to PCR primers useful in DNA mutation detection assays via CEL nuclease or other mismatch cutting DNA endonucleases which comprise a PCR primer labeled at a nucleotide internal to the 5′ end of the PCR primer. By internal to the 5′ end it is meant that the label, preferably a fluorescent label, is place on a nucleotide base of the primer at least 4, more preferably at least 7, even more preferably at least 10 nucleotide bases away from the 5′ end. Examples of such fluorescent dyes or labels useful in these primers include, but are not limited to 6-FAM, fluorescein, TAMRA, HEX, NED, ROX, rhodamines, JOE, Cy3, Cy5, Texas Red, and Alexa fluorescent dyes.
[0033] The present invention also provides a method for universal PCR amplification/fluorescence labeling using common universal fluorescent PCR primers labeled in this fashion for any target gene and universal PCR primers produced thereby. Examples of methods for incorporating fluorescent labels internally into DNA molecules include, but are in no way limited to, the use of polymerases, terminal deoxynucleotide transferases, or ligases to incorporate internal labels for the purpose of preserving the labels from removal by CEL nuclease and other mismatch cutting DNA endonucleases.
[0034] The method and universal primers offer advantages to preparing individual labeled PCR primers for each target gene. These advantages include significant cost reduction in having to prepare only two labeled primers rather than individual labeled primer pairs for each target, shorter turn around time to prepare PCR primers, prequalified and consistent universal fluorescent primers to avoid the variability in signal intensity associated with the use of individual primers labeled internally at different positions.
[0035] Exemplary universal primers of the present invention are depicted in FIG. 3 . As shown in FIG. 3 , universal primers with SK and KS sequences, as examples, are internally labeled with fluorophores, such as fluorescein and TAMRA. To generate fluorescent PCR product of a given gene, regular PCR primers are synthesized that include the SK or KS sequence as a universal priming site at the 5′ end. For example, primer pairs 5′-ACACCTGATCAAGCCTGTTCATTTGATTAC-3′ (SEQ ID NO:3) and 5′-CGCCAAAGAATGATCTGCGGAGCTT-3′ (SEQ ID NO:4) for regular PCR are synthesized as 5′-[CGCTCTAGAACTAGTGGATCC]ACACCTGATCAAGCCTGTTCATTTGATTAC-3′ (SEQ ID NO:5) and 5′-[TCGAGGTCGACGGTATCGAT]CGCCAAAGAATGATCTGCGGAGCTT-3′ (SEQ ID NO:6). Either one or both of the universal fluorescent primers (TSK or FKS) can be used as outlined in FIG. 4 to generate fluorescent PCR product for CEL nuclease mutation detection.
[0036] FIG. 4 sets forth an exemplary PCR reaction performed with primers of the present invention, wherein the target gene as the template is annealed with 0.05 μM forward primer and 0.05 μM reverse primer, in which (G1) is the gene specific forward priming sequence, (U1) is the universal priming site, (G2) is the gene specific reverse priming sequence, (U2) is the universal priming site, (F1) is the fluorescent universal primer with the same sequence as (U1), and (F2) is the fluorescent universal primer with the same sequence as (U2). In this example, (G1) and (G2) have a calculated Tm equal to or greater than 60° C. Further, in this example, (F1) and (F2) contain internally labeled fluorophores such as TSK or FKS described in FIG. 3 . For single reaction amplification/fluorescent labeling PCR depicted in this exemplary Figure, 0.5 μM fluorescent universal primers (F1) and/or (F2) are included. After 14 cycles of PCR at an annealing temperature of 60° C., the amplicon is amplified at 55° C. for additional 20 cycles. The 10-fold excess of fluorescent universal primers over unlabeled gene specific primers results in PCR product being labeled efficiently. In an alternative exemplary method, the target gene is first amplified by standard PCR for 30 cycles. The PCR product, preferably 10 ng, is then taken as the template in a separate nested PCR reaction with fluorescent universal primers F1 and F2.
[0037] The PCR can be carried out in one reaction or in two-steps similar to nested PCR. In the one-step reaction, the amount of the universal fluorescent primer is in 10-fold excess over the gene specific primer containing the universal priming site. In one embodiment, a single-reaction PCR was carried out with the following PCR cycles:
95° C. for 2 minutes 14 cycles of
95° C. for 30 seconds 60° C. for 30 seconds 72° C. for 1.5 minutes
20 cycles of
95° C. for 30 seconds 55° C. for 30 seconds 72° C. for 1.5 minutes 72° C. for 5 minutes
4° C. until use.
[0049] The labeling efficiency and product yield of this exemplary single-step PCR reaction of the present invention are displayed in FIG. 5 . The optimal ratio of universal fluorescent primer to gene specific primer was 9:1. The higher universal fluorescent primer to gene specific primer molar ratio (19:1) did not increase the fluorescence significantly and might reduce the reliability for a more complex DNA template such as genomic DNA.
[0050] As understood by the skilled artisan upon reading this disclosure, the number of cycles used in the first round of PCR is not limited to 14 cycles as exemplified herein, and a larger number of cycles may be required for a more complex DNA template such as a genomic DNA. Similarly, the skilled artisan will understand upon reading this disclosure that the number of cycles used in the second round of single-reaction PCR is not limited to 20 cycles as exemplified, but rather can be varied depending upon the yield of labeled PCR product desired. A preferred yield is at least 40 ng/μl of PCR reaction mixture.
[0051] Accordingly, another aspect of the present invention relates to a single reaction amplification/fluorescent labeling polymerase chain reaction (PCR) which comprises a plurality of cycles at an annealing temperature with primers of the present invention, preferably at least 14 cycles, followed by a plurality of cycles of amplification, preferably a sufficient number of cycles to produce a yield of 40 ng/μl of PCR reaction mixture. In an alternative embodiment, the present invention relates to an amplification/fluorescent labeling nested polymerase chain reaction (PCR) comprising amplifying a target gene by standard PCR and using the resulting PCR product as a template in a separate PCR reaction with primers of the present invention.
[0052] Using the primers and methodologies of the present invention, two 633 bp DNA sequences (Control G and Control C; see Appendix 1) with one G>C basepair change were amplified and fluorescently labeled by single-reaction PCR. The size of the PCR products was increased to 653 bp as the universal priming KS sequence was included at the downstream end. Control G DNA was annealed to itself (homoduplex) or with decreasing amounts of Control C (heteroduplex). The total amount of the DNA used as substrate was constant at 200 ng in a 5-μl reaction volume. The DNAs were annealed in 1×PCR buffer at 95° C. for 2 minutes, 95° C. to 85° C. cooling at −2° C./minute, 85° C. to 25° C. at −0.2° C./minute. Each of the DNA samples was digested with 5 units of CEL II nuclease incubated at 42° C. for 20 minutes and the reaction was stopped by addition of 1 μl 0.5 M EDTA. The digests were precipitated with 2.5 volume of ethanol and resuspended in 10 μl of HiDi solution containing ROX size standard. The samples were subjected to capillary electrophoresis analysis on an ABI PRISM 3100 Genetic Analyzer (see FIG. 6 ). The cleavage of the mismatch by CEL II nuclease produced two fragments: a 232-bp fragment labeled with FKS and a 411-bp fragment labeled directly with a primer containing an internal fluorescein. Due to the better fluorescein emission quality of the FKS-label, signal from the 232-bp fragment was stronger than that from the 411-bp fragment. Furthermore, the detection limit reached, 1% Control C in Control G, was greatly improved over that observed previously with 5′-end labeled Control G/C heteroduplex DNA substrate (12% detection limit; Qiu et al. BioTechniques 2004 36:702-707).
[0053] In addition to a G>C substitution in the Control G/C heteroduplex, the primers and methodologies of the present invention were used to examine other mutations including substitutions, insertions, and deletions in a collection of LacZ gene mutants. These LacZ mutants are depicted herein Appendix 2. Gene specific primers used in these experiments were 5′-CGCTCTAGAACTAGTGGATCCACACTTTATGCTTCCGGCTCGTATG-3′ (SEQ ID NO: and 5′-TCGAGGTCGACGGTATCGATAACGTTCTTCGGGGCGAAAACT-3′ (SEQ ID NO:8). FKS was used as the universal fluorescent primer in single reaction PCR. Mutations in Lac Z gene mutant DNAs PCR amplified and labeled in this fashion were correctly identified when digested with CEL II nuclease (see FIG. 7 ). Digestion of amplified DNAs from clones with multiple mutations produced digestion products of the expected sizes.
[0054] It was found that dual fluorescent dye labeling at both ends of Control G/C heteroduplexes with TSK (TAMRA label) and FKS (fluorescein) could be used to detect each fragment produced by CEL II nuclease cutting in separate color channels of fluorescence.
[0055] KAL III, isolated from kale, is another mismatch cutting DNA endonuclease similar to CEL II. To demonstrate applicability of the primers and methodologies described herein to other mismatch cutting DNA endonucleases, the DNA duplexes described above were also digested with KAL III Results from this experiment are depicted in FIG. 9 . KAL III produced digestion patterns similar to CEL II. Accordingly, the same methods of PCR product labeling and capillary electrophoresis are equally applicable to CEL II and KAL III nuclease and other plant DNA endonucleases similar to CEL II. These experiments are indicative of the primers and methodologies described herein to be useful with other mismatch cutting DNA endonuclease as well including but not limited to other endonucleases of the same family derived from celery, kale and other plants.
[0056] Proper sample processing is critical when high sensitivity mutation detection is desired. For example, one consideration that impacts capillary electrophoresis is that the buffer salt in the samples can interfere with the electrokinetic sample loading. For example, the maximum amount of the sample for straight loading is 1 μl of reaction mixture diluted 10 fold in HiDi loading dye for the ABI PRISM 3100 Genetic Analyzer ( FIG. 8 , upper panel). Ethanol precipitation serves to remove the salt and concentrate the sample ( FIG. 8 , middle panel) and produces greater than a 10-fold increase in signal intensity. Gel filtration with a Microspin G-25 column, which removes salt without concentrating the DNA in a reaction mixture, also improves the amount of DNA that is injected and thus the signal strength ( FIG. 8 , lower panel). Thus, in a preferred embodiment of the methodologies of the present invention, the DNA sample is treated to reduce the salt concentration without concentrating the DNA in the sample.
[0057] In preferred embodiments of any of the above methods or kits, universal priming sites are added to the 5′ end of normal PCR primer sequences designed for the amplification of a target sequence in DNA, such as genomic DNA. Amounts (1/10) of forward and reverse primers mixed with universal fluorescent primers (9/10) are included in a one-step amplification/labeling PCR reaction. Alternatively, target DNA can be PCR amplified first with unlabeled primers, and approximately 1% of the PCR reaction is used as the template in a second round of nested PCR with 100% universal fluorescent primers. DNA heteroduplex is formed by hybridization of mutant and wild-type DNA prepared with the methods described. After CEL nuclease digestion, the DNA is analyzed by capillary electrophoresis, such as with ABI PRISM® 3100 Genetic Analyzer. For increased sensitivity, the materials can be desalted by ethanol precipitation or G-25 spin column filtration to aid electrophoretic sample loading.
APPENDIX 1
Control G DNA Sequence (SEQ ID NO:9)
[0058] The base change from G to C in Control C is underlined.
[0000]
ACACCTGATCAAGCCTGTTCATTTGATTACCAGAGAGACTGTCATGATCC
ACATGGAGGGAAGGACATGTGTGTTGCTGGAGCCATTCAAAATTTCACAT
CTCAGCTTGGCCATTTCCGCCATGGAACATCTGATCGTCGATATAATATG
ACAGAGGCTTTGTTATTTTTATCCCACTTCATGGGAGATATTCATCAGCC
TATGCATGTTGGATTTACAAGTGATATGGGAGGAAACAGTATAGATTTGC
GCTGGTTTCGCCACAAATCCAACCTGCACCATGTTTGGGATAGAGAGATT
ATTCTTACAGCTGCAGCAGATTACCATGGTAAGGATATGCACTCTCTCCT
ACAAGACATACAGAGGAACTTTACAGAGGGTAGTTGGTTGCAAGATGTTG
AATCCTGGAAGGAAT G TGATGATATCTCTACTAGCGCCAATAAGTATGCT
AAGGAGAGTATAAAACTAGCCTGTAACTGGGGTTACAAAGATGTTGAATC
TGGCGAAACTCTGTCAGATAAATACTTCAACACAAGAATGCCAATTGTCA
TGAAACGGATAGCTCAGGGTGGAATCCGTTTATCCATGATTTTGAACCGA
GTTCTTGGAAGCTCCGCAGATCATTCTTTGGCG
APPENDIX 2
LacZ Wild Type DNA and Mutant Sequences
[0059] Bold indicates the starting point and end point of the amplified region.
[0060] Italics indicates a primer sequence.
[0061] Lowercase indicates the noncoding region.
[0062] Uppercase indicates the coding region.
[0063] The start codon is underlined.
[0064] Gray highlight indicates a point mutation.
[0065] Gray highlight with underline indicates a deletion.
[0066] Bold underline indicates an insertion.
[0000]
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Methods and kits are provided with DNA substrates having a fluorescent label positioned at a nucleotide internal from its 5′ end for use with CEL nuclease to determine whether a DNA sequence contains mutations or polymorphic changes.
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[0001] The present application claims priority from Japanese application serial No. 2009-172674, filed on (Jul. 24, 2009), the content of which is hereby incorporated by reference into this application.
FIELD OF THE INVENTION
[0002] The present invention relates to a technique for effective batch processing. More particularly, it relates to a technique which determines the optimum processing multiplicity in parallel execution of batch jobs using plural nodes for high speed batch processing of large volumes of account data.
BACKGROUND OF THE INVENTION
[0003] JP-A-2008-226181 proposes a technique for execution of batch jobs. In this technique, script data about job nets which defines the order of execution of jobs is received and a request for allocation of resource nodes for execution of the job nets is issued on a per-job-net basis in accordance with the script data so that resource nodes are allocated to each job net in response to the allocation request.
SUMMARY OF THE INVENTION
[0004] In batch processing, there are cases where the volume of data to be processed suddenly increases. For example, in the securities industry, it is necessary to cope with various situations: for example, all accounts for month-end reinvestment of investment trusts must be processed on a particular day; the number of stock transactions suddenly increases in some economic climate; and when there are many initial public offerings (IPO) in a short time, an increasing number of transactions must be dealt with, resulting in a longer batch processing time. Consequently, the volume of batch processing jobs largely varies day by day and sometimes a longer time must be taken for batch processing. This is likely to lead to a delay in the start of next day's online service and a shorter online service time for customers. Also, such lengthened batch processing may affect processing time for another job which is executed on the same node simultaneously, again resulting in a delay in the start of online service related to that job. Therefore, daily batch processing time should be constant even when the volume of data to be processed varies from day to day.
[0005] In order to address the above problem, the present invention dynamically determines multiplicity of processing including parallel processing in execution of a batch job on plural nodes. More specifically, the invention provides a system which flexibly determines execution multiplicity and execution nodes to shorten batch processing time by effective utilization of resources. Processing time can be made (almost) constant regardless of the number of batch jobs by batch processing in a scale-out manner on a particular day when the number of batch jobs increases. This eliminates the possibility that a long time is taken to batch-process large volumes of data on a particular day and a delay in the start of next-day online service occurs.
[0006] There are many types of batch processes: some batch processes require CPU resources and others require disk resources. In the present invention, the user can specify parameters for each job group and choose one of two methods for determining execution multiplicity so that the user can determine execution multiplicity by the more suitable method for the type of jobs and the location of input data to shorten batch processing time more effectively.
[0007] According to the present invention, batch processing is performed more efficiently.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a system configuration according to a preferred embodiment of the invention;
[0009] FIG. 2 shows the content of a node management table on a job management node;
[0010] FIG. 3 shows the content of a sub job management table on the job management node;
[0011] FIG. 4 shows the content of a job management table on the job management node;
[0012] FIG. 5 shows the content of a data location information table on the job management node;
[0013] FIG. 6 shows the content of a job group execution condition table on the job management node;
[0014] FIG. 7 shows the content of a job group execution node group table on the job management node;
[0015] FIG. 8 shows a job execution flow according to the preferred embodiment of the invention;
[0016] FIG. 9 shows the first half of a flow of multiplicity determination by a sub job synchronization method;
[0017] FIG. 10 shows the second half of the flow of multiplicity determination by the sub job synchronization method; and
[0018] FIG. 11 shows a flow of multiplicity determination by a sub job parallel method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Next, the preferred embodiment of the present invention will be described in detail referring to the accompanying drawings. The embodiment explained below is illustrative and the invention is not limited thereto.
[0020] For the sake of simplicity, the explanation given below is based on the assumption that the number of CPU cores 204 is allocated to one batch process, but the system does not depend on the number of physical CPU cores and processing multiplicity (number of CPU cores 204 ) can be freely set for each node 201 . Even when plural threads such as multi-threads or hyper-threads are used, processing multiplicity can also be freely set depending on the situation.
[0021] FIG. 1 shows a system configuration according to the preferred embodiment of the invention. This system includes a client node 101 , a job management node 102 , and job execution nodes 103 to 105 . These components are interconnected in a way that they can communicate with each other. The user can access the system through the client node 101 to set parameters. Specifically, the user can set minimum multiplicity 242 , maximum multiplicity 243 , a start key 244 and an end key 245 for object data to be processed, and an execution option 246 for a job group execution condition table 110 . Here, it does not matter what kind of means the user uses to set these parameters through the client node 101 .
[0022] Next, the flow of processing steps in this embodiment will be described referring to the flowcharts ( FIGS. 8 to 11 ).
[0023] First, prior to starting job execution, parameter values have been entered for a node management table 109 , a job management table 108 , a data location information table 112 , job group execution condition table 110 , and a job group/execution node group table 114 on the job management node 102 . Here, the type, entry method and location of parameters do not matter.
[0024] When a job group start condition (for example, timed start) is met, a job management section 106 starts a job group (Step 301 ). Job group start conditions here are the same as conventional job start conditions and there are various types of job start conditions: for example, timed start, log/event monitoring, preceding job, file creation, and manual function. In this embodiment, it does not matter what type of start condition is adopted.
[0025] As a start condition is met and the job group is started, the job management section 106 of the job management node 102 acquires the minimum multiplicity 242 , maximum multiplicity 243 , object data start key 244 and end key 245 for object data to be processed, and execution option 246 for the job group from the job group execution condition table 110 (Step 302 ).
[0026] Next, the job management section 106 acquires information on the node group 252 corresponding to the started job group 251 from the job group/execution node group table 114 (Step 303 ).
[0027] Next, the job management section 106 sends the minimum multiplicity 242 , maximum multiplicity 243 , object data start key 244 and end key 245 for object data to be processed for the job group, and information on the execution node group 252 to a node multiplicity calculating section 107 , and the node multiplicity calculating section 107 calculates multiplicity in job execution (Step 304 ). According to the execution option 246 sent by the job management section 106 , the node multiplicity calculating section 107 decides whether the multiplicity for the job group is determined by the sub job synchronization method or sub job parallel method (Step 305 ).
[0028] Next, how multiplicity in job execution is determined in the sub job synchronization method and the sub job parallel method will be explained.
[0029] First, the process of determining multiplicity by the sub job synchronization method is explained. In this method, processing multiplicity is determined depending on the workload on the CPU of each of the job execution nodes 103 to 105 in order to optimize multiplicity in execution of jobs. In this method, temporary multiplicity is first determined and then final multiplicity is determined based on the temporary multiplicity. Temporary multiplicity is multiplicity with which the largest number of cores among free cores are occupied (used), provided that it is within the range between minimum multiplicity 242 and maximum multiplicity 243 in the job group execution condition table 110 . In calculating final multiplicity based on the temporary multiplicity, the performances of the job execution nodes 103 to 105 are taken into consideration for the most effective use of the CPU resources. The determination of temporary multiplicity before the determination of final multiplicity makes it possible to find optimum multiplicity without calculating processing performances with different multiplicities, leading to reduction in multiplicity calculation time.
[0030] As the node multiplicity calculating section 107 of the job management node 102 starts calculation (Step 314 ), comparison is made between maximum multiplicity 243 in the job group execution condition table 110 and the total number of free cores 206 in the node management table 109 (Step 315 ). As a result of comparison, if it is found that the total number of free cores 206 is not smaller than maximum multiplicity 243 , as many free cores as expressed by the maximum multiplicity are occupied with preference given to nodes with higher performance ratios in the node management table 109 . In this case, the total number of free cores 206 is taken as temporary multiplicity (Step 316 ).
[0031] If the maximum multiplicity 243 is larger than the total number of free cores 206 , comparison is made between minimum multiplicity 242 in the job group execution condition table 110 and the total number of free cores 206 in the node management table 109 (Step 318 ). As a result of comparison, if it is found that the minimum multiplicity 242 is not larger than the total number of free cores 206 , the free cores are occupied and the number of free cores 206 is taken as temporary multiplicity (Step 317 ). If the minimum multiplicity 242 is larger than the total number of free cores 206 , the free cores 206 are occupied, provided that multiplicity value 1 is allocated to one node for as many nodes as expressed by the minimum multiplicity with preference given to nodes with higher performance ratios in the node management table 201 (Step 320 ). In this case, the value of temporary multiplicity is equal to the value of minimum multiplicity.
[0032] If the number of free cores is zero, the node multiplicity calculating section 107 allocates CPUs in accordance with the CPU allocation method selected for each node in the node management table 201 (Step 321 ). If “OTHER NODE” is selected for the CPU allocation method, allocation is made to other nodes (Step 321 ). If “QUEUING” is selected for the CPU allocation method, the system waits until the number of free cores becomes 1 or more (Step 320 ). In this case, without affecting the execution of jobs occupying the CPUs at that time, the system waits until a preceding job releases a CPU and the CPU becomes free.
[0033] At this stage, the node multiplicity calculating section 107 determines temporary multiplicity (Step 322 ). Once the temporary multiplicity has been determined, the node multiplicity calculating section 107 starts processing to determine (final) multiplicity based on the temporary multiplicity.
[0034] First, the system decides whether the temporary multiplicity is equal to maximum multiplicity 243 (Step 323 ). If the temporary multiplicity is not equal to the maximum multiplicity 243 , throughput is calculated using temporary multiplicity+1 as multiplicity (Step 325 ). This throughput is an index representing the processing performance of each node as calculated from a performance ratio 203 and the number of CPU cores 204 in the node management table 201 . A job is processed by a higher-throughput node in a shorter time than by a lower-throughput node.
[0035] If the total number of free cores is smaller than the number of jobs, the number of free cores/the number of jobs is calculated and the calculation result is taken as throughput (Step 324 ).
[0036] After throughput calculation, comparison is made between throughput with temporary multiplicity and throughput with temporary multiplicity+1 (Step 326 ). If throughput with temporary multiplicity+1 is higher, using temporary multiplicity+1 as temporary multiplicity and again the system decides whether the temporary multiplicity is equal to the maximum multiplicity (Step 323 ). By repeating these steps, the system determines to which level below the maximum multiplicity the value of temporary multiplicity should be increased.
[0037] Using a similar algorithm, the system determines to which level above the minimum multiplicity the value of temporary multiplicity should be decreased. In this case, comparison is made between throughput with temporary multiplicity and throughput with temporary multiplicity−1 (Step 330 ). If throughput with temporary multiplicity−1 is higher, temporary multiplicity−1 (temporary multiplicity minus 1) is taken as temporary multiplicity (Step 329 ).
[0038] By adjusting the value of temporary multiplicity in accordance with the above algorithm, multiplicity corresponding to the highest throughput is calculated and determined as (final) multiplicity (Step 331 ). Here, multiplicity corresponding to the “second highest” throughput may be chosen instead of multiplicity corresponding to the “highest” throughput.
[0039] After multiplicity has been determined as mentioned above, the node multiplicity calculating section 107 sends multiplicity information to the job management section 106 .
[0040] Thus, the sub job synchronization method provides a system in which processing multiplicity is calculated depending on how the job execution nodes 103 to 105 are being used, so that jobs are executed with optimum multiplicity.
[0041] Next, the process of determining multiplicity by the sub job parallel method is explained. This method provides a system which recognizes a node in which an input file for a job is located and executes the job on that node to minimize communication workload. Here, it does not matter how and where the input file is located.
[0042] As the node multiplicity calculating section 107 starts multiplicity calculation in accordance with the sub job parallel method, the system refers to a data location information table 112 and acquires the number of divisions of the input file for the job to be executed (Step 332 ). This number of divisions is the multiplicity for the job to be executed (Step 333 ). Here, the node which executes a job should be the node on which the data to be processed for the job is located. For example, on a node in which key #1 to #100 files are located, the job for processing the key #1 to #100 files is executed.
[0043] In the sub job parallel method, on a node in which a file to be processed is located, a job for processing the file is executed. This eliminates the need for processing a file located in another node, reducing the communication workload in job execution.
[0044] Once multiplicity has been determined, the job management section 106 acquires information on execution of each sub job from the node multiplicity calculating section 107 and creates a sub job management table 113 (Step 308 ).
[0045] The job execution command input section 111 of the job management node 102 sends a job execution command to the job execution nodes 103 to 105 with reference to the sub job management table 202 (Step 309 ). As the job execution nodes 103 to 105 receive the execution command, they execute jobs in accordance with the received job execution command (Step 310 ).
[0046] After the jobs have been executed, the job management section 106 updates execution status information on each sub job in the sub job management table 202 (Step 311 ).
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A batch job multiplex processing method which solves the problem that a system which performs multiplex processing including parallel processing on plural nodes cannot cope with a sudden increase in the volume of data to be batch-processed using a predetermined value of multiplicity, for example, in securities trading in which the number of transactions may suddenly increase on a particular day. The method dynamically determines the value of multiplicity of processing including parallel processing in execution of a batch job on plural nodes. More specifically, in the method, multiplicity is determined depending on the node status (node performance and workload) and the status of an input file for the batch job.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. application Ser. No. 60/889,121, filed Feb. 9, 2007.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a tool for installing compression connectors on the end of coaxial cable. Such connectors come in a variety of styles and sizes. Among the styles are F-type, BNC and RCA connectors. Among the sizes are RG-6, RG-1 and RG-59. Details of the three connector styles are shown in U.S. Pat. No. 7,153,159. Installation of each style of compression connector entails inserting the prepared end of a coaxial cable a predetermined distance into the connector and then compressing the connector to deform a portion of it and lock it onto the cable. Compression tools for performing this function are known. Such tools have a zone which receives a connector pressed onto the end of a coaxial cable. A compressive force then is applied to the ends of the connector to deform the connector and complete the installation.
[0003] One disadvantage of early compression tools is the compression chamber is sized to accept only a single size or type of connector. Several such tools were required in a technician's toolbox to accommodate all the sizes that might be needed. Some prior art tools addressed this problem by providing multiple, separate inserts or plungers to accommodate different connector sizes. However, this requires the technician to change out the tool parts every time a different size connector is encountered. Time is lost performing the change. Furthermore, this type of multiple component tool still does not remove the need to have separate tools or components for separate sizes of connectors.
[0004] A prior art tool that does accommodate two different connector sizes in a single tool with no removable parts is shown in U.S. Pat. No. 6,820,326. This tool has two pairs of split bases at separate longitudinal locations in the compression chamber. While this allows the tool to be used on two different connector sizes, it introduces problems of its own. Chief among these is the inability to release a finished cable/connector combination without separate manipulation of the split bases. A user typically holds the compression tool in the palm of one hand and the cable/connector in the other hand. The cable/connector is inserted into the compression chamber where the split bases engage the cable and provide the abutment for the back end of the connector. Then the tool handle is squeezed to perform the compression. Now the finished cable is ready for release from the tool but the split bases will not readily release it. Instead the user has to perform an awkward maneuver in which he or she balances the tool in the palm and outer fingers so the thumb and forefinger are available to actuate the split bases to the open position. Alternately, the user might try a similar maneuver with the opposite hand, that is, grasping the cable with a couple fingers while opening the split bases with two other fingers and then pulling one hand away to remove the cable from the tool. Neither of these methods of releasing a finished cable from the tool is convenient. It has also been found that this tool does not work well with RG-11 F-type compression connector.
SUMMARY OF THE INVENTION
[0005] The present invention provides a tool for installing compression connectors of various sizes and types on the end of a coaxial cable without the need for multiple tools or components. The tool of the present invention has a pair of movable anvils for engaging two different lengths of connectors and an abutment for engaging a third length of connector. The movable anvils have an aperture which defines a throat that is large enough to permit easy entry and exit of a cable and small enough to apply a suitable retention force so that a cable will not inadvertently come out of or move around in the aperture prior to compression. The anvils each have a pair of movable spring clips with a depression or cutout in an edge thereof such that opposed spring clips define the cable-receiving receptacle. A connector seated at the proper location on the end of the cable is placed between the plunger and face of the anvil with the cable extending through the aperture in the anvil. Then the plunger is actuated to compress the connector and fix it in place on the cable. After retraction of the plunger a radial movement of the finished cable/connector combination is all that is needed to remove the finished cable from the compression zone. The arrangement of the anvil apertures is such that separate releasing activation of the spring clips is not necessary. In an alternate embodiment, the anvil may have a tear-drop shaped aperture, either with or without a throat.
[0006] Another problem addressed by the present invention is the initial seating of a connector on a prepared coaxial cable. That is, sometimes the fit between a connector and cable is so tight that it can be difficult to slide the connector to the desired location on the end of a prepared cable. The present invention is further directed to a method of assisting with the initial seating of a connector on the end of a cable. The tool can be used for this initial phase as well as for the compression phase. A connector is placed in the tool's compression zone and the end of a cable is also placed in the compression zone, aligned with the connector but not yet attached thereto. One of the anvil apertures is sized to permit the anvil to be squeezed against the cable. This restrains the cable longitudinally. Then the plunger is advanced to push the connector on to the end of the restrained cable. This allows initial seating. Thereafter the anvil is released and the connector/cable combination moved to place the rear end of the connector against the appropriate anvil for compression.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side elevation view of the application tool of the present invention with the handle shown in an actuated position.
[0008] FIG. 2 is an exploded perspective view of the application tool.
[0009] FIG. 3 is a perspective view of a longitudinal section through the tool, with the plunger shown in a retracted position.
[0010] FIG. 4 is a perspective view of a longitudinal section through the tool, with the plunger shown in an actuated position.
[0011] FIG. 5 is a perspective view of a spring clip.
[0012] FIG. 6 is a front elevation view of the spring clip of FIG. 5 .
[0013] FIG. 7 is a side elevation view of the spring clip, looking in the direction of line 7 - 7 of FIG. 6 .
[0014] FIG. 8 is a bottom plan view of the spring clip.
[0015] FIG. 9 is a front elevation view of an anvil looking along line 9 - 9 of FIG. 14 , with the outline of the tool base shown in phantom.
[0016] FIG. 10 is a perspective view of a longitudinal section through the compression zone, showing an F-type connector loaded in engagement with the first anvil.
[0017] FIG. 11 is a perspective view of a longitudinal section through the compression zone, showing an BNC-type connector loaded in engagement with the second anvil.
[0018] FIG. 12 is a perspective view of a longitudinal section through the compression zone, showing an RG-11 F-connector loaded in engagement with the fixed anvil.
[0019] FIGS. 13 and 14 are perspective views of the application tool with portions broken away to illustrate adjustment of the lock nut and plunger.
[0020] FIGS. 15 and 16 are perspective views of the application tool, with portions broken away in FIG. 16 , illustrating the connector seating holder and its use.
[0021] FIG. 17 is a perspective view of the application tool looking toward the forward end of the compression zone.
[0022] FIG. 18 is a view similar to FIG. 9 , showing an alternate embodiment of the anvil.
[0023] FIG. 19 is a view similar to FIG. 9 , showing a further alternate embodiment of the anvil.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1 illustrates the application tool of the present invention generally at 10 . The tool includes a base 12 . The details of the base are best seen in FIGS. 2 and 3 . The base includes a central block member 14 having a bore 16 formed therein. A generally three-sided heel section 18 extends rearwardly from the block member. The heel section is hollow and open at its lower side. Rounded ears 20 are formed at the rear of the heel 18 . There are transverse, aligned holes 22 in the heel above the ears 20 . Extending forwardly of the block member 14 is a beam 24 . About midway along the beam there is an enlargement 26 which includes a transverse hole 28 . Forwardly of the enlargement 26 the front portion of the beam 24 carries a depending anvil mount 30 . Above the anvil mount there are two side walls 32 , 34 joined to the beam 24 . The side walls extend back to the block member 14 . There are windows 36 in the side walls. Two transverse slots 38 , 40 are formed in the anvil mount 30 . These slots extend up into the side walls 32 , 34 as best seen in FIG. 2 . Together the front surface of the block member 14 , the top surface of the beam 24 and the inside surfaces of the side walls 32 , 34 define a compression zone 42 having a longitudinal axis A. At its forward end the side wall 32 joins an abutment 44 which has a rearwardly-facing, fixed bearing surface 46 . Fixed bearing surface 46 extends transversely of the axis A. Similarly, side wall 34 terminates at an abutment 48 which includes a fixed bearing surface 50 . See FIGS. 15 and 17 also. The bearing surfaces 46 , 50 are coplanar. It will be noted that the forward ends of the abutments 44 , 48 have a curved lower portion which, taken together, define U-shaped opening 52 into the compression zone.
[0025] The front or nose of the anvil mount 30 has a connector seating holder 54 . In this embodiment the holder 54 is a hexagonal depression in the anvil mount with a central post 56 disposed in the depression. The post 56 surrounds a bore 58 ( FIG. 4 ) that extends longitudinally into the anvil mount 30 . The depression is sized to receive the front end of a compression connector therein. The holder 54 retains the connector while a prepared cable is seated on the back end of the connector prior to compression. Further details of this process will be described below.
[0026] Attention will now be turned to the components attached to the base 12 . First and second anvils 60 and 62 are retractably insertable into the compression zone 42 between open and closed positions. A complete anvil comprises two spring clips and a clip spring. Thus, first anvil 60 has a left spring clip 60 A, a right spring clip 60 B and a clip spring 60 C. Similarly, anvil 62 has a left spring clip 62 A, a right spring clip 62 B and a clip spring 62 C. The spring clips of the first anvil 60 are mounted in the transverse slot 38 of the anvil mount 30 , as seen in FIGS. 3 and 4 . The spring clips of the second anvil 62 are similarly mounted in the transverse slot 40 . All of the spring clips are pivotally mounted on a spring pin 64 which is set in the bore 58 of the anvil mount 30 .
[0027] Details of a spring clip 62 B are shown in FIGS. 5-8 . In this embodiment all of the four spring clips used in the two anvils are identical so all the others would look the same as 62 B shown, except the installed left spring clips would be flipped around from the orientation shown in FIG. 5 . The spring clip has a plate 66 . The rear surface of the plate defines a bearing surface. The plate is bounded on top by a head 67 and on one side by a generally vertical edge 68 . Near the bottom of the vertical edge is a knuckle 70 extending therefrom. At the lower portion of the plate a foot 72 carries a peg 74 . On the side edge of the plate opposite the knuckle 70 there is a circular ring 76 . An opening 78 extends through the ring. The opening receives the spring pin 64 when the clips are mounted in the anvil mount 30 so the clips are reciprocally movable into and out of the compression zone 42 . The ends of the clip springs 60 C or 62 C seat on the pegs 74 and normally bias the upper portions of the spring clip toward one another, i.e., into the compression zone 42 . It will noted that the ring has half the thickness of the remainder of the plate, as seen in FIGS. 5 , 7 and 8 . Thus when two spring clips are placed with their rings adjacent one another and the axes of the openings 78 aligned, the faces of the spring clips will be coplanar. This allows the spring clips to fit fairly snugly in the transverse slots, with sufficient clearance for easy movement but without allowing the spring clips to cant in their slots.
[0028] Above the ring 76 the edge of the plate has an aperture 80 . The aperture is beveled at the front and rear faces of the plate. In this case the aperture is circular, although its shape could be other than a circle. The center of the aperture circle is at C. The horizontal centerline of the aperture is shown at B. It defines upper and lower quadrants U and L of the aperture 80 . The portion of the plate edge that defines the aperture in the lower quadrant L, i.e., the edge portion below the centerline B can be considered a support surface 80 A. The portion of the plate edge that defines the aperture in the upper quadrant U, i.e., the edge portion above the centerline B defines a retention surface 80 B. The retention surface in this embodiment defines a circular arc. The retention surface terminates in the upper quadrant at terminus T. An angle between the horizontal centerline and a radius R through the terminus T defines what will be referred to herein as a closure angle α. By way of example, and not by limitation, the closure angle in the illustrated embodiment is about 50°. The terminus is joined to the head 67 by an entry surface 82 which is angled from the vertical to assist in guiding a cable into the aperture.
[0029] The closure angle α is important because it determines the ability of the spring clips to capture and release a cable inserted into the tool's compression zone. This will become evident by examination of anvil 62 in FIG. 9 . As mentioned above, the complete anvil 62 comprises the left and right spring clips 62 A and 62 B and clip spring 62 C. The apertures 80 of the cooperating spring clips lie side by side to define a cable receiving receptacle. There is a throat or gap G between the terminus points of the two spring clips' apertures. It is important to properly size this throat or gap such that coaxial cables can be readily inserted into and removed from the receptacle but at the same time the clips will impart a retaining force that prevents inadvertent slippage of the cable from the receptacle. In other words, a cable receptacle having a completely open slot at its entry point is undesirable because the cable is then totally free to move out of position for crimping. The spring clips must surround a portion of the upper quadrants of a cable therein to provide a retaining function. But the spring clips can only surround a portion of the cable. If the spring clips fully surround the cable they prevent ready release of the cable when it is finished, which would then require the awkward manipulation of the clips as described above. Thus, the spring clips must provide some, but not too much, restraint on a cable in the cable receiving receptacle. The compromise struck by the present invention between too little and too much restraint can be defined in two ways. One is by describing the closure angle as being at least 33° and not more than 75°. About 50° is preferred. This will extend the clip surface defining the aperture 80 sufficiently into the upper quadrant L to engage enough of an inserted cable to hold it for crimping and release it after crimping. Alternately, since the retention surfaces of the apertures 80 need not be circular, the throat or gap G between the terminus points of the apertures could be about 0.075 inches to about 0.250 inches, with about 0.19 inches being preferred. It has been found that a throat or gap of this amount will provide sufficient holding force on a cable in the receptacle prior to crimping while readily releasing a cable after crimping.
[0030] Returning now to FIGS. 1-3 , the remaining parts of the application tool will be described. A cylindrical slide rod 84 is mounted for slidable translation in the bore 16 of the block member 14 . The rod has a threaded bore 86 at its forward end and a clevis 88 at its rear end. A push head 90 has a slot 92 at its forward end. Much of the body of the push head has external threads which engage the internal threads of the slide rod 84 . Together the slide rod 84 and push head 90 form a plunger. A lock nut 94 has internal threads and external teeth. The lock nut is threaded on the push head and is engageable with the leading edge of the slide rod to prevent rotation of the push head. FIGS. 13 and 14 illustrate how the overall length of the plunger is adjustably fixed. To change the length of the plunger, a user inserts a screwdriver blade into the compression zone 42 to engage the teeth of the lock nut and loosen it from the slide rod. This then permits a screwdriver engaged with slot 92 in the push head to rotate the push head as needed to lengthen or shorten the plunger. Once the desired length is obtained by turning the push head, the lock nut 94 is tightened against the end face of the slide rod to prevent further rotation of the push head. Thus, the length of the plunger can be easily adjusted using ordinary tools that are always available.
[0031] A push rod 96 connects to the clevis 88 of the slide rod 84 by means of a groove pin 98 . The groove pin fits transversely through aligned openings in the clevis and slide rod. A second groove pin 99 joins the other end of the push rod 96 to a handle 100 . The handle has an elongated arm 102 connected at one end to a clevis 104 . Aligned openings in the clevis 104 receive the groove pin 99 . Another set of openings in the clevis receive a handle anchor pin 106 . Anchor pin 106 extends through the holes 22 in the ears 20 to mount the handle for rotation about the pin. An anchor pin screw 107 threads into the end of the pin 106 to fix it in position.
[0032] The anchor pin 106 also fits through a torsion spring 108 . One leg of the spring engages the inside of the heel 18 and the other leg engages the arm 102 to bias the arm away from the heel. A U-shaped wire hasp 110 has free ends which slip into either end of the transverse hole 28 in the beam 24 . The hasp pivots between open and closed positions where it either releases the handle or holds it in the closed position of FIG. 1 . A handle grip 112 slides over the arm 102 to provide a comfortable surface for a user to grasp. The hasp 110 is large enough to accommodate the grip 112 .
[0033] The use, operation and function of the application are as follows. The user first sets the plunger to the desired length as described above. The hasp 110 is rotated toward the anvil mount 30 to release the handle 100 . The torsion spring biases the handle open position as seen in FIG. 3 . This rotates the handle clevis 104 away from the block member 14 and causes retraction of the push rod 96 and slide rod 84 . The tool is now ready for use. The user prepares coaxial cable by stripping it appropriately and seating the desired connector type on the stripped cable end. The connector seating holder 54 can be used to assist in inserting the cable the requisite distance into the connector. As seen in FIGS. 15 and 16 a user grasps the tool 10 in one hand and puts a connector 114 loosely on the end of a coaxial cable 116 . The free end of the connector is then inserted into the depression of the seating holder 54 . The user can then press the tool and cable together to push the connector the required distance onto the cable. As this is done there is no possibility of the user being injured by a sudden thrusting of the central conductor of the cable through the front end of the connector.
[0034] Once the connector is properly seated on the cable, the connector/cable combination is placed into the compression zone 42 by a radial movement between the side walls 32 , 34 . The cable engages the entry surfaces of the spring clips and forces them apart sufficiently to permit the cable to fit into the cable receiving receptacle defined by the apertures 80 of the spring clips. Once the cable enters the receptacle the clip springs 60 C and 62 C will push the spring clips back to a closed position about the cable wherein the upper quadrant of the spring clip will engage the cable. The cable will extend out the front of the tool through the U-shaped opening 52 . The rear edge of the connector engages the bearing surfaces of one of the movable anvils or the abutments, depending on the size of the connector. FIG. 10 illustrates that a typical F-type connector 118 will engage the first anvil 60 . FIG. 11 shows a BNC connector 120 in engagement with the second anvil 62 . FIG. 12 illustrates that an RG-11 F-connector 122 is so large that its rear edge will extend all the way to the fixed bearing surfaces 46 , 50 of the abutments 44 , 48 .
[0035] With the rear edge of the connector in engagement with the appropriate bearing surface the user squeezes the handle 100 toward the base 12 . The push rod 96 then pushes the plunger forwardly. The push head 90 engages the front end of the connector. Continued movement of the slide rod and push head combination compresses the connector between the push head and the bearing surfaces, thereby compressing the connector and locking it onto the cable. The user then releases the handle 100 . The torsion spring 108 moves the handle to the open position, which causes the plunger to retract and disengage the connector. With the other hand, the user can then translate the finished cable out of the compression zone by a radial movement out the top of the compression zone. There is no need to manually engage the spring clips because their shape allows the user to simply lift the cable out of the compression zone. The spring clips will release the cable without undue effort on the part of the user. The tool is then ready for the next application. When the user is finished, the handle can be closed and the hasp rotated to retain the handle in the closed position.
[0036] FIG. 18 illustrates an alternate embodiment of an anvil 124 . This anvil has left and right spring clips 124 A, 124 B. These may be generally similar to the spring clips described above except for the shape of the aperture 126 . Aperture 126 has a tear-drop shape. That is, the lower quadrants of the aperture are circular but the retention surfaces in the upper quadrants have both a circular portion 126 A and a tangential portion 126 B. The circular portion 126 A defines an arc above the horizontal centerline B of about 30°. The retention surface then merges into the tangential portion 12613 , which is generally straight. The tangential portion ends at terminus T. There is a gap or throat G between the termini of the two spring clips.
[0037] FIG. 19 illustrates a further alternate embodiment of an anvil 128 . As is the case with all the anvils, anvil 128 has left and right spring clips 128 A, 128 B which are similar to those described above except for the shape of the aperture 130 . Aperture 130 has a tear-drop shape similar to the aperture 126 but in this case there is no gap or throat between the clips. Thus, the lower quadrants of the aperture are circular but the retention surfaces in the upper quadrants have both a circular portion 130 A and a tangential portion 130 B. The circular portion 130 A defines a circular arc above the horizontal centerline of about 30°. The aperture then merges into the tangential portion 130 B. As shown in the figure, the tangential portion 130 B defines an angle of greater than 35° with the horizontal centerline B. The tangential portion may have a small arc at its upper end just prior to terminus T. The termini are in contact with each other when the spring clips are closed. There is no gap or throat between the termini of the two spring clips.
[0038] In both of the tear-drop configurations of FIGS. 18 and 19 , the retention surface defined by the arcuate portion and the tangential portion provides the desired balance between retention ability before and during compression and ease of release after compression. It will be understood that the retention surface could have shapes other than the tear-drop configuration shown. For example, instead of having an arcuate portion, the retention surface could just have a straight tangential portion starting at the horizontal centerline. In such a configuration the tangential portion would not be tangential to the support surface in a strict geometric sense, but it will be understood that the term “tangential” as used herein is broad enough to cover alternative arrangements of the retention surface that do not meet strict geometric conditions. What is important is that the retention surface in these alternate embodiments have a portion that leads or slopes into the parting line between the spring clips. As a result of the leading configuration of the retention surface, outward radial movement of the cable will produce a lateral force on the spring clips that tends to separate the spring clips and allow release of the cable. The precise combination of arcuate, straight, curved or angular surfaces that comprise the retention surface may vary so long as the combination produces a lateral, separating force on the spring clips when a cable is moved radially outwardly of the compression zone.
[0039] In an alternate embodiment of the application tool the spring clips can be compressed against an inserted cable to restrain the cable during insertion of the cable onto the connector. That is, the compression tool can be used prior to compression to assist in initial seating of the connector to the proper location on the end of the cable. This is done by inserting a connector into the compression zone and engaging the plunger with the connector. Then the coaxial cable with an appropriately prepared end is inserted into the compression zone behind the connector. One set of spring clips has an aperture sized somewhat smaller than the cable diameter. The spring clips of this set are squeezed toward the closed position to engage the cable and retain it in a fixed longitudinal position while the plunger is actuated. This causes relative longitudinal movement between the connector and cable to push the connector onto the end of the cable
[0040] While the preferred form of the invention has been shown and described herein, it should be realized that there may be many modifications, substitutions and alterations thereto without departing from the scope of the following claims.
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A method for installing compression connectors of various sizes and types on the end of a coaxial cable utilizes a tool having a base mounting a pair of movable anvils for engaging two different lengths of connectors. The movable anvils define an aperture which is shaped to permit easy entry and exit of a cable while still applying a suitable retention force to an inserted cable. A slidably mounted plunger cooperates with the anvils to compress a connector. One of the anvils has an aperture size that permits the anvil to squeeze or pinch an inserted cable and thereby restrain a cable longitudinally during initial seating of the connector onto a cable by means of the plunger.
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TECHNICAL FIELD
[0001] The invention relates to an instrument which has been developed to be used in macular hole surgeries, closes and repairs the macular hole by drawing the retina tissue toward the center in the macula.
STATE OF THE ART
[0002] Macula is the name of the retina area which is used when looking at a point in the target, namely, provides central vision. It is also referred to as the “area of the central vision”. In this area, holes which looks like as if being bored using a puncher may be formed. This is called macular hole. Surgical operation is the only treatment method.
[0003] The existing macular hole repair operations comprise the processes of vitrectomy, namely removing the vitreous gel tissue filling inside of the eye, peeling the internal limiting membrane (ILM), the layer covering surface area of the macula as well as whole retina, and applying gas (air) tamponade.
[0004] However, the desired surgical success cannot always be achieved subsequent to performing these processes. During operation, closing the macular hole mechanically by drawing the same from the periphery toward the center increases the surgical success rate up to around 100%. When retina, a soft, dough-like tissue, is drawn from the edge of the hole toward the center of the same by a soft push, it is closed in the same manner as in the case of closing the hole section of a play dough the center of which is punched. Said surgical technique has also been developed by the present inventor.
[0005] After the standard surgical steps mentioned above, the fact that the present macular hole is closed 360 degrees toward the center by means of mechanical drawing method in a sensitive manner before applying the gas (air) tamponade, increases the success rate with respect to closing the hole up to around 100%.
[0006] However, a sensitive instrument which draws and closes macular hole having a diameter around 500 microns, mechanically with this sensitivity is not available. Thus, this process is achieved by using other vitreoretinal surgical instruments such as round blunt side of the forceps used for peeling the internal limiting membrane (ILM) or flute needle, etc. However, having not been designed for a sensitive process as such, these instruments can damage the sensitive macula and retina pigment epithelium.
[0007] To conclude, due to the aforementioned drawbacks and the inadequacy of the existing solutions regarding the subject, a development is deemed to be necessary in the related technical field.
OBJECT OF THE INVENTION
[0008] The invention aims to develop a new surgical instrument and to eliminate the drawbacks resulting in surgical failure in the operations for macular hole closure.
[0009] The object of the invention is to increase the success rate with respect to macular hole closure up to 100%.
[0010] One object of the invention is to shorten the duration of macular hole closure operation and to provide convenience for the surgeon during operation.
[0011] One object of the invention is to present a sensitive instrument which draws and closes macular hole mechanically and sensitively.
[0012] Another object of the invention is to achieve a surgical treatment without damaging the macula and retina pigment epithelium.
[0013] In order to achieve the objects mentioned above, the invention is a macular hole instrument which is used for mechanical macular hole closure in the macular hole surgeries and comprises a handle, wherein it also comprises a holder comprising at least one shaft connected to the handle, and at least one pressure leg positioned to the end of the shaft. Said holder is connected to the handle from a connection point. Said holder comprises two shafts and a total of two pressure applying and holding (serving as forceps) legs each of which will be positioned to the end of each shaft.
[0014] In a preferred embodiment of the invention, said pressure legs comprise inner sections and are positioned such that the inner sections thereof will face each other and form a sphere when coming together.
[0015] In a preferred embodiment of the Invention, said shafts with pressure legs being positioned to the ends thereof are positioned in a manner to be combined in the central axis extension of said handle.
[0016] In a preferred embodiment of the invention, said connection point comprises a moveable connection which allows the holder to move independent of the handle.
[0017] In a preferred embodiment of the Invention, said pressure legs comprise a moveable connection which allows independent movement thereof from said shaft.
[0018] In a preferred embodiment of the invention, said pressure legs have a hemisphere shape.
[0019] The structural and characteristic features and all the advantages of the present invention will be more clearly understood thanks to the figures below and the detailed description written with reference to those figures and therefore, the evaluation needs to be done by taking said figures and the detailed description into consideration.
FIGURES FACILITATING UNDERSTANDING OF THE INVENTION
[0020] FIG. 1 is the view of the forceps pressure legs (holders) of the instrument according to the invention.
[0021] FIG. 2 is the view of the spherical structure obtained when the inner sections of the forceps pressure legs of the instrument according to the invention are closed in a manner to face each other.
[0022] FIG. 3 is the spherical view obtained when the inner sections of the forceps pressure legs of the instrument according to the invention are closed in a manner to face each other.
[0023] FIG. 4 is the view of the end section of the instrument, namely the forceps pressure legs according to the invention, when opened.
[0024] FIG. 5 is the view of the instrument according to the invention with a holder comprising a single spherical pressure leg.
[0025] FIG. 6 is the illustration of the connection point-centered movement of the holder of the instrument according to the invention.
[0026] FIG. 7 is the illustration of the movement from section where pressure leg of the instrument according to the invention is connected with the shaft of the same.
[0027] FIG. 8 and FIG. 9 are the illustrations of the alternative forms of the instrument with a single pressure leg according to the invention.
[0028] FIG. 8 a and FIG. 9 a are the illustrations of the various forms of pressure surfaces of the instrument with a single pressure leg according to the invention.
DESCRIPTION OF THE REFERENCES
[0000]
1. Macular Hole Repairment Instrument
2. Handle
2.1. Connection point
3. Holder
3.1. Shaft
3.2. Pressure Legs
3.2.1 Pressure Surfaces
3.3 Inner Section
[0037] The drawings do not need to be scaled and the details that are not necessary for understanding the present invention may have been ignored. Besides, the members that are at least substantially identical or have at least substantially identical functions are referred with the same number.
DETAILED DESCRIPTION OF THE INVENTION
[0038] In this detailed description, the preferred embodiments of the instrument according to the invention used in the macular hole treatment are described only for a better understanding of the subject.
[0039] In general terms, macular hole closure instrument ( 1 ) according to the invention consists of a handle ( 2 ) which is also available in standard forceps, holder ( 3 ) and connection point ( 2 . 1 ) where the holder ( 3 ) is connected to the handle ( 2 ). The connection point ( 2 . 1 ) can comprise a hinge-like connection member as well as serving as a continuing part of the handle ( 2 ) by means of welding. Said holder ( 3 ) comprises shaft ( 3 . 1 ) and pressure legs ( 3 . 2 ) comprising inner sections ( 3 . 3 ).
[0040] The handle ( 2 ) is a standard structure which is also available in all other instruments used in vitreoretinal surgeries and comprises a collapsible mechanism with spring.
[0041] The pressure legs ( 3 . 2 ) have a hemisphere shape preferably. Therefore, inner sections ( 3 . 3 ) of said pressure legs ( 3 ) have also a hemispherical inner volume. In an alternative embodiment, they can be designed in various shapes or forms.
[0042] When the holder ( 3 ) is used in a closed state, namely when the pressure legs ( 3 . 2 ) are combined such that the inner sections ( 3 . 3 ) thereof will face each other, a shape of sphere is obtained. In this manner, macular hole closure instrument ( 1 ) according to the invention having a spherical end allows the macular hole to be drawn and closed mechanically (without damaging or with a minimum damage to the macula and pigment epithelium).
[0043] The instrument according to the invention, in addition to allowing mechanical closure of the macular hole, functions as forceps to be used for peeling ILM or removing the residues of ILM or glial tissue appearing during the closure of the macular hole by mechanical drawing.
Usage of the Invention;
[0044] Standard macular hole surgical process is achieved by including also peeling the ILM. The macular hole closure instrument ( 1 ) according to the invention is entered into the eye with the holder ( 3 ) being closed. The instrument is drawn from the periphery toward the center by a spherical end, thereby allowing the mechanical closure of the macular hole. Subsequent to drawing, residues of the surface glial tissue drawn toward the center of the macular hole are removed by the holder ( 3 ) when opened and used as forceps this time.
[0045] Peeling ILM is also achieved with the invention. In other words, the instrument can also be used as ILM forceps. As the edges thereof are designed to be thin, it is also used to serve as ILM forceps.
[0046] In the alternative embodiments of the instrument, the holder ( 3 ) can be provided to be one-piece, namely not to be a collapsible structure. As a continuing part of the handle ( 2 ), it can comprise a single shaft ( 3 . 1 ) and a spherical pressure leg ( 3 . 2 ) at the end section of this shaft ( 3 . 1 ) ( FIG. 5 ).
[0047] In another alternative embodiment, the connection point ( 2 . 1 ) can have the characteristics of a joint or ball connection member. The holder ( 3 ) can move to various directions by centering on the connection point ( 2 . 1 ) ( FIG. 6 ). Besides, connection of the pressure leg ( 3 . 2 ) with the shaft ( 3 . 1 ) can also be a moveable connection (e.g. hinge-like) ( FIG. 7 ).
[0048] In another alternative embodiment, the holder ( 3 ) can be fitted into the handle ( 2 ) along the shaft ( 3 . 1 ).
[0049] Some combinations of said alternative embodiments can be presented together.
[0050] In the embodiment according to the invention, rather than the spherical end section, the bottom surface contacting the retina, namely the pressure surface ( 3 . 2 . 1 ) of the retina is important. When the pressure surface ( 3 . 2 . 1 ) is completely spherical sometimes, it can be incapable of removing by drawing the thin surface irregularities from the front thereof. Therefore, the bottom section (pressure surface ( 3 . 2 . 1 )) of the pressure legs ( 3 . 2 ) contacting the retina can be formed to be quadrilateral ( FIG. 8 ), with one edge being concave, the other edge being convex and the two side edges being flat. In addition, the pressure surface ( 3 . 2 . 1 ) can also be formed to be triangular, with two edges being flat and one edge being convex.
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The invention relates to an instrument which has been developed to be used in macular hole surgeries closes and repairs the macular hole by drawing the retina, wherein it comprises a holder comprising at least one shaft connected to the handle, and at least one pressure leg positioned to the end of the shaft.
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[0001] This Application claims priority from German Application Number 100 63 537.7 which was filed on Dec. 20, 2000, the disclosure of which is incorporated into this application by reference.
FIELD OF AND BACKGROUND OF THE INVENTION
[0002] The invention relates to a display and operating element for an electronic scale having a display area in which the weighing results and values, parameters or selection lists for user prompting can be displayed, either spatially separated or in succession over time, and having at least one button for operating the scale.
[0003] Display and operating elements for scales of this type are generally known.
[0004] For example, German Patent DE 32 13 015 C2 describes a scale with an integrated display and operating element that has several programs and in which the individual program numbers are shown on the display in sequence when the scale is switched on so that the number of the desired program can be selected. Since this scale requires a delay to allow the operating personnel to decide whether to make a selection and react accordingly at each program number, sequencing through the program numbers can only be carried out slowly. As a result, program selection is very time-consuming.
[0005] In addition, a scale with a separate display and operating element is known from U.S. Pat. No. 4,650,014, in which a ten-key keypad is provided, e.g., for inputting a specified value. Therefore, numerical values can easily be input using this keypad. However, because of the ten-key keypad, the display and operating element is required to be relatively large, especially if the scale is designed to be operated while wearing protective gloves. If the system is further adapted to receive instructions by inputting letters as well as numerals, this would require approximately 30 additional keys, and thereby compound the problem.
[0006] In addition, it is also known from German Laid-Open Publication DE 36 38 210 A1 that an operating button of the scale-in this case the tare button-can be divided into several partial areas. For example, if the operating button is divided into four partial areas, it is possible to provide, e.g., a counting scale the permits selection between four different quantities or number of reference units by pressing the appropriate partial area. However, this method is useful for a selection of values only when there are at most a few values that can be selected.
[0007] Providing one button for incrementing and one button for decrementing in a measurement scale is also known from U.S. Pat. Nos. 5,847,328 and 5,902,965. These patents are incorporated by reference in their entirety into the present application. With these two buttons, at each actuation, the scale value can be increased or lowered by 1 and, thus, the displayed value can be brought to a specified value during an incorrect measurement. This method is good for small changes, but, for large changes, the button needs to be actuated a large number of times, which makes the procedure cumbersome.
[0008] Finally, mounting the weighing pan of a scale so that it can rotate and using the angle of rotation to adjust a parameter is known from German Patent No. DE 41 37 919 C1. However, this method is not useful for scales with a square scale pan or for scales with a conveyor device mounted on the scale pan to supply/remove the material to be weighed-for example, it is not at all possible with a roller conveyor. However, even during weighing with a round scale pan, the contact with the scale leads to a disturbance in the weighing result so that each time it is necessary to wait after a parameter change for the weighing result to settle to its rest value. As a result, changing parameters is time-consuming.
OBJECTS OF THE INVENTION
[0009] One object of the present invention is to provide an electronic scale having a display and operating element that makes possible the fast and simple adjustment of values/parameters and/or the selection of a specific point out of a selection list.
SUMMARY OF THE INVENTION
[0010] According to the invention, this and other objects are achieved by providing a rotary knob for the display element (for example, on one side of the display element), so that when the knob is turned in one direction or in the other, the values, parameters or marked areas of the selection list shown in the display area are changed in one direction or the other. Additionally, a button is assigned to the rotary knob as an acknowledgement button, such that actuation of this acknowledgement button results in the acceptance into the scale's electronic evaluation unit of the value, parameter or marked area of the selection list selected by using the rotary knob.
[0011] Because the selection is made by turning a rotary knob, both fast and accurate selection is rendered possible, so that even when there are many available alternatives—e.g., in the selection of letters—fast and precise selection remains possible. The selection is completed by actuating the acknowledgement button, and the selected alternative is accepted into the electronic evaluation unit and processed there.
[0012] In an advantageous aspect of the invention, the rotary knob is located on one side of the display and operating element and the acknowledgement button on the other side, so that one hand is free to operate the rotary knob without releasing it while the other hand can operate the acknowledgement button. In an alternative advantageous aspect of the invention, the acknowledgement button is integrated in the rotary knob. Either the acknowledgement button is installed in the rotary knob or the acknowledgement function is actuated by pressing the entire rotary knob. As a result, in this aspect of the invention, the turning (selection) and the pressing (acknowledgement) can be carried out with one hand. Accordingly, the present invention provides a scale in which its operation is simple, fast and reliable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention and further advantageous refinements of the invention according to the features of the claims are explained in more detail below with the aid of diagrammatic, exemplary embodiments in the drawings, which are not necessarily drawn to scale and in which:
[0014] [0014]FIG. 1 shows a display and operating element (during menu selection) connected to a scale housing according to a first preferred embodiment of the invention, FIGS. 2 a - 2 c show the display area 3 from FIG. 1 with three possible display images,
[0015] [0015]FIG. 3 shows the display and operating element during the selection of color formulas,
[0016] [0016]FIG. 4 shows the display and operating element during specification of the total quantity of a formula,
[0017] [0017]FIG. 5 shows the display and operating element during the dosing of one component of a formula,
[0018] [0018]FIG. 6 shows the display and operating element in the case of overdosing or overfilling,
[0019] [0019]FIG. 7 shows the display and operating element in the case of overdosing in a color-mixing scale without formula memory,
[0020] [0020]FIG. 8 shows the display and operating element during the selection of letters in formula storing,
[0021] [0021]FIG. 9 shows the display and operating element during the selection of numbers for quantity specification of the components during formula storing,
[0022] [0022]FIG. 10 shows the display and operating element during an operation specifying the desired number of units for a counting scale,
[0023] [0023]FIG. 11 shows an alternative design of the display and operating element according to a second preferred embodiment of the invention, and
[0024] [0024]FIG. 12 shows another alternative design of the display and operating element according to a third preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The embodiments of the display and operating element 1 shown in FIGS. 1 - 10 have a display area or portion 2 for the display of a weighing result, a display area or portion 3 for user prompting, a rotary knob 4 on the right side, an associated acknowledgement button 5 on the left side, and other operating buttons 6 - 8 that serve, e.g., as an on/off switch, a tare button, a printer initiation, and buttons for other known functions. The entire display and operating element 1 is connected, in the example shown, by way of a support 9 , to the scale housing 10 . The entire display and operating element 1 can also be connected to the scale housing directly without the support 9 , or indirectly in known ways. The rotary knob 4 and the acknowledgement button 5 are identified as belonging together by being made in the same color. In the figures, this is indicated by the shaded background. The way they are used together when the scale is operated will be explained using the following examples.
[0026] [0026]FIG. 1 shows the display and operating element displaying a basic menu used in the selection of functions of a color-mixing scale. Only display area 3 with its three possible display images is shown in FIGS. 2 a - 2 c for explanation. A selection can be made between processing a request, searching for stored formulas, and storing a new formula. In FIGS. 1 and 2 a , the top line 11 of this selection list is identified, i.e., is highlighted, by inverting the brightness. If the rotary knob 4 is turned, this inverse representation changes to the center line 12 , as is shown in FIG. 2 b . If rotary knob 4 is turned still further, the inverse representation moves to the lower line 13 , as shown in FIG. 2 c . From the status according to FIG. 2 b , i.e., with center line 12 marked, by turning the rotary knob 4 in one direction, the user goes to the condition shown in FIGS. 1 and 2 a , i.e., with top line 11 marked, and by turning the knob in the other direction to the condition shown in FIG. 2 c , i.e., with the bottom line 13 marked.
[0027] If the acknowledgement button 5 is pressed, for example, in the condition according to FIG. 2 b , i.e., with the center line “FIND FORMULA” highlighted, this menu item is selected and will be accepted into the electronic evaluation unit in the scale and processed there. In the “FIND FORMULA” example, the list of formulas that have been stored and are available for selection will be displayed. This is shown in FIG. 3 for the example of the color-mixing scale. The various formulas are stored using an identification number and an explanatory color indicator. The illustrated embodiment allows three identification numbers to be displayed simultaneously. By turning rotary knob 4 , e.g., downward, first formula No. 255 is marked with reverse representation. By turning further in the same direction, formula No. 256 is then displayed in the bottom line 33 and marked (in this process, formula No. 255 moves into center line 32 and formula No. 254 into top line 31 ). By further turning rotary knob 4 , formula No. 257 is marked and displayed, etc. If rotary knob 4 is turned quickly, the change in formulas also occurs quickly so that it is also possible to “scroll through” a large number of formulas that are available for selection. When rotary knob 4 is turned in the opposite direction, the user “scrolls through” the formula numbers the same way in the opposite direction. If the desired formula is found in this way, it is selected by pressing the acknowledgement button 5 . If acknowledgement button 5 is pressed while formula No. 254 is marked as shown in FIG. 3, this formula will be selected and accepted into the working memory of the electronic evaluation unit and can then be processed.
[0028] Before the individual components of the selected formula are dosed, for many color mixture scales, the desired total quantity can be specified. This specification is also possible in an advantageous manner with the display and operating element according to the present embodiment as shown in FIG. 4. It is possible to “scroll through” the various total quantities, again with rotary knob 4 , and accept a selected quantity by pressing acknowledgement button 5 . In the example of FIG. 4, the quantity of 0.5 liters is selected.
[0029] Dosing of the first component of the accepted formula in the accepted total quantity is carried out with the displays shown in FIG. 5. Display field 3 indicates the component with its abbreviated form B141 and the specified quantity of 168.8 g. The specified quantity is also displayed at first in the display field 2 , with a negative sign; during measurement this display changes according to the quantity dosed in and reaches the display value 0.0 g when the specified value has been reached. This method of dosing in toward zero is generally known and, therefore, does not need to be explained in detail here.
[0030] [0030]FIG. 6 shows the case of an overdosing or overfilling by 0.8 g as an example. In display unit 3 , at first the fact of overfilling is displayed in top line 61 . Below this, a decision by the user is requested in lines 62 and 63 of whether a recalculation should be carried out or not. This decision is made again by turning the rotary knob 4 and actuating acknowledgement button 5 . In the example shown, “RECALCULATION” is set and can be input or accepted by pressing acknowledgement button 5 . The scale's electronic evaluation unit then accepts the overfilling of 0.8 g, calculates the quantities to be added in for the components that were already dosed in, and displays these (as shown in FIG. 5 but with the note “RECALCULATION”).
[0031] However, the display and operating element according to the invention can also be advantageously used in color-mixing scales without a formula memory installed, as known from U.S. Pat. No. 5,847,328 that has already been mentioned above. In these scales, the specified amounts for the individual components are not stored in the scale or in a connected data processor, but rather, the user works directly, e.g., from a paper document. Assignment of the specified value with a negative sign, as shown in FIG. 5, is thus not possible and/or would have to be input manually first. Therefore, in these scales, the dosing starts from 0.0 g and goes to the specified value. If a scale value of 122.0 g is then reached, as shown in FIG. 7 in display area 2 , and this value is the correct specified value, line 71 “OK” is selected by turning rotary knob 4 and pressing the acknowledgement button 5 , thus, inputting the correct value. However, if the desired value is, e.g., 121.0 g, the component is overdosed by 1.0 g. Then “RECALCULATION” is selected in display area 3 by turning rotary knob 4 , as shown, and the recalculation is initiated by pressing the acknowledgement button 5 . During the recalculation, the scale result of 122.0 g is first accepted in display area 3 , reset to 121.0 g by turning rotary knob 4 , and this value is sent to the electronic evaluation unit as the correct specified value by pressing acknowledgement button 5 . The evaluation unit then calculates the overfilling by comparing of the specified value in display area 3 to the actual value in display area 2 , and from this the necessary re-measurement of the components that have already been added and the necessary adjustments for the other components of the formula can be determined. Reference is made to the incorporated U.S. Pat. No. 5,847,328, mentioned above, with regard to the details of this correction procedure.
[0032] The display and operating element is also useful in storing new formulas in a scale with formula memory. FIG. 8 shows the selection of letters. The correct letter is selected by turning the rotary knob 4 . In this process, the series of letters displayed shifts automatically, as soon as the letter N is reached and the rotary knob continues to be turned in the same direction. If the acknowledgement button 5 is pressed with the display status according to FIG. 8, the selected letter W will be accepted into the upper line 81 of the upper display area 3 and added after the letter V. Selection of other letters then occurs in the same manner.
[0033] [0033]FIG. 9 shows the input of the specified value of a component in a corresponding manner. If acknowledgement button 5 is pressed with the display status according to FIG. 9, the selected number 2 is accepted in the top line 91 the of display area 3 in the one's place. Then the next number will be selected by turning the rotary knob 4 and the first place after the decimal will be accepted by pressing the acknowledgement button 5 . For round values, e.g., 100.0 g, the successive zeroes can then be taken over very quickly by pressing acknowledgement button 5 several times.
[0034] [0034]FIG. 10 shows the selection of the desired quantity of items for a counting scale. The number selected by turning rotary knob 4 is not indicated by an inverse representation in this example, but rather by an arrow 99 . When rotary knob 4 is turned, this arrow moves to the left or the right depending on the direction of rotation. Acceptance into the electronic evaluation unit of the scale again is carried out by pressing acknowledgement button 5 .
[0035] The examples described above for advantageous use of a rotary knob as an adjustment/selection element and an associated acknowledgement button for scales are naturally only representative of the possible application areas. Further examples, like the selection of various baud rates, the setting of standstill parameters, the selection of various dimensional units, the selection of the random sample size during final packaging inspections, input of article numbers, specification and feedback of identification numbers in repeat weighing, parameter specification in the scope of a personal menu, etc., can easily be added.
[0036] In the preceding, rotary knob 4 and acknowledgement button 5 have always been shown as separate components. However, it is possible to combine the functionality of both into one module. This is shown by way of example in FIGS. 11 and 12. In FIG. 11, rotary knob 100 can be turned and pressed in axially as is indicated by arrows 104 and 105 . After the rotary knob is turned, a separate acknowledgement button will not be actuated, rather the rotary knob is pressed in and the acknowledgement signal is thus generated. Because of this, the selection and acceptance procedure can be accomplished with one hand. The procedure is otherwise preferably identical to the examples above. In FIG. 12, the acknowledgement button 115 is integrated into the side surface of the rotary knob 110 . Again, one-hand operation is possible.
[0037] The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.
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A display and operating element ( 1 ) for an electronic scale with a display area ( 2, 3 ) in which the weighing results and values, parameters or selection lists can be displayed for user prompting either separated spatially or in succession over time, and having at least one button ( 6 - 8 ) for operating the scale. The display and operating element ( 1 ) has a rotary knob ( 4 ) on one side that turns in both directions to cause the values, parameters or marked areas of the selection list displayed in the display area ( 3 ) to change in one or the other direction. A button ( 5 ) is assigned to the rotary knob ( 4 ) as an acknowledgement button. Operation of this acknowledgement button ( 5 ) causes the value, parameter and marked area of the selection list selected using the rotary knob ( 4 ) to be accepted into the electronic evaluation unit of the scale. Accordingly, simple and fast setting of values and/or parameters and a fast selection of a specific item from a selection list can be achieved.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to devices and apparatus for providing personal protection from the weather elements, namely sun, rain and wind, and more particularly to a retractable personal canopy apparatus for an individual which is connectable to a separate support structure and having uniquely configured features thereof.
2. Description of Related Art
For those who work and play in the outdoors, whether hunting, fishing, boating, stadium watching, camping, beach going, farming, gardening, relaxing and the like, where the activity places the individual in a situation where the elements of weather such as excessive sunlight, wind and rain, or the presence of insects, cause an individual discomfort and/or impose excessively adverse weather or environmental conditions, a broad array of inventions have been developed to offer various levels of protection from those conditions. The following U.S. and foreign patents are known to applicant which represent a broad array of such devices and apparatus for providing physical comfort when individuals are subjected to the elements of nature:
U.S. Pat. No. 4,836,232 to De Rosa U.S. Pat. No. 6,244,286 to Russo U.S. Pat. No. 5,255,954 to Rogers U.S. Pat. No. 4,809,724 to Fuser U.S. Pat. No. 4,915,120 to Ziolkowski U.S. Pat. No. 5,203,363 to Kidwell U.S. Pat. No. 5,215,109 to Kent, Jr. U.S. Pat. No. 5,240,020 to Byers U.S. Pat. No. 4,781,411 to Kolb U.S. Pat. No. 4,433,699 to Schultes U.S. Pat. No. 6,422,252 to Pilz U.S. Pat. No. 3,032,046 to Coonradt U.S. Pat. No. 4,389,057 to Richard, Jr. U.S. Pat. No. 5,932,258 to Francois U.S. Pat. No. 4,440,187 to Fiddler U.S. Pat. No. D378,540 to Becker U.S. Pat. No. 3,007,735 to Cohn U.S. Pat. No. 4,086,931 to Hall U.S. Pat. No. 3,890,989 to Kuxhouse U.S. Pat. No. 4,069,833 to Johansson U.S. Pat. No. 5,263,505 to Yeom U.S. Pat. No. 6,296,002 to Tashchyan U.S. Pat. No. 5,937,882 to Harbaugh U.S. Pat. No. 5,937,881 to Villa U.S. Pat. No. 5,806,547 to Derlinga U.S. Pat. No. 5,320,405 to Foster U.S. Pat. No. 5,102,190 to Akin U.S. Pat. No. 4,865,381 to Van Rogue U.S. Pat. No. 5,873,625 to Uchtman U.S. Pat. No. 5,797,650 to Gonzalez, Jr. U.S. Pat. No. 5,579,797 to Rogers U.S. Pat. No. 6,116,256 to Pawsey U.S. Pat. No. Des. 399,367 to Sieland U.S. Pat. No. 5,135,281 to Pappalardo U.S. Pat. No. 5,441,067 to James U.S. Pat. No. 4,930,838 to Brabant U.S. Pat. No. 5,638,849 to Scott DE3536049A1 to Fantasia GmbH FR1250940A to Glatz GB2216850A to Balurn Limited
A number of these prior art disclosures are somewhat more related to the present invention. For example, the Pilz '252 patent discloses a sun protection device with a fan-like sunshade coupled to a support pole via a pivotal joint.
In the '046 patent, Coonradt discloses a collapsible awning for use on small boats, one of the applicant's targeted modes of use for the present invention. However, Coonradt teaches that the awning panel has edge flaps and wraps around a frame and secured by fasteners thereto. A separate clamp is used to attached the Coonradt device to a gunnel of a small boat.
Schultes, in the '699 patent and Johansson in the '833 patent also discloses sunshade frames which are retractable from a semi-circular shape to a compact pole-like shape.
Kolb in U.S. Pat. No. '411 also discloses a portable sunshield constructed of PVC piping for quick attachment to a bracket assembly of a fisherman's chair. In U.S. Pat. No. '020, Byers, teaches a retractable fisherman's sunshade wherein, when the fisherman stands up to stretch or to reel in a fish, the sunshade will automatically pivot upwardly out of the way of the head and shoulders of the fisherman.
The weather shelter invented by Kent in U.S. Pat. No. '109 teaches a weather shelter having a multi-positional placement adjustment and formed of an arcuate lightweight framework over which a flexible cover is stretched and anchored. A portable canopy attachment invented by Kidwell in U.S. Pat. No. '363 also teaches a portable device insertable into the ground and having a horizontally extendable canopy member for sun and rain protection.
In U.S. Pat. No. '724, Fuser teaches a sunshade holder uniquely attachable to the side margins of the back of a lawn or beach-type chair for weight economy and simplicity. Another sunshade umbrella connectable to the back of a chair is taught by Rogers in U.S. Pat. No. '954. The unique arrangement for interconnection to the back of the seat in conjunction with a conventionally configured umbrella provides a simplistic shade structure for a user positioned on the seat.
A collapsible canopy device by Russo in U.S. Pat. No. '286 includes an arcuate telescoping support member positioned at each side margin of a protective canopy utilized, for example, at an outdoor football game. A fold-up umbrella by De Rosa in U.S. Pat. No. '232 teaches an umbrella with a telescoping tubular standard centrally positioning a flexible cover made of panels arranged in a circular pattern. The angle between each radially extending rib or batten is variable so as to regulate the size of the umbrella pattern.
The present invention provides a personal canopy apparatus for protecting an individual from the elements while in a seated or a standing position and offering a uniquely deployable two section canopy which is supported and pivotally extendable in radial or fan-like fashion from the forward distal end of the top spine of the device. By a unique arrangement of pivotal axes, a broad array of protective orientation for the user is achievable.
BRIEF SUMMARY OF THE INVENTION
This invention is directed to a personal canopy apparatus for an individual or individuals which is connectable to a separate structure enabling its use in a variety of applications, including that found in a boat. The canopy apparatus includes a main spine connectable at a lower end thereof to the separate structure, a top spine pivotally connected in a generally laterally extending orientation to an upper end of said main spine and a retractable canopy. The canopy includes two flexible covers each supported along a proximal edge thereof by said top spine. A leading edge support arm and a plurality of battens are supportively connected to each of the covers, support arms and battens pivot connected at a proximal end thereof about one of two closely spaced third pivotal axes to a distal end of the top spine whereby, when each of the covers are open in a fan-like manner, the support arms extend laterally in opposite directions from the top spine to form a leading edge of the canopy with the battens arranged in a spaced apart array radiating from the third pivotal axis. The support arms, covers and battens are stored in closely aligned fashion within a substantially hollow length of said top spine.
It is therefore an object of this invention to provide a personal canopy apparatus offering various levels of comfort and protection which will protect the user in a seated or standing position from the elements of sun, wind and rain or insects without substantially interfering with outdoor activity such as in fishing from a boat.
It is another object of this invention to provide a uniquely configured arrangement of main spine and top spine pivotally connected together and supporting a fan-like deployable canopy section from either one or both sides of the top spine for added versatility. Attachable back, side and front panels offer additional levels of comfort, cover and protection.
Still another object of this invention is to provide a personal canopy which includes attachable side, back and front panels which afford additional levels of comfort, cover and protection.
A unique arrangement of pivotal axes of a personal canopy apparatus of the present invention satisfies yet another object of this invention by greatly expanding the positional versatility and adjustability through multiple pivotal axes between respective spine members and attaching member for greater weather protection.
Another object of the canopy apparatus is to be compact, taking up minimal space when not deployed and portable to be taken off particular separate structure and stored or used in another application by attaching to a different structure.
Still another objective is to minimize the wind resistance to enable use in windy conditions or while moving.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
FIG. 1 is a front perspective view of the invention in its deployed in-use position.
FIG. 2 is another front perspective view of the invention shown in FIG. 1 .
FIG. 3 is a rear perspective view of the invention of FIG. 1 .
FIG. 4 is still another front perspective view of the invention of FIG. 1 wherein only one half of the retractable canopy is in the in-use position.
FIG. 5 is a side elevation view of the invention of FIG. 1 showing the canopy in a tilted position.
FIG. 6A is a side elevation view of the invention of FIG. 1 in an extended height position of the canopy.
FIG. 6B is a view similar to FIG. 6A showing the canopy in a more lowered retracted position.
FIG. 7 is a perspective view of the locking arrangement associated with the upright main spine of the invention.
FIG. 8 is a rear perspective view of the invention of FIG. 1 with the canopy fully stored in the top spine which is in a folded non-use position against the main spine.
FIG. 9 is an enlarged perspective view of a lower portion of the main and top spine of FIG. 8 .
FIG. 10 is a top plan schematic view of the canopy and top spine of the invention.
FIG. 11 is a perspective view of another embodiment of the invention.
FIG. 12 is a front elevation view of an upright partially transparent protective front panel attachable to the apparatus of FIG. 1 and FIG. 11 .
FIGS. 13A to 13 E depict side elevation views of various configurations of use of the invention.
FIG. 14 is an enlarged perspective view of the distal end portion of the top spine of the invention with the top end cover removed for clarity.
FIG. 15 is a view similar to FIG. 14 with the top end cover and upper tensioning knob in place.
FIG. 16 is a perspective view of the distal end portion of the top spine channel member.
FIG. 17 is an exploded view of the pivotal attachment of the leading edge support arm and radially extending battens about one of the pivotal axes positioned at the distal end portion of the main spine.
FIGS. 18A , 18 B, and 18 C depict various modes of attaching the device to a separate support structure.
FIG. 19 a perspective view of a lower attaching bracket attachable to a gunnel bench seat, console of a boat, pedestal boat seat, railing or other types of structures of a boat.
FIG. 20 is an enlarged perspective view of the floor attachment of FIG. 18 B.
FIG. 21 is a perspective view of another embodiment of the invention.
FIG. 22 is a perspective view of still another embodiment of the invention.
FIG. 23 is a perspective view of yet another embodiment of the invention.
FIG. 24 is a perspective view of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, and particularly to FIGS. 1 to 5 , a preferred embodiment of the invention is there shown generally at numeral 10 . This personal canopy apparatus 10 which, in this case, is sized for use by an individual but may also be up-scaled for two or more individuals and includes an elongated rigid top spine 12 , an elongated rigid upright spine 16 and a canopy 14 . The upright or main spine 16 is formed of two telescoping members 26 and 28 which facilitate vertical telescopic height positioning of the canopy 14 and top spine 12 as will be described herebelow.
The lower main spine member 28 is pivotally releasably attached along axis 76 to the base of a swivel seat S by a universal mount 18 which is attachable to the upper pedestal support P of the boat seat S having a back B and a seating panel or support C. The upper end portion of the main spine 16 is interconnected to a proximal end of the top spine 12 by a pivotal tilt connection arrangement 22 . This tilt connection 22 has a pivotal axis 74 which is oriented at an acute angle to the main spine 16 and the top spine 12 .
As best seen in FIG. 8 , the tilt connection 22 includes mating connector halves 23 and 25 connected together at the proximal ends of the upper member 26 and the top member 24 of the main spine 16 and top spine 12 , respectively. A tensioning knob 27 provides loosening of this pivotal joint 22 for the angular adjustment of the top spine 12 about the axis 74 which is then resecured by tightening the knob 27 . Features of this tilt connection 22 will be described in more detail herebelow.
In this preferred embodiment 10 , the top spine 12 extends, when adjusted about axis 76 of the main spine 16 as shown, generally forwardly from the tilt connection 22 . The forward or distal end of the top spine 12 terminates in a canopy support mechanism 20 . The retractable canopy 14 is comprised of two flexible water tight or water resistant covers 66 and 68 which are deployable and retractable about pivotal axes 70 and 72 as seen in FIGS. 2 and 4 and described in more detail as best seen in FIG. 10 . Each of the flexible covers 66 and 68 are supported at a leading edge thereof by a leading edge support arm 34 each of which is pivotally connected at a proximal end thereof to the respective pivotal axis 70 or 72 . A plurality of evenly spaced battens 48 , each sewn into or concealed within covering layer portions of each of the covers 66 and 68 , are also pivotally connected at a proximal end thereof about axes 70 and 72 and radiate outwardly therefrom in fan-like fashion as each of the flexible covers 66 and 68 are opened in the direction of arrows G and H, respectively.
As seen in FIG. 4 , only one of the flexible covers 66 in this case or 68 , may be separately deployed with the other flexible cover 68 held in a stored configuration within the top spine member 24 as will be described herebelow. Moreover, as seen in FIG. 5 , the entire canopy 14 may be oriented to one side or the other as pivotally adjusted about pivotal axis 74 where wind or sun protection from that direction is desired.
As seen in FIGS. 6A and 6B , the telescoping features of the upright spine 14 are there shown wherein the upper spine member 26 may be moved downwardly in the direction of arrow D and then resecured by locking collar 30 by locking handle 32 as seen in FIG. 7 to secure the desired telescopic relationship. By this arrangement, the height of the canopy 14 and top spine 12 are easily adjustable vertically without sacrificing protective overhang forwardly of the user seated in the swivel boat seat S.
In FIGS. 8 and 9 , the canopy 14 has been stored within the top spine 12 in a manner described herebelow and pivotally connected about axis 74 into a stored position generally alongside of the main spine 26 and there locked in place by the suitable tensioning of knob 27 .
As will be more fully appreciated at this point in the description of the present invention, there are substantial benefits to forming each of the main and top spines 16 and 12 , respectively into the arcuate configuration shown. The clearance with the back B of the swivel seat S by this arcuate configuration allows the main spine mount 18 to be shorter and thus closer to the base of pedestal P, additional head clearance is provided beneath the arched configuration of the center of top spine 12 and the unique side protection offered as shown in FIG. 5 when the entire canopy 14 is pivoted about axis 74 is easily achievable.
Canopy and Canopy Support
Referring now to FIGS. 14 to 17 , the details of the canopy support assembly 20 and canopy storage arrangement within the top spine member 24 of the top spine 12 are there shown. As best seen in FIGS. 14 and 16 , the elongated top spine member 24 , generally formed by metal or plastic extrusion, includes upright strengthening webs extending centrally therealong and storage cavities 58 which are accessible by side access slots 56 formed along either side portion of this elongated oval shaped section configuration. Each rigid leading edge support arm 34 , interconnected by a plastic molded coupling 64 of a mounting boss 36 or 36 ′, is mounted about one of the pivotal axis 70 or 72 . A support shaft 40 in alignment with each of the pivotal axes 70 and 72 provide the support for rotation only of each of the mounting bosses 36 and support arms 34 .
Variable tensioning of the pivoting movement effort of each of the leading edge support arms 34 in the direction of arrows G and H in FIG. 10 is regulated by the tensioning produced by rotation of tensioning knobs 42 and 60 in the direction of arrow L. The elongated threaded fastener 44 acting on threaded boss 46 against a tensioning plate 38 urges each of the mounting bosses 36 against a compression spring 53 and spacer 54 shown in FIG. 17 .
Each of the battens 48 are also mounted about the corresponding pivot shaft 40 and are pivotal about the corresponding pivotal axes 70 or 72 . The proximal end 50 of each batten 48 is looped as best seen in FIG. 17 and mounted between the mounting boss 36 and the spacer 54 . Again, by tensioning knobs 42 and 60 , the compressive force exerted on the mounting boss 36 and the looped proximal ends 50 of each of the battens 48 regulate the ease with which each of the canopy portions is deployable and storable.
As best seen in FIGS. 14 and 15 , the storage cavities 58 accessible via longitudinal slots 56 provide for the easy storage of the battens 48 , cover 66 or 68 (not shown for clarity) and leading edge support arm 34 of each canopy half. Likewise, deployment is effected by simply pivotally moving the leading edge support arm 34 out from the cavity 58 through the corresponding longitudinal access slot 56 as seen in FIG. 14 . Once each of the leading edge support arms 34 are individually fully deployed in the direction of arrows G and H in FIG. 10 to fully tension each of the flexible covers 66 and 68 , respectively, the mating tensioning knobs 42 and 60 best seen in FIG. 15 are then utilized to provide adequate tension to hold the leading edge support arms 34 in the forwardly deployed position.
Referring now to FIGS. 11 to 13 , various additional panel options and apparatus positioning are there described. In FIGS. 11 and 12 , two alternate embodiments of a front screen positionable in front of the user for wind and sun protection are there shown at 90 and 100 , respectively. In FIG. 11 , the front screen 99 , which attaches along the leading edge of canopy 14 as by zipper or VELCRO along 94 , includes a large flexible transparent area 92 . The front screen 100 in FIG. 12 also includes a zipper 104 for attachment to the leading edge of the canopy and tie straps 106 (or zippers or VELCRO) which facilitate attachment to a lower rear panel 96 which is separately attached to the rearward margin of the canopy 14 . Wind slits 108 formed as arcuate cuts in the lower portion of this front panel 100 reduce wind load while also maintaining reasonable protection against driving rain.
In FIGS. 13A to 13 E, various positions and protective panel accessories are there shown. In FIG. 13A , the invention 10 is shown in its stored position with the top spine 12 in the stored position adjacent to the main spine 16 as previously described. In FIG. 13B , the entire apparatus 10 is moved rearwardly in the direction of arrow J by mount assembly 18 with respect to pedestal P of swivel seat S.
In FIG. 13C , the addition of the front protective panel 90 of FIG. 11 and the side protective panel 96 attached along a trailing edge of the canopy 14 as shown in FIG. 11 are depicted. In FIG. 13D , a transparent side panel 95 is there shown while in FIG. 13E , the substantial pivotal movement about axis 76 in the direction of arrow K of the entire device 10 is there shown which provides for weather protection from the rear or back side of the user when the canopy 14 is deployed and also shows an alternate stored position of the device 10 when the canopy is fully stored within the top spine 12 .
Referring now to FIGS. 18 , 19 and 20 , various embodiments of the means for attaching the device 10 to various support structures are there shown. In FIG. 18A , the previously described swivel seat mount bracket 18 is there shown attached to a boat swivel seat S while in FIG. 18B , a floor bracket 82 into which the lower end 80 of the main spine 16 is releasably connectable. The floor mounting bracket 82 shown in FIG. 20 includes a cavity 84 for receiving the mating lower end 80 of the main spine 16 and is attachable by flanges and attaching fasteners (not shown) to the deck of, for example, a boat, dock or outdoor deck. Slots 88 receive the molded lower end 80 of the main spine 16 as earlier described in FIG. 9 after which tensioning handle 78 secures this arrangement for later quick release.
In FIG. 18C , the canopy apparatus 10 is shown connected at the lower end 80 of the main spine 16 to a butt seat R which is typically found on a fishing boat and the like. In FIG. 19 , a mounting bracket 110 is there shown which provides cavity 112 and slots 114 for releasable interconnection of the molded lower end 80 of the main spine 16 . This bracket embodiment 110 is connectable by orthogonally oriented flanges 116 to, for example, the gunnel of a boat, a bench-type seat and the like.
Referring now to FIGS. 21 to 24 , several additional embodiments of the invention are there shown. All of these embodiments include the canopy apparatus 10 as previously described.
In FIG. 21 , this embodiment 120 also includes a relatively short in height wrap-around side and back panel protector 122 . This protector 122 includes side panels 124 and 128 and a rear panel 126 all of which are attached by zipper, VELCRO or snaps along the side and back margins 123 of the canopy apparatus 10 .
The embodiment 130 in FIG. 22 , includes an elongated side and back protector shown generally at 132 which also includes two front panel protectors 134 and 136 which are separable along a vertical separation line 138 by zipper, VELCRO or snaps. Again, this embodiment 130 includes conventional connectors of snaps, VELCRO or zipper along the leading edge 142 and the side and rear margins of the canopy apparatus 10 .
In FIG. 23 , this embodiment 150 again includes the canopy apparatus 10 as previously described, the protector panel arrangement 132 as described in FIG. 22 , and a lower protector 152 which includes side and back panels 162 along with front panels 154 and 156 which are separate releasably connectable along vertical separation line 158 . This lower protector 152 is attached along 160 by zipper, VELCRO or snaps. The length of the lower protector 152 is such as not to extend to the ground or support surface M but rather to leave a gap therebetween for air movement and circulation.
In the embodiment 170 shown in FIG. 24 , the lower protector panel 152 as previously described with respect to FIG. 23 has been extended by ground panel 172 which releasably attaches along 180 to the lower protector 152 . This ground protector extends down to the ground or support surface M having a side and back panel 182 and front panels 174 and 176 which are weighted at their lower margins for establishing and maintaining contact with support surface M. The front panels 176 and 178 are separable along vertical line of separation 178 by zipper, VELCRO or snaps.
All of these embodiments 120 , 130 , 150 and 180 may have these side, back and front panel additions fabricated of either flexible woven material or may alternately be formed of screen material for enhanced circulation. With respect to the embodiment 170 shown in FIG. 24 , the screen or material being utilized will also render this embodiment 170 to be relatively insect-free.
While the instant invention has been shown and described herein in what are conceived to be the most practical and preferred embodiments, it is recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be afforded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.
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A personal canopy apparatus connectable to a separate structure. The canopy apparatus includes a main spine connectable to the separate structure, a top spine pivotally connected in a generally forwardly extending orientation to an upper end of said main spine, and a retractable canopy. The canopy includes two flexible covers each supported along a proximal edge by the top spine. A leading edge support arm and battens are supportively connected to each of the covers and are pivotally connected at a proximal end about one of two closely spaced third pivotal axes at a distal end of the top spine. When each of the covers are open in a fan-like manner, the support arms extend laterally in opposite directions from the top spine to form a leading edge of the canopy. The support arms, covers and battens are stored in closely aligned fashion within a substantially hollow length of said top spine.
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FIELD OF THE INVENTION
This invention relates to electronic test and measurement instruments and more particularly to computerized control of such measurement instruments. Even more particularly, the invention relates to compiling an instrument control language to improve performance in a computer controlled test system.
BACKGROUND OF THE INVENTION
Many types of electronic test instruments can be controlled from a computer to create a computerized test system. The control of these instruments is accomplished by sending the instruments commands which consist of characters, typically in the ASCII character set. The command characters form words which are understandable by engineers and programmers in order to make the programming of the instruments easier.
In an automated test system, the instrument commands are embedded within the programming statements of a conventional programming language used to create test software. The conventional programming language statements may be compiled or interpreted, however, the instrument commands remain in their original, human readable form as character strings within the resulting test software. During processing of the test software, these character strings are sent to an instrument to cause it to perform some test function, and the results, usually in character string form, are returned to the test software.
When programmability was first introduced into test and measurement instruments, the instrument commands were cryptic and often the data sent and received from the instrument was in a computer readable, binary, form, rather that in a displayable format such as ASCII. This binary form, however, was difficult to read and interpret by the test design engineer, so a more readable, character oriented, form was adopted.
In order to use the character oriented form, however, the program commands and data must be parsed by the instrument and converted into a machine usable form. Also, after an instrument performs the requested function, any resulting data contained in the instrument would be converted back into a character oriented form before it is returned to the computer that requested the operation. When the test software in the computer must process this resulting data, rather than simply display it to a user, the data must be re-converted back into a machine usable form before the processing can be performed.
While all this parsing, conversion and re-conversion takes processing time, and thus degrades the performance of the test system, it has been considered necessary in order to allow the commands and data to remain in a human readable form.
In a typical test environment, many instrument operations are repeated over a long period of time. Thus each time an operation is performed, the program command interpretation and the data conversion must be repeated for each operation. For example if an instrument is programmed to take several thousand measurements--a very common occurrence--the measurement command and resulting data would be interpreted and converted several thousand times.
Often instruments are connected over a serial interface, such as RS-232, or an instrument bus, such as the IEEE 488 bus. Because of the speed of these busses, instrument performance is significantly affected by the amount of data interchanged with an instrument. Although human readable ASCII characters improve the ability to understand the commands and data, performance is limited by interchanging commands and data in this format.
There is need in the art then for a system that can reduce the time needed to perform an operation, while maintaining the human readability of the instrument programming commands and data. Another need in the art is for a system that improves the efficiency of moving information from the computer system to and from the instrument. A further need is for a system that avoids command interpretation and data conversion of each command sent to an instrument. A still further need is for such a system to avoid converting data that is sent from an instrument back to a computerized test system. The present invention meets these and other needs.
SUMMARY OF THE INVENTION
It is an aspect of the present invention to compile the statements of an instrument control language, along with the conventional programming language statements of test software, prior to execution of the statements.
It is another aspect of the invention to compile the Standard Commands for Programmable Instruments language.
Another aspect of the invention is to compile the commands in a manner that allows all parameter information to be passed to an instrument driver in a single data structure.
Another aspect of the invention is to compile the commands in a manner that allows the each parameter passed to have an associated type specification.
Another aspect of the invention is to compile the commands in a manner that allows the each parameter to be passed in a character array, regardless of the actual format of the parameter data.
A further aspect is to optimize the compiled code during the compilation process.
The above and other aspects of the invention are accomplished in a system which compiles instrument commands and data into a machine usable form at the same time that the conventional programming language statements of the test software containing the instrument commands is compiled. The compiled instrument commands then sent to the instrument are significantly smaller than the original human readable instrument commands comprising ASCII characters. Since the compiled commands are already in machine usable form, there is no need to parse the commands in the instrument thus improving instrument performance. Because of the compilation of the commands, the data associated with the commands is also placed in machine usable form, which is smaller than the human readable form, so less time is required to send and receive data from the instrument.
During the compilation process, all parameter data being sent to an instrument is placed into a single data structure, which reduces the number of parameters passed between the test software and any device drivers used to access the instrument. Also, data returned from the instrument is placed in a single data structure.
Each parameter stored in the data structure is stored in an area defined with a single format, and the actual format of the data is defined in a type parameter associated with the parameter. This provides for efficiency in moving data to and from an instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other aspects, features, and advantages of the invention will be better understood by reading the following more particular description of the invention, presented in conjunction with the following drawings, wherein:
FIG. 1 shows a block diagram of a computer system incorporating the present invention;
FIG. 2 shows a diagram of a prior art method of performing programmed test instrument commands;
FIG. 3 shows a diagram of the present method of performing programmed test instrument commands; and
FIG. 4 shows a data flow diagram of the compiler of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best presently contemplated mode of carrying out the present invention. This description is not to be taken in a limiting sense but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined by referencing the appended claims.
FIG. 1 shows a block diagram of a computer system incorporating the present invention. Referring now to FIG. 1, a computer system 100 contains a processing element 102 which processes the instructions created by the present invention. The processing element 102 communicates to other elements of the computer system 100 over a system bus 104. A keyboard 106 is used by the user of the system to input information to the computer system 100, and a display 108 is used by the computer system 100 to output information to the user. A disk 112 is used to store the software and data of the present invention. A memory 116 attached to the system bus 104 contains an operating system 122, the compiler 126 of the present invention, and test software 124 created by the compiler 126.
Electronic test and measurement instruments may be connected to the computer system 100 in several different ways. For example, internal instrument 110 may be connected directly to the system bus 104 of the computer system 100. As will be described below, a command module 128 may or may not be needed to connect the instrument card 130 to the system. When connected directly to the system bus, data and command registers on the internal instrument 110 can be directly read and written to by instructions processed by the processing element 102.
An electronic instrument can also be connected over a standard instrument bus, for example external instrument 120 is connected over an IEEE 488 bus 118 to an IEEE 488 interface card 114 which in turn connects to the system bus 104. To access external instrument 120, software in the memory 116 must send data through the interface 114 over the instrument bus 118 to the instrument 120. Conversely, any data received from the external instrument 120 must also traverse the bus 118 through the interface 114 and into memory 116. When connected in this manner, all information sent to the external instrument 120 and received from the external instrument 120 must be sent or received through the bus 118. Thus, connecting an instrument over a bus, such as the bus 118, prevents any direct access to the registers within an instrument.
Although not shown in FIG. 1, an external instrument could also be connected through a common serial interface, such as RS-232.
In order to program the internal instrument 110 or external instrument 120, a user enters programming commands through the keyboard 106 using a conventional text editor. These commands are then stored on the disk 112 and used to cause the instrument 110, or the instrument 120, or both, to perform the desired functions. The present invention provides an improved method of setting up and performing the commands stored on the disk 112.
FIG. 2 shows a diagram of a prior art method of performing the programmed test instrument commands stored on the disk 112 of FIG. 1. Referring now to FIG. 2, the programmed test instrument commands, identified here as an SCPI user program 202 are input into the computer system 100. SCPI is an acronym for Standard Commands for Programmable Instruments, and is published by the SCPI Consortium as an industry wide definition of commands to be used with all programmable test instruments. Once the commands from the user program 202 are input into the computer system 100 they are processed by the test software 204 and passed by I/O library 206 to the instrument which performs the actions requested. Before passing the commands to the instrument, library 206 calls a number builder module 207 to transform numbers from the internal computer format to an ASCII format. Library 206 then sends the commands, in the form of ASCII characters, to a device driver module 208. ASCII characters are used in order to improve readability of the program test instrument commands. As discussed in the background section above, when test instruments were first made programmable, they used a more cryptic, machine oriented, command set. This was difficult for programmers to use, because of very low association between the machine oriented commands and conventional test terminology. As programmable test instruments developed, the commands sent to the instrument became more symbolic, thus improving the readability of the commands being sent to the test instruments at the expense of execution time.
I/O Library 206 sends the ASCII commands to the device driver module 208 which then sends the ASCII to the instrument device driver 210 in the SCPI Command Module. As discussed above with respect to FIG. 1, the connection between the device driver 208 and the instrument driver 210 may be over the system bus 104, or it may be through the IEEE 488 interface 114 and instrument bus 118 to the instrument 120. In either case, the ASCII commands arrive in the command module 128 at the instrument driver 210 and are sent to the SCPI parser module 212. Because the commands are in an ASCII, readable, format, they must be parsed and converted into a machine format before the command can actually be performed. In the process of this conversion, an additional module called the number builder 214 is used to change the format of any numbers in the commands into a binary format for use by the machine. After the commands have been parsed and converted to machine instructions, they are sent to a card driver module 216 which activates an electronic instrument card 130 to perform the measurements.
Data returning from the instrument card 130 is sent to an SCPI parser 220 in order to convert this data back into an ASCII, readable, format to be sent back to the computer system 100. In order to convert the machine data back into an ASCII format, the SCPI parser 220 often uses a number builder 222 to convert all numbers from binary format into ASCII format. After the data has been converted back to an ASCII format, it is sent to an instrument driver 224 which in turn sends the data over the interface to the device driver 226 in the computer system 100. The device driver 226 sends the data to an I/O Library 228 and a number builder 230 where it is re-converted back into machine oriented form to be processed by the test software 204 contained in the computer system 100.
Thus, in the prior art, human readable commands are sent to the instrument where they must be parsed and converted to a machine readable form, processed, converted back to a human readable ASCII form, and sent back to the computer system. After arriving back in the computer system, before the data from the instrument can actually be processed, the numbers must be re-converted back into a machine oriented form within the computer system 100. Furthermore, if a test is run multiple times, all this conversion is repeated each time the test is run.
FIG. 3 shows a diagram of the present method of performing the program test instruments commands to an internally connected instrument such as instrument 110 of FIG. 1. Referring now to FIG. 3, in the present invention, the SCPI user program 202 is sent to the SCPI compiler 126 of the present invention. The commands within the SCPI user program 202 are identical to the commands used in the prior art method, thus, the commands are still in a very human readable form. In the present invention, however, the commands are converted by the SCPI compiler 126 (also shown in FIG. 1) prior to any processing of those commands by the computer system 100. This conversion is performed only one time, regardless of the number of times the test will be run with the programmable test instrument. After the compiler 126 has converted the commands into a machine usable form, the computer system 100 then executes the commands as part of the test software 302. Because these commands are already in a machine usable form, the commands can be sent directly to the card driver 304, which performs the same functions as the card driver 216 (FIG. 2). There is no need to convert the commands to an ASCII form only to have the commands be converted back by a parser within the electronic instrument. Thus, the parser in the instrument can be eliminated. Also, as shown in FIG. 3, the driver modules, such as the device driver 208 (FIG. 2) and the instrument driver 210 (FIG. 2) are eliminated. In other embodiments of the present invention, however, the device driver and instrument drivers may be retained.
With an internally connected instrument, the card driver 304 may be incorporated into the computer system 100, as shown in FIG. 3 thus eliminating the command module shown in FIG. 2. In other embodiments, the command module could be retained.
Once the commands have arrived at the card driver 304, the card driver manipulates registers on the instrument card 130 to cause the instrument card to perform the requested operations. The instrument card then sends machine formatted data back to the card driver 304. The card driver 304 then sends this machine formatted data directly back to the computer system 100, thus bypassing the SCPI parser 220, the number builder 222, the I/O Library 228, and the number builder 230 of FIG. 2.
If the instrument is an externally connected to the computer system 100, such as external instrument 120 (FIG. 1), the device drivers and I/O library, as shown in FIG. 2, would still be needed. The Number builders shown in FIG. 2 would be eliminated. Also, a simple form of parser would still be needed in the instrument, however, this parser is significantly simpler and faster than the parsers 212 and 220 of FIG. 2. Although the savings is less for an externally connected instrument than for an internally connected instrument, a savings is still realized in using the SCPI compiler with an external instrument.
FIG. 4 shows a data flow diagram of the compiler 126 (FIG. 1) of the present invention. As described above with respect to FIG. 3, the compiler illustrated in the data flow diagram of FIG. 4 takes the SCPI user program 202 and converts it into a machine usable form within the computer system 100. Referring now to FIG. 4, the SCPI user program 202 is sent to the parse process 406 over the C -- WITH -- SCPI data flow 404. Parse process 406 removes all comments and standard computer language statements and sends these over the C -- STATEMENTS data flow 430 to the C -- WITH -- INST -- STATEMENTS file 422. Although the present invention is usable with any computer language, in the preferred embodiment the present invention is implemented as a preprocessor for the "C" and "C++" programming languages. Therefore, the parse process 406 removes all standard C and C++ statements and all standard C and C++ comments from the SCPI user program and sends these over data flow 430 to the file 422. After removing the comments, the parse process 406 searches the file for SCPI statements. When an SCPI instrument declaration statement is encountered, this statement is sent over data flow DECL -- STRUCT 424 to the PREPROC -- DECL process 408. When an SCPI instruction to send data to an instrument is encountered, parse process 406 sends this statement over the SEND -- STRUCT data flow 426 to the PREPROC -- SEND -- QUERY process 410. When an SCPI instrument query statement is encountered, parse process 406 sends this statement over the QUERY -- STRUCT data flow 428, also to the PREPROC -- SEND -- QUERY process 410. When an SCPI initialize instrument statement is found, parse process 406 sends this statement over the INIT -- STRUCT data flow 434 to the PREPROC -- INIT process 414.
When an instrument declaration statement is received by the PREPROC -- DECL process 408, this process queries the INSTR -- LIST file 418, located on the disk 112 (FIG. 1) to determine if the instrument has been defined to the system. If the instrument has been defined, the information about the instrument is retrieved by the PREPROC -- DECL process 408 and used to build a device list entry which is stored in the DEVICE -- LIST file 420. The entry in the device list file 420 includes all the information about the instrument from the INSTR -- LIST 418 as well as the address of the device. This allows the compiler to determine later whether the device is directly addressable over the system bus, for example, such as instrument 110 (FIG. 1) or whether the instrument must be addressed through an interface such as IEEE 488 interface 114 (FIG. 1). Using this information allows the compiler to later optimize the instructions that are generated for addressing this particular instrument. For example, if an instrument is directly addressable on the system bus, such as instrument 110, certain SCPI commands might be implemented as direct reads or writes to registers directly addressable on the system bus. However, if the instrument must be addressed through the IEEE 488 interface 114, these commands would have to be sent through a device driver module instead.
When the PREPROC -- INIT process 414 receives an SCPI initialization statement over data flow 434, it generates C code to call the initialization function of a device driver to initialize the instrument The generated statements are sent in the INST -- INIT data flow 444 to the C -- WITH -- INST -- STATEMENTS file 422.
SCPI initialization statements include the INST -- STARTUP statement as well as the INST -- OPEN statement described below with respect to Table 1.
When an SCPI instrument query statement is received over data flow 428, the PREPROC -- SEND -- QUERY process 410 queries the DEVICE -- LIST file 420 to get the instrument address, and a definition of the SCPI commands and expected parameters for the instrument. If the query statement parameters match the expected parameters, the PREPROC -- SEND -- QUERY process 410 generates C statements to perform the query function and sends these over the INST -- QUERY data flow 438 to the C -- WITH -- INST -- STATEMENTS file 422. When the DEVICE -- LIST file defines that access to the instrument will be through the use of driver routines, the PREPROC -- SEND -- QUERY process creates C statements to build a single data structure to pass all parameters to the driver routine, and creates C statements to build a second single data structure to return all information from the instrument. Also, the data structure for passing parameters contains a character array for each parameter as well as a type field for each parameter. Parameters may be of different types, even though they are each stored in a character array, and the type field identifies the specific parameter type to the driver routine.
The PREPROC -- SEND -- QUERY process also determines from the DEVICE -- LIST file whether the instrument can be accessed directly on the system bus. Based on this determination the PREPROC -- SEND -- QUERY process can create C statements to bypass the device drivers and access instrument registers directly through the system bus.
The data flow diagram of FIG. 4 and the description thereof occurring above are exemplary only. Other SCPI instrument statements are processed in a similar manner as described above with respect to FIG. 4. After all of the SCPI user program 202 has been processed the statements in the C -- WITH -- INST -- STATEMENTS file 422 are processed by the C compiler in the computer system 100 to generate the test software 124. After the test software 124 has been created, the user may enter commands through the keyboard 106 to execute the test software as many times as desired. Because all the human readable commands and ASCII data contained in the SCPI user program 202 have been converted to machine usable data by the compiler 126, no additional processing of ASCII information is required.
Table 1 shows an example program containing SCPI statements embedded within a "C" language program. Table 2 shows the output of the compiler 126 after processing the program of Table 1. Referring now to Table 1 and Table 2, the following will discuss the example program of Table 1 and how the compiler 126 generates the resulting statements shown in Table 2.
Lines 1 through 4 of Table 1 show "include" statements which are a part of the C programming language, so the parse process 406 (FIG. 4) copies these statements directly to the file 422, resulting in lines 1 through 4 shown in Table 2. Line 5 of Table 1 is an instrument declaration statement which is directed by the parse process 406 to the PREPROC -- DECL process 408. The word "counter" shown in line 5 of Table 1 is the name of the instrument and this name is used to build an "int" statement shown as line 5 in Table 2. The other two parameters, "E1333A" and "DIRECT" are parameters used to build the DEVICE -- LIST file 420. These parameters are also shown as a comment in line 5 of Table 2.
Lines 6, 7, and 8 of Table 1 are conventional C language statements, so the parse process 406 copies these lines directly to Table 2 where they appear as lines 6, 7, and 8.
Line 9 is a SCPI instrument start up command. This command is directed by the parse process 406 to the PREPROC -- INIT process 414 which generates a call to the OS -- INIT subroutine. This call is shown on line 9 in Table 2. Also, line 9 includes a comment with the word "STARTUP" to indicate that this line was generated from the start up command of the input file in Table 1.
Line 10 of Table 1 shows an instrument open command. This command is sent by the parse process 406 to the PREPROC -- INIT process 414. The PREPROC -- INIT process 414 generates a block of code within the C language, which is all shown on line 10 of Table 2. The block of code starts with a left brace character followed by an extern statement which identifies that a function called "E33 -- HEADER FN" is an externally defined function. The next C statement within the block calls the function "OS -- OPEN" and passes the second parameter from line 10 of Table 1 as a parameter to this function. The E33 -- HEADER -- FN function identified in the previous extern statement of Table 2 is also passed as a parameter. The results of the OS -- OPEN call are placed in the first variable of the instrument open command, counter, shown in line 10 of Table 1. The block is terminated by a right brace. Thus, considerable manipulation of the statement of Table 1 is performed in order to create the series of statements in Table 2.
Lines 11 through 14 of Table 1 are conventional C language programming statements, and these are passed directly into table 2 as lines 11 through 14.
Line 15 of Table 1 is a query statement which is used to generate lines 15 through 21 of Table 2. In line 15 of Table 2 two data structures are created. The first of these data structures, given the name "in", is used to pass information into the device driver which will be called in a subsequent statement, and the second of these data structures, called "out" is used to return information from the device driver. Within these data structures all parameters are defined as character data, even though information actually passed to the device driver may be in other formats, for example, floating point. In addition, each parameter passed into the device driver has an associated parameter type which is used to tell the device driver the actual format of the data in the parameter. Lines 16 through 19 load information from the input statement 15 of Table 1 into the "in" data structure to be passed to the device driver. Line 20 then calls the device driver to perform the query command within the instrument. Line 21 stores the results of the query into the user data area.
Lines 16 through 19 of Table 1 are conventional C language statements which are copied directly to lines 22 through 25 of Table 2.
As can be seen by the above example, the input statements of Table 1 require considerable processing to result in the statements of Table 2. Because of the method of the present invention, however, this processing is only performed once while the actual instrument query may occur many times.
Having thus described a presently preferred embodiment of the present invention, it will now be appreciated that the aspects of the invention have been fully achieved, and it will be understood by those skilled in the art that many changes in construction and circuitry and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the present invention. The disclosures and the description herein are intended to be illustrative and are not in any sense limiting of the invention, more preferably defined in scope by the following claims.
TABLE 1__________________________________________________________________________1 #include <stdlib.h>2 #include <stdio.h>3 #include <types.h>4 #include <hpsl.sub.-- types.h>5 INST.sub.-- DECL(counter, "E1333A", DIRECT);6 main( )7 {8 double counter.sub.-- reading;9 INST.sub.-- STARTUP( );10 INST.sub.-- OPEN(counter, "VXI,16");11 if (! counter) {12 (void) fprintf(stderr, "Failed to open counter card n");13 exit(1);14 }15 INST.sub.-- QUERY(counter, "MEASURE:FREQUENCY? 1000", "", &counter.sub.-- reading);16 (void) printf("The reading returned by the counter was %f17 n",- counter.sub.-- reading);18 return(0);19 }__________________________________________________________________________
TABLE 2__________________________________________________________________________1 #include <stdlib.h>2 #include <stdio.h>3 #include <types.h>4 #include <hpsl.sub.-- types.h>5 int counter; /* name E1333A, mode DIRECT */6 main( )7 {8 double counter.sub.-- reading;9 os.sub.-- init( );/* STARTUP */10 {extern E33.sub.-- header.sub.-- fn( );counter = os.sub.-- open("VXI,16",E33.sub.-- header.sub.-- fn);}11 if (! counter) {12 (void) fprintf(stderr, "Failed to open counter card n");13 exit(1);14 }15 { struct {short sub1;short p1.sub.-- type; char p1[10];short p2.sub.-- type; char p2[10];} in;struct {char p1[10];} out;16 in.sub1= 0;17 in.p1.sub.-- type= 0;((HPSL.sub.-- FLOAT64*)&in.p1)-->num= 1000;18 ((HPSL.sub.-- FLOAT64*)&in.pl)-->suffix=0;19 in.p2.sub.-- type= -1;20 {extern E33Lmeas.sub.-- freq.sub.-- qry( );if (!instr.sub.-- query(coun ter,E33Lmeas.sub.-- freq.sub. -- qry,&in,&out)){21 *&counter.sub.-- reading=(*(HPSL.sub.-- FLOAT64*)&out.p1).num;}}}22 (void) printf("The reading returned by the counter was %f n",23 counter.sub.-- reading);24 return(0);25 }__________________________________________________________________________
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Disclosed is a system which compiles instrument commands from a test instrument programming language, along with data in the commands, into a machine usable form. The machine usable instructions thus sent to the instrument are significantly smaller than the original human readable ASCII characters of the source language, and the machine usable form of the commands avoids additional parsing in the instrument. During the compilation process, all parameter data being sent to an instrument is placed into a single data structure, which reduces the number of parameters passed between the test software and any device drivers used to access the instrument.
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BACKGROUND OF THE INVENTION
In the past, felting needles have been grouped in two general types. The first type is the regular felting needle with a round, pointed end and barbs spaced at various points along the lateral edge of the blade. Such a needle is designed to interlock fibers so as to produce a felted fabric. The second type of needle is the forked needle which has two spaced-apart points and a fiber receiving slot between them for pushing fibers toward a batt. The primary function of such a needle is to embellish the surface of felted fabrics.
Patents which illustrate needles in the first group are my own U.S. Pat. Nos. 3,307,238; 3,641,636; 3,815,186; 3,844,004; and 4,156,305; and patents which illustrate needles in the second group are my own U.S. Pat. Nos. 3,727,276 and 4,110,875. The older, long-established felting needle with barbs formed in longitudinal lateral edges of the needle body have long been known, and specific terminology has become identified with such needles, such as barb angle, throat depth, kickup and throat length. Such portions of a felting needle must be held to very close tolerances to make possible the production of the desired fabric. Barb angles, with their precise forward inclination, are very critical. It is essential on the regular felting needle that the barb angle be such that engaged fibers can shed off the barb tip and be felted into the fabric. The design of the forked needle with longitudinal sidewalls adjacent the fiber-receiving slot makes shedding impossible and confines the function of the needle to the production of fiber loops and tufts.
SUMMARY OF THE INVENTION
In the present invention, in order to overcome the disadvantages of the felting needles or the tufting needles of the prior art, I provide a unique barb structure at the forward tip of the needle. This I have identified as an "open double-barb."
In one embodiment, the needle has a spatulate or wedge-shape tip, with a barb which has two forwardly-inclined barb angles diametrically opposed to each other across the centerline of the needle. The two symmetrical barb angles cooperate to provide a single fiber-engaging indentation at the leading edge of the needle.
Contrary to the ordinary barb formed in the lateral edge of a needle body, this symmetrical open double-barb with its "positive" but very slight barb angle allows the fibers to slip off to either side of the needle when the indentation is "loaded" with fibers. This clearly distinguishes from the standard barb heretofore known in the art wherein the barb with its lateral throat in the needle body prevents the fibers from slipping off with resultant damages to the fibers.
In another embodiment the barb angle can be zero degrees (i.e., at 90° to the centerline of the needle), and in a third embodiment a "negative" barb angle is provided, each of which afford even greater ability to shed the fibers and prevent fiber damage.
Because the open double-barb is formed on the tip of the needle, it always accepts fibers and thus the needle always "loads". The loading can be controlled by the barb angle. Also, because of its location, the open double-barb only needs to penetrate the bed plate and thus considerable needle breakage is eliminated. A further attraction of this needle is that because of its construction, the length of the needle stroke is shortened.
Another advantage of the double barb is that it can consistently pick up extremely small punching loads, and since small punching loads are the only way to eliminate needle marks and craters in the fabric, the open double-barb needle of the present invention produces a much finer and more attractive fabric.
In addition, because the needle does not enter the bed plate, the full capacity of the needle loom is utilized, and this means that a higher number of strokes per minute and thus higher density needle board providing higher fabric production is available.
Therefore, it is an object of the present invention to provide a felting needle with an open double-barb at its forward end which permits fibers to slip off the barb and which prevents fiber breakage.
Another object of the present invention is to provide a barb at the point of the needle which is always open to accept fibers and, therefore, always "loads."
Another object of the present invention is to provide a needle structure which reduces needle breakage because the needle does not have to enter a bed plate on the back side of the fabric being punched.
Finally, an object of the present invention is to provide a felting needle with a pair of opposed barb angles in the tip thereof to provide a single fiber-engaging surface.
With the above and other objects in view, more information and a better understanding of the present invention can be achieved by referring to the following detailed description:
DETAILED DESCRIPTION
For the purpose of illustrating this invention, there is shown in the accompanying drawings several forms thereof which are at present preferred, although it is to be understood that the various instrumentalities of which the invention consists can be variously arranged and organized and that my invention is not limited to the precise arrangements and organizations of the instrumentalities as herein shown and described.
In the drawings wherein like reference characters indicate like parts:
FIG. 1 is a side elevational view of a felting needle having the open double-barb of the present invention.
FIG. 2 is a greatly enlarged fragmentary front elevational view of the tip of the felting needle, showing the details of the open double-barb.
FIG. 3 is a side elevational view of the tip of the needle of FIG. 2.
FIG. 4 is an end elevational view taken generally along line 4--4 of FIG. 2.
FIG. 5 is a schematic diagram of the tool used to form the flat wedge-shaped portion of the tip of the open double barb of the present invention.
FIG. 6 is a fragmentary front elevational schematic view of the needle tip of FIG. 2, illustrating "positive" barb angles.
FIG. 7 is a view similar to FIG. 6, illustrating zero barb angles.
FIG. 8 is a view similar to FIGS. 6 and 7 illustrating negative barb angles.
Felting needles, like the felting needle 10 of the present invention, generally include a shank 11, a crank 12, and a blade 13. The blade 13 may be circular in cross section with its end tapered to a tip 14. It is at this tip 14 that the open double-barb of the present invention is formed.
For the purpose of illustrating this invention, the drawings must be greatly enlarged, and it is to be understood that felting needles of which this invention is illustrative, are made of relatively fine wire. For instance, the felting needle of the present invention may be a 32 gauge needle, which is approximately 0.026" in diameter. The blade 13 shown in the drawings of FIG. 1 appears much larger than 0.026" in diameter, and FIG. 2 and 3 are shown on a scale of approximately 1/4" to 0.001".
The end of the blade 13, where it tapers to the tip 14, is ground in the shape of a cylindrical cone at 15. The included angle of this portion 15 is 12°, as is shown particularly in FIGS. 2 and 3, and the point of the tip preferably is 0.006" in diameter. This dimension is shown in dotted lines in FIG. 3.
Thereafter, I form a wedge-shaped portion in the tip of the needle by use of a swaging tool illustrated schematically in FIG. 5. This tool may include a lower stationary portion 19 and an upper movable portion 20, which come together at the meeting line 21. Each of the portions 19 and 20 has an angular surface 22 and 23, respectively, ground therein at an angle of 15° to provide an included angle between the two tool portions of 30°.
Then the tip of the needle is placed between the swaging tool portions 19 and 20, whereupon the tools are brought together to flatten the needle tip between the surfaces 22 and 23, to form a spatulate wedge-shaped portion, defined by the surfaces 24 and 25 as shown in FIGS. 3 and 4.
During formation of the wedge-shaped portion, the outermost end of the tip is not only flattened (to provide the surfaces 24 and 25), but it also may expand slightly sidewardly beyond the 0.006" dimension, as is illustrated in FIG. 2.
Thereafter, in one embodiment illustrated in FIG. 2, I form a 140° included angle in the wedge edge 26. This can be done either by swaging or by grinding, but it will be clearly noted from the illustrations in FIG. 2, and particularly in FIG. 3, there are no sharp corners and the wedge-edge is a smoothly rounded surface.
The open double-barb illustrated in FIGS. 2 and 6 includes one surface 27 and another surface 28. The throat length of approximately 0.006" is shown between the arrows 29 and 30 in FIG. 2.
The throat depth of approximately 0.0015" is indicated between the arrows 31 and 32.
Thus I have provided a felting needle with a body portion having a wedge edge front end. In one embodiment, that wedge edge is the forwardly directed fiber-engaging open double-barb located equally on each side of the centerline of the needle. It consists of opposed symmetrical outwardly and forwardly extending surfaces which engage the fibers to be felted. The indentation may be curved or generally concave, or it may be angular, and I have chosen to illustrate an angle between the fiber-engaging surfaces of 140°. This design is specifically intended to felt the fibers uniformly on both sides of the needle.
In the embodiment illustrated in FIG. 6, the indentation formed by the surfaces 27 and 28 provides positive barb angles which may vary from 0° to 30°, and I have illustrated a 20° angle.
In the embodiment illustrated in FIG. 7, the barb angles are 0°, that is, the leading edges of the open double barb are in alignment and disposed at a 90° angle to the centerline of the needle, as is illustrated at 16 in FIG. 7.
In FIG. 8, I illustrate still another embodiment wherein negative barb angles are chosen and surfaces 17 and 18 can be disposed at a negative angle of between 0° to 30°. In FIG. 8 I have illustrated a negative angle of 10°.
With the conventional throated-barb felting needle, the fabric can be entangled and compacted just so far and a point is reached where further needling becomes counter-productive. At this point the barb engages and holds fibers already entangled into the fabric, there is no give, and the continuing downward needle action breaks the engaged fibers. With the provision of a felting needle such as shown in FIGS. 7 and 8, there is no throat or pocket that holds fibers. These needles provide a front end fiber engaging surface having the configuration and needle action of a sliding cam which imparts a transient friction motion to work the fibers into the fabric and thus increase its density without fiber or fabric damage.
It is clear that this open double-barb configuration does not include any kickup. Because the double-barb is on the wedge-edge of the needle, and open to accept fibers, it always "loads." Furthermore, because of its location, the open double barb need penetrate only through the batt of fibers, and it does not enter the bed plate. Thus considerable needle breakage is eliminated.
The open double-barb wedge edge needle of this invention thus eliminates needle marks and craters in the fabric and permits more rapid operation of the felting machine, and along with this high density performance, improved operation, better productivity and a better quality of finished product is insured.
It is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes hereof, and it is therefore desired that present embodiments be considered in all respects as illustrative and therefore not restrictive, reference being made to the appended Claims rather than the foregoing description to indicate the scope of the invention.
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A felting needle having a wedge-like tip with an open double barb formed in the leading edge of the tip. The double barb includes a pair of opposed outwardly diverging fiber-engaging surfaces with precisely formed angles. One outwardly diverging barb angle extends to one side of the needle, and the other outwardly diverging barb angle is disposed symmetrically and diametrically opposite thereto. Unlike ordinary barbs formed in a lateral edge of a felting needle, the double-barb of the present invention allows fibers to slip off to either side of the needle and thus prevent fiber damage.
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[0001] The application claims the benefit of Taiwan Patent Application No. 101112115, 101112120, 101112121, 101112122, filed on Apr. 5, 2012, in the Intellectual Property Office of Republic of China, the disclosure of which is incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The present invention relates to an itinerary planning method, particularly to the itinerary planning method for an itinerary planning system.
BACKGROUND OF THE INVENTION
[0003] With the global community entering into the commercial and the industrial era, people's life becomes more and more busy. No matter business or personal, the exchange becomes more and more frequent, and the affairs become more complicated than usual. The calendar and even schedule which assist people to record the things to be done, the people to be met and the place to be gone to in monthly, daily, every hour and every moment become indispensable tools for the modern busy age.
[0004] In the traditional business model, the consumer can only select the planned trip by the travel dealer, and the trip planned by the travel dealer often unable to meet the requirement of the travel of all and the scenic spots and the accommodation can not be customized. In addition, with the prevalence of the individual travel, the consumer can decide their itinerary, and let the travel be more arbitrary to get rid of the shackle of the group tour. Therefore, the “package tour” planned by the travel agency is difficult to satisfy the demands of the consumer, so that the development of the customized and personalized travel is a trend of the future.
[0005] In the existing travel website, the arrangement of the itinerary usually place the travel location to a shopping cart (staging area) first, then arrange the travel location in the shopping cart into the itinerary. However, if it needs to plan multi-day itinerary, it will need to complete the first-day itinerary then can arrange the itinerary of another day. Therefore, when the user has decided the date of a location but not the time, the user can only put the location into the shopping cart. When more and more locations are put into the shopping cart which causes the amount of the location in the shopping cart become more and chaotic, resulting in the inconvenience for the user to arrange the itinerary. Furthermore, in the general travel website, the itinerary is only displayed the order of the various locations without the corresponding time, causing the user will ignore the time required by each location when arranging the itinerary, causing the user arranges excessive itinerary but can not to go to or compress the time of each location.
[0006] In addition, when the user does not know how to arrange the sequence of the itinerary, the manually scheduled itinerary will make the user to pay the time planning the itinerary. Further, it is also possible that the defects may exist in the itinerary such as the traffic time takes excessive time or the attraction does not open during the planning time, because of the negligence of the user.
[0007] Although the general online itinerary planning system can open multi-people editing privilege, the user still has many inconveniences. For example, when many people edit one itinerary at the same time, the added, deleted and regulated of the itinerary by one of the editors can not immediately show to another editor, and will be shown to another editor by clicking the “refresh”. Such time difference that can not synchronized edit the itinerary will make one editor does not know the itinerary result edited by another editor, causing the same itinerary will be edited repeated, and lead to the result that the excess editing results will be canceled or the editing effects does not match the expectation by the user.
[0008] To sum up the above disadvantages, it is necessary to provide a new antenna structure for overcoming the above-mentioned defects. It is therefore attempted by the applicant to deal with the above situation encountered in the prior art.
SUMMARY OF THE INVENTION
[0009] In order to improve the shortcomings of the existing general online itinerary planning system, the present invention provides a system for arranging the itinerary manually by a user, wherein the system comprises an interface including an itinerary displaying board, a general information displaying module and a geographic information displaying module, and any two of which may produce the interactions by selecting of the user. The interface let the user can search the itinerary information conveniently and arrange the itinerary information according to their personal preferences into the itinerary displaying board to obtain a customized itinerary. Furthermore, the itinerary planning system of the present invention also can estimate whether the sequence of the itinerary is the best, sequence the itinerary automatically according to the interest of the user, and edit the same itinerary by the multiple people real-timely and synchronously, to make the itinerary planning system of the present invention is more convenience for the user to use the system.
[0010] In accordance with one aspect of the present disclosure, an itinerary planning system is provided. The itinerary planning system includes an itinerary board displaying an itinerary, a general information module displaying a general information and a geographic information module displaying a geographic information, wherein there is at least one interactive relationship among the itinerary board, the general information module and the geographic information module.
[0011] In accordance with another aspect of the present disclosure, an itinerary planning method is provided. The method includes steps of displaying a first itinerary information, receiving a specific itinerary information, providing an itinerary board having a time and displaying a second itinerary information including at least one of a geographic information and a general information.
[0012] In accordance with one more aspect of the present disclosure, an itinerary planning method is provided. The method includes steps of displaying a multi-day itinerary board comprising a plurality of dates and allocating an itinerary information into the multi-day itinerary board for at least one of the plurality of dates.
[0013] Other objects, advantages and efficacy of the present invention will be described in detail below taken from the preferred embodiments with reference to the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1( a ) is an itinerary planning system according to the present invention.
[0015] FIG. 1( b ) is a schematic diagram illustrating the interaction between the itinerary displaying board, the general information displaying module and the geographic information displaying module according to the present invention.
[0016] FIG. 2 is a single-day itinerary according to the present invention.
[0017] FIG. 3( a ) is a schematic diagram illustrating a sub-day itinerary according to the present invention.
[0018] FIG. 3( b ) is a schematic diagram illustrating the planning of the sub-day itinerary according to the present invention.
[0019] FIG. 4 is a schematic diagram illustrating an itinerary information screen according to the present invention.
[0020] FIG. 5 is a schematic diagram illustrating a traffic planning screen according to the present invention.
[0021] FIG. 6 is a flow chart illustrating a method for automatically estimating an itinerary according to the present invention.
[0022] FIG. 7 is a schematic diagram illustrating an itinerary estimating interface according to the present invention.
[0023] FIG. 8 is a first flow chart illustrating a method for automatically producing an itinerary according to the present invention.
[0024] FIG. 9 is a second flow chart illustrating a method for automatically producing an itinerary according to the present invention.
[0025] FIG. 10( a ) is a schematic diagram illustrating a travel preference interface according to the present invention.
[0026] FIG. 10( b ) is a schematic diagram illustrating a property configuration interface according to the present invention.
[0027] FIG. 11 is a schematic diagram illustrating a system for planning an itinerary real-timely and synchronously according to the present invention.
[0028] FIG. 12 is an operation flow chart illustrating the system for planning the itinerary real-timely and synchronously according to the present invention.
[0029] FIG. 13 is a schematic diagram illustrating a system for planning an itinerary real-timely and synchronously according to the present invention.
[0030] FIG. 14 is a schematic diagram illustrating a system for planning an itinerary real-timely and synchronously according to the present invention.
DETAILED DESCRIPTION
[0031] The present disclosure will be described with respect to particular embodiments and with reference to certain drawings, but the disclosure is not limited thereto but is only limited by the claims. 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. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice.
[0032] Furthermore, the terms first, second and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequence, either temporally, spatially, in ranking or in any other manner. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments described herein are capable of operation in other sequences than described or illustrated herein.
[0033] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments described herein are capable of operation in other orientations than described or illustrated herein.
[0034] It is to be noticed that the term “including”, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device including means A and B” should not be limited to devices consisting only of components A and B.
[0035] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.
[0036] Similarly it should be appreciated that in the description of exemplary embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the detailed description are hereby expressly incorporated into this detailed description, with each claim standing on its own as a separate embodiment.
[0037] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the disclosure, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.
[0038] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
[0039] The disclosure will now be described by a detailed description of several embodiments. It is clear that other embodiments can be configured according to the knowledge of persons skilled in the art without departing from the true technical teaching of the present disclosure, the claimed disclosure being limited only by the terms of the appended claims.
[0040] Please refer to FIG. 1( a ), which is an itinerary planning system 100 according to the present invention. The itinerary planning system 100 includes a data base 110 , an user interface 120 , a data processing module 130 and a computing device 140 , wherein the data base 110 stores a plurality of general information, the user interface 120 includes a general information displaying module 111 , an itinerary displaying board 112 and a geographic information displaying module 113 as showed in FIG. 1( b ), the computing device 140 is connected to the user interface 120 through an internet, and the user interface 120 may be a web page or a menu displayed through the computing device 140 . The computing device 140 is selected from a group consisting of a personal computer, a note book or a portable device, wherein the portable device includes a personal digital assistant (PDA), a tablet computer, a mobile phone, a smart phone and a digital camera.
[0041] Please refer to FIG. 1( b ), which is a schematic diagram illustrating the interaction between the itinerary displaying board, the general information displaying module and the geographic information displaying module according to the present invention. In FIG. 1( b ), any two of the general information displaying module 111 , the itinerary displaying board 112 and the geographic information displaying module 113 may produce the interactions by selecting of the user. For example, selecting the general information displaying module 111 , the itinerary displaying board 112 and/or the geographic information displaying module 113 may display a screen related to the general information displaying module 111 ; selecting the itinerary displaying board 112 , the general information displaying module 111 and/or the geographic information displaying module 113 may display a screen related to the itinerary displaying board 112 ; and selecting the geographic information displaying module 113 , the general information displaying module 111 and/or the itinerary displaying board 112 may display a screen related to the geographic information displaying module 113 .
[0042] The present invention provides a method for planning an itinerary to let the user planning the itinerary conveniently. Please refer to FIG. 2 , which is a single-day itinerary 200 of the present invention. The single-day itinerary 200 includes a date field 210 , a time list 220 and a plurality of fields 230 for displaying a date, wherein the time list 220 includes a plurality of time slots 221 which corresponding to the plurality of fields 230 . The user can drag an itinerary information into the plurality of fields 230 , wherein the itinerary information includes a tourist information and/or a commercial information. The time list 220 could be any time interval as a minimum time period, such as 15 minutes, 30 minutes, 1 hour, 2 hours and so on, and hour, minute or second can be used as unit of the time slot 221 . In the present embodiment, 30 minutes is the minimum time period of the time list 220 , and the time slot 221 can across day (e.g. from 23:45 to 00:15). The user can drag the itinerary information into the field 230 corresponding to one time slot 221 and manually adjust the spending time of the itinerary information. If the field of one itinerary information overlaps with that of another itinerary, the single-day itinerary 200 will adjust the position of one itinerary information and another itinerary information automatically, to make the field not overlap. The date field 210 further includes a staging area 240 which can let the itinerary information be dragged into by the user to temporarily store the itinerary information. When the user wants to go to one itinerary information at a determined time, the user can drag that itinerary information into the field 230 corresponding to the time slot 221 which the user wanted to go to.
[0043] Please refer to FIG. 3( a ), which is a schematic diagram illustrating a sub-day itinerary 300 of the present invention. The sub-day itinerary 300 displays a date list 310 , wherein the date list 310 includes multiple date area 311 and a total staging area 312 , and each multiple date area 311 is a single-day itinerary 200 . The user can drag the itinerary information into the multiple date area 311 and the total staging area 312 , wherein the itinerary information includes a tourist information and/or a commercial information. Please refer to FIG. 3( b ), which is a schematic diagram illustrating the planning of the sub-day itinerary of the present invention. When the user does not determine the date of the itinerary information would like to go to, the itinerary information can temporarily store in the total staging area 312 ; when the user determines the date but has not yet determined the itinerary information time that wanted to go to, the itinerary information can temporarily store in the date area 311 corresponding to the date, until the user determines the date and the time of the itinerary information that the user would like to go to, and then placing the itinerary information into the date area 311 or the field 230 according to the date and the time of the itinerary information that the user would like to go to. When the number of the specific itinerary information is exceeded a threshold, it will produce another line of the single-day itinerary.
[0044] Please refer to FIG. 4 , which is a schematic diagram illustrating an itinerary information screen of the present invention. The computing device 140 receives an itinerary information selected or entered by the user, an itinerary information screen 400 will display different information after the selecting and the entering of the user, wherein the itinerary information screen 400 is the user interface 120 of the present invention. In FIG. 4 , the itinerary information screen 400 displays an itinerary information board 410 , an itinerary 420 , a geographic information board 430 and the sub-day itinerary 440 , wherein the itinerary information board 410 includes an itinerary information list 411 which including multiple itinerary information 414 to provide the user entering a keyword, a condition list 412 providing the user to select the itinerary information would like to browse, and a retrieved field 413 providing the user to enter the keyword, wherein the itinerary information 414 comes form internet searching and the database 110 . The itinerary 420 is the single-day itinerary 200 , which including a date field 421 , a time list 422 and a plurality of fields 423 for displaying a date, wherein the time list 422 includes a plurality of time slots which corresponding to the plurality of fields 423 . The user can drag an itinerary information into the plurality of fields 423 . The geographic information board 430 includes a map, wherein the map may display different geographic location according to the selecting of the itinerary information by the user. The sub-day itinerary 440 displaying a date list 441 including multiple date areas and a total staging area 442 , wherein the date areas and the total staging area 442 provides the user to drag the itinerary information 414 into the corresponding date according to the suitable date for the itinerary information 414 , then drag the itinerary information 414 into the corresponding field 423 according to the suitable time slot for the itinerary information 414 . When the user selects the itinerary 414 would like to browse, the itinerary information screen 400 displays one of the geographic information and the general information, and the user may drag at least one itinerary information into the itinerary 420 according the locations would like to go to. The itinerary information in the single-day itinerary 200 , the date areas, and the total staging area can be moved or removed.
[0045] The itinerary information 414 of the present invention includes but not limited to a travel itinerary information, a business information and a manufacturing information.
[0046] The itinerary information of the present invention is selected from a group consisting of a regional name, a location, an address, a drink name, a food name, a commodity name, a way of transportation, a traffic route, an activity, a command, a keyword, a character, an itinerary, a ticket, a resource, and a combination thereof.
[0047] The geographic information of the present invention is selected from a group consisting of a map, an electronic map, a 3D map, a satellite map, a street map, a topographic map, a road diagram, a weather diagram, a transportation route diagram, a high-speed rail route diagram, a train route diagram, a passenger transport route map, a bus route map, a MRT route map, a subway route map, a bicycle lane diagram, a flight route map, a navigation route map, and a combination thereof.
[0048] The general information of the present invention is defined as any people, event and object related to travel, which including an industrial and commercial service information containing at least one of a trade union organizations information, all walks of life information, a real estate information, a social welfare agency information and a financial institution; an utilities information containing at least one of a gas station information, an electricity company information and telecommunications information; an educational organization information containing at least one of an bookshop information, a cram information, a library information and a school information; a transportation construction information containing at least one of a public transportation information, a major road construction information, a vehicle maintenance plant information, a towing field information and a parking information; a casual shopping information containing at least one of a life shopping information, a leisure and entertainment information and an audio-visual entertainment information; an attractions information containing at least one of a natural ecological attractions information, a festival information, a theme park information, a tourist night market information, a bicycle road information, a landmark building information, a railway information, a farm information and a park information; a government authority information containing at least one of a central authority information, a local authority information, an authority to Taiwan information and a police and firefighting information; a food information containing at least one of a Chinese cuisine information, a Japanese cuisine information, a chafing dish information, a BBQ information, a variety of snacks information, a buffet of unlimited information, a western-style cuisine information, an entertainment food information, a tea ice product information, an exotic cuisine information and a self-cultivation vegetarian information; a healthcare information containing at least one of a health center information, an animal hospital information, a clinic information, a hospital information, a drug store information and as a pharmacy information; an art and cultural information containing at least one of a studio information (such as an art classrooms, a dance studio, a studio, a design studio) a Hakka cultural information, a grading monument information, a religion information, a memorial information, an exhibition pavilion information, a museum information, a art gallery information and an art center information; and a accommodation information containing at least one of a hotel information (e.g. a star tourist hotel, a leisure hotel, a business hotel, a resort hotel, a cheap hotel, a spa hotel, a motel, a pet hotel, a youth hostel, etc.), a guest house information, a farm information, a campsite information and a hotel-style apartment information.
[0049] Please refer to FIG. 5 , which is a schematic diagram illustrating a traffic planning screen of the present invention. The itinerary information scene further includes a traffic route planning screen 510 containing a route menu 511 , wherein the route menu displays one or various kinds of the time and the price to provide the selected by the user, and a preference list 513 . The traffic route planning screen 510 displays different traffic route according to the preference way, price and time selected by the user. When a route is selected the traffic route planning screen 510 displays a route planning map 512 , and the map 430 may display the road map of the route.
Embodiment 1
[0050] When the user would like to search a location information, the user can fill the location (such as Longshan Temple) in the searching field, at this time, the itinerary information screen may search the related or peripheral scenic spot and map according to the location which the user filled in. The user may select a location information (such as Longshan Temple) from these related or peripheral scenic spot, and the itinerary information board in the itinerary information screen may display the pictures about Longshan Temple. The user also can click a site location on the map (such as Huaxi Street Night Market), then the itinerary information board in the itinerary information screen may display the pictures about Huaxi Street Night Market.
Embodiment 2
[0051] When the user would like to search a food information, the user can fill the food (such as Casa Della Pasta) in the searching field, at this time, the itinerary information screen may search the information and map related to the Casa Della Pasta according to the food which the user filled in. The user may select one of the food information (such as Casa Della Pasta Normal Shop) from these food information related to the Casa Della Pasta (such as Liangni Casa Della Pasta), and the itinerary information board in the itinerary information screen may display the pictures about Casa Della Pasta Normal Shop, and the map may search the geographic location about Casa Della Pasta Normal Shop.
Embodiment 3
[0052] When the user would like to search a hotel information, the user can fill the hotel information (such as Grand Hotel) in the searching field, at this time, the itinerary information screen may search the information and map related to the Grand Hotel according to the hotel which the user filled in. The user may select one of the hotel information (such as Shihlin Night market) from these hotel information related to the Grand Hotel, and the itinerary information board in the itinerary information screen may display the pictures about Grand Hotel, and the map may search the geographic location about Grand Hotel.
Embodiment 4
[0053] When the user would like to search a location information, but does not know the place yet, the user can select the itinerary information list on the itinerary information board, wherein the itinerary information list may display the location information which is more click, high popularity and excellent evaluation. If the user likes one of the location information (such as Ximenting) and clicks it, then the itinerary information board in the itinerary information screen may display the pictures about Ximenting, and the map may search the geographic location about Ximenting according to the location information which is clicked.
Embodiment 5
[0054] When the user would like to search a food information, but does not know the food yet, the user can select the itinerary information list on the itinerary information board, wherein the itinerary information list may display the food information which is more click, high popularity and excellent evaluation. If the user likes one of the food information (such as Hell Ramen) and clicks it, then the itinerary information board in the itinerary information screen may display the pictures about Hell Ramen, and the map may search the geographic location about Hell Ramen according to the location information which is clicked.
Embodiment 6
[0055] When the user would like to search a hotel information, but does not know the hotel yet, the user can select the itinerary information list on the itinerary information board, wherein the itinerary information list may display the food information which is more click, high popularity and excellent evaluation. If the user likes one of the hotel information (such as Grand Hyatt Taipei) and clicks it, then the itinerary information board in the itinerary information screen may display the pictures about Grand Hyatt Taipei, and the map may search the geographic location about Grand Hyatt Taipei according to the location information which is clicked.
Embodiment 7
[0056] When the user would like to search the food at the Taichung Gongyi Rd. from the map, the user may click the map on the itinerary information screen to enlarge the map to the Taichung Gongyi Rd. In the clicking process, the itinerary information board may change according the clicked by the user. The user may select any one location (such as Akaoni Steak) on the map, at this time, the itinerary information screen may search the location which the user selected, and the itinerary information board may display the pictures and the related information about Akaoni Steak.
Embodiment 8
[0057] When the user searches a travel information (such as Yangmingshan), and fills the Yangmingshan at the searching field on the itinerary information board of the itinerary screen. The itinerary information screen may search the information related to the Yangmingshan according to the Yangmingshan which is filled by the user, and display a single-day itinerary. The user may select the scenic spot information (such as Xiaoyou Keng) related or peripheral to the Yangmingshan, and the itinerary information board of the itinerary information screen may search the pictures of the Xiaoyou Keng after clicking such information. If the user would like to go to the Xiaoyou Keng, the user may drag the Xiaoyou Keng into the single-day itinerary. When the user has dragged too many itinerary information into the single-day itinerary, the user may select the itinerary information (such as Jhuzihhu) in the single-day itinerary, then the itinerary information board of the itinerary information screen may search the information related to the Jhuzihhu.
Embodiment 9
[0058] When the user would like to search the travel scenic spot by using the map, the user can click the map to enlarge the map to the place (such as Chingjing Veteran's Farm) which the user would like to go to, then the Chingjing Veteran's Farm and the peripheral map thereof may showed on the map of the itinerary screen, and provide the single-day itinerary. The user may select the itinerary information (such as Small Swiss Garden) of the Chingjing Veteran's Farm, and the itinerary information board of the itinerary information screen may search the pictures of the Small Swiss Garden after clicking such information. If the user would like to go to the Small Swiss Garden, the user may drag the Small Swiss Garden into the single-day itinerary. When the user has dragged too many itinerary information into the single-day itinerary, the user may select the itinerary information (such as Temperate Flower Seedling Farm) in the single-day itinerary, then the itinerary information board of the itinerary information screen may search the information related to the Temperate Flower Seedling Farm.
Embodiment 10
[0059] When the user would like to plan a single-day travel itinerary, the user may fill the place would like to go to and the food would like to eat (such as Taipei 101 or Diamond Tony's Italian Restaurant), at this time, the itinerary information screen may search the scenic spot and the map related or peripheral to the Taipei 101 or Diamond Tony's Italian Restaurant according to the location filled by the user, and show the single-day itinerary. The user may select the scenic spot information (such as Warner Village or Taipei World Trade Center) related or peripheral to the Taipei 101 or Diamond Tony's Italian Restaurant, and the map of the itinerary information screen may search the geographic location of the Warner Village or the Taipei World Trade Center after clicking such information. The user may select one itinerary information (such as Taipei 101 or Diamond Tony's Italian Restaurant) from the itinerary information screen and drag it into the itinerary field corresponding to the time period in the single-day itinerary. The user also can click the itinerary information on the map, the itinerary information board of the itinerary information screen may search the information about the Eslite flagship store (XinYi Branch) after clicking such itinerary information. If the user would like to go to the Eslite flagship store (XinYi Branch), the user may drag the itinerary information of the Eslite flagship store (XinYi Branch) into the itinerary field corresponding to the time period in the single-day itinerary. When several itinerary information has placed into the field of the single-day itinerary, the user also can further select one of the itinerary information (such as Shin Kong Mitsukoshi), at this time, then the itinerary information board of the itinerary information screen may search the information related to the Shin Kong Mitsukoshi and show the scenic spot and geographic information related or peripheral to the Shin Kong Mitsukoshi.
Embodiment 11
[0060] When the user would like to plan a multi-day travel itinerary, the user may fill the place would like to go to, the food would like to eat and the hotel would like to live, but does not know where to go, where to eat and where to live yet, the user can use the general information, having more hits, popularity and excellent evaluation, provided from the on the itinerary information board. After searching, the itinerary information screen will display the itinerary information list, the single-day itinerary, the map and the sub-day itinerary. The user can drag the itinerary information into the single-day itinerary. If the user wants to go to a place (such as Feng Chia Night Market) but has not decide which date to go to, then the Feng Chia Night Market itinerary information can be dragged into the staging area of the sub-day itinerary. If the user wants to eat a food (such as Tripodking Hot Pod) and has decided which date to eat but has not decide the time yet, then the user can drag the Tripodking Hot Pod itinerary information into one date area of the sub-day itinerary, when the user has decided when to eat, then drag the Tripodking Hot Pod itinerary information into the corresponding itinerary field of the single-day itinerary. When the user decides which date to go to the Feng Chia Night Market but not decide the exactly time yet, the user can drag the Feng Chia Night Market into one date area of the sub-day itinerary from the staging area. If the user has decided when to go to the Feng Chia Night Market, the user can drag the Feng Chia Night Market into the itinerary field corresponding to the time period of the sub-day itinerary. If the user would like to change the itinerary information in the single-day itinerary, the user can drag the itinerary information out of the single-day itinerary and put into the sub-day itinerary or staging area, and adjust the occupied time of the itinerary to produce a customized multi-day travel itinerary.
Embodiment 12
[0061] When the user wants to planning a single-day or multi-day business trip, the user can fill the place (such as Taipei Council) in the searching field have to go to or select the place on the map, at this time, the itinerary information screen will search the scenic spot and the map related to the Taipei Council according to the place that the user filled in or selected, and display a single-day itinerary and a sub-day itinerary. The user may select the scenic spot information related or peripheral to the Taipei Council, and the map of the itinerary information screen may search the geographic location of the Eslite flagship store (XinYi Branch) after clicking such information. The user also can click the itinerary information (such as Taipei Council) from the itinerary information screen and drag it into the itinerary field corresponding to the time period in the single-day itinerary or stage the itinerary information in the staging area or date area, when determining the time of the itinerary information, then drag the itinerary information into the corresponding itinerary field. The user can adjust the occupied time of the itinerary to produce a customized single-day or multi-day travel itinerary.
Embodiment 13
[0062] When the user wants to planning a multi-day international trip, the user can fill the place (such as Hong Kong) in the searching field have to go to or select the place on the map, at this time, the itinerary information screen will search the scenic spot and the map related to the Hong Kong according to the place that the user filled in or selected, and display a single-day itinerary and a sub-day itinerary. The user may select the geographic information and the general information (such as Hong Kong Disneyland) related to the Hong Kong, and the itinerary information board of the itinerary information screen may search the pictures of the Hong Kong Disneyland and the map of the itinerary information screen may search the geographic location of the Hong Kong Disneyland after clicking such information. The user also can click at least one itinerary information (such as Hong Kong Disneyland and Hong Kong Ocean Park) from the itinerary information screen and drag it into the itinerary field corresponding to the time period in the single-day itinerary or stage the itinerary information in the staging area or date area, when determining the time of the itinerary information, then drag the itinerary information into the corresponding itinerary field. The user can adjust the occupied time of the itinerary to produce a customized single-day or multi-day international travel itinerary.
Embodiment 14
[0063] When the single-day itinerary or multi-day itinerary have arranged, but the traffic route has not be planned yet, the user can click the “the traffic has not be planned yet” in the itinerary, then the itinerary information screen will show a traffic route planning screen. The traffic route planning screen has planned many traffic routes according to different traffic way, the traffic route may display the time and the price that needed. When the user selects one of the traffic routes, the traffic route planning screen may display the route planning map of the traffic route, and the map may display the road map of the traffic route at the same time. The user also can select the preference way, the price level and time length in the preference list, then the system will display the suitable traffic route on the traffic route planning screen according the selecting by the user to provide the user to use the best traffic route.
Embodiment 15
[0064] The user has arranged a itinerary that leave the Caesar Hotel at AM 9:00, AM 9:30-PM 12:00 is at the National Taiwan Science Education Center, PM 12:30-PM 1:30 is a lunch time at the Heresy's Space near the National Taiwan Science Education Center, PM 2:00-PM 5:30 is at the National Palace Museum, PM 5:30-PM 9:30 is at the Shihlin Night Market, and PM 10:00 is back to the Caesar Hotel. When the user selecting the “the traffic has not be planned yet” in the itinerary, the system has planned four traffic routes displayed on the traffic route planning screen of the itinerary information screen, wherein the traffic route 1 needs 175 min, 90 dollars, the traffic route 2 needs 120 min, 110 dollars, the traffic route 3 needs 100 min, 470 dollars and the traffic route 4 needs 90 min, 950 dollars. When the user choices the traffic route 2, then the traffic route map of the traffic route 2 will be shown in the itinerary information screen (walking to the MRT Taipei Main Station from the Caesar Hotel (2 min, 0 dollar), MRT to the MRT Jiantan Station (10 min, 25 dollar), bus red 30 or 41 to the National Taiwan Science Education Center (20 min, 15 dollar), bus red 30, red 12 or 620 to the MRT Shihlin Station (15 min, 15 dollar), walking to the Heresy's Space (3 min, 0 dollar), bus red 30 to the National Palace Museum (30 min, 15 dollar), red 30 to the Shihlin Night Market (35 min, 15 dollar), walking to the MRT Jiantan Station (6 min, 0 dollar), and walking to the Caesar Hotel (2 min, 0 dollar)), and the traffic route 2 is shown on the map at the same time. When the user choices one route of the traffic route 2, such as walking to the Heresy's Space, the map of the itinerary screen will display the walking map. If the user would like to use the traffic route 2, the use need to click the “choose this route” to plan the traffic route of the itinerary. If the user also can select the preference traffic transport, the price level and the time length in the preference list, the system will plan the traffic route according to the requirement (such as the time length) of the user, and the planned traffic route will sequence according to the time length to provide the user to choose. Of the user wants to drive their own car rather than to use the traffic route planned by the system, the user can select the “driving” option, then the system will plan the time required for driving their own car to each destination, and the road map of driving will be shown in the map of the itinerary information screen to convenient the user. The user can adjust the starting and the ending time of each itinerary according to the traffic route that the user chosen.
[0065] After the user planning their itinerary, the itinerary planning system of the present invention will automatically estimate the itinerary that the user planned. Please refer to FIG. 6 , which is a flow chart illustrating a method for automatically estimating an itinerary 600 of the present invention. After the user entering the itinerary through the user interface 120 (step 11 ), the itinerary will be compared with a reference (step 12 ), then obtaining an estimating result according to the comparison (step 13 ), wherein the itinerary is one of the business itinerary and the travel itinerary. The itinerary includes a location and a condition of a time which expected to go to the location and/or a period which expected to stay at the location, and further includes a condition of a budget, a traffic way or a requirement of the itinerary.
[0066] For example, of the user enters a travel itinerary A, and the travel itinerary A is (a) touring in the “Taipei Museum of the Drinking Water” at 7:00-12:00, (b) going to the “Danshui Old Street” at 12:00-12:30, (c) touring in the “Danshui Old Street” at 12:30-15:30, (d) going to the “Sansia Qingshui Temple” at 15:30-16:00, (e) touring in the “Sansia Qingshui Temple” at 16:00-18:00, (f) going to the “Shihlin Night Market” at 18:00-19:00, and (g) dining at the “Shihlin Night Market” at 19:00-23:00. Then, the travel itinerary can be compared with the reference to produce the estimating result/suggestion, wherein the estimating result/suggestion can include the embodiments as follows.
Embodiment 16
[0067] After comparing with the internet searching or the data in the data base, it is found that the opening time of the “Taipei Museum of the Drinking Water” is 9:00-17:00, so that the estimating result will inform the user that the “Taipei Museum of the Drinking Water” is not open yet at 7:00-9:00, the daily opening time of the “Taipei Museum of the Drinking Water” is 9:00-17:00, the planning (a) is not a suitable information, and/or showing a selection that amending the touring time of planning (a) become 9:00-12:00 through a way of the word, the score, the picture, the color, the animation, the sound or the combination thereof. In addition, if the user changes the planning (a) into touring the “Taipei Museum of the Drinking Water” at 9:00-12:00, then the amended travel itinerary A will be compared with the reference, a new reference and/or the combination thereof to provide another estimating result of the amended travel itinerary A to the user.
Embodiment 17
[0068] In the travel itinerary A, it can further enter the traffic way directed against the traffic planning, for example, the user enters proceeding towards by “walking”. After comparing with the reference, it is found that “walking” from the “Taipei Museum of the Drinking Water” to the “Danshui Old Street” cannot be realized because the time is too short. Thereof, the estimating result will inform the user (1) the requirement time for each transport (such as walking for 10 hours, taking a taxi for 45 min, taking the MRT for 30 min and so on), (2) the transport complies to the time condition (such as taking the MRT for 30 min) and/or (3) no transport/method complies to the time condition through the above way. However, if the user enters proceeding towards by the “MRT” in planning (b), after comparing with the reference, it is found that the time is appropriate for going to the “Danshui Old Street” from the “Taipei Museum of the Drinking Water” by “MRT” at 12:00-12:30, and the estimating result will display proper or not display.
Embodiment 18
[0069] After comparing with the internet searching or the data in the database, it is found that most tourists recommend the best time to go to the “Danshui Old Street” is at the nightfall to watch the sunset, so that the estimating result will inform such information to the user through above way.
Embodiment 19
[0070] If the user has pre-entered an itinerary requirement, the itinerary requirement is a specific purpose of the “watch the sunset at the Danshui Old Street”, then the estimating result will inform the information that there may not watch the sunset in the “Danshui Old Street” at 12:30-15:30 through above way and the planning (c) is not suitable and/or the best time for watching the sunset in the Danshui at 17:00-18:00 to the user. The suggestion of the best time for watching the sunset in a day (such as 17:00-18:00), the reference not only can include other suggestion of the user, but also include the daily sunset time of the Central Weather Bureau. Furthermore, if the weather says there is a typhoon passing through the north of Taiwan, then the estimate result will inform the information that that day will not see the sunset at the nightfall to the user. Besides, the itinerary requirement can be the “couple journey” or “humanities journey”, and can be the specific expectation or purpose, such as the above “watch the sunset in Danshui” or “eat Danshui Agei”, “must to go to Howard Fort” and so on.
Embodiment 20
[0071] After comparing with the reference, it is found that the planning (d) which is going to the “Sansia Qingshui Temple” from the “Danshui Old Street” cannot be realized by driving or taking the bus because of the time is too short, so that the estimating result will inform such information to the user through above way.
Embodiment 21
[0072] After comparing with the reference, it is found that the original sequence of the scenic spot planned by the travel itinerary A “Taipei Museum of the Drinking Water”→“Danshui Old Street”→“Sansia Qingshui Temple”→“Shihlin Night Market” will take more time in traffic compared with the best sequence “Taipei Museum of the Drinking Water”→“Sansia Qingshui Temple”→“Danshui Old Street”→“Shihlin Night Market”, so that the estimating result will inform such information to the user through above way. If the original itinerary entered by the user is the best traffic sequence “Taipei Museum of the Drinking Water”→“Sansia Qingshui Temple”→“Danshui Old Street”→“Shihlin Night Market”, then the estimating result will inform that the sequence of the scenic spot is the best sequence to the user through above way. In addition, if the itinerary entered by the user is more than two days, the present invention also can provide a suggestion of the best traffic sequence, and/or whether the itinerary which is more than two days is the best traffic sequence based on the above illustration. Besides, the best traffic sequence of the present invention not only can use the traffic time as the best condition, but also can use the traffic price as the best condition, i.e. the best traffic order of the present invention can show the best order of the traffic time and the traffic price simultaneously or individually.
Embodiment 22
[0073] After comparing with the reference, it is found that the dining time of the planning (g) is too long and too late to leave, so that the estimating result will inform such information to the user through above way.
Embodiment 23
[0074] The total time of the itinerary is 16 hours, wherein the traffic time occupies for 2 hours (planning (b), (d) and (f)), and the dining time occupies for 4 hours (planning (g)), so that the estimating result will inform that the traffic time and the dining time respective occupies the total time 2/16 and 4/16 or the corresponding percentage (i.e. 12.5% and 25%) to the user through above way. Furthermore, if the travel itinerary entered by the user does not specific plan the traffic time, the method of the present invention also can calculate the traffic time between each location and/or total traffic time based on the traffic way entered by the user or the system default value, i.e. about the sub-time or the sum of the traffic item and display in the estimating result. Similarly, the sub-time also can presuppose as the sub-time of the “dining”, the “shopping” items and so on based on the requirement of the user. Besides, the method of the present invention also can display different properties such as the “accommodation time”, the “fun time”, or the “visiting time” in the estimating result based on the content of the itinerary.
Embodiment 24
[0075] Continuing embodiment 23, if the user has pre-entered the requirement of the “slow itinerary”, after comparing with the reference, it is found that the “slow itinerary” usually means the total traffic time is 10% less than the total itinerary time, or the itinerary requirement “slow itinerary” that the user has pre-entered means the total traffic time is 10% less than the total itinerary time, then the itinerary result will inform the information/suggestion that the travel itinerary A does not comply with the requirement of the “slow itinerary”, which itinerary is too fast, and shorten the browsing time and/or take another transport that has shorter traffic time to the user. In addition, this embodiment also can specific collocate the embodiment 6, comparing whether the itinerary is the best traffic sequence, if so, then the estimating result will not display or display as the best traffic sequence, let the user can adjust other itinerary, if not, then the estimating result will suggest the user to adjust the sequence between each scenic spot to provide a plurality of itinerary suggestions to the user for shortening the traffic time of the best traffic sequence. However, the suggested plurality itinerary does not need to comply with the requirement of the “slow itinerary”. Even if the percentage of the traffic time of the best traffic sequence of the itinerary is 10% higher than the total itinerary time, the suggested plurality of itinerary still can provide to the user, let the user shorten the traffic time of the itinerary.
Embodiment 25
[0076] Continuing embodiment 23, if the user has pre-entered the requirement of the “food journey”, after comparing with the reference, it is found that the “dining time” of the “food itinerary” usually occupies the total traffic time more than 50%, or lower than the standard that the user has pre-entered (such as the itinerary requirement of the “food itinerary” means the “dining time” occupies the total itinerary time more than 50%), then the estimating result will inform the information/suggestion that the percentage of the dining time is too low, shortening the traveling time of the scenic spot except the dining time and/or arranging the traffic time to shorten the traffic time to the user according to the above way.
Embodiment 26
[0077] Continuing embodiment 23, the “traveling time”, the “traffic time” and the “dining time” of the travel itinerary A respective occupy 50%, 12.5% and 25% of the percentage of the total itinerary time. However, the “traveling time”, the “traffic time” and the “food time” in the “food journey” usually respective occupy 35%, 15% and 50% of the percentage of the total itinerary time. Then the estimating result will inform the suggestion that to adjust the “traveling time”, the “traffic time” and the “food time” of the travel itinerary A to the user according to the above way.
Embodiment 27
[0078] If the user set a budget for the travel itinerary A, after preparing with the reference, the estimating result will inform that whether the budget is enough to pay the travel itinerary A to the user thorough the above way. In addition, the budget can individual setting according to planning (a)-(g), and also can set the purpose of the “traffic”, the “hotel”, the “dining” or “fun”, and the estimating result will inform the user that whether the budget is enough to pay the individual plan or the specific purpose according to the above way, to understand the condition of the cost of the specific purpose and whether the cost is in the budget.
Embodiment 28
[0079] If the user cancels the touring in the “Sansia Qingshui Temple” at 16:00-18:00 of the planning (e) in the travel itinerary A, then the amended travel itinerary A will compare with the reference, a new reference, and/or the combination thereof, to provide another estimating result of the amended travel itinerary A to the user.
[0080] The above embodiments are comparing with the reference after entering the travel itinerary by the user to obtain the estimating result. Besides, the above embodiments can individually show the estimating result or merge into the same estimating result. That is to say, the above embodiments can combine to each other. However, the method of the present invention may real-time compare with the reference when the user entering the individual plan, the user can adjust the entered plan according to the obtained estimating result to reach the effect of real-time interaction. The following will be illustrative embodiment.
Embodiment 29
[0081] After the user entering the touring in the “Taipei Museum of the Drinking Water” at 7:00-12:00 of the planning (a), the planning (a) will be compared with the reference, then the estimating result will inform the user that the “Taipei Museum of the Drinking Water” is not open yet at 7:00-9:00, the daily opening time of the “Taipei Museum of the Drinking Water” is 9:00-17:00, the planning (a) is not a suitable information. At this time, the user can amend the planning (a) into: (I) touring in the “National Taiwan University” at 7:00-12:00 or (II) planning (a1) dining at the “Shuiyuan Market” at 7:00-9:00 and planning (a2) touring at the “Taipei Museum of the Drinking Water” at 9:00-12:00. the amended planning (a), (a1) or (a2) will be compared with the reference to obtain a new estimating result. Of course, the user also can adjust the traffic way, the budget or the itinerary requirement after entering the individual plan to obtain a newer estimating result. Besides, the modified location (such as amended planning (a)), the newly added location (such as planning (a1) and (a2)) or the combination thereof of this embodiment can also be implemented when the user has entered the travel itinerary to obtain a newer estimating result.
[0082] Another method of the present invention can also arrange the sequence of each scenic spot of the itinerary rather than the specific time of arrival to provide the estimating result. The following will be illustrative embodiment.
Embodiment 30
[0083] When the user enters a travel itinerary B, the travel itinerary B is staring from Taipei and respectively go to (a) Hualien Liushidanshan, (b) Ilan Jiaosi and (c) Kenting. Then, the travel itinerary B can be compared with the reference to obtain the estimating result/suggestion. This embodiment can be combined with the above embodiments. For example, the travel itinerary B can arrange the best traffic, and the estimating result will inform the user that respectively go to (b) Ilan Jiaosi, (a) Hualien Liushidanshan and (c) Kenting is the best traffic sequence according to the above way. When an itinerary of the method of the present invention only has the time sequence of each location, it also can estimate and compare according to the time sequence of the itinerary to obtain the estimating result/suggestion. Please refer to FIG. 7 , which is a schematic diagram illustrating an itinerary estimating interface of the present invention, which can display through the computing device 140 . In FIG. 7 , the monitor of the mobile phone 700 displays a first block 710 and a second block 720 , wherein the first block 710 is used to enter (or show) the itinerary, the location, the time, the budget or the requirement as the above embodiments, and the second block 720 is used to output the estimating result after comparing with the reference. Of course, the information entered by the user and the output estimating result are not necessary displayed in different block, for example, it also feasible displaying at the same block but under different item.
[0084] The itinerary planning system can produce the itinerary automatically according to the preference of the user. Please refer to FIG. 8 , which is a first flow chart illustrating a method for automatically producing an itinerary of the present invention. The system provides a plurality of general information (step 211 ), receives at least one travel parameter (step 212 ), sifts the plurality of general information (step 23 ) after calculating of an algorithm (step 22 ), arranges the sifted general information (step 24 ) and outputs the travel itinerary (step 25 ). The sequence above can be a sequence of time or a sequence of sifted general information.
[0085] Please refer to FIG. 9 , which is a second flow chart illustrating a method for automatically producing an itinerary of the present invention. The system provides a plurality of general information (step 311 ), receives at least one travel parameter (step 312 ) and outputs the travel itinerary (step 33 ) after calculating of an algorithm (step 32 ). The algorithm abovementioned includes:
[0086] Deciding the itinerary range: calculating the itinerary range according to the city, the scenic spot/restaurant/hotel must to go to, the travel days, and the traffic way designated by the user.
[0087] Deciding the itinerary location: calculating the total itinerary locations according to the scenic spot/restaurant/hotel must to go to, the itinerary range, the travel purpose, and the preference and requirement of the user designated by the user.
[0088] Location cluster analysis: analyzing the location cluster according to the travel days, and distributing each location to each day. For example, 5 groups for 5 travel days.
[0089] Each day location sequence: arranging the location except the hotel and the restaurant according to the route condition (the shortest route, the lowest budget route) choose by the user.
[0090] Producing the traffic route between any two locations: calculating the traffic route, traffic time and traffic budget between any of two locations according to the site of the location and traffic way of the user.
[0091] Determining the receiving time and playing time of each location: setting the arrival time and touring time of each location according to the touring time recommended by friends, the time of getting up and going to bed of the user, and the traffic time between the two locations.
[0092] There is no absolute sequence or combination of the above algorithm, one skilled person in the art can proceed different optimization for a variety of cases. The algorithm is an iteration and a recursion algorithms which is used to let the itinerary to achieve optimization. The algorithm further including a sub-algorithm, wherein the sub-algorithm is one selected form a group consisting of an information matching method and an itinerary estimating method. The information matching method includes: providing an itinerary information; receiving a personal preference parameter; and calculating the itinerary information according to the personal preference parameter to obtain a calculating result.
[0093] Please refer to FIG. 10( a ), which is a schematic diagram illustrating a travel preference interface of the present invention. The user interface displays a plurality of general information ( 1010 , 1020 , 1030 and 1040 ) to provide the user to fill the parameter. When the user selects one of the general information, the interface will enter a property setting interface, as shown in FIG. 10( b ), and the property setting interface includes the property of the general information for clicking ( 1011 , 1012 and 1013 ). When the user clicks one property, such as property 1 ( 1011 ), can show a plurality of parameters (parameters 1-6), and the plurality of parameters (parameters 1-6) are degrees of emphasis and preference. The user can give an evaluation of 1-5 scores (such as parameters 1-3) according to the degrees of emphasis and preference of the different parameters, or the user can enter a key word on the parameter field (such as parameters 4-6). Repeating the above steps, the user will obtain a weighting table after filling all parameters (please refer to the embodiments as follows).
Embodiment 31
[0094] After the user A filling the travel preference of the user interface, it will generate different weighting table according to the various types of travel resources as follows:
[0095] The preference and demand tables of the guesthouse:
[0000]
Parameter
User A
Public order of the guesthouse
5
Architectural features of the guesthouse
5
Cleanliness of the guesthouse
4
[0096] The preference and demand table of the scenic spot:
[0000]
Parameter
User A
Scenery special of the scenic spot
2
Not many tourists of the scenic spot
1
Strong cultural atmosphere of the scenic spot
3
[0097] The preference and demand table of the restaurant:
[0000]
Parameter
User A
Fresh ingredients of the restaurant
5
Environmental health of the restaurant
5
Cuisine features of the restaurant
2
[0098] Furthermore, the itinerary set by the user A is as follows:
[0000]
Travel date
2012/02/14 17:00~2012/02/15
18:00
Travel purpose
To celebrate Valentine's Day
Travel rhythm (fast, medium, slow)
Slow
Budget
15000
The scenic spot must to go to
Chingtienkang
Traffic way
Car
[0099] According to the data above, the data processing module 130 is calculated according to the requirement filled by the user, and searched 10 hotels from the database 110 nearby the Chingtienkang within 5 km. Because of the Valentine's Day, the system sifts the guesthouse having night scene and hot spring, at last, the data processing module 130 calculates that the user can live in the Mountain Star.
[0100] After deciding the hotel, because the Chingtienkang is the scenic spot which is must to go to, the evaluation of the Chingtienkang in the database 110 contains “recommending to go to the Chingtienkang at that can see the grazing”, “sunset is a very special landscape”, “recommending to go to the Chingtienkang for three hours, you can lie and chat on the grassland” and so on. Therefore, the data processing module 130 arranges to go to the Chingtienkang on the second day at 14:00-17:00, and the suggestion activities: (1) walking in the forest; (2) chatting on the grassland; and (3) the grazing scenic spot.
[0101] In addition, according to the general information in the database 110 , the flower clock is the cherry blossom season in February, there is no special time recommended by the users, but only recommended that walking within 2 hours, so that the data processing module 130 arranges to walk at flower clock from 9:00-11:00.
[0102] After deciding the scenic spot and the hotel, the system searches the restaurant according to the preference and the requirement of the user in the Yangmingshan, and finds the Zhuzihu GAP.
[0103] After calculating, the automatically itinerary producing system generates an itinerary (the output interface refers to FIG. 4 , wherein the empty time is the traffic time) as follows:
[0000]
2012/02/14
itinerary
18:00~
the Mountain Star (eat, hot spring, live)
2012/02/15
itinerary
09:00~11:00
Flower Clock
12:00~13:30
Zhuzihu GAP
14:00~17:00
Chingtienkang
[0104] The present invention also allows planned the same itinerary by many people using different computing devices 140 . Please refer to FIG. 11 , which is a schematic diagram illustrating a system for planning an itinerary real-timely and synchronously of the present invention. The computing device 1110 , 1120 includes an itinerary planning module 1111 , 1121 , a itinerary synchronous module 1112 , 1122 , an information transmitting module 1113 , 1123 , and an information receiving module 1114 , 1124 . The itinerary planning module 1111 , 1121 includes a plurality of input units to let the user to edit the itinerary, wherein the itinerary planning module 1111 , 1121 further includes a schedule planning module to allow the user to plan their journey, a traffic planning module to let the user to arrange the move route and transport between the locations, a budget planning module to let the user to edit the budget of the itinerary, a resource planning interface to let the user arrange the resource of the itinerary, or a filing planning interface to allow the use to arrange other filing, and the object of the itinerary planning module 1111 , 1121 includes a travel itinerary, a business itinerary and a manufacturing itinerary. The itinerary synchronization 1112 , 1122 can calculate the partial or all itinerary synchronization of the date received by the information received module 1114 , 1124 , to calculate the newest state of the itinerary and refresh the itinerary state according to this newest state of the itinerary. The information transmitting module 1113 , 1123 is used for transmitting an user operation information or a itinerary state information according to the itinerary information. The information receiving module 1114 , 1124 is used to receive the user operation and instruction through the internet. The internet 1103 is used to connect and transmit the multi-information and instructions.
Embodiment 32
[0105] The present invention is located at the user end device according to the itinerary synchronous module 1111 , 1121 , and planned the itinerary real-timely and synchronously without a server, as shown in FIG. 11 , and referring to FIG. 12 at the same time. The steps are as follows:
[0106] (1) the first user 1101 and the second user 1102 use the multi-people planning system, and browse the same itinerary state on the one-to-one correspondence itinerary interface.
[0107] (2) the first user 1101 operates the first itinerary planning module 1111 to plan the itinerary, wherein the scenic spot A, restaurant, hotel are arranged in the first day at 10:00-12:00 of the itinerary, and arranges into the itinerary, as shown at P 1 of FIG. 12 .
[0108] (3) the first transmitting module 1113 transmits the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00 through the internet 110 as shown in P 2 of FIG. 12 .
[0109] (4) the second information receiving is the user operation information and the itinerary state information of the scenic spot A is arranged in the first day at 10:00-12:00, as shown in P 3 of FIG. 12 .
[0110] (5) the second synchronous module 1122 calculates the newest itinerary received form the information according to the second received module 1124 , as shown in P 4 of FIG. 12 .
[0111] (6) the second planning module 1121 refreshes the newest user interface according to the newest itinerary state, and display the newest itinerary in front of the second user 1102 , as shown in P 5 of FIG. 12 .
Embodiment 33
[0112] The present invention plans the itinerary real-timely and synchronously by the user end and the server device 1130 , as shown in FIG. 13 , wherein the server 1130 includes a third information receiving module 1133 for receiving any information transmitted from the user end of the itinerary planning system, the third information synchronous module 1131 is used to synchronous calculate the partial itinerary according to the information received from the third information receiving module 1133 , a third information transmitting module 1132 for transmitting the information calculated by the itinerary synchronous module, and a database 1134 for storing the newest itinerary state. The steps are as follows:
[0113] (1) the first user 1101 and the second user 1102 use the multi-people planning system, and browse the same itinerary state on the one-to-one correspondence itinerary interface.
[0114] (2) the first user 1101 operates the first itinerary planning module 1111 to plan the itinerary, wherein the scenic spot A, restaurant, hotel are arranged in the first day at 10:00-12:00 of the itinerary, and arranges into the itinerary.
[0115] (3) the first transmitting module 1113 transmits the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00.
[0116] (4) the third information receiving module 1133 in the server 1130 starts to receive the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00 transmitted from the first information transmitting module 1113 through the internet 1103 .
[0117] (5) the third synchronous module 1131 in the server 1130 synchronously calculates the partial itinerary according to the information received by the third information receiving module 1133 .
[0118] (6) the third synchronous module 1131 stores the calculating result in the database 1134 , and transmits the calculating result to the third information transmitting module 1132 .
[0119] (7) the third information transmitting module 1132 transmits the calculating result to the second information receiving module 1124 through the internet 1103 .
[0120] (8) the second information receiving module 1124 receives the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00 transmitted from the third information transmitting module 1132 through the internet 1103 .
[0121] (9) the second synchronous module 1122 calculates the newest itinerary state according to the information received by the second information receiving module 1124 , as shown in P 4 of FIG. 12 .
[0122] (10) the second itinerary planning module 1121 refreshes the newest user interface 120 according to the newest itinerary state, and display the newest itinerary in front of the user, as shown in P 5 of FIG. 12 .
[0123] The present invention plans the itinerary real-timely and synchronously by the server device 1130 , as shown in FIG. 14 .
[0124] There are further embodiments provided as follows. The steps are as follows:
[0125] (1) the first user 1101 and the second user 1102 use the multi-people planning system, and browse the same itinerary state on the one-to-one correspondence itinerary interface.
[0126] (2) the first user 1101 operates the first itinerary planning module 1111 to plan the itinerary, wherein the scenic spot A, restaurant, hotel are arranged in the first day at 10:00-12:00 of the itinerary, and arranges into the itinerary. The first transmitting module 1113 transmits the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00 to the third information receiving module 1133 of the server 1130 .
[0127] (3) the third information receiving module 1133 in the server 1130 starts to receive the user operation information and the itinerary state information of the scenic spot A which is arranged in the first day at 10:00-12:00, and transmits to the third synchronous module 1131 .
[0128] (4) the third synchronous module 1131 calculates the newest itinerary state and stores the calculating result in the database 1134 , and transmits the calculating result to the third information transmitting module 1132 .
[0129] (5) the third information transmitting module 1132 transmits the received information to the second information receiving module 1124 through the internet 1103 .
[0130] (6) the second information receiving module 1124 transmits the information proceeded by the server 1130 to the second itinerary planning module 1121 .
[0131] (7) the second itinerary planning module 1121 refreshes the newest user interface 120 according to the newest itinerary state, and display the newest itinerary in front of the user.
Embodiment 1
[0132] In an antenna, including: a piezoelectric substrate and a radiating portion configured on the piezoelectric-substrate. The radiating portion includes a first radiating portion including a ground end and a signal feed end and a second radiating portion electrically connected with the first radiating portion and having a self-similar conformation.
Embodiment 2
[0133] In the antenna according to the above-mentioned embodiment 1, further including a dielectric substrate and a coplanar wave guide metal strip configured on the dielectric substrate.
Embodiment 3
[0134] In the antenna according to the above-mentioned embodiment 2, the coplanar wave guide metal strip includes: a ground metal strip electrically connected with the ground end and a coupling feed metal strip having a signal transmission end and a coupling feed end. The coupling feed end is electrically connected with the signal feed end.
Embodiment 4
[0135] In the antenna according to the above-mentioned embodiment 3, further including a bifurcation point connected to the first radiating portion and the second radiating portion. There is a specific distance between the bifurcation point and the coupling feed end.
Embodiment 5
[0136] In the antenna according to the above-mentioned embodiment 4, the specific distance is at least 1/80 wavelength of the lowest resonant frequency of the antenna in a free space. The bifurcation point is configured on a site of the specific distance from the coupling feed end.
Embodiment 6
[0137] In the antenna according to the above-mentioned embodiment 1, the second radiating portion has a sub-structure and a similar structure that is formed by an nth-order self-similar iteration process including a trimming step, a scaling step and a combining step based on the sub-structure. N is an integer greater than zero.
Embodiment 7
[0138] In the antenna according to the above-mentioned embodiment 6, the similar structure is formed as a structure of a quasi-Sierpinski Gasket fractal conformation.
Embodiment 8
[0139] In the antenna according to the above-mentioned embodiment 6, the sub-structure is one of a triangle and a quadrangle after trimmed. The quadrangle is one selected from a group consisting of a trapezoid, a rectangle and a square.
Embodiment 9
[0140] In the antenna according to the above-mentioned embodiment 1, the dielectric substrate is a printed circuit board substrate.
Embodiment 10
[0141] In the antenna according to the above-mentioned embodiment 1, the first radiating portion is surroundingly configured at a periphery of the second radiating portion.
Embodiment 11
[0142] In the antenna according to the above-mentioned embodiment 1, the first radiating portion has a hollow-out area. The pattern of the hollow-out area is corresponding to the whole pattern of the second radiating portion.
Embodiment 12
[0143] In the antenna according to the above-mentioned embodiment 1, the first radiating portion and the second radiating portion are conducting metal strips configured on the piezoelectric-substrate.
Embodiment 13
[0144] In the antenna according to the above-mentioned embodiment 1, the first radiating portion is a loop radiating portion. The second radiating portion is a quasi-fractal radiating portion.
Embodiment 14
[0145] In an antenna, including: a dielectric substrate layer and a quasi-fractal radiating layer configured on the dielectric substrate layer.
Embodiment 15
[0146] In the antenna according to the above-mentioned embodiment 14, the dielectric substrate layer is a piezoelectric material substrate layer.
Embodiment 16
[0147] In the antenna according to the above-mentioned embodiment 14, the quasi-fractal radiating layer has a quadrangle sub-structure and a similar structure that is formed by an nth-order self-similar iteration process including a trimming step, a scaling step and a combining step based on the quadrangle sub-structure. N is an integer greater than zero.
Embodiment 17
[0148] In the antenna according to the above-mentioned embodiment 14, the quadrangle is one selected from a group consisting of a trapezoid, a rectangle and a square.
Embodiment 18
[0149] In an antenna, including: a coplanar wave guide layer and a quasi-fractal antenna layer configured on the coplanar wave guide layer and having a self-similar conformation.
Embodiment 19
[0150] In the antenna according to the above-mentioned embodiment 18, the coplanar wave guide layer and the quasi-fractal antenna layer are connected by one of a flip chip process and a non-conductive adhesive method.
Embodiment 20
[0151] In the antenna according to the above-mentioned embodiment 18, the coplanar wave guide layer and the quasi-fractal antenna layer perform a coupling feed by a coplanar wave guide form.
[0152] While the invention has been described in terms of what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention needs not be limited to the disclosed embodiments. Therefore, it is intended to cover various modifications and similar configuration included within the spirit and scope of the appended claims, which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures.
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The present invention provides an itinerary planning system and an itinerary planning, estimating and automatic producing method, wherein the itinerary planning system including an itinerary displaying board for displaying an itinerary, a general information displaying module for displaying a general information and a geographic information displaying module for displaying a geographic information, wherein an interaction existing among them. The itinerary planning system is capable of planning an itinerary, estimating the best sequence of the itinerary, sequencing the itinerary automatically according to the interest of the user, and editing the same itinerary by the multi-people real-timely and synchronously, to make the itinerary planning system of the present invention is more convenience for the user to use the system.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 10/907,134, filed Mar. 22, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an automotive vehicle having an onboard apparatus for suppressing a vehicle fire.
[0004] 2. Disclosure Information
[0005] Police vehicles are subject to increased exposure to collisions, particularly high-speed rear-end collisions, arising from the need for police officers to stop on the shoulders, or even in the traffic lanes, of busy highways. Unfortunately, other motorists are known to collide with police vehicles employed in this manner. These accidents can compromise the fuel system on any vehicle and may cause fires. The present system is designed to suppress the spread of, or potentially, to extinguish such a fire. U.S. Pat. No. 5,590,718 discloses an anti-fire system for vehicles in which a number of fixed nozzles are furnished with a fire extinguishing agent in response to an impact sensor. The system of the '718 patent suffers from a problem in that the fixed nozzles are not suited to the delivery of the extinguishing agent at ground level. Also, the '718 patent uses a valving system which could become clogged and therefore inoperable. U.S. Pat. No. 5,762,145 discloses a fuel tank fire protection device including a powdered extinguishing agent panel attached to the fuel tank. In general, powder delivery systems are designed to prevent ignition of fires and are deployed upon impact. As a result, the powder may not be able to follow the post-impact movement of the struck vehicle and may not be able to prevent the delayed ignition or re-ignition of a fire.
[0006] The present fire suppression system provides significant advantages, as compared with prior art vehicular fire suppression systems.
SUMMARY OF THE INVENTION
[0007] According to an aspect of the present invention, an onboard fire suppression system includes at least one reservoir containing a fire suppressant agent. The reservoir includes a resin vessel having a discontinuous fiber reinforcement defining at least one pressure-configurable discharge orifice. A propellant which is operatively associated with the reservoir expels a fire suppressant agent from the reservoir under pressure. Either a remote distribution system receives a portion of the fire suppression agent which is not expelled through the pressure-configurable discharge orifice, or the reservoir accomplishes the distribution without additional hardware. If employed, the distribution system distributes the remaining suppressant agent in at least one location separated from the reservoir. The remote distribution itself may include a number of nozzles having pressure-configurable orifices.
[0008] The pressure-configurable orifice characteristic of the present reservoir is achieved through the use of fiber reinforcement which may include carbon fiber, with or without wound filaments, with the pressure-configurable discharge orifices functioning as a wall segment of the vessel having a generally annular section of woven fiber reinforcement which is overlapped and wrapped upon itself, with at least one overlapping portion unwrapping in response to the axially directed extension of the woven reinforcement following fracturing of the resin as a result of deployment of the propellant, such that the suppression agent will be allowed to flow through the interstices of the woven reinforcement. As an alternative, the pressure-configurable discharge orifice may include a wall segment of the vessel having a number of apertures formed in the reinforcement during manufacturing of the reservoir, with the apertures being filled with frangible resin prior to deployment of the propellant. Nozzles used with the present reservoir preferably include generally tubular fiber-reinforced resin conduits having discontinuous fiber reinforcements including apertures which are filled with pressure-frangible resin prior to deployment of the propellant. As used herein, the term “pressure configurable” means that, in essence, orifices do not exist in the reservoir prior to deployment of the fire suppression system.
[0009] It is an advantage of a onboard fire suppression system reservoir according to the present invention that the system may be produced with lower weight and greater resistance to corrosion, as compared with known metallic reservoir systems.
[0010] It is yet another advantage of the present system that the physical configuration of the composite reservoir may be easily altered, without the need for the creation of new tooling which is attendant the use of metallic reservoirs.
[0011] Other advantages, as well as features of the present invention will become apparent to the reader of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a ghost perspective view of an automotive vehicle having a fire suppression system according to the present invention.
[0013] FIG. 2 is an exploded perspective view of a portion of a fire suppression system according to the present invention.
[0014] FIG. 3 is a perspective view of a control module used with a system according to the present invention.
[0015] FIG. 4 is a perspective view of a manually activatable switch used with a fire suppression system according to the present invention.
[0016] FIG. 5 illustrates a portion of a wiring harness used with the present system.
[0017] FIG. 6 is a flowchart showing a portion of the logic used to control a system according to the present invention.
[0018] FIG. 7 is a cutaway perspective view of a fire suppression agent reservoir according to one aspect of the present invention.
[0019] FIG. 8 is a perspective view of a variable geometry fire suppression agent nozzle according to one aspect of the present invention.
[0020] FIG. 9 is a block diagram of a fire suppression system and with additional components for occupant restraint according to one aspect of the present invention.
[0021] FIG. 10 is a perspective view of a vehicle having a fire suppression system with a reservoir having pressure-configurable orifices according to one aspect of the present invention.
[0022] FIG. 11 is a perspective view of a suppression agent reservoir according to one aspect of the present invention.
[0023] FIG. 12 is a sectional view of a first embodiment of an orifice portion of the reservoir of FIG. 11 , prior to deployment of the fire suppression system.
[0024] FIG. 13 illustrates the orifice portion of FIG. 12 during deployment of the fire suppression system.
[0025] FIG. 14 is a sectional view of a second embodiment of an orifice portion of the reservoir of FIG. 11 , prior to deployment of the fire suppression system.
[0026] FIG. 15 illustrates the orifice portion of FIG. 14 during deployment of the fire suppression system.
[0027] FIG. 16 illustrates a composite, pressure-configurable nozzle according to one aspect of the present invention.
[0028] FIG. 17 illustrates the nozzle of FIG. 16 during deployment of the fire suppression system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] As shown in FIG. 1 , vehicle 10 has a passenger airbag restraint 48 and a driver's airbag restraint 50 mounted adjacent steering wheel 52 . A fire suppression system includes controller 66 which is mounted upon floor pan 68 of vehicle 10 , and reservoirs 18 which are mounted under floor pan 68 in the so-called kick-up area adjoining the rear axle of vehicle 10 . Those skilled in the art will appreciate in view of this disclosure that additional passenger restraint devices, such as seat belt pretensioners and side airbags, may be installed in a vehicle and controlled at least in part by, or in conjunction with, controller 66 .
[0030] FIG. 1 shows not only reservoirs 18 but also a portion of right and left side fire suppression conduits 28 , as well as fixed geometry nozzles 30 and variable geometry nozzles 36 . As seen in FIG. 1 , variable geometry nozzles 36 project downwardly to allow fire suppression agent to be expelled from reservoirs 18 and placed at a low angle to the ground surface the vehicle is operating upon. This mode of operation is possible because variable geometry nozzles 36 are, as shown in FIG. 2 , telescopingly extensible. This telescoping feature, which is shown in greater detail in FIG. 8 , is produced by a sliding spray head, 40 , which is slidingly engaged with conduit 28 such that gas pressure within conduit 28 forces spray head 40 downwardly into its extended position, causing fire suppression agent 22 to be discharged through a number of holes 42 formed in spray head 40 . As shown in FIG. 2 , at least two variable geometry nozzles 36 may be employed with single reservoir 18 , along with at least two fixed nozzles 30 which are spray bars each having a number of orifices 34 . While in their normally closed state, variable geometry nozzles 36 are liquid-tight by virtue of seals 46 , which are interposed between an end of each of spray heads 40 and the corresponding ends of conduits 28 . In a preferred embodiment, seals 46 comprise elastomeric boots attached to an outer surface of conduit 28 . Seals 46 are simply sheared by the deploying spray head 40 when the present system is discharged. Fixed nozzles 30 are also rendered liquid-tight by covers 44 , which are simply blown off when the present system is discharged. The sealing of nozzles 30 and 36 is important, because this prevents the ingress of road splash, which could block the system in sub-freezing weather or cause corrosion or blockage due to mud or other foreign matter.
[0031] Additional details of reservoir 18 are shown in FIG. 7 . Tank 90 contains approximately 1.5 L of fire suppression agent 22 , and a propellant 92 . Propellant 92 includes two squibs (not shown) which are activated simultaneously by controller 66 via lines 91 so as to release a large amount of gas, forcing fire suppressant agent 22 from tank 90 and into distribution system 26 , including conduit 28 and the various fixed and variable geometry nozzles. A preferred propellant, marketed by Primex Aerospace Company as model FS01-40, is a mixture including aminotetrazole, strontium nitrate, and magnesium carbonate. This is described in U.S. Pat. No. 6,702,033, which is hereby incorporated by reference into this specification.
[0032] Those skilled in the art will appreciate in view of this disclosure that other types of propellants could be used in the present system, such as compressed gas canisters and other types of pyrotechnic and chemical devices capable of creating a gas pressure force in a vanishingly small amount of time. Moreover, fire suppressant agent 22 , which preferably includes a water-based solution with hydrocarbon surfactants, fluorosurfactants, and organic and inorganic salts sold under the trade name LVS Wet Chemical Agent® by Ansul Incorporated, could comprise other types of agents such as powders or other liquids, or yet other agents known to those skilled in the art and suggested by this disclosure. If two reservoirs 18 are employed with a vehicle, as is shown in FIG. 1 , all four squibs will be deployed simultaneously.
[0033] FIG. 4 shows manually activatable switch 54 for use with the present system. As shown in FIG. 1 , switch 54 may be advantageously located on the headliner of vehicle 10 between the sun visors, or at any other convenient position. To use this switch 54 , hinged clear cover 56 is first opened by pressing on cover 56 . Thereafter, the fire suppression system may be triggered by manually pressing pushbutton 58 . If the vehicle occupants are not disposed to release cover 56 , the system may be triggered by merely sharply depressing cover 56 , thereby closing contacts (not shown) contained within platform 60 .
[0034] Because the present system is intended for use when the vehicle has received a severe impact, controller 66 , which is shown in FIG. 3 , contains a redundant power reserve or supply, which allows operation of the fire suppression system for about nine seconds, even if controller 66 becomes isolated from the vehicle's electrical power supply. Wiring harness 80 , as shown in FIG. 5 , is armored, and has a para-aramid fiber inner sheath, 82 , of about 2 mm in thickness, which helps to shield the conductors within harness 80 from abrasion and cutting during a vehicle impact event. This para-aramid fiber is sold under the trade name KEVLAR® by the DuPont Company. This armoring helps to assure that communication between controller 66 and reservoirs 18 remains in effect during an impact event. Post-impact communications are further aided by redundancy in the control system. Specifically, four independent sets of primary conductors, 79 a - d , extend from controller 66 to reservoirs 18 protected by sheath 82 . Moreover, an H-conductor, shown at 81 in FIG. 5 , extends between reservoirs 18 . Thus, if one or both of the primary conductors 79 a - b , or 79 c - d , extending to one of reservoirs 18 should become severed, H-conductor 81 will be available to carry the initiation signal from the undamaged lines to both of reservoirs 18 .
[0035] As noted above, an important feature of the present invention resides in the fact that the control parameters include not only vehicle impact, as measured by an accelerometer such as that shown at 70 in FIG. 9 , but also vehicle speed, as measured by means of speed sensors 74 , also shown in FIG. 9 . Speed sensors 74 may advantageously be existing sensors used with an anti-lock braking system or vehicle stability system. Alternatively, speed sensors 74 could comprise a global positioning sensor or a radar or optically based ground-sensing system. Accelerometer 70 , as noted above, could be used with a conventional occupant restraint airbag system, thereby maximizing use of existing systems within the vehicle. Advantageously, accelerometer 70 may be an amalgam of two or more accelerometers having differing sensing ranges. Such arrangements are known to those skilled in the art and suggested by this disclosure. At least a portion of the various sensors could either be integrated in controller 66 or distributed about vehicle 10 .
[0036] FIG. 6 shows a sequence which is used according to one aspect of the present invention for activating a release of fire suppressant agent.
[0037] Beginning at block 100 , controller 66 performs various diagnostics on the present system, which are similar to the diagnostics currently employed with supplemental restraint systems. For example, various sensor values and system resistances will be evaluated on a continuous basis. Controller 66 periodically moves to block 102 , wherein the control algorithm will be shifted from a standby mode to an awake mode in the event that a vehicle acceleration, or, in other words, an impact, having a magnitude in excess of a relatively low threshold is sensed by accelerometer 70 . Also, at block 102 a backup timer will be started. If the algorithm is awakened at block 102 , controller 66 disables manually activatable switch 54 at block 104 for a predetermined amount of time, say 150 milliseconds. This serves to prevent switch 54 from inadvertently causing an out-of-sequence release of fire suppression agent. Note that at block 104 , a decision has not yet been made to deploy fire suppression agent 22 as a result of a significant impact.
[0038] At block 106 , controller 66 uses output from accelerometer 70 to determine whether there has been an impact upon vehicle 10 having a severity in excess of a predetermined threshold impact value. Such an impact may be termed a significant, or “trigger”, impact. If an impact is less severe than a trigger impact, the answer at block 106 is “no”, and controller 66 will move to block 105 , wherein an inquiry is made regarding the continuing nature of the impact event. If the event has ended, the routine moves to block 100 and continues with the diagnostics. If the event is proceeding, the answer at block 105 is “yes”, and the routine loops to block 106 .
[0039] If a significant impact is sensed by the sensor system including accelerometer 70 and controller 66 , the answer at block 106 will be “yes.” If such is the case, controller 66 moves to block 108 wherein the status of a backup timer is checked. This timer was started at block 102 .
[0040] Once the timer within controller 66 has counted up to a predetermined, calibratable time on the order of, for example, 5-6 seconds, controller 66 will cause propellant 92 to initiate delivery of fire suppressant agent 22 , provided the agent was not released earlier. Propellant 92 is activated by firing an electrical squib so as to initiate combustion of a pyrotechnic charge. Alternatively, a squib may be used to pierce, or otherwise breach, a pressure vessel. Those skilled in the art will appreciate in view of this disclosure that several additional means are available for generating the gas required to expel fire suppressant agent 22 from tank 90 . Such detail is beyond the scope of this invention. An important redundancy is supplied by having two squibs located within each of tanks 90 . All four squibs are energized simultaneously.
[0041] The velocity of the vehicle 10 is measured at block 110 using speed sensors 74 , and compared with a low velocity threshold. In essence, controller 66 processes the signals from the various wheel speed sensors 74 by entering the greatest absolute value of the several wheel speeds into a register. This register contains both a weighted count of the number of samples below a threshold and a count of the number of samples above the threshold. When the register value crosses a threshold value, the answer at block 110 becomes “yes.” In general, the present inventors have determined that it is desirable to deploy fire suppression agent 22 prior to the vehicle coming to a stop. For example, fire suppression agent 22 could be dispersed when the vehicle slows below about 15 kph.
[0042] At block 112 , controller 66 enters a measured vehicle acceleration value into a second register. Thereafter, once the acceleration register value decays below a predetermined low g threshold, the answer becomes “yes” at block 112 , and the routine moves to block 114 and releases fire suppressant agent 22 . In essence, a sensor fusion method combines all available sensor information to verify that the vehicle is approaching a halt. The routine ends at block 116 . Because the present fire suppression system uses all of the available fire suppression agent 22 in a single deployment, the system cannot be redeployed without replacing at least reservoirs 18 .
[0043] FIG. 6 does not include the activation of occupant restraints 48 and 50 , it being understood that known control sequences, having much different timing constraints, may be employed for this purpose. In point of contrast, the low velocity threshold allows the present system to deliver the fire suppression agent while the vehicle is still moving, albeit at a very low velocity. This prevents the rear wheels of the vehicle from shadowing, or blocking dispersion of fire suppressant agent 22 . Also, in many cases, a vehicular fire may not become well-established until the vehicle comes to a halt.
[0044] As shown in FIGS. 10 and 11 , vehicle 200 has a controller, 204 , for operating the present fire suppression system including reservoirs 208 , which contain a fire suppressant agent, 206 . Each of reservoirs 208 includes a resin vessel having a discontinuous fiber reinforcement, 216 , defining at least one pressure-configurable discharge orifice. A propellant, 212 , as explained above, is operatively associated with each of reservoirs 208 , for expelling the fire suppressant agent from the reservoir under pressure. A remote distribution system including fiber reinforced resin nozzles 232 , receives a portion of fire suppressant agent expelled from the reservoir and distributes the suppression agent in at least one location and separated from reservoirs 208 .
[0045] FIG. 11 illustrates reservoir 208 with propellant 212 and wall 210 which is shown in detail in FIGS. 12-15 . Moving now to FIG. 12 , wall 210 includes resin 214 and fiber reinforcement 216 , which is shown as being overlapped and wrapped upon itself such that the unwrapping of reinforcement 216 will be accompanied by axially directed extension of the woven reinforcement. Unwrapping is intended to occur only after resin 214 has fractured due to pressure produced by propellant 212 . Once this fracturing occurs, section 218 expands as shown in FIG. 13 and suppressant agent flows out through orifices 220 formed at the interstices of woven reinforcement 216 . Reinforcement 216 may be constructed with either carbon fiber, or other fibers, either as a wound filament, or as other preforms known to those skilled in the art and suggested by this disclosure.
[0046] In contrast with the situation in FIGS. 12 and 13 , in the embodiment of FIGS. 14 and 15 , fiber reinforcement 216 need not be woven with flowable interstices. Rather, reinforcement 216 of FIGS. 14 and 15 has a series of discrete apertures, 224 , formed therein. As shown in a normal operating state in FIG. 14 , wall section 210 has apertures 224 which are filled with frangible resin 214 . Once propellant 212 has been activated, however, the resin within apertures 224 fractures, thereby allowing suppressant to escape through orifices 228 , which are defined by the fractured resin and by apertures 224 .
[0047] FIGS. 16 and 17 disclose a fiber reinforced resin nozzle 232 , which has a discontinuous reinforcement 240 located within a frangible resin, 236 . When propellant 212 is activated, resin is broken and blown out of apertures 242 and forms orifices 244 , allowing discharge of fire suppressant.
[0048] Although the present invention has been described in connection with particular embodiments thereof, it is to be understood that various modifications, alterations, and adaptations may be made by those skilled in the art without departing from the spirit and scope of the invention set forth in the following claims.
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An automotive vehicle includes a vehicle body and at least one reservoir containing a fire suppressant agent. A distribution system receives the fire suppression agent from the reservoir and conducts the agent to at least one location about the vehicle's body in response to the determination by a sensor system and controller that the vehicle has been subjected to a significant impact. The distribution system includes a composite reservoir containing pressure-configurable orifices.
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TECHNICAL FIELD
[0001] The present invention relates to a fluid compression system and, more particularly, to a connecting duct for a fluid compression system having a series of compression stages.
BACKGROUND
[0002] Many applications require a supply of a pressurized fluid, such as, for example, pressurized air. These applications may include a compression system that increases the pressure of a fluid from a first pressure to a second pressure for use in the particular application. The compression system may include a series of compression stages that apply work to the fluid to achieve the desired pressure increase. For example, the compression system may include a first compressor that increases the pressure of the fluid from a first pressure to an intermediate pressure and a second compressor that increases the pressure of the fluid from the intermediate pressure to the second pressure.
[0003] A vehicle such as, for example, an on highway truck, is one example of an application that may require a flow of pressurized air. A compression system on a vehicle may include one or more superchargers and/or turbochargers that increase the pressure of a flow of intake air for an internal combustion engine. The pressurized intake air may be used to increase the air mass within the combustion chambers of the engine, which may lead to an increase in the mass of fuel that may be injected and, thus, an increase in the power output of the engine. A compression system with a greater efficiency may provide a greater power increase than a compression system with a lower efficiency.
[0004] The efficiency of a compression system may be increased by reducing the amount of energy required to increase the pressure of the fluid from the first pressure to the second pressure. A compressor may most efficiently increase the pressure of a flow of fluid when the fluid enters the compressor with a uniform flow profile, such as, for example, in a laminar flow. However, the fluid flowing out of a compressor typically includes a rotational component or vortex. This rotational component contains dynamic pressure that may be lost when the fluid flow enters a second compressor. Thus, additional energy may be required to drive the second compressor to achieve the desired pressure increase. In other words, the presence of the swirl, or other irregularity in the fluid flow between compression stages, may result in a reduction of the overall efficiency of the compression system.
[0005] The present disclosure is directed to overcoming one or more of the problems as set forth above.
SUMMARY OF THE INVENTION
[0006] According to one aspect, the present disclosure is directed to a connecting duct for providing a fluid pathway between an outlet of a low pressure compressor and an inlet of a high pressure compressor. The connecting duct includes a main body that defines a fluid pathway adapted to direct a flow of fluid between a main body inlet and a main body outlet. The main body also includes a diffusing section that decreases a velocity of the flow of fluid. A flow de-swirling section is disposed between the diffusing section and the outlet of the main body to straighten the flow of fluid.
[0007] According to another aspect, the present disclosure is directed to a method of compressing a flow of fluid. A flow of fluid is compressed from a first pressure to an intermediate pressure with a first compressor. A velocity of the flow of fluid from the first compressor is reduced. The flow of fluid is straightened. The flow of fluid is compressed to a second pressure with a second compressor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagrammatic and schematic illustration of a compression system in accordance with an exemplary embodiment of the present invention;
[0009] FIG. 2 is a top plan view of a connecting duct for a compression system in accordance with an exemplary embodiment of the present invention; and
[0010] FIG. 3 is a diagrammatic and schematic illustration of an exemplary engine system having a compression system in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
[0011] FIG. 1 illustrates an exemplary embodiment of a compression system 10 . Compression system 10 includes a first compressor 12 and a second compressor 14 . First and second compressors 12 and 14 may be radial compressors, such as, for example, impeller type compressors. First and second compressors 12 and 14 may also be any other type of compressor that is typically used in a turbocharging or supercharging system that may be associated with an internal combustion engine.
[0012] Compression system 10 also includes an inlet passage 11 . Inlet passage 11 directs a flow of fluid to an inlet of first compressor 12 . The fluid may be, for example, air, such as intake air for an internal combustion engine.
[0013] Compression system 10 may also include a power source to drive first compressor 12 . The power source may be a first motor 16 that is connected to first compressor 12 through a shaft 17 . It is contemplated that compression system 10 may include other types of power sources to drive first compressor 12 . For example, the power source may be a turbine, such as when first compressor 12 is included within a turbocharger.
[0014] First motor 16 may be operated to drive first compressor 12 . The operation of first compressor 12 may increase the pressure of the fluid received through inlet passage 11 . The pressurized fluid may be discharged through the outlet of first compressor 12 .
[0015] Compression system 10 may include a connecting duct 20 that has a main body 21 , a duct inlet 24 , and a duct outlet 30 . Main body 21 defines a fluid passageway 22 between duct inlet 24 and duct outlet 30 . Fluid passageway 22 of connecting duct 20 may have, for example, a substantially circular cross-sectional shape. Duct inlet 24 may be connected to the outlet of first compressor 12 and duct outlet 30 may be connected to an inlet of second compressor 14 to provide fluid communication between first and second compressors 12 and 14 .
[0016] As shown in FIG. 2 , duct inlet 24 may include a flexible section 48 . Flexible section 48 may include, for example, a series of bellows that provide for easy connection with the outlet of first compressor 12 . One skilled in the art will recognize that connecting duct 20 may be connected to first and second compressors 12 and 14 in any readily apparent manner.
[0017] Connecting duct 20 may also include an arcuate section 23 . Arcuate section 23 may redirect the flow of fluid between first compressor 12 and second compressor 4 . For example, arcuate section 23 may redirect the flow of fluid through an angle of between about 90° and 180°. Arcuate section 23 may allow first and second compressor 12 and 14 to be arranged relative to the other in a manner that reduces the total amount of space required for compression system 10 .
[0018] Compression system 10 may also include a power source to drive second compressor 14 . The power source used to drive second compressor 14 may be similar to the power source used to drive first compressor 12 . For example, compression system 10 may include a second motor 18 that is connected to second compressor 14 through a shaft 19 . Alternatively, compression system 10 may drive second compressor 14 with a power source that is different than the power source used to drive first compressor 12 . For example, first compressor 12 may be driven by a motor, whereas second compressor 14 is driven by a turbine.
[0019] Second motor 18 may be operated to drive second compressor 14 . The operation of second compressor 14 may further increase the pressure of the fluid received through connecting duct 20 . The pressurized fluid may be discharged from second compressor 18 through a fluid outlet 32 .
[0020] Compression system 10 may be adapted to increase the pressure of the flow of fluid from a first pressure, which may be, for example, ambient pressure, to a second pressure. First compressor 12 may be adapted to increase the pressure of the flow of fluid from the first pressure to an intermediate pressure. Second compressor 14 may be adapted to further increase the pressure of the flow of fluid from the intermediate pressure to the second pressure. Since second compressor 14 compresses the fluid to a higher pressure than first compressor 12 , second compressor 14 may be referred to as a high pressure compressor and first compressor 12 may be referred to as a low pressure compressor.
[0021] First and second compressors 12 and 14 may be sized to provide substantially similar compression ratios. For example, first and second compressors 12 and 14 may both provide compression ratios of between 1.5 to 1 and 3 to 1. Alternatively, first and second compressors 12 and 14 may have different compression ratios. For example, first compressor 12 may have a compression ratio of 1.5 to 1 and second compressor 14 may have a compression ratio of 3 to 1.
[0022] It should be noted that compression system 10 may include additional compression stages. Some applications may require a greater increase in fluid pressure that may be best achieved by adding additional compression stages. It is contemplated connecting duct 20 may be used to provide fluid communication with the additional compression stages.
[0023] As will be recognized by one skilled in the art, the flow of fluid leaving first compressor 12 will typically include a steady swirl, such as, for example, a rotational component or vortex. This swirl is caused by the exit characteristics of the compressor. The swirl may include a relatively high magnitude of dynamic energy. Connecting duct 20 may be adapted to recover the dynamic energy from the swirl.
[0024] As shown in FIG. 2 , connecting duct 20 may include a diffuser 26 and a flow de-swirling section 27 . Diffuser 26 is adapted to reduce the velocity of the flow of fluid. Flow de-swirling section 27 is adapted to straighten the flow of fluid. For the purposes of the present disclosure, the phrase “straighten the flow” includes reducing the swirl induced by first compressor 12 or altering the profile of the fluid flow to achieve a substantially uniform flow profile.
[0025] Diffuser 26 includes a diffuser inlet 40 and a diffuser outlet 42 . Diffuser inlet 40 has a cross-sectional area that is less than the cross-sectional of diffuser outlet 42 . The increase in the cross-sectional area of flow passageway 22 between diffuser inlet 40 and diffuser outlet 42 will cause a reduction in the velocity of the fluid flowing through diffuser 26 . Thus, diffuser 26 will decrease the velocity of the pressurized fluid flowing from the outlet of first compressor 12 .
[0026] Flow de-swirling section 27 is connected with diffuser outlet 42 . Flow de-swirling section 27 includes a turning vane 28 , which divides flow passageway 22 into a first flow path 44 and a second flow path 46 . Turning vane 28 will, therefore, split the flow of fluid into a first flow through first flow path 44 and a second flow through second flow path 46 . Turning vane 28 may be disposed in actuate section 23 to divide the flow of fluid after the fluid has passed through a predetermined portion of arcuate section 23 . For example, a leading edge 29 of turning vane 28 may be positioned to split the flow of fluid after direction of flow of fluid has been changed by approximately 30°.
[0027] Turning vane 28 and the walls of connecting duct 20 surrounding turning vane 28 will act to straighten the flow of fluid. The curvature of arcuate section 23 may be adapted to oppose the swirl induced at the exit of first compressor 12 . In addition, the relative positioning of turning vane 28 within arcuate section 23 may further reduce the amount of swirl in the flow of fluid. In other words, the swirl may act to turn the flow of fluid into turning vane 28 and the walls of main body 21 . The impingement of the flow of fluid into turning vane 28 and the walls of main body 21 may act to straighten the flow. In this manner, the profile of the flow of fluid through connecting duct 20 may be altered to reduce the amount of swirl and/or approach a uniform flow profile.
[0028] It is contemplated that the above described compression system may be used in a variety of applications. For example, as shown in FIG. 3 , a compression system 100 may be included in a vehicle 90 to provide pressurized air to an intake manifold of an internal combustion engine 110 . The engine 110 includes an engine block 111 defining a plurality of combustion chambers 112 . In the illustrated embodiment, engine 110 includes six combustion chambers. It is contemplated that engine 110 may include a greater or lesser number of combustion chambers, depending upon the particular application.
[0029] Internal combustion engine 110 may also include an intake manifold 114 and an exhaust manifold 116 . Intake manifold 114 provides fluid, such as, for example, air or a fuel/air mixture, to the combustion chambers 112 . The exhaust manifold 116 receives exhaust gas from combustion chambers 112 .
[0030] Compression system 100 may include a first turbocharger 120 and a second turbocharger 140 that are arranged in series. First turbocharger 120 may have a first turbine 122 that includes a turbine wheel 128 and a first compressor 124 that includes a compressor wheel 134 . First turbocharger 120 may further include a first shaft 130 that is rotatably mounted within a housing 132 and carries both turbine wheel 128 and compressor wheel 134 . A rotation of turbine wheel 128 will, therefore, result in a corresponding rotation of compressor wheel 134 .
[0031] Second turbocharger 140 may have a second turbine 142 that includes a turbine wheel 146 and a second compressor 144 that includes a compressor wheel 150 . Second turbocharger 140 may further include a second shaft 148 that is rotatably mounted within housing 132 and carries both turbine wheel 146 and compressor wheel 150 . A rotation of turbine wheel 146 will, therefore, result in a corresponding rotation of compressor wheel 150 .
[0032] An air inlet 136 may provide fluid communication between the atmosphere and first compressor 124 . Connecting duct 20 may provide fluid communication between first compressor 124 and second compressor 144 . An intake duct 152 may provide fluid communication between second compressor 144 and intake manifold 114 .
[0033] One or more air coolers 156 may be disposed in intake duct 152 . Air coolers 156 are structured and arranged to extract heat from the air to lower the intake manifold temperature and to increase the air density. It is contemplated that an additional air cooler (not shown), for example, an intercooler, may be disposed between first compressor 124 and second compressor 144 .
[0034] It should be noted that an inter-stage air cooler, such as a heat exchanger, may be combined with connecting duct 20 and/or turning vane 28 . For example, turning vane 28 may include an internal passage (not shown) through which a coolant may be directed. The coolant may absorb heat from the flow of fluid passing through connecting duct 20 . In this manner, the temperature of the flow of fluid may be reduced as the fluid flows from first compressor 12 to second compressor 14 .
[0035] An exhaust duct 126 may connect exhaust manifold 116 with second turbine 142 . The fluid flow path from the exhaust manifold 116 to the second turbine 142 may include a variable nozzle (not shown) or other variable geometry arrangement adapted to control the velocity of exhaust fluid impinging on turbine wheel 146 . A conduit 137 may provide fluid communication between second turbine 142 and first turbine 122 . An exhaust outlet 154 may provide fluid communication between first turbine 122 and the atmosphere.
INDUSTRIAL APPLICABILITY
[0036] For the purposes of explaining its operation, the compression system of the present disclosure will be described in connection with the vehicle application described above and illustrated in FIG. 3 . During standard vehicle use, internal combustion engine 110 may operate in a known manner using, for example, the diesel principle of operation. Internal combustion engine 110 will draw intake air through intake manifold 114 and will expel exhaust gases to exhaust manifold 116 .
[0037] With reference to FIG. 3 , exhaust gas from the internal combustion engine 110 is directed from exhaust manifold 116 to exhaust duct 126 . Exhaust duct 126 directs the exhaust gas to second turbocharger 140 , where the exhaust gas impinges on and causes rotation of turbine wheel 146 . The rotation of turbine wheel 146 causes a corresponding rotation of compressor wheel 150 . The rotational speed of compressor wheel 150 will therefore correspond to the rotational speed of turbine wheel 146 .
[0038] The exhaust gas exits second turbocharger 140 through conduit 137 , which directs the exhaust gas to first turbocharger 120 . The exhaust gas impinges on and causes rotation of turbine wheel 128 . The rotation of turbine wheel 128 causes a corresponding rotation of compressor wheel 128 . The rotational speed of compressor wheel 134 will, therefore, correspond to the rotational speed of turbine wheel 128 . Exhaust gas from the first turbocharger 120 may be directed to the atmosphere via exhaust outlet 154 .
[0039] Rotation of compressor wheel 134 of first turbocharger 120 draws air from the atmosphere through air inlet 136 . Compressor wheel 134 applies work to the air to increase the pressure of the air from an ambient pressure to an intermediate pressure and directs the flow into connecting duct 20 . In this manner, a portion of the energy of the exhaust gas from engine 110 is used to increase the pressure of the intake air flow.
[0040] As noted previously, the flow of air exiting first compressor 124 may include a constant swirl. This swirl represents dynamic pressure that may be recaptured. The dynamic pressure may be recaptured by reducing the velocity of the flow of fluid and then straightening the flow of fluid.
[0041] The velocity at which the air is flowing will decrease as the flow of air passes through diffuser 26 . The flow area of diffuser 26 increases between diffuser inlet 40 and diffuser outlet 42 . The reduction in velocity also translates to an increase in the flow pressure of the fluid as some of the dynamic pressure of is converted to flow pressure.
[0042] As the flow of air enters de-swirling section 27 , the flow of air is split into two flows by turning vane 28 . The split in flow provides a narrowed diameter flow path for each flow of fluid. The walls of the first flow path 44 and second flow path 46 (referring to FIG. 2 ) will act to straighten, or de-swirl, the flow of fluid. The straightened flow may then be directed through duct outlet 30 .
[0043] The air flows from duct outlet 30 to second compressor 144 . Compressor wheel 150 of second compressor 144 further increases the pressure of the air to a second pressure. The flow of pressurized air may then be directed to intake manifold 114 of engine 110 via air outlet line 152 . The compressed air may be cooled by one or more air coolers 156 before reaching intake manifold 114 . The pressurized air flows from intake manifold 114 into combustion chambers 112 .
[0044] Accordingly, the described connecting duct may increase the efficiency of a multi-stage compression system. The efficiency increase results from the recapture of dynamic pressure present in a flow of fluid that leaves a first compressor. The flow of fluid is also straightened to approach a uniform profile flow. This allows the second compressor to increase the pressure of the fluid to the desired magnitude with a reduced energy input. It is contemplated that the concepts of the present disclosure may be applied to any multi-stage compression system, including, for example, an intake air compression system for an internal combustion engine.
[0045] It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed compression system without departing from the scope of the disclosure. Other embodiments of the system may be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein. It is intended that the specification and examples be considered as exemplary only.
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A connecting duct for providing a fluid pathway between an outlet of a low pressure compressor and an inlet of a high pressure compressor is provided. The connecting duct includes a main body that defines a fluid pathway adapted to direct a flow of fluid between a main body inlet and a main body outlet. The main body also includes a diffusing section that decreases a velocity of the flow of fluid. A flow de-swirling section is disposed between the diffusing section and the outlet of the main body. The flow de-swirling section straightens the flow of fluid.
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FIELD
[0001] This invention relates to smoking article assembly and associated machinery. In particular, but not exclusively, it relates to a cigarette assembling machine comprising a plurality of modules.
BACKGROUND
[0002] Known filter cigarette assembling machines comprise a filter attachment unit for attaching a filter and tobacco rod to form a filter cigarette. In a known filter attachment unit, a “double length” filter rod (also called a “2-up” rod) is aligned with two tobacco rods at either end, and the three rods are wrapped with a wrapper known as a “tipping paper” so as to join them together. The centrally positioned 2-up filter rod is then cut into two so as to form two filter cigarettes. This process is well known per se to those skilled in the art.
[0003] Known filter rods and tobacco rods are conveyed in a filter attachment unit by a plurality of cylindrical drums, with rod articles passing from drum to drum as they are conveyed through the unit. Known drums have a plurality of grooves for holding rod articles during transport, the grooves being spaced around the curved periphery of a drum, with each groove extending in the direction of the drum axis.
[0004] Certain drums are configured so that particular operations are carried out as the rod articles are conveyed by the drum. For example known filter attachment machines include a swash plate drum for longitudinally compressing two tobacco rods and a 2-up filter rod before tipping paper is applied, and a rolling drum which co-operates with a roll hand to wrap a tipping paper segment around the three rods. Other known drums include cutting drums which cooperate with a cutting knife to cut rod articles, separating drums for separating rod articles, inspection drums to inspect for the presence of filters or to carry out a leakage test, laser drums to burn small perforations in filter rods, and turning drums to change the orientation of cigarettes. Other known drums include transfer drums (also referred to as “intermediate drums”), takeover drums and feed drums. Known filter attachment machines also include a tipper unit for supplying individual cut segments of tipping paper (known as tipping “patches”) and a glue unit for applying glue to the tipping paper.
[0005] Known filter attachment units also include a machine controller which controls the drums of the unit. Such controllers can control the acceleration, deceleration and speed of drums and the registration of the rotational position of drums relative to one another, and can also carry out self-diagnosis on the drums.
SUMMARY
[0006] In accordance with various embodiments of the present invention, a modular apparatus for smoking article assembly is provided. The modular apparatus is configured to receive rods of smokable material and to cause said received rods of smokable material to undergo a first sequence of operations, wherein the modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different to the first sequence of operations, wherein the first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising a said rod of smokable material, which is smoked in use.
[0007] The modular apparatus comprises a plurality of modules. Two or more of the modules may be of different types and may have different functions to one another.
[0008] In a first configuration, the modular apparatus may comprise a plurality of modules having different functions and may thereby be configured to carry out the first sequence of operations.
[0009] The modular apparatus may be reconfigured into a second configuration in which the modular apparatus comprises a plurality of modules having different functions and in which the modular apparatus is configured to carry out the second sequence of operations.
[0010] In some examples, all of the modules of the first configuration are of different types to one another. In some examples, all of the modules of the second configuration are of different types to one another.
[0011] In various embodiments, the modular apparatus includes a controller configured to control the modules. The controller may comprise a logic controller, e.g: a servo controller with programmable logic control (PLC) functionality.
[0012] In various embodiments, the controller is configured to control modules of the modular apparatus in the first configuration and in the second configuration.
[0013] In embodiments, the controller is a generic controller. A generic controller is a controller which can control any number of modules up to a module limit for the controller, in any desired module combination.
[0014] In various embodiments of the invention, two or more modules of the modular apparatus comprise respective interface units. The controller is configured to control the modules via the interface units. The interface unit of a module comprises input/output electronics to mediate communication between the module and the controller. In some implementations, each of the modules of the modular apparatus comprises a respective interface unit.
[0015] In some implementations, each module having an interface unit has one or more drums which can be controlled by the controller via the interface unit. In some implementations, the controller controls a plurality of drums of the module via the interface unit. The controller may control the drums individually, or as a group. The controller may control the acceleration, deceleration and speed of the drums, and the registration of the rotational position of drums relative to one another. In some implementations, the controller controls all of the drums of the module.
[0016] In some implementations, each drum of each module has a respective drive mechanism to drive the drum. Each drive mechanism is controlled by the controller via the interface unit for the corresponding module. The drive mechanism for each drum may comprise an integrated servo drive.
[0017] In some implementations, the controller may alternatively or in addition carry out suitable self-diagnosis on one or more drums of one or more modules via one or more respective interface units. Self-diagnosis of drums by drum controllers is known per se to those skilled in the art and will not be described here.
[0018] In some implementations, the modules receive electrical power from the controller via the interface units.
[0019] As will be understood from the foregoing, according to various embodiments, the present invention provides a modular apparatus comprising a plurality of modules, the modular apparatus having a control arrangement comprising a controller and a plurality of interface unit, wherein said plurality of modules are controlled by the main controller via the interface units.
[0020] If a new module is added the modular assembly, the interface unit of the new module is connected to the main controller. Similarly, if a module is replaced with a module of a different type, the interface unit of the module to be replaced is disconnected from the controller and the interface unit of the new module is connected
[0021] In this way, the modular apparatus can be reconfigured without the need to replace or extensively reconfigure the control arrangement, while maintaining central control of the modules. Thus, the control arrangement facilitates flexible reconfiguration of the modular apparatus.
[0022] The control arrangement may comprise a single controller. Each module may have a single interface unit.
[0023] In various embodiments, each module of the modular apparatus comprises a separate base unit. The base units of the modules are separable from one another to allow for alternative module arrangements. In this way, the modular apparatus is configured so that modules can be added and/or removed and so that modules can be rearranged relative to one another.
[0024] In some embodiments, the modular apparatus includes three modules. In some embodiments, the modular apparatus includes eight modules. In some embodiments, the modular apparatus includes nine modules.
[0025] The modular apparatus may comprise a first rod inserter configured to insert a first rod article between two tobacco rods, a first rod divider configured to divide the first rod article into two segments, a rod separator configured to separate a first group comprising a rod of smokable material and one of said segments from a second group comprising a rod of smokable material and another of said segments, and a second rod inserter configured to insert a second rod article between the first and second groups.
[0026] According to embodiments of the invention, a flexibly configurable smoking article assembly apparatus is provided which facilitates changes in the assembly process.
[0027] The flexibly configurable apparatus may also provide a useful tool in product development. Rather than designing and building a dedicated machine for carrying out a particular sequence of assembly operations, the modular apparatus may be configured to carry out the sequence. Thus, the time and cost to develop new products may be reduced.
[0028] Some of the operations of the first sequence of operations may be included in the second sequence of operations. In some examples, the first and second sequences may differ by only one operation. Alternatively, the second sequence of operations may include all of the operations of the first sequence, and may differ in that the second sequence includes one or more further operations not included in the first sequence. Alternatively, the first and second sequences may each consist of the same operations, arranged in a different order. For example, the first and second sequences may differ in that the position of two operations in the first sequence is interchanged in the second sequence. Alternatively, in some examples, none of the operations in the first sequence may be included in the second sequence.
[0029] The modular apparatus may comprise a first module comprising said first inserter and a second module comprising said second inserter.
[0030] The modular apparatus may further comprise a second rod divider configured to divide the second rod article into two segments. The modular apparatus may further comprise a wrapping station configured to wrap a wrapper at least partially around an inserted rod article after the inserted rod article is inserted between the two tobacco rods and before the inserted rod article is divided by a rod divider. The said inserted rod article may comprise said first rod article inserted by said first inserter, or said second rod article inserted by said second inserter.
[0031] The modular apparatus may comprise a plurality of rod inserters, each said rod inserter being configured to insert a rod article between two tobacco rods. The modular apparatus may include a plurality of rod dividers, each said rod divider being configured to divide a rod article into two segments. The modular apparatus may include a plurality of wrapping stations, each said wrapping station being configured to wrap a wrapper at least partially around an inserted rod article after the rod article is inserted between two tobacco rods and before the inserted rod article is divided by a rod divider.
[0032] Preferably, the first process for assembling smoking article forms a first configuration of smoking article and the second process for assembling smoking articles forms a second configuration of smoking article different to the first configuration.
[0033] The modular apparatus may therefore facilitate changes in the type of cigarette produced. Thus, rather than having separate dedicated machines in a factory to produce different types of cigarette, a single flexible machine is provided. In this way, floor space in the factory can be saved.
[0034] The first and second sequences of operations may cause rods of smokable material to be respectively combined with one or more rod articles such as filter rods.
[0035] Preferably each rod of smokable material comprises a tobacco rod.
[0036] The modular apparatus may include a plurality of modules. The modules may comprise a plurality of functional units configured to cause said rods of smokable material to undergo said first sequence of operations.
[0037] Some functional units may for example comprise a conveying element such as a drum, e.g: a swash plate drum, rolling drum, cutting drum, separating drum or transfer drum. The modules may also include functional units other than drums, for example a tipper unit or glue unit.
[0038] The drums are preferably arranged to define a conveyance path through the modular apparatus, along which rods of smokable material are caused to undergo said first sequence of operations.
[0039] Reconfiguring the modular apparatus may comprise repositioning modules relative to one another. Alternatively, or in addition, one or more further modules may be added. Alternatively, or in addition, one or more of the modules may be removed.
[0040] In some cases where manufacture of a desired cigarette configuration is required, this may be achieved by adding only one further module to the modular apparatus, or by replacing only one module with another module.
[0041] The modules may include one or more reconfigurable modules. Reconfiguration of the modular apparatus may comprise reconfiguring a reconfigurable module.
[0042] When reconfigured, the modular apparatus preferably comprises a plurality of modules, said plurality of modules comprising a plurality of functional units (e.g: drums) configured to define a conveyance path and cause rods of smokable material to undergo said second sequence of operations.
[0043] Preferably, modules are arranged in a row to cause said rods of smokable material to undergo said first and second sequences of operations. Preferably, the modules are arranged in a row by being arranged in a straight line. However, optionally, the modules may be arranged in a row by being arranged in a curved line.
[0044] At least one module may be left unchanged when the modular apparatus is reconfigured for said second sequence of operations. For example, an in-feed module configured to receive rods of smokable material may be configured in the same position and in the same way before and after reconfiguration of the modular apparatus.
[0045] The modular apparatus may comprise a first group-forming apparatus configured to associate a rod of smokable material with a first rod article to form a first group, and a second group-forming apparatus configured to associate a second rod article with the first group to form a second group. The first group-forming apparatus may be included in a first module and the second group-forming apparatus may be included in a second module.
[0046] The modular apparatus may include one or more modules which are linked to a rod attachment unit. Suitable rod attachment units may for example comprise one of a “Max S” unit from Hauni Maschinenbau, a “Max 90” unit, also from Hauni Maschinenbau, or a GD AF12 unit. Other suitable rod attachment units include M5 or M8 filter tip attachment units from Hauni, the GD 121 filter attachment unit, or similar machines. Those skilled in the art will appreciate that other rod attachment units could alternatively be used.
[0047] One or more of said rod inserters may be included in the rod attachment unit. The rod attachment unit may be configured to receive at least a tobacco rod from a module of the the modular apparatus, directly or indirectly, and to couple a rod article to the tobacco rod to form a smoking article.
[0048] According to various embodiments, a smoking article assembling apparatus comprising one or more modules of the modular apparatus is provided.
[0049] The smoking article assembling apparatus may comprise a tobacco rod source. The tobacco rod source may comprise a tobacco rod making unit. Alternatively, the tobacco rod source may comprise a tobacco rod hopper. The modular apparatus may be arranged to receive tobacco rods from the tobacco rod source, directly or indirectly.
[0050] At least one of the modules of the modular apparatus may be a reconfigurable module comprising a base unit configured to removably receive a plurality of different parts. The module may comprise a drum-receiving portion adapted to selectively receive first and second drums. The module may comprise a suction control element configured to apply suction to either the first or second drum.
[0051] The modular apparatus may comprise some modules which are each configured to receive the same number of drums positioned in the same way. There may be two or more of such modules (e.g: two or more reconfigurable modules). Although the number of drums and their position may be the same for these modules, the drums may be of different types depending on the desired configuration of the modules, so that the functionalities of similarly positioned drums may be different for different modules. In embodiments, all of the modules of the modular apparatus may be configured to receive the same number of drums, positioned in the same way, with the exception of an initial infeed module, which may have a different number of drums.
[0052] Each module may comprise a base unit and two or more drums. One or more of the modules may have four drums, or alternatively less than four drums. One or more modules may have more than four drums.
[0053] The present invention also provides a kit of parts to assemble the modular apparatus. The kit of parts preferably comprises a plurality of modules.
[0054] The present invention also provides a method of reconfiguring the modular apparatus, comprising repositioning modules relative to one another and/or removing one or more modules and/or adding one or more modules and/or reconfiguring one or more of the modules.
[0055] The invention also provides an assembler to assemble a smoking article by coupling one or more rod articles to a rod of smokable material which is smoked in use, comprising a first wrapping station to apply a first wrapper to the smoking article and a second wrapping station to apply a second wrapper to the smoking article after the first wrapper has been applied.
[0056] A first module may comprise the first wrapping station and a second module may comprise the second wrapping station.
[0057] As used herein the term “rod article” includes rods of smokable material such as tobacco rods, filter rods, and also other rod-like articles suitable for inclusion in a smoking article. A rod article may be formed of a single rod, or alternatively may comprise two or more segments.
[0058] As used herein the term “filter rod” refers to a rod comprising material suitable for removing certain elements from smoke. The filter rod may be longer than filter elements of the eventual cigarettes. For example, the filter rod may be a “2-up” or “4-up” rod, which is divided into segments during cigarette assembly, each segment being coupled with one tobacco rod in the eventual cigarette. As is known in the art, “2-up filter rod” refers to a filter rod which is intended to be divided into two segments and “4-up filter rod” refers to a filter rod which is intended to be divided into four segments. Similarly, “6-up filter rod” refers to a filter rod which is intended to be divided into six segments.
[0059] As used herein, the term “smoking article” includes smokable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not-burn products. The smoking article may be provided with a filter for the gaseous flow drawn by the smoker.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] In order that the invention may be more fully understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0061] FIG. 1 is a schematic showing elements of a cigarette manufacturing apparatus.
[0062] FIG. 1A shows a module of a first type.
[0063] FIG. 2 shows a module of a second type;
[0064] FIG. 3 shows a module of a third type;
[0065] FIG. 4 shows a module of fourth type;
[0066] FIG. 5 shows an arrangement of modules;
[0067] FIG. 6 a shows a Max S unit;
[0068] FIG. 6 b illustrates a modification to a Max S unit;
[0069] FIG. 7 shows an arrangement of modules linked to the modified Max S unit for making a first type of cigarette, and FIG. 7 a illustrates the corresponding cigarette assembly process.
[0070] FIG. 8 shows an arrangement of modules for making a second type of cigarette, and
[0071] FIG. 8 a illustrates the corresponding cigarette assembly process.
[0072] FIG. 9 is a perspective view of the base unit of the modules of FIGS. 2 , 3 and 4 mounted with four drums.
[0073] FIG. 10 is the perspective view of FIG. 9 , with one drum removed.
[0074] FIG. 11 is a schematic illustrating the regions where suction is applied to the drums, and the direction of rotation of the drums;
[0075] FIG. 12 is the perspective view of FIG. 10 with a suction control element and suction housing removed.
[0076] FIG. 13 is view of the base unit of FIG. 9 from behind.
[0077] FIG. 14 illustrates a variation of the module of FIG. 1A .
DETAILED DESCRIPTION
[0078] FIG. 1 is a schematic showing elements of a cigarette manufacturing apparatus 100 . Apparatus 100 comprises a tobacco rod maker 101 and a cigarette assembly machine 104 . As shown, cigarette assembly machine 104 comprises a modular apparatus, which includes a group 102 of modules 102 a arranged in row, and a filter attachment unit 103 . As shown the modules 102 a of FIG. 1 are positioned between tobacco rod maker 101 and filter attachment unit 103 , and receive tobacco rods directly from tobacco rod maker 101 .
[0079] Modules 102 may be configured in different ways to provide different manufacturing options in which different types of cigarette are produced by apparatus 100 . Modules 102 may be reconfigured to produce different cigarette types by adding/removing module(s), repositioning modules relative to one another and/or reconfiguring individual modules. In this way, a flexible cigarette assembly machine is provided which facilitates changes in the type of cigarette produced.
[0080] The cigarette manufacturing apparatus 100 includes a control arrangement for electrically controlling the modules of the apparatus. The control arrangement comprises a main cabinet 120 , which acts as the central controller of the control arrangement. The main cabinet 120 includes a logic controller comprising a servo controller with programmable logic control (PLC) functionality, such as a C600 controller. The main cabinet 120 is configured to control the modules 102 a via a plurality of interface units in the form of local cabinets 110 .
[0081] As shown in FIG. 1 , each module 102 a has a respective local cabinet 110 in electrical communication with the main cabinet 120 . Each local cabinet 120 comprises input/output electronics to mediate communication between the main cabinet 120 and the module 102 a . Each local cabinet 110 is connected to the main cabinet 120 by one or more cables.
[0082] According to various embodiments, each module 102 a comprises a number of servo drive motors to drive components of the module, which are controlled by the main cabinet 120 via the local cabinets 110 . The electronics to drive each servo motor may be provided away from the main cabinet and may be provided on the servo motor itself. Consequently, the controller 120 may comprise a generic controller, which means that it can control any number of modules (up to a module limit for the controller), in any desired module combination.
[0083] If a new module is to be added to the group 102 , the new module is positioned appropriately and the local cabinet of the new module is connected to the main cabinet 120 . Similarly, if a module 102 a is replaced with a module of a different type, the local cabinet of the module 120 a which is to be replaced is disconnected from the main cabinet and the new local cabinet 120 a is connected. In this way, the modular apparatus can be reconfigured without the need for replacing or extensively reconfiguring the main cabinet, whilst maintaining central control. Thus, control arrangement of FIG. 1 facilitates flexible reconfiguration of the modular apparatus.
[0084] FIGS. 1A , 2 , 3 and 4 illustrate exemplary modules 1 , 2 , 3 , 4 , and FIGS. 7 and 8 illustrate exemplary configurations of the modular apparatus 102 , 103 . The configuration of FIG. 7 forms cigarettes having triple-segment filters, discussed in more detail below. The configuration of FIG. 8 forms cigarettes having an extendible filter, discussed in more detail below.
[0085] FIG. 1A shows a module 1 of a first type. The module 1 comprises a base unit 5 , which is fitted with a plurality of drums 6 , 7 , 8 for conveying rod articles through the module 1 . The drums 6 , 7 , 8 include a takeover drum 6 , a cutting drum 7 and a separating drum 8 . The takeover drum 6 is configured to receive double-length tobacco rods from a tobacco rod making machine. The tobacco rods are conveyed by the takeover drum and passed to the cutting drum 7 . As shown cutting drum 7 has a circular knife 7 a configured to cut each double length rod into two tobacco rods, which are fed from the cutting drum to separating drum 8 . Separating drum 8 is configured to longitudinally separate the two tobacco rods and then feed them out of the module 1 . Separating drum 8 is of a known type having four segments on each side which have cam followers running in a track cam. The segments holding the tobacco rods can move from inner to outer position to create a gap between the tobacco rods. Although not shown in FIG. 1A , the module 1 includes a local cabinet 110 comprising interface electronics configured to allow control of the module drums 6 , 7 , 8 by the main cabinet 120 . In various embodiments, the main cabinet 120 can control the acceleration, deceleration and speed of the drums 6 , 7 8 and the registration of the rotational position of the drums relative to one another, and can also carry out self-diagnosis on the drums.
[0086] FIG. 2 shows a module 2 of a second type. As shown, this module 2 includes a base unit 9 , which is fitted with a feed drum 10 , a cutting drum 11 and circular knife 11 a , an intermediate drum 12 and a separating drum 13 . As shown, drums 10 , 11 , 12 , 13 form a conveyance path for rod articles through the module 2 .
[0087] The module 2 is configured to cut a central rod in a group of received rod articles into two segments, and to then separate the cut segments to form two spaced rod groups.
[0088] As illustrated in FIG. 2 a , the module 2 may receive two tobacco rods 14 together with a centrally positioned filter rod 15 , e.g. from a preceding module, such that the three rods are aligned with one another in a groove of the feed drum 10 . In this case, the feed drum 10 conveys the three aligned rods into a groove of cutting drum 11 in which the central filter rod 15 is cut into two segments 15 a , 15 b . The separating drum 13 then separates the rods into two groups such that each group includes one cut segment 15 a , 15 b and one tobacco rod 14 . Both groups are then fed out of the module 2 by the separating drum 13 . Although not shown in FIG. 2 , the module 2 includes a local cabinet 110 comprising interface electronics configured to allow control of the module drums 10 , 11 , 12 , 13 by the main controller 120 . In various embodiments, the main cabinet 120 can control the acceleration, deceleration and speed of the drums 10 , 11 , 12 , 13 and the registration of the rotational position of the drums relative to one another, and can also carry out self-diagnosis on the drums.
[0089] In some exemplary configurations, rather than receiving two tobacco rods together with a single centrally positioned filter rod, the module 2 may alternatively be configured to receive two tobacco rods together with three filter rods positioned centrally between the tobacco rods. In this case, the cutting drum 11 may be configured to cut the central filter rod at a central point into two segments and the separating drum 12 may be configured to separate the rods into two groups such that each group includes one of the cut segments, one rod which has not been cut by the cutting drum 11 , and one tobacco rod.
[0090] It will be appreciated that in other configurations, the module 2 may receive two tobacco rods together with five filter rods, or another odd number of filter rods. In some examples, the centrally positioned filter rod or rods may be attached to the tobacco rods (and/or one another) with one or more wrappers when received by the module 2 .
[0091] In some embodiments, some or all of the filter rods may be multi-segment filter rods. Alternatively, the filter rods may be single-segment rods.
[0092] FIG. 3 shows a module 3 of a third type. The module 3 of FIG. 3 is the same as the module 2 of FIG. 2 , except that the module 3 further comprises a filter feed mechanism 16 . Thus, the same reference numerals are retained for corresponding features. The module 3 acts to receive two tobacco rods which are longitudinally separated by a gap, insert a filter rod into the gap, cut the inserted filter rod into two segments and then separate the cut segments to form two spaced rod groups. As with the module 2 , the module 3 includes a local cabinet 110 . to allow control of the drums 10 , 11 , 12 , 13 by the main cabinet 120 .
[0093] Suitable filter feed mechanisms 16 for the module 3 are known per se. For example, feed mechanisms from known “Max S” and “Max 90” machines may be used. The filter feed mechanism may be arranged to output a desired type of rod article, for example 2-up, or alternatively 4-up filter rods. As shown in FIG. 3 , the feed mechanism 16 has an input 17 for receiving filter rods and an output 18 located for feeding filter rods onto the feed drum 10 . The filter feed may also include a cutting mechanism to cut each received rod into filter two rod segments, which are then fed onto the feed drum. For example, the filter feed mechanism may receive 4-up rods, cut each 4-up rod into two 2-up rods and then feed each 2-up rod onto the feed drum. Alternatively, the filter feed mechanism may receive filter rods of a different length, for example 6-up rods, and in some configurations cut the received rods to make segments of a desired length.
[0094] Thus, the module 3 may receive tobacco rods from a preceding module, and also filter rods from the feed mechanism 16 . The tobacco rods are received on the feed drum spaced by a suitable gap, the gap being sized to receive a rod article from the feed mechanism 16 .
[0095] As illustrated in FIG. 3 a , in some configurations, a groove of the feed drum 10 may receive two aligned tobacco rods 14 from a preceding module, the tobacco rods being separated by a gap. The filter feed mechanism may be configured to place a 2-up filter 15 in the gap as the tobacco rods are being conveyed by the feed drum. The cutting drum 11 is configured to cut the inserted filter rod 15 centrally and the separating drum 12 is configured to separate the rods into two groups such that each group includes a filter segment 15 a and one tobacco rod 14 . The two groups are then fed out of the module 3 .
[0096] In other configurations, the module 3 may receive two tobacco rods together with two filter rods from a preceding module so that the four rods are aligned in a groove of the feed drum 10 . The rod articles may be received with a central gap sized for receiving a further “2-up” filter rod. In this case, the module 4 may be configured to 1) insert a 2-up filter in the gap, 2) cut the inserted filter rod into two rods and then 3) separate the rods into two groups such that each group includes a cut segment of the inserted rod, one of the filter rods received from the previous module, and one of the tobacco rods.
[0097] FIG. 4 shows a module 4 of a fourth type. As shown, the module 4 includes a base unit 9 , which is fitted with a filter feed 16 , a feed drum 19 , a swash plate drum 20 , a rolling drum 21 , a roll hand 22 , a transfer drum 23 , a tipper unit 24 and a glue unit 25 . The module 4 is configured to insert a rod article such as a filter rod between two received tobacco rods, and to apply a wrapper in the form of a tipping paper.
[0098] As illustrated in FIG. 4 a , the feed drum 19 may receive two tobacco rods from a preceding module. The tobacco rods may be separated by a gap sized to receive a “2-up” filter rod. The filter feed is arranged to fit a 2-up filter rod into the gap. The swash plate drum 20 , rolling drum 21 , roll hand 22 , tipper unit 24 and glue unit 25 then cooperate to wrap the three rods with a tipping paper to join them together, in a manner which is well known to those skilled in the art. In more detail, the swash plate drum acts to longitudinally compress the three rod articles, and a glue lined patch of tipping paper is then applied on the rolling drum to join the three rod articles together. The joined group of two tobacco rods and one double length filter rod are then fed out of the module 4 by the transfer drum 23 .
[0099] Although not shown in FIG. 4 , the module 4 includes a local cabinet 110 to permit control of the module drums 19 , 20 , 21 , 23 by the main cabinet 120 . In various embodiments, the main cabinet 120 can control the acceleration, deceleration and speed of the drums 19 , 20 , 21 , 23 and the registration of the rotational position of the drums relative to one another, and can also carry out self-diagnosis on the drums.
[0100] As mentioned above, the tipper unit 24 , glue unit 25 and rollhand 22 are well known components per se, but a brief description of these components will nonetheless now be given.
Tipper Unit
[0101] The tipper unit 24 has carbide knives cutting against a carbide drum, which cuts the tipping paper to a required length. The tipping patches are then transferred by the carbide drum (tipping drum) onto the cigarettes. The length of the tipping patches is determined by the feed roller which is mounted before the glue unit, and can be varied. The patch length is usually equal to the cigarette circumference plus about 2 mm. The tipper unit can apply patches of different widths depending on the width of the tipping paper used.
Glue Unit
[0102] The glue unit 25 includes a glue roller which runs in the glue. This roller then transfers the glue to the transfer roller. The paper runs over the transfer roller to transfer the glue from the roller to the paper.
Rollhand/Rolling Drum
[0103] The rollhand 22 is a static curved block which sits below the rolling drum 21 . When the cigarettes, which are on the rolling drum, get to the entry point of the roll hand a scraper pushes the cigarette out of the groove and it is then rolled between the drum and roll hand till the cigarette falls into the next groove.
[0104] Rather than receiving two spaced tobacco rods, in some configurations the module 4 may receive two tobacco rods together with two filter rods, the rod articles being received from a preceding module. The received filter rods may be separated by a gap sized to receive a further 2-up filter. The feed mechanism 16 may be arranged to insert a 2-up filter into the gap. In this case the swash plate drum acts to compress the five rod articles together and the inserted rod is wrapped with a tipping paper on the rolling drum to join it to the rods received from the previous module.
[0105] In some configurations, the module 4 may apply tipping in two separated bands. The configuration for applying banded tipping is the same as for application of conventional tipping, but a slitting knife is also included to split the single tipping band into 2 bands. Also, paper guides are provided to open the two bands to the required positions before gluing. The tipping band is slit after the splicing unit and scraper (not shown), at a position before the glue applicator.
[0106] In embodiments, the filter rods which are inserted by the modules 2 , 4 may comprise multiple segments, ie: they may comprise multi-segment rods formed for example of a central “double length” rod segment with two “single length” rod segments to either side of the central segment. Alternatively however, in some embodiments the filter rods which are inserted may be single-segment rods.
[0107] The modules described above may be linked together in different arrangements to provide different sequences of operations for forming the same or different types of cigarettes. The final drum of one module may be aligned with the initial drum of the next module so that rods pass from the out-feed of one module to the in-feed of the next.
[0108] Still further flexibility can be achieved by reconfiguring individual modules. The modules 2 , 3 and 4 of FIGS. 2 to 4 share a base unit 9 having four drum-receiving shafts, each adapted for removably receiving a drum. Thus, each of the drums on the modules 2 , 3 and 4 may be replaced with another suitable drum so as to vary the functionality of the module.
[0109] For example, the cutting drum 11 of FIG. 2 can be replaced with a transfer drum or a swash plate drum. The intermediate transfer drum 12 of FIG. 2 can be replaced with a rolling drum, transfer drum, ejection drum, laser drum or other suitable drum. Other components may also be added/removed, for example a filter feed, tipper unit, gluing unit, rolling device and a laser for laser perforation.
[0110] The module 2 of the second type can thus be converted to a module 3 of the third type by a reconfiguration process comprising adding a filter feed 16 . Furthermore, the module 3 of the third type can be converted to a module 4 of the fourth type by a reconfiguration process comprising replacing the cutting drum 11 with a swash plate drum 20 , replacing the intermediate transfer drum 12 with a rolling drum 21 , replacing the separating drum 13 with a transfer drum, and adding the tipper unit 24 , the glue unit 25 and the roll hand 22 .
[0111] In replacing a drum on the base unit 9 , a replacement drum typically has the same number of grooves as the drum which it replaces. In FIGS. 2 , 3 , 4 , the first drum 10 , 19 may have 20 grooves, the second drum 11 , 20 may have 20 grooves, the third drum 12 , 21 may have 22 grooves and the fourth drum 13 , 23 may have 20 grooves.
[0112] FIG. 9 is a perspective view showing the base unit 9 fitted with a feed drum 19 , swash plate drum 20 , roll drum 21 (and roll hand 22 ), and transfer drum 23 . As shown, each drum 19 , 20 , 21 , 23 is mounted on a shaft 19 a , 20 a , 21 a , 23 a which rotates the drum. As illustrated in FIG. 10 , each drum can be unscrewed and detached from its shaft so that another drum can be alternatively fitted.
[0113] As shown in FIGS. 9 and 10 , the base unit 9 include a suction housing 200 which applies suction for holding rod articles on the drums 19 , 20 , 21 , 23 and for transferring rod articles from one drum to the next. Referring to FIG. 10 , suction housing 200 is in communication with suction control elements 201 , which each have a suction outlet 202 shaped to selectively apply suction to appropriate points during rotation of the corresponding drum.
[0114] FIG. 11 is a schematic which illustrates with shading the regions in which suction is applied by the suction control elements, and the direction of rotation of the drums 19 , 20 , 21 , 23 .
[0115] Some drums may be replaced without changing the suction control element. For example, the intermediate drum 12 of the module 2 may be replaced by a cutting drum 11 without changing the suction control element. In some cases however the suction element may be changed before a new drum is fitted.
[0116] FIG. 12 shows the base unit 9 with drum 19 and its suction control element 201 removed, and with the suction housing 200 also removed. As shown, vacuum may be applied to suction housing 200 via a hole 203 in the base unit 9 .
[0117] Each drum may be driven by a respective servo drive motor. Those skilled in the art cognizant of the present disclosure will appreciate that the servo motor may be connected to its respective drum by a gearbox and a coupling to turn the drum.
[0118] The servo drive motor for each drum is an integrated servo drive. Integrated servo drives are known per se and will not be described in detail. Briefly, in an integrated servo drive, the electronics to drive the motor is integrated with the motor.
[0119] The interface electronics of the local cabinet 110 of the module is configured to transfer control signals from the main controller to appropriate servo drive motors to control the module drums. The servo driver motors for each drum may thus be individually controlled by the main cabinet 120 via the interface electronics of the local cabinet 110 of the module. It will be appreciated that the servo drives may also send signals, e.g: status or diagnostic signals back to the main controller.
[0120] FIG. 13 is a rear view showing an alternative scheme for driving the drums of the base unit 9 . As shown, in this example the base unit includes a gearbox 205 configured to turn the four drums synchronously. In use, one of the shafts is driven by a servo motor (not shown) to turn the drums. The servo motor may receive control signals from the main controller 120 via the local cabinet 110 of the module.
[0121] Turning again to FIG. 9 , as shown the base unit 9 has a joining member 204 at either end to overlap with complementary joining members on other modules. The joining members 204 ensure that the final drum on one module is automatically aligned with the first drum of the next module when two modules are engaged together.
[0122] FIG. 5 shows one possible configuration of modules 26 , in which modules 2 , 4 , 3 , 1 of the second, fourth, third and first type are arranged one after the other in a row. As described above, each module may include one or more servo motors to drive the drums. Other components, e.g: tipper unit, glue unit, may be driven by further servo motors. These further servo motors may be controlled by the main cabinet 120 via the local cabinets 110 of the modules, in the same manner in which the servos which drive the drums are controlled.
[0123] Those skilled in the art, cognizant of the present disclosure will appreciate that self-diagnosis and safety features of the module components may also be controlled by the main cabinet via the local cabinets.
[0124] In some embodiments, the main cabinet also provides electrical power via the local cabinet 110 to power the servo drive motors. In some embodiments, the modules may include one or more sensors, and the electrical output of the sensors may be provided to the main cabinet 120 via the local cabinet 110 .
[0125] In various embodiments, the local cabinet 110 of each module is connected to the main cabinet 120 by one or more cables. For example, one cable may carry control signals (input/output signals) and another cable may carry electrical power. Those skilled in the art will appreciate that further cables may also be provided for example for 3-phase and Ethernet communication.
[0126] According to various embodiments, local cabinets may be easily connected/disconnected from the main cabinet by connecting/disconnecting the respective cables.
[0127] In embodiments, the servo motors of each module may be synchronised with one another so that rotation of all of the drums in a particular arrangement is synchronised. Servo motors driving other components may also be appropriately synchronised with the servo modules used to drive the module drums.
[0128] The combination of modules 26 may be linked to a filter attachment unit such as a modified Max S unit to carry out further processing. FIG. 6 a illustrates a commercially available Max S machine 27 and FIG. 6 b illustrates a modified machine 28 adapted for use with the modules 1 , 2 , 3 , 4 . As shown, the modified machine 28 of FIG. 6 b differs from the known machine 27 only in that the infeed section 27 a is removed in the modified machine 28 .
[0129] Since the modified unit 28 differs from the known unit 27 only by the absence of the infeed unit 27 a , it will not be described in any further detail here.
[0130] Although FIGS. 6 a and 6 b show a modified Max S, any filter attachment unit could alternatively be linked to the modules, for example a commercially available machine such as a GD AF12 or a Max 90 unit modified in a similar manner as described above, i.e.: by removing the infeed section. Where a Max 90 is used for example, the modified unit can carry out all of the functions of a Max 90, which include: addition of a filter rod, tipping application and rolling, laser perforation, cutting, turning cigarettes, inspections and a link-up to a tray filler.
[0131] FIG. 7 shows an arrangement of successive modules 29 linked to a modified Max S unit 28 for making a particular type of cigarette. As shown, the arrangement 29 includes a module 1 of the first type, a module 3 of the third type, a module 4 of the fourth type and a module 2 of the second type, arranged successively in a row and linked to a modified Max S unit 28 . The first module 1 receives a “double length” tobacco rod from a tobacco rod maker (not shown), and the received tobacco rod is caused to undergo a sequence of operations in the modules 1 , 3 , 4 , 2 and subsequently in the Max S unit 28 to form a filter cigarette 30 . As shown in FIG. 7 a , the eventual cigarette 30 includes a triple segment filter and is wrapped with two separate tipping papers separated longitudinally by a gap 31 .
[0132] FIG. 7 a illustrates the sequence of operations carried out by the machinery of FIG. 7 . Each box in FIG. 7 a illustrates the operations which occur in one of the modules. As shown, each box is labelled with the reference sign of one of the modules 1 , 3 , 4 , 2 to indicate that the operations illustrated in the box occur in the referenced module.
[0133] Referring to FIG. 7 a , in the module 1 , a “double length” tobacco rod 32 is received from a tobacco rod maker (not shown) and cut into two equal segments 32 a , 32 b . The two segments are then separated and the separated segments are fed into the next module 3 .
[0134] In the module 3 , a 2-up filter rod 33 , supplied by the module's filter feed mechanism, is inserted in the gap between the two separated tobacco rods 32 a , 32 b received from the module 1 . The filter 33 is then cut centrally into two segments 33 a , 33 b . A first group 34 a comprising one tobacco rod 32 a and one filter rod segment 33 a is then separated from a second group 34 b comprising one tobacco rod 32 b and one filter rod segment 33 b , and the two separated groups 34 a , 34 b are fed onto the first drum of the next module 4 .
[0135] In the next module 4 , a further filter rod 35 is added in the gap between the two separated groups 34 a , 34 b . The module 4 then applies tipping in two separated bands 36 a , 36 b . The first band 36 a is wrapped around the tobacco rod 32 a , the rod segment 33 a and the further rod 35 to join these three rods together. The second band 36 b is wrapped around the tobacco rod 32 b , the rod segment 33 b and the further rod 35 to join these rods together. Thus, filter 35 is joined to a filter segment 33 a from the first group 34 a and to a segment 33 b from the second group 34 b by wrapping with the bands 36 a , 36 b . The wrapped rods 34 a , 34 b , 33 a , 33 b , 35 are then fed to the next module.
[0136] In the next module 2 , the centrally positioned double length filter rod 35 is cut into two segments 35 a , 35 b . A first group of rods G 1 comprising a filter rod segment 33 a , a filter rod segment 35 a and a tobacco rod 32 a is then separated from a second group of rods G 2 comprising a filter rod segment 33 b , a filter rod segment 35 b , and a tobacco rod 32 b . The separated groups G 1 , G 2 are then fed to the first drum of the modified Max S machine 28 , as shown in FIG. 7 .
[0137] As illustrated in FIGS. 7 and 7 a , the modified Max S unit has a filter feed 38 which inserts a 2-up filter rod 37 between the group G 1 and the group G 2 . The 2-up filter rod 37 is then joined to the filter rod segment 35 a of the group G 1 and to the filter rod segment 35 b of the group G 2 by wrapping with a single wrapper 39 . The wrapper 39 is sized so that it does not overlap with the bands 36 a , 36 b . Instead, the wrapper 39 is sized so that there is a gap 31 between each end of the wrapper 39 and the bands 36 a , 36 b.
[0138] The wrapped 2-up filter rod 37 is then cut centrally into two segments 37 a , 37 b to form two cigarettes 30 which are turned so as to adopt a parallel configuration. As shown, the two cigarettes 30 are identical, and each includes three filter segments 37 a , 35 a , 33 a and two wrappers, the wrappers being longitudinally separated by a gap 31 .
[0139] FIG. 8 shows an alternative configuration 40 of successive modules for making a different type of cigarette 41 . The eventual cigarette 41 is of the extendible (telescopic) type, in which two filters can be separated by a variable amount by sliding an outer sleeve. Telescope cigarettes are known per se, from for example FR 1547656.
[0140] As shown, the configuration 40 comprises six modules 51 , 52 , 53 , 54 , 55 , 56 .
[0141] The first module 51 is the same as the module 1 of FIG. 1A .
[0142] The second module 52 is the same as the module 4 of FIG. 4 .
[0143] The third module 53 comprises a modified version of the module 2 of FIG. 2 . The third module 54 is different to the module 2 of FIG. 2 in that the first drum (feed drum 10 ) has been replaced with a cutting drum, the second drum (cutting drum 11 ) has been replaced with a separating drum, and the fourth drum (separating drum 13 ) has been replaced with an inspection drum to inspect for the presence of filters.
[0144] The fourth module 54 is the same as the module 4 shown in FIG. 4 .
[0145] The fifth module 55 comprises a modification of the module 4 shown in FIG. 4 . The module 55 is different to the module 4 in that the filter feed 16 has been removed and in that the fourth drum (transfer drum 23 ) is replaced with a laser drum to form perforations in the cigarette.
[0146] The sixth module 56 is a module comprising four drums 56 a , 56 b , 56 c , 56 d . The first drum 56 a is a cutting drum, the second drum 56 b is a transfer drum, the third drum 56 c is a turning drum and the fourth drum 56 d is an inspection drum configured to perform a leakage test on the cigarettes. The turning drum is known per se, and may be configured to turn the front row of cigarettes over to have the same orientation as the rear row, or may alternatively be configured to turn the rear row of cigarettes over to have the same orientation as the front row.
[0147] A further module may also be provided (not shown) including final end scanners and an ejection drum which serves as a link-up to further downstream machines.
[0148] FIG. 8 a illustrates the sequence of operations carried out the form the cigarette 41 . Each box in FIG. 8 a illustrates the operations which occur in one of the modules 51 , 52 , 53 , 54 , 55 , 56 . As shown, each box is labelled with the reference sign of one of the modules 51 , 52 , 53 , 54 , 55 , 56 to indicate that the operations illustrated in the box occur in the referenced module.
[0149] As shown, the module 51 is an infeed module configured to receive “double length” tobacco rods 60 , for example from a tobacco rod maker. In the module 51 , each tobacco rod 60 is cut into two segments 60 a , 60 b , which are separated and fed into the next module 52 .
[0150] The next module 52 is configured to insert a 2-up filter rod 61 between the separated tobacco rods received from the module 52 , and to wrap the three rods 60 a , 60 b , 61 with a wrapper 62 to join them together. The wrapped rods are then fed into the next module 53 .
[0151] The next module 53 is configured to cut the filter rod 61 into two segments 61 a , 61 b , and to separate the segments to form two groups, each comprising a tobacco rod 60 a , 60 b joined to a filter rod segment 61 a , 61 b . Each group forms an inner cigarette C of an eventual extendible cigarette 41 . The inspection drum then carries out an inspection for the presence of filters. The separated inner cigarettes C are then fed to the next module 54 .
[0152] The next module 54 is configured to insert a further filter rod 63 between the filter segments 61 a , 61 b and to wrap a wide tipping paper patch 64 around the tobacco rods 60 a , 60 b , the filter rod segments 61 a , 61 b and the filter rod 63 . The glue unit is configured to apply glue to the tipping patch 64 so that the tipping patch 64 is only glued to the centre filter rod 63 and on the overlap of the tipping, so as to form a tube which is only attached to the centre rod 63 . The wrapped rods are then fed to the next module 55 .
[0153] The next module 55 is configured to apply a further tipping patch 65 around the tipping patch 64 so that it overlaps with the tipping patch 64 . The laser drum then applies a pulsed beam to make small perforations through the tipping layers 64 , 65 .
[0154] The next module 56 is configured to cut the filter 63 , through the tipping layers 64 , 65 so as to divide the filter 63 into two segments 63 a , 63 b and thus form two extendible cigarettes 41 a , 41 b . The turning drum then turns the two cigarettes 41 a , 41 b so that they are parallel to one another.
[0155] As described above, the inner cigarette C of each extendible cigarette 41 a is not glued to the tipping layers 64 , 65 , so that the inner cigarette C can be slid in the tube formed by the tipping layers 64 , 65 to vary the separation between the filter rod 61 a , 61 b and the filter rod 63 a , 63 b.
[0156] The modules can be reconfigured to vary the cigarette assembly process as desired, for example by replacing one or more of the drums. Also, the modules can be repositioned relative to one another and/or one or more modules may be added/removed so as to provide yet further cigarette assembly options.
[0157] Many further modifications and variations are possible. For example, although the module 1 of FIG. 1A receives “double length” tobacco rods one at a time from a tobacco rod maker, in some example multiple “double length” tobacco rods may be received at a time, for example from a “double track” tobacco rod maker. FIG. 14 shows a variation of the module 1 of the first type for use with a “double track” tobacco rod maker which makes two tobacco rods at a time. As shown, the modified module 1 of FIG. 14 has a modified take over drum 6 a for receiving the two tobacco rods, and two additional intermediate transfer drums I 1 , I 2 . As shown, the takeover drum 6 a has a plurality of pivoted arms, which each swing out sequentially in use to collect two tobacco rods from the maker. As the drum rotates further in an anticlockwise direction, the arms fall back into position against the drum. As illustrated in FIG. 14 , the arms then deliver tobacco rods one at a time to the first intermediate transfer drum I 1 .
[0158] Other modules may also be included in certain configurations to carry out other operations. For example, a discharge module may be included in some arrangements to discharge assembled rod articles at different heights. The discharge module may be configured to discharge rods articles at a particular height for linking to a mass flow feed, for example to a conveyor to carry discharged rod articles to further machinery for further processing. Alternatively, the discharge height may be varied when discharge to a packaging machine is required, or when discharge to a tray filler for storage is required.
[0159] Further, although coupling filter rods to tobacco rods is described above, in some configurations a module may insert a component other than a filter rod, e.g: a rod article such as a tobacco rod, or a rod element comprising one or more plastic elements, e.g: twistable elements having first and second parts which can be rotated relative to one another to change the characteristics of a smoking article, as described for example in EP0395291A1.
[0160] According to various embodiments of the present invention, modules may carry out one or more of the following operations: transfer, insert separate, wrap, rotate, inspect, reject, press-together, laser-cut, turn, sample cigarettes for test, roll tipping. In embodiments, each module carries out two or more of these operations. Each individual operation may be carried out by a single functional unit (e.g: by a single drum).
[0161] As will be appreciated from the foregoing, the drums of the modules may be selected so that each module carries out a selected sequence of assembly operations. Also, the number of modules and their relative position may be chosen so that the modules carry out their respective assembly operations sequentially in a selected order.
[0162] In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior apparatus and methods. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.
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A modular apparatus for smoking article assembly comprises a plurality of modules and a plurality of respective interface units, and a controller to control said plurality of modules via said interface units. The modular apparatus is configured to cause received rods of smokable material to undergo a first sequence of operations. The modular apparatus can be reconfigured so as to cause received rods of smokable material to undergo a second sequence of operations, different to the first sequence of operations. The first and second sequences of operations respectively form at least part of first and second processes for assembling smoking articles, each smoking article comprising one of said rods of smokable material, which is smoked in use.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is to an article dispenser, such as a candy or gum dispenser, having a transparent dome and rotary internal housing including dispensing apertured parallel relatively rotating disks combined with amusements.
2. Description of Related Art
The prior art provides for dispensing candy and gum and for rotary movements for amusement by using spring loaded reciprocated plungers. As examples:
A. Morin, U.S. Pat. No. 5,238,440, issued Aug. 24, 1993, teaches a toy top having a transparent enclosure that houses balls supported on a stationary apertured base over a rotatable disk having a projection that passes through slots within pockets in the base to propel balls upwardly from the pockets and into the transparent enclosure. The rotation for the disk is provided by a twisted rod and clutch mechanism, a spring loaded plunger reciprocates a twisted rod that passes through a drive friction clutch mechanism that converts linear motion to rotary motion that is used for rotation of the disk.
A. Abe. U.S. Pat. No. 4,618,330, issued Oct. 21, 1986, teaches an amusement device that has a transparent cover with animated and rotating articles put in motion by pushing on a spring loaded plunger that uses gears to convert the reciprocating motion of the plunger into rotary motion.
A. Goldfarb, U.S. Pat. No. 3,077,254, issued Feb. 12, 1963, teaches a toy gum ball dispensing machine that dispenses gum balls from a transparent container by pressing a spring loaded valve with an opening that can pick up a gum ball, that falls through an aperture in the bottom of the container, and transports it to a sloping discharge chute that leads to plural differing value compartments, from where it is transported to a dispensing lip for removal.
Coleman et al, U.S. Pat. No. 5,913,453, issued Jun. 22, 1999, teach a candy or gum dispenser with a spring loaded chute at the base of a container. The spring holds the chute in a closed downward position. To dispense the contents of the container, pressure is applied to the container forcing the chute upwardly into the container exposing an opening in the upper chute. A candy or gum piece enters the opening and travels down the dispensing chute.
SUMMARY OF THE INVENTION
The invention device combines amusement and dispensing. A plunger sits over a transparent or translucent dome covering. A reciprocated rod on the plunger engages a clutch or gear means on a rotatable internal housing converting reciprocal motion into rotary motion. The lower extent of the rotary inner housing forms a first disk that acts as a support for articles and has an aperture in it. Beneath the first disk, a second disk, also having an aperture, is free to rotate on a supporting base. Friction between the rotary internal housing first disk and the second disk, turns the second disk in the same direction as the rotary internal housing but at a slower speed. The size and positioning of the two disks periodically aline the two apertures and allow an article to be passed through the two disks for random dispersal. Dispersing is into one of several chutes, formed within the legs of the base. Each of the legs can be labeled to represent something, such as indicia for a game. Article carousel arms on the rotary internal housing act in part as a stop or deflector for articles propelled upwardly from the rotary inner housing first disk and/or provide a support for amusement indicia that provides an animated display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the dispensing amusement device of the invention.
FIG. 2 is a cross-sectional view of the device along the section lines 2 — 2 shown in FIG. 1 .
FIG. 3 is a side view of the clutch or gear means of the invention.
FIG. 4 is a top view of the clutch or gear drive.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The device of the present invention provides a pleasing, useful attraction that can maintain the attention and interest of children and adults alike. FIG. 1 is a side view of the dispensing amusement device 1 . It shows a plunger 2 , in the shape of a hat 8 having a brim 3 and indicia 52 on the hat. A spherical top palm press 30 , provides for using the palm of the hand to press downwardly on the plunger 2 , and the brim 3 can be used for finger and thumb pressing on the plunger. The plunger is over a stationary tube 6 that sits on top of a transparent dome 10 . A lid 14 fits over a supply opening 13 that gives access into the dome interior. The rotary internal housing 20 is seen through the transparent dome with carousel arms 21 extending from a main housing 15 with a figure 53 on one carousel arm. The first disk 23 , located at the lower end of the rotary internal housing, has an upwardly extending containment wall 18 that confines candy or gum 16 on the disk. An upper extension 17 conceals the motion transmitting rectangular spiral drive rod. The rotary internal housing is supported by a base 31 including legs 35 provided with dispenser openings 34 . Random dispersal can be associated with game indicia 51 associated with each leg 35 . Under the first disk a second disk 25 is positioned between low friction surface spacers 27 , 28 .
The working details of the device 1 can be seen in FIGS. 2-4. A stationary base 31 supports a rotary internal housing 20 and a stationary transparent cover or dome 10 , that in turn supports the plunger 2 . The base includes a pivot pin 22 that passes through a central opening 37 in the second disk 25 and fits within a central alinement indentation or recess 38 formed in the bottom center of the first or primary disk 23 . This alines the disks and radially positions apertures 24 , 26 in them. The rotary inner housing is supported by the base through a lower spacer 28 , that freely rotatably supports the second disk 25 , and upper spacer 27 , that supports the first rotary disk 23 that is or can be an integral part of the internal rotary housing 20 .
The plunger 2 is positioned at the top of the transparent dome 10 . The plunger has a rectangular spiral drive rod 9 attached to it or as an integral part of it and is provided with an alinement tube 5 that surrounds the upper portion of a return spring 4 . A stationary tube 6 is placed between the transparent dome and the plunger to limit downward movement of the plunger and to house a portion of the return spring and rectangular spiral drive rod. The alinement tube 5 fits inside the stationary tube to position the rectangular spiral drive rod and assist its linear movement into the rotary internal housing 20 . A return spring stop 7 can be used to position and maintain the lower end of the return spring at the top of the transparent dome.
Rotation of the rotary internal housing and disks is by way of the plunger 2 . Depression of the plunger 2 reciprocates a rectangular spiral drive rod 9 against a return spring 4 . The downward movement of the plunger passes the rectangular spiral drive rod through a clutch means 39 . The rectangular spiral drive rod passes through a rectangular slot 42 of a drive gear 40 , best seen in FIGS. 3 and 4. The drive gear is provided with a hollow downwardly projecting skirt 45 that projects through an opening 46 in a driven gear flange 12 at the upper end of a rotary internal housing 20 and the lower surface of the flange 41 of drive gear 40 tends to seat against the upper surface of the driven gear flange 12 . The hollow flange 41 provides a passage 50 for the rectangular spiral drive rod 9 . As the drive gear 40 cannot move downwardly as the rectangular spiral rod 9 moves down through it, the spiral of the rod causes the drive gear to rotate. As the drive gear rotates, due to gravity and friction created between the drive gear and the rectangular spiral drive rod, the tapered drive protrusions 43 on the flange 41 lower surface of the drive gear enter into the recesses of the tapered slots 44 of the driven gear flange 12 upper surface on the inner housing 20 . The tapered slots can be integral with the rotary internal housing or a separate element attached thereto. With the tapered drive protrusions engaged in the tapered slots, rotation of the drive gear causes the inner housing 20 to rotate. The inner housing rotates about the pivot pin 22 . Release of pressure from the plunger 2 allows the return spring 4 to raise the rectangular spiral drive rod back through the drive gear 40 slot 42 . The reverse rotation of the rectangular spiral drive rod 9 in the slot 42 reverses the rotation of the drive gear and moves it upwardly. The rapid upward movement and reverse rotation disengages the tapered drive protrusion from the tapered slot in the rotary internal housing. This rapid disengagement permits free rotation of the rotary internal housing.
The drive gear 40 and driven gear 12 are within an enclosure 48 . Just as the rectangular spiral drive rod 9 presses downwardly on the drive gear 40 the flange 41 of the drive gear against the driven gear flange 12 prevents the drive gear from leaving the enclosure 48 at the bottom, the enclosure upper wall flange 47 and drive skirt 49 prevent removal from the top. As the rectangular spiral drive rod 9 is withdrawn upwardly by the spring 4 , the upper surface of the flange 41 of the drive gear engages the limit flange 47 on the upper wall of the enclosure to stop upward movement of the drive gear. The skirt 45 on the drive gear within the opening 46 in the flange driven gear 12 is long enough to not raise above the driven gear flange 12 . This results in a smooth transition and operation when converting from reciprocal to rotary motion and when raising the rectangular spiral drive rod and drive gear from the driven gear for permitting free rotation of the rotary internal housing.
Free rotation of the inner housing includes free rotation of the attached or integral primary first disk 23 having the articles 16 thereon, such as candies or gum. Below and adjacent to the primary first disk a parallel second or secondary disk 25 is supported by the base 31 . The second disk is free to rotate as it is supported by the base through the lower spacer 28 , and it in turn supports the first disk 23 through the upper spacer 27 . The spacers have a low friction surface so as to transmit rotation to the second disk 25 from the rotating first disk 23 . The second disk rotates slower than the first disk because of inertia and the small friction that does exist between the two disks created by the upper spacer 27 , and because of the small friction from the lower spacer 28 . Any rotation of the lower spacer is subject to drag due in part to pressure against the stationary base 31 . High speed does not allow enough time for gravity to pass an article through the alined adjacent apertures 24 , 26 , as they rotate relative to one another. As the rotation of the disks slows down due primarily to friction, the apertures within the disks eventually aline long enough for an article or candy on the first disk to pass through both the aperture 24 in the first disk and the aperture 26 in the second disk and to randomly fall into one of four sloped or tapered areas 36 on the base, into one of the four dispenser chutes 33 within base legs 35 , to a dispenser opening 34 at the bottom of the chute. The chute traversed depends on the sloped or tapered area 36 of the base upper surface at the location the article happens to pass through the apertures 24 , 26 . The slope will be toward the nearest leg 35 of the base. A variety of indicia 51 can be provided on or adjacent to each leg for amusement or entertainment purposes, such as playing a game.
Indicia 52 or figures of articles, animals, etc. 53 can be attached to the rotary internal housing 20 upper extension 17 and/or main housing 15 and/or on carousel arms 21 and carried or placed inside or outside the stationary transparent cover. Additionally, the plunger 2 can be formed in the shape of various articles or animals, including shapes associated with the indicia placed on the rotary internal housing. The shape of the plunger 2 at the brim 3 , and spherical top 30 , such as that shown as a hat 8 , can accommodate a finger and/or thumb or a hand palm.
For animation, the primary first disk 23 can be provided on its upper outward surface with one or more raised humps 19 that can propel upwardly any article placed on the prinary first disk 23 during rotation, due to inertia and impact. Midway up the rotary internal housing main housing 15 carousel arms 21 extend outwardly. These carousel arms are spaced apart and extend radially outwardly so that there is enough space at the outer ends of the arms to pass an article through unobstructed at these outer areas. The arms tend to deflect angularly articles propelled upwardly by the raise raised humps 19 that do not directly strike the base of the arms, and reject back downwardly articles that directly strike the base of the arms. The arms also provide a support for amusement pieces or figures 53 that can be placed thereon.
It can be seen that pressing on the plunger 2 causes the rotary internal housing 20 to rotate, setting the indicia 52 on the rotary housing in motion and the figures 53 on the carousel arms in motion, and the rotation of the humps 19 on the first disk 23 to propel loose articles 16 upwardly, due to impact and the changing speed of the first disk and the inertia of the articles. The carousel arms 21 being spaced allows some articles to pass upwardly therethrough, blocks some articles back downwardly, and randomly deflects other articles in different directions for a continuously changing scene within the transparent dome during rotation of the rotary internal housing. For added variety, different size, shape and/or color articles can be used. Together a pleasing animation is achieved in addition to the dispensing of articles and game that can be associated with the random article dispersal.
It is believed that the construction, operation and advantages of this invention will be apparent to those skilled in the art. It is to be understood that the present disclosure is illustrative only and that changes, variations, substitutions, modifications and equivalents will be readily apparent to one skilled in the art and that such may be made without departing from the spirit of the invention as defined by the following claims.
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A combined dispensing and amusement device has a reciprocating plunger on a transparent dome for rotating parallel disks. An upper first disk on an internal rotary housing supports articles and has an aperture that can aline with an aperture in a parallel adjacent lower second disk. The upper first disk frictionally drives the lower second disk at a lower speed so that the apertures periodically aline. Alinement of the apertures permits random dispensing of articles. Dispensing is into one of several chutes in the legs of a base support. Due to the random nature of dispensing, with the inclusion of indicia, the legs can be used as part of a game. Carousel arms on the internal rotary housing can act as stops and can variably deflect articles and/or can act as an animated indicia amusement support.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process for producing tin oxide fibers.
2. Description of the Prior Art
Tin oxide is highly durable against acids and alkaline materials, and also stable against heat. Therefore, if such tin oxide can be formed into fibers, such fibers are expected to be useful as chemically resistant and heat resistant fibers, and it is also expected that such tin oxide is applicable as electrically conductive fibers.
Heretofore, there has been known no method which is capable of producing a substantial amount of fine tin oxide fibers having uniform diameters.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a process whereby it is possible to obtain fine tin oxide fibers having uniform diameters in a substantial amount.
The present inventors have conducted extensive researches to attain the above object, and have found it possible to obtain fine tin oxide fibers by forming a melt comprising a solute of tin oxide and a solvent of copper, a copper alloy, tin or a tin alloy, evaporating tin oxide as the solute from the melt, and introducing the evaporated tin oxide to a low temperature zone thereby to permit the tin oxide precipitate and grow. The present invention has been accomplished based on this discovery.
Thus, the present invention provides a process for producing tin oxide fibers, which comprises forming a melt comprising a solute composed essentially of tin oxide and a solvent selected from the group consisting of copper, a copper alloy, tin or a tin alloy, evaporating the solute from the melt, and introducing the evaporated solute to a low temperature zone, whereby tin oxide fibers are permitted to precipitate and grow in the low temperature zone.
It has also been found that by incorporating into the solute of tin oxide a metal or metal oxide to increase the electrical conductivity of tin oxide, it is possible to obtain electrically conductive tin oxide fibers.
Now, the present invention will be described in detail with reference to the preferred embodiments.
DETAILED DESCRIPTION OF THE INVENTION
The ratio of the solute to the solvent is not critical since tin oxide may or may not completely be dissolved in the solvent such as copper. However, it is preferred that the weight ratio of the solute to the solvent in the melt is from 20:80 to 2:98.
The solute is composed essentially of tin oxide. In a preferred embodiment, however, the solute further contains a metal or metal oxide to increase the electrical conductivity of tin oxide, whereby the resulting tin oxide fibers will have excellent electrical conductivity. As such a metal or metal oxide, there may be mentioned antimony, vanadium, indium, iridium or their oxides. Such a metal or metal oxide may be incorporated in an amount of up to 30% by weight, preferably from 2 to 5% by weight, relative to the total solute.
The solvent is selected from the group consisting of copper, a copper alloy, tin or a tin alloy. The copper alloy is preferably an alloy of copper with a metal, such as tin or zinc, which lowers the melting point of copper. Likewise, the tin alloy is preferably an alloy of tin with a metal, such as copper or zinc, which raises or lowers the melting point of tin. Thus, when such an alloy is employed, it is possible to adjust the melting point by selecting the type or amount of the metal in the copper or tin alloy.
A mixture of the solute and the solvent put in a heat resistant vessel such as a crucible is heated in a furnace such as an electric furnace in a non-oxidizing atmosphere such as an inert gas (e.g. nitrogen) atmosphere or an atmosphere with an oxygen partial pressure being sufficiently low to avoid oxidation of the solvent. Then, the melt is further heated to a temperature higher than the temperature at which tin oxide starts to evaporate, whereby tin oxide is evaporated. When the solute contains a metal or metal oxide to increase the electrical conductivity, such a metal or metal oxide will be included in the evaporated tin oxide. The temperature for the evaporation is adjusted depending upon the amount of the evaporation and is usually within a range of from 400° to 1400° C. The evaporated solute is then led to a low temperature zone provided in the furnace. The temperature of the low temperature zone is kept at a temperature lower than the temperature of the melt, e.g. at a temperature lower by from 50° to 500° C. than the temperature of the melt. When the evaporation is continued under these conditions for at least one day, tin oxide fibers precipitate and grow in the low temperature zone.
The low temperature zone may be formed by blowing a low temperature gas to such a zone or by circulating a cooling medium such as water to such a zone.
The tin oxide as the starting material may be stannous oxide, stannic oxide or a mixture thereof. In any case, the resulting fibers will be stannic oxide fibers. When a metal or metal oxide to increase the electrical conductivity is incorporated in the tin oxide as the starting material, electrically conductive stannic oxide fibers doped with some particular metal oxide, such as antimony oxide will be obtained.
Now, the present invention will be described in further detail with reference to Examples. However, it should be understood that the present invention is by no means restricted by these specific Examples.
EXAMPLE 1
Four g of stannic oxide having a purity of 99.99% and 100 g of copper having a purity of 99.99% were mixed. The mixture was placed in a Tamman tube. This Tamman tube was placed in an electric furnace which is capable of controlling the ambient gas. Nitrogen gas was supplied from the top of the electric furnace at a rate of some 10 liters per minute to create a low temperature zone at the upper portion of the Tamman tube made of alumina. The temperature of the electric furnace was raised to 1250° C. at a rate of 50° C./hr, whereby the mixture was melted. The system was maintained under these conditions for 20 days, whereby tin oxide fibers precipitated at the low temperature zone in the Tamman tube. Twenty days later, the temperature was gradually lowered to room temperature, and the tin oxide fibers were taken out.
The temperature at the low temperature zone was about 1000° C.
The tin oxide fibers thereby obtained had a diameter of at most 0.5 μm and a length of about 3 mm.
In a similar manner, tin oxide fibers were likewise obtainable when a copper alloy (Cu-Sn) (Cu: 50 wt. %) was used instead of copper.
EXAMPLE 2
Four g of stannic oxide having a purity of 99.99%, 0.5 g of antimony pentoxide having a purity of 99.99% and 100 g of copper having a purity of 99.99% were mixed. This mixture was placed in a Tamman tube. The Tamman tube was placed in an electric furnace capable of controlling the ambient gas. Nitrogen gas was supplied from the top of the electric furnace at a rate of some 10 liters per minute to create a low temperature zone at the upper portion of the Tamman tube. The temperature of the electric furnace was raised to 1250° C. at a rate of 50° C./hr, whereby the mixture was melted. The system was maintained under these conditions for 20 days, whereby tin oxide fibers precipitated at the low temperature zone in the Tamman tube. Twenty days later, the temperature was gradually lowered to room temperature, and the tin oxide fibers were taken out.
The temperature at the low temperature zone was about 1000° C.
The tin oxide fibers thereby obtained had a diameter of at most 0.5 μm and a length of 3 mm.
In a similar manner, tin oxide fibers were likewise obtainable when a copper alloy (Cu-Sn) (Cu: 50 wt. %) was used instead of copper.
EXAMPLE 3
Fifteen g of stannous oxide of 99.99% purity, and 100 g of tin having a purity of 99.99% were mixed. An alumina boat containing the above mixture was introduced into an alumina reaction tube which had been placed in a horizontal electric furnace. The boat was laid at the spot of the highest temperature gradient of the furnace. The ratio of the length between the spot and nitrogen inlet-end of the tube and that between the spot and nitrogen outlet-end was set to be approximately 2:3. Nitrogen gas was flowed at the rate of 0.8 to 1.0 litter per minute through the fiber-growth run. The temperature was raised to 1050° C. at a rate of 50° C./hr, whereby the mixture was melted and SnO 2 was evaporated. The system was maintained under these conditions for 4 days, whereby stannic oxide fibers grew on the inner wall of the tube, keeping apart from the boat and toward the direction of the nitrogen flow. Five days later, the temperature was gradually lowered to room temperature, and the stannic oxide fibers were taken out.
The stannic oxide fibers thereby obtained had a diameter of about 1 μm and a length of about 3 mm. The electrical conductivity of the fibers was 100Ω.cm.
EXAMPLE 4
In the same manner as in Example 3, similar stannic oxide fibers were likewise obtained when a tin-copper alloy (Sn: 50 wt. %) was used instead of tin alone.
EXAMPLE 5
Fifteen g of stannic oxide of 99.99% purity, 0.25 g of antimony pentoxide having a purity of 99.99% and 100 g of tin of a purity of 99.99% were mixed. An alumina boat containing the above mixture was introduced into a mullite reaction tube which had been placed in a horizontal electric furnace. The boat was laid at the spot of the highest temperature gradient of the furnace. The ratio of the length between the spot and nitrogen inlet-end of the tube and that of the spot and nitrogen outlet-end was set to be approximately 2:3. Nitrogen gas was flowed at the rate of 0.8 to 1.0 liter per minute through the fiber-growth run. The temperature was raised to 1050° C. at a rate of 50° C./hr, whereby the mixture was melted and SnO 2 was evaporated. The system was maintained under these conditions for 4 days, whereby stannic oxide fibers grew on the inner wall of the tube, keeping apart from the boat and toward the direction of the nitrogen flow. Five days later, the temperature was gradually lowered to room temperature, and the stannic oxide fibers were taken out.
The stannic oxide fibers thereby obtained had a diameter of about 1 μm and a length of about 3 mm. The electrical conductivity of the fibers was 100Ω.cm.
EXAMPLE 6
Electrically conductive stannic oxide fibers were obtained in the same manner as in Example 5 except that a tin-zinc alloy (tin: 90%) was used instead of tin. The obtained fibers were substantially the same as the fibers obtained in Example 5.
EXAMPLE 7
Stannic oxide fibers were prepared in the same manner as in Example 5 except that 10 g of commercially available SnO and 2.5 g of SnO 2 doped with 10 molor % of antimony oxide were used instead of SnO 2 and antimony pentoxide in Example 5. The fibers thereby obtained and their electric conductivity were substantially the same as those of Example 5.
Thus, according to the present invention, it is possible to readily obtain tin oxide fibers or electrically conductive tin oxide fibers, which used to be difficult to obtain in a substantial amount.
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A process for producing tin oxide fibers, which comprises forming a melt comprising a solute composed essentially of tin oxide and a solvent selected from the group consisting of copper, a copper alloy, tin or a tin alloy, evaporating the solute from the melt, and leading the evaporated solute to a low temperature zone, whereby tin oxide fibers are permitted to precipitate and grow in the low temperature zone.
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The present invention relates to an epoxy resin composition, and, more particularly, relates to an epoxy resin material which has an excellent moisture resistance and is highly qualified as a sealant for electronic components.
BACKGROUND OF THE INVENTION
The last few years have witnessed rapid expansion in the electronic device and equipment sector, and this has resulted in the production of large numbers of semiconductor-based electronic components. Within the arena of epoxy resins used to seal semiconductors, there has also been an accompanying strong demand for technical improvements in correspondence to the required maintenance of the characteristics and properties of semiconductors. Among these, improvements in the moisture resistance of epoxy resins are particularly important.
With regard to the development of epoxy resins in response to this demand, epoxy resin compositions are known in which an epoxy group-containing silane, amino group-containing silane, mercapto group-containing silane, ureide group-containing silane, or phenol group-containing silane has been blended into epoxy resin (for example, refer to Japanese Patent Application Laid Open [Kokai] Number 59-124923 [124,923/84]).
Nevertheless, the moisture resistance of these epoxy resin compositions is still inadequate, and, inter alia, they suffer from a sharp decline in bending strength after a boiling test in water. They are therefore unsatisfactory as sealants for electronic components.
SUMMARY OF THE INVENTION
As the result of extensive research, the present inventors discovered that the admixture of a special silane coupling agent into epoxy resin largely solves the preceding problem, and the present invention was achieved based on this.
In other words, the present invention takes as its object the introduction of a strongly moisture-resistant epoxy resin composition which is highly qualified for use as a sealant for electronic components. The invention therefore relates to a composition comprising:
(A) 100 parts by weight of an epoxy resin having at least two epoxy groups in each molecule;
(B) a sufficient quantity of a compound having at least two phenolic hydroxyl groups in each molecule to cure component (A);
(C) from 0.05 to 70 parts by weight of a silane coupling agent selected from the group consisting of compounds represented by the formulas ##STR1## wherein R 1 and R 2 are monovalent hydrocarbon groups having 1 to 6 carbon atoms, R 3 is selected from the group consisting of the hydrogen atom and a monovalent hydrocarbon group having 1 to 6 carbon atoms, Ar is an organic group selected from ##STR2## in which Q is selected from the group consisting of the hydrogen atom and a trialkylsilyl group represented by the formula --SiR 4 3 , where R 4 is an alkyl group having 1 to 6 carbon atoms, x is an integer between 1 and 3, y is an integer between 1 and 6, z is 1 or 2 and n is an integer between zero and 2; and
(D) from about 30 to about 600 parts by weight of an inorganic filler.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a composition composed of (A) an epoxy resin, (B) a compound for curing component (A), (C) a silane coupling agent, described infra, and (D) an inorganic filler.
To explain this in greater detail, the epoxy resin comprising component (A) should be a compound which has at least 2 epoxy groups in its molecule and is cured by the compound having phenolic hydroxyl groups as discussed below for component (B), but its molecular structure and molecular weight are not specifically restricted. Epoxy resins within this context are exemplified by bisphenol-based aromatic epoxy resins, alicyclic epoxy resins based on, for example, cyclohexane derivatives, epoxy novolac-type epoxy resins, and halogen atom-containing (chlorine, bromine, etc.) epoxy resins.
The component (B) used by the present invention functions as a curing agent in order to cure the aforementioned component (A), and it takes the form of a compound which has at least 2 phenolic hydroxyl groups in each molecule. Again, its molecular structure and molecular weight are not specifically restricted. Examples of such compounds are phenol novolac-type phenolic resins and cresol novolac-type phenolic resins. This component should be used in quantities sufficient to bring about the curing of component (A), as readily determined by routine experimentation.
The silane coupling agent comprising component (C) is the component which distinguishes or characterizes the invention under consideration, and it functions to bring about a remarkable improvement in the moisture resistance of the composition of the present invention. Silane (C) is selected from the group consisting of compounds having formulas (i) and (ii): ##STR3## In the above formulas, the groups R 1 and R 2 are independently selected monovalent hydrocarbon groups having 1 to 6 carbon atoms as exemplified by alkyl groups such as methyl, ethyl, propyl, and butyl; R 3 is the hydrogen atom or a monovalent hydrocarbon group having 1 to 6 carbon atoms, as exemplified by alkyl groups such as methyl, ethyl, propyl, and butyl, and aryl groups such as phenyl; the group Ar is an organic group selected from ##STR4## and the group Q is the hydrogen atom or a trialkylsilyl group as represented by --SiR 4 3 in which R 4 is an alkyl group having 1 to 6 carbon atoms, such as methyl, ethyl, and propyl. Furthermore, x is an integer having a value of 1 to 3, y is an integer having a value of 1 to 6, z is an integer having a value of 1 or 2, and n is an integer having a value of zero to 2.
The silane coupling agent under consideration is exemplified by the following compounds. ##STR5##
Component (C) can be prepared, for example, by a dehydrohalogenation reaction between (a) a triorganosilylalkyl halide and (b) an aminophenol, in the presence of (c) a hydrogen halide binder. The triorganosilylalkyl halide may be represented by the following general formula ##STR6## wherein R 1 and R 2 have their above defined meanings; the group A is a halogen atom selected from fluorine, chlorine, bromine or iodine; and x and y also have their above defined values.
The aminophenol (b) may be represented by the general formula ##STR7## wherein Q, Ar and R 3 have their above defined meanings and p is an integer having a value of 1 or 2.
The triorganosilylalkyl halide, or derivative thereof, comprising the component (a) used by this method is its principal starting material. Organosilicon compounds corresponding to this component (a) can be procured on an industrial basis. These organosilicon compounds are exemplified by
gamma-chloropropyltrimethoxysilane and
gamma-chloropropylmethyldimethoxysilane.
The aminophenol, or derivative thereof, comprising the component (b) used by this method participates in a dehydrohalogenation reaction with the aforesaid component (a) in the presence of a hydrogen halide binder to afford the silane coupling agent comprising component (C). Among such compounds, the following, for example, are available on an industrial basis: meta-aminophenol, ortho-aminophenol, para-aminophenol, and so forth.
When too little of silane (C) is added, no effects associated with its addition will appear, while the addition of too much will impair the native properties of the epoxy resin. Accordingly, it should be added at 0.05 to 70 weight parts, and preferably at 0.1 to 35 weight parts, per 100 weight parts component (A).
The inorganic filler (D) used by the present invention imparts such physical properties as cracking resistance, low stress, etc., to the composition of the present invention. This component takes the form of those fillers typically used in epoxy or silicone resins, and examples in this regard are silica, talc, mica, clay, glass fiber, etc. The component under consideration should be added at about 30 to about 600 weight parts and preferably at 200 to 450 weight parts per 100 weight parts component (A).
As necessary, various additives may also be suitably added and mixed into the epoxy resin composition of the present invention as long as the object of the present invention is not compromised, and examples here are release agents, such as natural and synthetic waxes and the metal salts of straight-chain fatty acids; flame retardants, such as antimony trioxide; colorants such as carbon black; curing accelerators, such as imidazole and derivatives thereof, tertiary amine derivatives, and phosphine derivatives; stress-reducing agents, such as silicones; and so forth.
The epoxy resin composition of the present invention is quite easily prepared by mixing the aforementioned components (A) through (D) to homogeneity, or by mixing the aforementioned components (A) through (D) to homogeneity along with the various additives. In the case of use as a molding material, the epoxy resin is preferably converted into a particulate by grinding or pulverizing to a suitable size.
EXAMPLES
The present invention is explained in greater detail below through illustrative examples, in which parts=weight parts.
EXAMPLE 1
Three hundred and fifty parts of fused silica (FB-74 from Denki Kagaku Kogyo Kabushiki Kaisha, Japan) was placed in a Henschel mixer and preliminarily mixed for 15 minutes while spraying in 1.4 parts silane coupling agent as reported in Table 1. To this were then added 100 parts cresol novolac-type epoxy resin (EOCN-1020 from Nippon Kayaku Kabushiki Kaisha, Japan) 50 parts phenol novolac resin (BRG-557 from Showa Kobunshi Kabushiki Kaisha), 1 part carnauba wax (release agent), and 1.5 parts phenylphosphine (curing accelerator) followed by mixing and kneading for 4 to 6 minutes on a six-inch two-roll mill heated to 70 to 90 degrees Centigrade. Cooling then afforded the epoxy resin composition, which was pulverized to give the granular epoxy resin composition. The bending strength, water absorption, and bending strength after immersion in boiling water were measured on the obtained epoxy resin after curing and its fluidity when uncured was also measured. The obtained measurement values are reported in Table 2. The following measurement methods were employed.
Measurement of the Bending Strength, Water Absorption, and Bending Strength after Immersion in Boiling Water
The epoxy resin composition was molded into a 90×10×4 (mm) test specimen under the following conditions using a transfer molder: molding temperature=175 degrees Centigrade, molding pressure=70 kg/cm 2 , and molding time=2 minutes.
The obtained test specimen was post-cured for 9 hours at 170 degrees Centigrade, and the bending strength and water absorption were measured on the post-cured test specimen in accordance with JIS K611-1979 (General Test Methods for Thermosetting Plastics).
With regard to testing after immersion in boiling water, a test specimen post-cured as above was introduced into a pressure cooker (2 atm, 120 degrees Centigrade), maintained there for 96 hours, removed, and its bending strength was then measured.
Measurement of the Fluidity
The spiral flow was measured based on SPI-EMMI 1-66, and this value is reported for the fluidity.
TABLE 1______________________________________com-positionnumber silane coupling agent______________________________________ ##STR8##2 ##STR9##3 ##STR10##______________________________________
TABLE 2______________________________________bending strength (kgf/mm.sup.2) water spiralcomposition after immersion in absorption flownumber initial boiling water (%) (inch)______________________________________1 16.1 13.7 0.69 432 16.3 13.4 0.70 423 16.7 13.5 0.68 43______________________________________
EXAMPLE 2
Epoxy resin compositions were prepared as in Example 1, but using the following silane coupling agent in the quantity of addition reported in Table 3 in place of the 1.4 parts silane coupling agent reported in Table 1 of Example 1. ##STR11##
The bending strength after curing, bending strength after immersion in boiling water, water absorption, and fluidity were measured on these epoxy resin compositions as in Example 1, and these measurement results are reported in Table 4.
TABLE 3______________________________________composition number use quantity of silane coupling agent (parts)______________________________________4 0.55 1.06 3.0______________________________________
TABLE 4______________________________________bending strength (kgf/mm.sup.2) water spiralcomposition after immersion in absorption flownumber initial boiling water (%) (inch)______________________________________4 16.0 12.5 0.69 415 15.9 12.8 0.71 426 15.7 13.0 0.71 42______________________________________
COMPARISON EXAMPLE
Epoxy resin compositions were prepared proceeding as in Example 1, but using the silane coupling agents given below in Table 5 in place of the silane coupling agents given in Table 1 for Example 1. The properties of these compositions were measured as in Example 1, and the obtained results are reported in Table 6.
TABLE 5______________________________________compositionnumber silane coupling agent______________________________________7 3-glycidoxypropyltrimethoxysilane8 3-ureidopropyltrimethoxysilane ##STR12##______________________________________
TABLE 6______________________________________bending strength (kgf/mm.sup.2) water spiralcomposition after immersion in absorption flownumber initial boiling water (%) (inch)______________________________________7 13.8 11.0 0.87 428 13.2 11.5 0.67 439 12.7 9.6 0.71 48______________________________________
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A water resistant epoxy resin composition is disclosed, said composition comprising an epoxy resin, a compound having at least two phenolic hydroxyl groups sufficient to cure the epoxy resin component, an aromatic nitrogen-containing silane coupling agent and an inorganic filler. The epoxy resin composition is well suited for use as a sealant for electronic components.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part application of copending application bearing U.S. Ser. No. 804,853, filed June 8, 1977 and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to aliphatic diamines, and more particularly to aromatic-aliphatic diamines containing no hydrogen atoms beta to the central arylene group or to the amino groups. This invention also relates to stable, rigid polymers derived from said diamines.
2. Description of the Art
Neopentyl diamine is known and polyamides have been made from this diamine. No aromatic bis(neopentylamine) has been found in the art.
U.S. Pat. No. 2,497,673 to Kirk Jr. (I) discloses diamines of the formula ##STR3## wherein Ar includes certain of the Ar groups described in the instant application.
U.S. Pat. No. 2,464,693 to Kirk Jr. (II) discloses diamines of the formula ##STR4## wherein Ar includes certain of the Ar groups described in the instant application.
U.S. Pat. No. 2,900,369 to Edwards et al discloses a diamine having the formula ##STR5##
U.S. Pat. No. 3,422,143 to Bottomley discloses diamines of the formula ##STR6## where R 1 and R 2 are lower alkyl, R 3 and R 4 are hydrogen or lower alkyl wherein Ar includes certain of the Ar groups described in the instant application.
The above-cited patents disclose homologs and an isomer of the diamines of this invention. These known diamines have the general formula ##STR7## wherein n is 0, 1, 2 or 4. All of these diamines contain hydrogen atoms in positions beta to arylene or to nitrogen, or both. Such diamines provide polymers which are demonstrably inferior in thermal stability to polymers prepared from diamines of this invention which contain no hydrogen atoms beta to either arylene or nitrogen. In this regard see the Comparative Examples preceding the claims.
British Pat. No. 799,762 to Bataafsche discloses diamines of the formula ##STR8## where R 2 represents the same or different alkyl groups of 1 to 6 carbon atoms, and X represents an alkylene group containing 2 to 5 carbon atoms. All of the "X" alkylene groups actually disclosed are straight chain alkylene groups containing only repeating --CH 2 -- groups; such diamines contain hydrogen atoms beta to both arylene and nitrogen. Finally, this patent contains no enabling disclosure for preparing the diamines of the instant invention.
U.S. Pat. No. 3,175,007 to Berhenke discloses various dianilines which are diamines of the formula ##STR9## where --X-- is --O--, --S--, ##STR10## or a lower alkylidene radical. One disclosed compound, methylenedianiline (column 2, line 23), is without aliphatic beta hydrogen atoms but is completely different structurally from the diamines of the instant invention.
SUMMARY OF THE INVENTION
There have now been discovered aromaticaliphatic diamines of the formula ##STR11## where Ar is an arylene selected from the group consisting of 1,2-phenylenes, 1,3-phenylenes, 1,4-phenylenes, 2,2'-biphenylenes, 3,3'-biphenylenes, 4,4'-biphenylenes, and 2,6-naphthylenes, said arylene being unsubstituted or substituted with methyl or chloro.
There have further been discovered thermally stable, rigid, polyamides, polyureas and polyurethanes having the repeating unit ##STR12## in which Ar is arylene as defined above, X is --NH-- or --O--, n is 0 or 1, and R is Ar, alkylene of 1 to 20 carbon atoms or oxygen-interrupted alkylene of 3 to 20 chain atoms, particularly ##STR13## where m is 1 to 6. The term "rigid" denotes the presence of a sufficient quantity of aromatic rings in the backbone of the polymer to provide stiffness.
When n is 0, formula II represents the repeating unit of a polyamide. When n is 1 and X is --NH--, formula II represents the repeating unit of a polyurea. When n is 1 and X is --O--, formula II represents the repeating unit of a polyurethane.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The novel diamines of formula I are prepared by heating a dinitrile of the formula ##STR14## in which Ar is arylene as defined above with a dialkylaluminum hydride, preferably diisobutylaluminum hydride, for several hours in an inert anhydrous nonprotic solvent, e.g., a hydrocarbon and preferably an aromatic hydrocarbon, at a temperature sufficiently elevated above room temperature, e.g., 120° C., so that the reaction occurs at a convenient rate, under a dry inert atmosphere such as nitrogen, argon, helium and the like. After the reaction period is over, the intermediate aluminum salts are hydrolyzed by the gradual addition of a solution of water in a lower aliphatic alcohol, e.g., methanol. The following equations are believed to represent the steps involved. ##STR15## The by-product hydrated aluminum oxide is removed by filtration and the desired diamine is isolated and purified by conventional means.
The dinitriles of formula III are prepared by reacting the lithium salt of isobutyronitrile, generated in situ, with an α,α'-dihaloaromatic compound of the formula ##STR16## in which Ar is arylene as defined above, and X is Br or Cl at a temperature low enough to prevent the undesired decomposition of the lithium salt, e.g., in the range of -50° C. to -100° C., in a medium which at the appropriate temperature is a satisfactory solvent for both the lithium salt and the α,α'-dihaloaromatic compound, and under an inert dry atmosphere, e.g., nitrogen, helium, argon and the like, according to the following equation: ##STR17## The solvent must also be nonreactive with the lithium salt, and its progenitors, e.g., it must be nonprotic. Ethers, especially cyclic ethers, e.g, tetrahydrofuran, are preferred solvents.
The lithium salt is generated in the reaction medium at the appropriate temperature by first reacting a hindered secondary amine, such as diisopropylamine, with a lower alkyllithium, such as n-butyllithium, to bring about the formation of the lithium salt of the hindered secondary amine, followed by addition of anhydrous isobutyronitrile. After allowing an appropriate time for the reaction to take place at the prescribed temperature, e.g., at least several hours, the reaction mixture is allowed to warm to room temperature, and the product is isolated and purified by conventional methods.
The arylene groups embraced in the definition of Ar above are readily obtained by selection of the α,α'-dihaloaromatic compound of formula IV. For example, suitable compounds include:
α,α'-dibromo-m-xylene
α,α'-dibromo-p-xylene
α,α'-dibromo-o-xylene
α,α'-dichloro-m-xylene
α,α'-dibromo-2-chloro-p-xylene
α,α'-dibromo-2-methyl-p-xylene
3,6-bis(chloromethyl)durene
2,2'-bis(bromomethyl)biphenyl
2,2'-bis(chloromethyl)biphenyl
3,3'-dichloro-4,4'-bis(bromomethyl)biphenyl
3-chloro-4,4'-bis(bromomethyl)biphenyl
2,6-bis(bromomethyl)naphthalene
2,6-bis(chloromethyl)naphthalene
1,5-dichloro-2,6-bis(bromomethyl)naphthalene
1-chloro-2,6-bis(bromomethyl)naphthalene
3,3'-bis(bromomethyl)biphenyl
4,4'-bis(bromomethyl)biphenyl
4,4'-bis(chloromethyl)biphenyl
and the like.
The polyamides are prepared by reacting the diamines with either acid chlorides of dibasic acids in the presence of an acid acceptor, or with diphenyl esters of dibasic acids. With the acid chlorides of aliphatic dibasic acids, e.g., sebacyl chloride, ##STR18## a convenient method for preparing the polyamides comprises a solution polymerization in which a solution of the acid chloride in an inert nonprotic solvent, e.g., chloroform, carbon tetrachloride, and the like, is added quickly to a stirred solution of the diamine and a tertiary amine, e.g., triethylamine, as the acid acceptor, in the same solvent. These condensation polymerizations are usually carried out at ambient temperature, but higher or lower temperatures are also satisfactory. The isolation of the product usually involves the addition of a nonsolvent for the polymer, followed by thorough washing of the polymer in water. These procedures are discussed by P. W. Morgan in "Condensation Polymers by Interfacial and Solution Methods", Wiley, 1965.
A convenient method for the preparation of polyamides from the acid chlorides of aromatic dibasic acids, e.g., terephthaloyl chloride, involves an interfacial polymerization technique in which the diamine is dispersed in a rapidly stirred mixture of water, an inert water-immiscible solvent, e.g., chloroform, carbon tetrachloride and the like, a dispersing agent, e.g., sodium lauryl sulfate, and a water soluble acid acceptor, e.g., sodium carbonate. The acid chloride, dissolved in the same inert, water-immiscible solvent, is then added rapidly. Such procedures and the methods for isolating and purifying the products are also described by P. W. Morgan in the reference noted above.
Suitable acid chlorides of dibasic acids for reacting with the diamines of this invention to prepare polyamides include:
adipyl dichloride
sebacyl dichloride
malonyl dichloride
phthaloyl dichloride
isophthaloyl dichloride
terephthaloyl dichloride
chloroterephthaloyl dichloride
methylterephthaloyl dichloride
ethylterephthaloyl dichloride
5-tert-butylisophthaloyl dichloride
tetrafluoroterephthaloyl dichloride
tetrachloroterephthaloyl dichloride
tetrabromoterephthaloyl dichloride
tetraiodoterephthaloyl dichloride
tetramethylterephthaloyl dichloride
2,5-diphenylterephthaloyl dichloride
4,4'-biphenyldicarbonyl dichloride
2,2',3,3',5,5',6,6'-octafluoro-4,4'-biphenyldicarbonyl dichloride
2,2'-dibromo-4,4'-biphenyldicarbonyl dichloride
2,2',6,6'-tetrachloro-4,4'-biphenyldicarbonyl dichloride
2,2'-diiodo-4,4'-biphenyldicarbonyl dichloride
2,2'-dimethyl-4,4'-biphenyldicarbonyl dichloride
4,4'-oxydibenzoyl dichloride
3,3'-dimethyl-4,4'-oxydibenzoyl dichloride
2,6-naphthalenedicarbonyl dichloride
1,3,4,5,7,8-hexachloro-2,6-naphthalenedicarbonyl dichloride
1,4-cyclohexanedicarbonyl dichloride
1-methyl-2,3-cyclobutanedicarbonyl dichloride
bis(4-chlorocarbonylphenyl)methane
bis(4-chlorocarbonylphenyl)dichloromethane
2,2-bis(4-chlorocarbonylphenyl)propane
and the like.
To prepare polyamides by reactions of the diamines with diphenyl esters, it is only necessary to intimately mix the diamine and the diphenyl ester in a suitable vessel and then apply heat so that an exchange reaction occurs with the expulsion of phenol: ##STR19## At temperatures of about 200° C. and higher the reaction occurs at a convenient rate, and is completed in a few hours. The temperature can be raised in the later portion of the reaction period to facilitate the driving off of by-product phenol. The removal of phenol is also facilitated by evacuation of the reaction vessel, e.g., with an oil pump. When the reaction is completed, the polymer is isolated and purified by conventional methods. Exchange reactions for the preparation of polyamides from diamines and the aryl esters of dibasic acids are described in "Encyclopedia of Polymer Science and Technology", Vol. 10, p. 487, Wiley, 1969. The diphenyl esters corresponding to the diacid chlorides listed above may be used in this exchange reaction with the diamines of this invention to prepare polyamides.
Polyureas are prepared by reacting diamines of formula I with diisocyanates using the general procedure of Example 15 below. ##STR20## When other diisocyanates are substituted for the bis(4-isocyanatophenyl)methane in that procedure, the corresponding polyureas are obtained. Other polyureas are obtained by using other diamines of formula I.
Suitable diisocyanates for use in preparing the polyureas of this invention include:
tetramethylene diisocyanate
hexamethylene diisocyanate
1,3-phenylene diisocyanate
4-methyl-1,3-phenylene diisocyanate
1,4-phenylene diisocyanate
4,4'-biphenylene diisocyanate
3,3'-dimethyl-4,4'-biphenylene diisocyanate
bis(4-isocyanatophenyl)methane
2,2-bis(4-isocyanatophenyl)propane
bis(4-isocyanatophenyl)ether
1,4-cyclohexylene diisocyanate
and the like.
Polyurethanes are prepared by reacting diamines of formula I with bischloroformates using the general procedure of Example 16 below. ##STR21## When other bischloroformates are substituted for the bischloroformate of neopentyl glycol in this procedure, the corresponding polyureas are obtained. Other polyurethanes are obtained by using other diamines of formula I.
Suitable bischloroformates for use in preparing the polyurethanes of this invention include:
ethylene bischloroformate
trimethylene bischloroformate
2,2-dimethyltrimethylene bischloroformate
1,4-cyclohexylene bischloroformate
p-phenylene bischloroformate
2,2-bis(4-chlorocarbonyloxyphenyl)propane
2,2-bis(4-chlorocarbonyloxy-3,5-dichlorophenyl)propane
3-oxapentane-1,5-bischloroformate
and the like.
Because the diamines of this invention are free of hydrogen atoms beta to the amino groups, the polyamides, polyureas and polyurethanes prepared from these diamines are much superior in thermal stability to the corresponding polymers having beta hydrogen atoms. This is particularly advantageous in melt processing these polymers, for example, in melt spinning of fibers. The most thermally stable of these polymers, and therefore a preferred group, are the polymers of formula II in which R is Ar as defined above.
EXAMPLES OF THE INVENTION
The following examples illustrate the novel diamines, polyamides, polyureas and polyurethanes of this invention and their preparation. In these examples parts are by weight unless otherwise indicated, and all temperatures are expressed in degrees Centigrade. All equipment was dried in an oven at 135° before assembly and flushed with dry nitrogen after assembly. Weighing and handling of all the diamines was carried out in a nitrogen dry box. The alcohol used in these examples was 95% ethanol denatured with benzene.
EXAMPLE 1
(a) 1,4-Bis(2-methyl-2-cyanopropyl)benzene ##STR22##
In a 2-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, a dropping funnel, and a syringe adapter, was placed 900 ml of anhydrous tetrahydrofuran (THF) and 42 ml (30.32 g, 0.30M) of diisopropylamine (via syringe). The stirred mixture was cooled in a dry ice-acetone bath, and then 138.6 ml of 2.17N (0.30M) n-butyllithium in hexane was added via syringe. After the mixture had stirred for 1 hr., a solution of 20.52 g (0.297M) of freshly distilled isobutyronitrile in 60 ml of anhydrous THF was added in 20 minutes. Following an additional 1 hr and 7 min of stirring at dry ice temperature, a solution of 39.57 g (0.150M) of α,α'-dibromo-p-xylene in 450 ml of anhydrous THF was added in 1 hr 23 min. The mixture was stirred at dry ice temperature for 2 hr 15 min and then overnight as the cooling bath warmed to room temperature. Stirring was continued for 4 days at room temperature. The suspended white solid was removed by filtration, rinsed on the filter with THF and dried: WT=13.74 g, mp=193° to 195°. The filtrate was distilled on the water pump to remove the solvent, and the residue, a mixture of brown oil and solid, was stirred and 100 ml of methanol which dissolved the brown oil. Filtration of the mixture, rinsing of the solid on the filter with methanol, and drying of the solid under nitrogen gave an additional 15.7 g of crude 1,4-bis(2-methyl-2-cyanopropyl)benzene melting at 192° to 194.5° (total yield=82%). Dissolving of this material in refluxing acetone (28.5 ml/g), filtration of the hot solution through a course sintered glass funnel to remove some insoluble material, and cooling of the filtrate at 8° to 10° gave the product as colorless needles melting at 194° to 195°.
Anal. Calcd. for C 16 H 20 N 2 : C, 79.95; H, 8.39; N, 11.66. Found: C, 79.79; H, 8.21, N, 11.83. C, 79.76; H, 8.37; N, 11.67.
(b) 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene ##STR23##
In a 2-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, and an addition funnel, was placed 7.50 g (0.0312M) of 1,4-bis(2-methyl-2-cyanopropyl)benzene and 300 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 24.1% solution (0.150M) of diisobutyl-aluminum hydride in toluene was added from the addition funnel in 28 minutes. The mixture was then refluxed for 16 hrs. After the mixture had been cooled in an ice-water bath, a solution of 6 ml of water in 30 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 30 ml of water in 60 ml of methanol. The mixture was stirred vigorously for 1 hr while being cooled in the ice-water bath, and then for an additional hour at room temperature. The mixture was filtered under nitrogen, the solid was washed thoroughly on the filter with toluene, and the combined filtrate and rinsings were distilled on the water pump. The resulting residue crystallized on cooling to room temperature. Further drying on the oil pump gave 5.28 g (68%) of crude 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene melting at 53° to 56° to a cloudy melt. Distillation of this material through a small Vigreux still gave the product as a colorless liquid boiling at 131° to 132°/0.60 mm. The solidified material melted to a clear melt at 53.5° to 54.75°.
Anal. Calc'd for C 16 H 28 N 2 : C, 77.36; H, 11.36; N, 11.28. Found: C, 77.68, 77.07, 77.15; H, 11.44, 11.30, 11.27; N, 11.04, 11.14.
The infrared spectrum contains bands at 2.93, 3.00 and 6.15μ (--NH 2 ), 3.28μ (shoulder) (═CH), 3.38 and 3.48μ (saturated CH), 6.59 and 6.77μ (aromatic C═C), 7.21 and 7.33μ (gem-dimethyl), and 11.86μ (p-disubstituted aromatic).
EXAMPLE 2
(a) 1,3-Bis(2-methyl-2-cyanopropyl(benzene) ##STR24##
In a dry 2-liter flask, equipped with a large magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, an addition funnel, and a syringe adapter, was placed 900 ml of anhydrous THF and 42 ml (30.32 g, 300M) of diisopropylamine (via syringe). The mixture was cooled in a dry ice-acetone bath and, with stirring, 125.3 ml of 2.4 molar (0.300M) n-butyllithium in hexane was added via syringe. After the mixture had stirred for 1 hr 35 min, 20.52 g (0.297M) of freshly distilled isobutyronitrile in 60 ml of THF was added in 30 minutes. Following another 70 minutes of stirring, 39.57 g (0.150M) of α,α'-dibromo-m-xylene was added all at once. The mixture was stirred for 2 hrs at -76°, and then overnight as the cooling bath warmed to room temperature. After an additional day of stirring at room temperature, the mixture was distilled on the water pump to yield a semisolid residue. Dissolving this material in 700 ml of chloroform, followed by three extractions of the resulting solution with 200 ml of water (with HCl acidification during the first extraction), drying over anhydrous magnesium sulfate, and removal of the solvent on the water pump, gave 35.5 g (98%) of a slowly crystallizing, brown solid. This material was further dried on an oil pump: mp=58° to 63°. All of this material was stirred with 2 liters of refluxing cyclohexane, but an appreciable quantity of an oily material was insoluble. Decanting of the solution from this oil, followed by cooling, yielded 18.0 g of 1,3-bis(2-methyl-2-cyanopropyl)benzene as almost colorless prisms melting at 69° to 70°. Refluxing of the filtrate with Darco, followed by filtration, evaporation to about 500 ml, seeding, and cooling, yielded an additional 9.16 g of product melting at 68° to 70°.
Anal. Calc'd for C 16 H 20 N 2 : C, 79.95; H, 8.39; N, 11.66. Found: C, 79.88; H, 8.04; N, 11.74. C, 79.69; H, 8.31; N, 11.56.
(b) 1,3-Bis(2,2-dimethyl-3-aminopropyl)benzene ##STR25##
In a 1-liter flask equipped with a paddle stirrer, a reflux condenser capped with a nitrogen bubbler, and an addition funnel, was placed 7.50 g of 1,3-bis(2-methyl-2-cyanopropyl)benzene and 250 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 1 hr. The mixture was refluxed for 17 hrs 15 min. The mixture was then worked up as described in Example 1(b). Upon distillation of the isolated product through a small Vigreux still, there was obtained 3.51 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene as a colorless liquid distilling at 105° to 110°/0.05 mm.
Anal. Calc'd for C 16 H 28 N 2 : C, 77.36; H, 11.36; N, 11.28. Found: C, 77.59; H, 11.31; N, 11.36. C, 77.29; H, 11.23; N, 11.50.
EXAMPLE 3
(a) 1,4-Bis(2-methyl-2-cyanopropyl)tetramethylbenzene ##STR26##
In a 1-liter flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, an addition funnel, and a syringe adapter, was put 500 ml of anhydrous THF and 14 ml (10.10 g, 0.10M) of diisopropylamine (via syringe). The flask was cooled in a dry ice-acetone bath and, with stirring, 41.8 ml of 2.4 molar (0.100M) n-butyllithium in hexane was added via a syringe. The mixture was stirred for 1 hr, and then a solution of 6.48 g (0.094M) of freshly distilled isobutyronitrile in 20 ml of anhydrous THF was added in 20 minutes. After an additional 65 minutes of stirring, 11.55 g (0.050M) of 3,6-bis(chloromethyl)durene was added all at once. The mixture was stirred for 5 hrs at -76°, and then overnight as the cooling bath warmed to room temperature. Filtration of the solid, rinsing on the filter with THF, and drying under nitrogen, yielded 8.50 g of crude 1,4-bis(2-methyl-2-cyanopropyl)tetramethylbenzene melting at 187° to 190°. Evaporation of the filtrate to dryness yielded additional solid which was dissolved in 325 ml of chloroform. Extraction of this solution three times with 100 ml of water (with HCl-acidification during the first extraction), drying of the chloroform solution over anhydrous magnesium sulfate, and removal of the solvent in vacuo, yielded an additional 5.30 g of crude product (93% total yield) melting at 162° to 180°. Recrystallization of this material from acetone yielded the product as colorless needles melting at 192.5° to 193°.
Anal. Calc'd for C 20 H 28 N 2 : C, 81.03; H, 9.52; N, 9.45. Found: C, 81.31; H, 9.35; N, 9.46. C, 81.14; H, 9.57; N, 9.41.
The infrared spectrum of this material contains bands at 3.31μ (═CH), 3.35 and 3.40μ (saturated CH), 4.48μ (--C.tbd.N), 6.69μ (aromatic C═C) and 7.18 and 7.30μ (gem-dimethyl).
(b) 1,4-Bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene ##STR27##
In a 1-liter flask, equipped as described in Example 1(b), was put 6.17 g of 1,4-bis(2-methyl-2-cyanopropyl)tetramethylbenzene and 200 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 71.3 ml of a 24.1% solution of diisobutylaluminum hydride in toluene was added in 25 min. The mixture was refluxed for 22 hrs and allowed to stand at room temperature for 3 days. After the mixture had been cooled in an ice-water bath, a solution of 4 ml of water in 20 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 20 ml of water in 40 ml of methanol. The mixture was then stirred at room temperature for several hours and allowed to stand at room temperature for 3 days. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. A solid residue resulted which, after further drying in a vacuum oven at room temperature, weighed 5.21 g and melted at 97° to 99°. Sublimation of this material at 125° to 145°/0.50 mm gave 1,4-bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene as a colorless crystalline solid melting at 97.5° to 98.5°.
Anal. Calc'd for C 20 H 36 N 2 : C, 78.88; H, 11.92; N, 9.20. Found: C, 78.62; H, 12.05; N, 9.89. C, 78.55; H, 12.08; N, 10.09.
The infrared spectrum contains bands at 2.96, 3.03, and 6.20μ (--NH 2 ), 3.38 and 3.43μ (saturated CH), 6.73μ (aromatic C═C), and 7.23 and 7.36μ (gem-dimethyl).
EXAMPLE 4
(a) 3,3'-Bis(2-methyl-2-cyanopropyl)biphenyl ##STR28##
In a 500-ml flask, equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, a dropping funnel and a syringe adapter, was put 150 ml of anhydrous THF and 7.0 ml (5.05 g, 0.050M) of diisopropylamine (via syringe). The flask was cooled in a dry ice bath, and with stirring, 23.1 ml of 2.17 molar (0.050M) n-butyllithium in hexane was added via syringe. The mixture was stirred for 55 minutes, and then a solution of 3.42 g (0.049M) of freshly distilled isobutyronitrile in 10 ml of anhydrous THF was added dropwise in 7 minutes. After an additional 20 minutes of stirring, a solution of 8.50 g (0.0250M) of 3,3'-bis(bromomethyl)biphenyl in 75 ml of anhydrous THF was added during 38 minutes. The mixture was allowed to warm to room temperature as it stirred overnight. During the addition, the mixture developed an intense blue color. This color was still apparent on the day after the mixture had warmed to room temperature, but after two additional days of stirring at room temperature, the mixture was light brown and clear. The solvent was removed on the water pump and the resulting residue was dissolved in 200 ml of chloroform. Washing of this solution three times with 100 ml of water (with HCl acidification during the first washing), drying the solution over anhydrous magnesium sulfate, removal of the solvent on the water pump, and drying the resulting residue in vacuo, gave 7.50 g (95%) of crude 3,3'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 96° to 103°. Dissolving this material in hot cyclohexane, refluxing the resulting solution with Darco, filtering through Celite, evaporating the filtrate to 125 ml, and cooling it at 8° to 10°, gave 5.36 g of the product as colorless prisms melting at 106.5° to 108.5°.
Anal. Calc'd for C 22 H 24 N 2 : C, 83.50; H, 7.64; N, 8.86. Found: C, 83.74; H, 7.60; N, 8.63. C, 83.57; H, 7.53; N, 8.60.
The infrared spectrum (KBr) contains bands at 3.25μ (═CH), 3.32, 3.37 and 3.44μ (saturated CH), 4.45 (--C.tbd.N), 6.19 and 6.28μ (aromatic C═C) and 12.7 and 14.04μ (meta disubstituted benzene).
(b) 3,3'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl ##STR29##
In a 2-liter flask, equipped as described in Example 1(b), was put 10.90 g of 3,3'-bis(2-methyl-2-cyanopropyl)biphenyl and 500 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 118 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 25 minutes. The mixture was refluxed for 18 hrs, and then allowed to stand at room temperature for 1 day. After the mixture had been cooled in an ice-water bath, a solution of 7 ml of water in 35 ml of methanol was added dropwise with stirring. This was followed by the dropwise addition of a solution of 33 ml of water in 66 ml of methanol. The ice-water bath was removed, and the mixture was stirred for 1 hour. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The cloudy viscous residue weighed 10.8 g after it was evacuated for several hours with the oil pump at room temperature. Distillation of this material through a small Vigreux still gave 5.94 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl as a clear, colorless, viscous liquid boiling at 159° to 168°/0.2-0.5 mm.
Anal. Calc'd for C 22 H 32 N 2 : C, 81.42; H, 9.94; N, 8.63. Found: C, 81.31; H, 10.19; N, 8.29. C, 81.40; H, 10.57; N, 8.47.
EXAMPLE 5
(a) 2,6-Bis(2-methyl-2-cyanopropyl)naphthalene ##STR30##
In a 1-liter flask, equipped as described in Example 4(a), was put 400 ml of anhydrous THF and 14.00 ml (10.10 g, 0.10M) of diisopropylamine. The flask was cooled in a dry ice bath and, with stirring, 48.3 ml of 2.29 molar (0.111M) n-butyllithium in hexane was added via a syringe. The mixture was stirred for 75 minutes and then 6.84 g of freshly distilled isobutyronitrile in 20 ml of anhydrous THF was added during 12 minutes. After an additional 23 minutes of stirring, 15.2 g of 2,6-bis(bromomethyl)naphthalene was added all at once. The mixture was stirred at -76° for 21/2 hrs and then overnight as the bath warmed to room temperature. After an additional 31/2 days of stirring at room temperature, the mixture was filtered and the resulting solid was rinsed on the funnel with THF and dried under nitrogen: wt=3.13 g, mp=181.8° to 184°. Evaporation of the filtrate to dryness on the water pump yielded additional solid which was dissolved in 700 ml of chloroform. Extraction of the chloroform solution three times with 300 ml of water (with HCl acidification during the first extraction), and removal of the solvent in vacuo yielded additional crude product, which after drying in a vacuum oven at room temperature, weighed 10.00 g and melted at 178° to 180°. Recrystallization of this material from acetone yielded 2,6-bis(2-methyl-2-cyanopropyl)naphthalene melting at 183.5° to 184.5°.
Anal. Calc'd for C 20 H 22 N 2 : C, 82.71; H, 7.64; N, 9.65. Found: C, 83.21; H, 7.84; N, 9.70. C, 82.93; H, 7.73; N, 9.62.
The infrared spectrum of this material contains a C.tbd.N stretch band at 4.45μ.
(b) 2,6-Bis(2,2-dimethyl-3-aminopropyl)naphthalene ##STR31##
In a 1-liter flask, equipped as described in Example 2(b), was put 9.06 g of 2,6-bis(2-methyl-2-cyanopropyl)naphthalene and 300 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 107 ml of a 25% solution of diisobutylaluminum hydride in toluene was added in 55 minutes. The mixture was then refluxed for 20 hrs. After the mixture had been cooled in an ice-water bath, a solution of 6 ml of water in 30 ml of methanol was added with stirring during 55 minutes. This was followed by the addition of a solution of 30 ml of water in 60 ml of methanol during 1 hr 35 min. The mixture was stirred for 1 hr while being cooled in the ice-water bath and then at room temperature overnight. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The resulting solid residue, after being dried in vacuo for about 2 hrs, weighed 8.0 g and melted at 97° to 98.25°. Sublimation of this material at 145° to 165°/0.6 mm gave 2,6-bis(2,2-dimethyl-3-aminopropyl)naphthalene as a colorless, crystalline solid melting at 96.75° to 98.50°.
Anal. Calc'd for C 20 H 30 N 2 : C, 80.48; H, 10.13; N, 9.39. Found: C, 82.09; H, 10.45; N, 9.85. C, 81.74; H, 10.48; N, 9.77.
The infrared spectrum contains bands at 2.98 and 3.06μ (--NH 2 ), 3.29μ (unsaturated CH), 3.38, 3.43 and 3.50μ (saturated CH), 6.23, 6.65 and 6.80μ (--NH 2 and/or aromatic C═C), and 7.22 and 7.33μ (gem-dimethyl).
EXAMPLE 6
(a) 4,4'-Bis(2-methyl-2-cyanopropyl)biphenyl ##STR32##
In a 500-ml flask, equipped as described in Example 4(a), was placed 250 ml of anhydrous THF and 7.00 ml of diisopropylamine (via syringe). The flask was cooled in a dry ice bath and, with stirring, 21.0 ml of 2.4 molar n-butyllithium in hexane was added via a syringe. The mixture was stirred for 1 hour and then 3.42 g of freshly distilled isobutyronitrile in 20 ml of THF was added in 20 minutes. After an additional hour of stirring, 8.50 g of 4,4'-bis(bromomethyl)biphenyl was added all at once. Stirring at -76° was continued for several hours and overnight as the cooling bath warmed to room temperature. After an additional day of stirring, the solvent was distilled on the water pump. The resulting semisolid residue was dissolved in 500 ml of chloroform and the chloroform solution was extracted 4 times with water (with HCl acidification during the first extraction). Drying the solution over anhydrous magnesium sulfate, filtering, and removal of the solvent in vacuo gave 6.8 g of crude 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 174° to 182°. After several recrystallizations from acetone, the product melted at 189.3° to 190.8°.
Anal. Calc'd for C 22 H 24 N 2 : C, 83.50; H, 7.64; N, 8.86. Found: C, 82.81; H, 7.94; N, 8.69. C, 83.43; H, 7.86 N, 8.79. C, 82.94; H, 7.90 N, 8.80.
(b) 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl ##STR33##
In a 1-liter flask, equipped as described in Example 2(b), was put 6.54 g of 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl and 400 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 71 ml of a 25% solution of diisobutyl-aluminum hydride in toluene was added in 30 minutes. The mixture was then refluxed for 17 hrs 40 min. After the mixture had been cooled in an ice-water bath, a solution of 5 ml of water in 22 ml of methanol was added dropwise with stirring in 1 hr. This was followed by the dropwise addition of a solution of 20 ml of water in 40 ml of methanol in 1 hr. The mixture was stirred for 1 hr while being cooled in the ice bath and for 1 hr at room temperature. It then stood at room temperature for one day. The mixture was filtered under nitrogen, the solid was washed thoroughly with toluene on the filter, and the combined filtrate and rinsings were distilled on the water pump. The resulting solid, after drying in vacuo, weighed 5.5 g and melted at 97° to 99°. Sublimation at 185° to 200°/0.10 mm gave 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl as a colorless crystalline solid.
Anal. Calc'd C 22 H 32 N 2 : C, 81.42; H, 9.94; N, 8.63. Found: C, 81.31; H, 10.11; N, 8.87. C, 81.29; H, 10.36; N, 8.68.
EXAMPLE 7
(a) 3,3'-Dichloro-4,4'-bis(2-methyl-2-cyanopropyl)biphenyl ##STR34##
In a 500-ml flask, equipped as described in Example 4(a), was placed 150 ml of anhydrous THF and 7.0 ml of diisopropylamine (via syringe). The flask was cooled at -76° and, with stirring, 21.0 ml of 2.4 molar n-butyllithium in hexane was added via syringe. The mixture was stirred for 1 hr 25 min and then 3.42 g of freshly distilled isobutyronitrile in 10 ml of THF was added in 20 minutes. After an additional 25 minutes of stirring, a solution of 10.22 g of 3,3'-dichloro-4,4'-bis(bromomethyl)biphenyl in 100 ml of THF was added with stirring during 1 hr 20 min. The mixture was stirred at -76° for 1 hr 45 min and then overnight as the cooling bath warmed to room temperature. After an additional 2 days of stirring at room temperature, the solvent was removed in vacuo. The resulting residue was dissolved in 200 ml of chloroform and the chloroform solution was extracted 3 times with 100 ml of water (with HCl acidification during the first extraction). Drying the solution over anhydrous magnesium sulfate, filtering, and removal of the solvent in vacuo, gave 7.5 g of crude 3,3'-dichloro-4,4'-bis(2-methyl-2-cyanopropyl)biphenyl melting at 148° to 156°. A recrystallization from acetone, with a filration of the hot solution to remove some insoluble material, gave product melting at 162° to 164°.
Anal. Calc'd for C 22 H 22 Cl 2 N 2 : C, 68.57; H, 5.76; Cl, 18.40; N, 7.27. Found: C, 68.36; H, 5.93; Cl, 18.14; N, 7.48. C, 68.80; H, 6.09; Cl, 18.34; N, 7.19. C, 68.28; H, 5.69.
(b) 3,3'-Dichloro-4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl
When an equivalent amount of 3,3'-dichloro-4,4'-bis(2-methyl-2-cyanopropyl)biphenyl is substituted for the 4,4'-bis(2-methyl-2-cyanopropyl)biphenyl in the procedure for Example 6(b), 3,3'-dichloro-4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl of the formula ##STR35## is formed.
EXAMPLE 8
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Sebacyl Chloride ##STR36##
In a 3-liter flask, equipped with a paddle stirrer, a reflux condenser, and a nitrogen bubbler, was placed 25.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene, 31.0 ml of triethylamine, and 350 ml of chloroform which had been passed through basic alumina under nitrogen directly into the reaction flask. With vigorous stirring at room temperature, 24.07 g of freshly distilled sebacyl chloride in 100 ml of purified chloroform was added all at once. The mixture was stirred for 45 minutes and then 1500 ml of hexane was added to precipitate the polymer. After 15 minutes of stirring, the mixture was allowed to stand overnight. With stirring, a solution of 150 ml of concentrated hydrochloric acid in 600 ml of water was added. The coagulated polymer was filtered, rinsed on the filter with water, and then washed in a blender once with 600 ml of water, once with 600 ml of acetone and three times with 600 ml of water. The isolated polymer was dried overnight in a vacuum oven at 70°. There was thus obtained 32.6 g (78%) of product: inherent viscosity (0.05% in m-cresol at 25°)=1.32.
A clear, tough, colorless film was pressed from a portion of the polymer at 180° and 500 lbs pressure. Another portion of the polymer was melt spun through a spinnerette (0.020"×0.04") at 248° to 270° to give filament which, after cold drawing, had strengths of about 1.5 grams/denier.
The product of another experiment, on 1/10 the scale of that just described, was further characterized by elemental analysis and infrared spectroscopy.
Anal. Calc'd for (C 26 H 42 N 2 O 2 ) n : C, 75.31; H, 10.21; N, 6.76. Found: C, 75.20; H, 10.90; N, 6.94; C, 75.66 H,10.89 N, 6.95.
The infrared spectrum contained bands at 3.03μ (--NH), 3.42 and 3.48μ (saturated CH), 6.08 and 6.45μ (amide I and II bands), 6.60μ (aromatic C═C), and 7.30 and 7.32μ (gem-dimethyl).
EXAMPLE 9
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Adipyl Chloride ##STR37##
In a 300-ml flask, equipped as described in Example 8, was put 4.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene, 5.0 ml of triethylamine, and 50 ml of chloroform which had been passed through basic alumina. With vigorous stirring at room temperature, a solution of 2.95 g of freshly distilled adipyl chloride in 20 ml of dried chloroform was added all at once. After a few minutes of stirring 25 ml of chloroform was added, and the mixture was stirred vigorously for 1/2 hr. Addition with stirring of 300 ml of hexane and 150 ml of alcohol gave a mushy precipitate which after filtration and stirring with water became a hard colorless solid. Evaporation of the filtrate and the rinsings to remove the hexane, gave more precipitate. The combined solids were dried in a vacuum oven at 70°, washed twice in a blender with 200 ml of water and then washed twice with 200 ml of methanol. The resulting polymer, after being dried in a vacuum oven at room temperature, weighed 2.00 g: inherent viscosity (0.05% in m-cresol at 25°)=0.73.
Anal. Calc'd for (C 22 H 34 N 2 O 2 ) n : C, 73.70; H, 9.56; N, 7.82. Found: C, 72.92; H, 9.57; N, 7.42. C, 73.07; H, 9.63; N, 7.50.
Fibers could be hand drawn from the polymer heated on a metal block at 165° to 210°.
EXAMPLE 10
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Terephthaloyl Chloride ##STR38##
In a 1-liter blender was put 125 ml of distilled water, 50 ml of chloroform (which had been passed through basic alumina), 1.00 g of sodium lauryl sulfate, and 4.26 g of anhydrous sodium carbonate. The mixture was stirred moderately fast until a uniform emulsion was obtained. Then, 5.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene was added and stirring was continued for several minutes. A solution of 4.09 g of terephthaloyl chloride in 75 ml of purified chloroform was added with stirring in 30 seconds. After 5 minutes of vigorous stirring, 275 ml of hexane was added followed by 200 ml of alcohol. After a few additional minutes of stirring, the precipitated polymer was filtered, washed on the filter with water and alcohol and air dried. The isolated polymer was then washed twice in the blender with water. After being dried in a vacuum oven at 60°, it weighed 5.45 g (72%): inherent viscosity (0.05% in m-cresol, at 25°)= 0.77. Long fibers could be drawn from a sample of the polymer heated on a metal block at 270° to 280°.
The infrared spectrum contained bands at 3.04μ (--NH), 3.39 and 3.43μ (saturated CH), 6.08 and 6.53μ (amide I and II bands), 6.69μ (aromatic C═C), and 7.32 and 7.34μ (gem-dimethyl).
EXAMPLE 11
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Diphenyl Terephthalate ##STR39##
In a polymer tube (23 cm×2.5 cm), fitted with a side arm, was put 5.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene and 6.41 g of diphenyl terephthalate. A nitrogen capillary was positioned in the tube so that the end of the capillary was above the reaction mixture. The tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 3 hr 40 min. After 2 hrs and 20 min, solid polymer was evident. The tube was then heated in a 280° vapor bath for 2 hr 55 min. During the last 1 hr 45 min of this heating, the tube was evacuated at <0.5 mm. After the tube had cooled to room temperature, it was broken and 7.20 g (95%) of polymer was isolated. Successive washings of the polymer in a blender with 100 ml of water, 100 ml of acetone, and three times with 100 ml of water, and drying in a vacuum oven at 70° gave 6.61 g of product: inherent viscosity (0.05% in m-cresol at 25°)=0.49. A thermal gravimetric determination on this material shows that it does not begin to decompose until about 425°.
EXAMPLE 12
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Diphenyl Isophthalate ##STR40##
In a 50-ml flask was placed 5.00 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene and 6.41 g of diphenyl iosphthalate. The flask was fitted with a 15-cm extension tube and a short path still head which had a nitrogen capillary inserted into it reaching to above the reaction mixture and a small round-bottomed flask as receiver. The assembled set-up was connected to a nitrogen bubbler. The flask was then heated in an oil bath at 220°. Within the first few minutes of heating, the charge became liquid, whereupon the flask was agitated to insure completed mixing of the reactants. The mixture became progressively more viscous as the heating was continued. After 3 hr 20 min of heating at 220°, the temperature of the oil bath was increased so that after 15 min the temperature was 268° to 270°. The oil bath was maintained at this temperature for 3 hr 5 min, during the final 1 hr 30 min of which the system was evacuated at about 0.5 mm. The reactor was then allowed to cool under vacuum. The polymer was isolated, ground up in a blender with 300 ml of water, reisolated by filtration, and finally dried in a vacuum oven at 70°: wt=7.0 gms. The inherent viscosity (0.05% in m-cresol at 25°)=0.32.
EXAMPLE 13
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene- and Diphenyl Bibenzoate ##STR41##
In a 50-ml round-bottomed flask was placed 5.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene and 7.94 g of diphenyl bibenzoate. The flask was then fitted with a 15-cm extension tube which had an adaptor for connecting to a nitrogen bubbler and for the insertion of a nitrogen capillary into the reaction vessel. The flask was then heated in an oil bath at 220° with the nitrogen capillary above the reaction mixture. Within the first few minutes of heating, the charge became liquid whereupon the flask was agitated to insure thorough mixing of the reactants. After 8 minutes of heating at 220°, the reaction mixture had resolidified. After 1 hr 8 min of heating at 220°, the temperature of the oil bath was increased so that at the end of an additional 2 hrs, the temperature was 265°. The reactor was then evacuated with an oil pump for 1 hr 35 min with the temperature maintained at 265° to 270° . The reactor was allowed to cool under vacuum. The isolated polymer was washed in a blender successively with 200 ml of water, 100 ml of acetone and then three times with 200 ml of water. After being dried in a vacuum overn at 70°, the polymer weighed 8.5 g: inherent viscosity (0.05% in m-cresol at 25°)=0.24.
EXAMPLE 14
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Diphenyl 2,6-Naphthalenedicarboxylate ##STR42##
In a polymer tube (23 cm×2.5 cm) fitted with a side arm was put 5.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene and 7.41 g of diphenyl 2,6-naphthalenedicarboxylate. A nitrogen capillary was positioned in the tube so that the end of the capillary was above the reaction mixture. The tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 3 hrs 30 min. The tube was then heated in a 280° vapor bath for 2 hrs 45 min. During the last 1 hr 30 min of this heating, the tube was evacuated at 0.5 mm. After the tube had cooled to room temperature, it was broken and 8.00 g (93%) of polymer was isolated. After washing and drying as described in Example 11, there was obtained 7.60 g of product: inherent viscosity (0.05% in m-cresol at 25°)=0.45. A thermal gravimetric determination on this material shows that it does not begin to decompose until about 425°. A clear, brittle film was pressed at 320° and 500 lbs pressure.
EXAMPLE 15
A Polyurea from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and Bis(4-isocyanatophenyl)methane ##STR43##
In a blender was put 4.225 g of bis(4-isocyanatophenyl)methane dissolved in 90 ml of a 70:30 mixture (by volume) of tetramethylene sulfone and chloroform. With vigorous stirring, a solution of 4.194 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene in 90 ml of the same solvent was added all at once. Vigorous stirring was continued for 10 minutes whereupon 130 ml of a 4% (by volume) solution of n-butylamine in water was added. This was followed by the addition of 350 ml of water and several additional minutes of stirring. The polymer, isolated by filtration, was washed once in a blender with 300 ml of a 1:1 (by volume) solution of acetone and water, and then three times with 100 ml of water. After being dried in a vacuum oven at 70°, the polymer weighed 8.00 g (95%).
Anal. Calc'd for (C 31 H 38 N 4 O 2 ) n : C, 74.67; H, 7.68; N, 11.24. Found: C, 73.01; H, 7.76; N, 11.01. C, 72.73; H, 7.57; N, 10.98.
A colorless, transparent film was pressed from this polymer at 230° and 500 lbs pressure. Fibers could be drawn from the polymer on a metal block at 275° to 285°.
EXAMPLE 16
A Polyurethane from 1,4-Bis(2,2-dimethyl-3-aminopropyl)benzene and the Bis-chloroformate of Neopentyl Glycol ##STR44##
In a blender was put 150 ml of distilled water, 60 ml of chloroform (which had been passed through basic alumina), 1.20 g of sodium lauryl sulfate, 6.36 g of anhydrous sodium carbonate and 7.45 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)benzene. The mixture was stirred until a uniform emulsion was obtained. Then a solution of 6.87 g of the bischloroformate of neopentyl glycol in 50 ml of purified chloroform was added in about 20 seconds with stirring. After 5 minutes of stirring, 500 ml of hexane was added. Stirring was continued for another 5 minutes. The polymer was isolated by filtration and washed in the blender twice with 200 ml of water, once with 200 ml of 1:1 (by volume) acetone:water, and once again with 200 ml of water. After being dried for several hours in a vacuum oven at 70°, the polymer weighed 8.3 g (68%): inherent viscosity (0.05%, in m-cresol at 25° )=0.67. A clear, colorless, tough film was pressed at 180° and 500 lbs pressure.
EXAMPLE 17
A Polyamide from 1,3-Bis(2,2-dimethyl-3-aminopropyl)benzene and Sebacyl Chloride ##STR45##
In a 300 ml flask, equipped with a paddle stirrer, a reflux condenser and a nitrogen bubbler, was put 4.00 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene, 5.00 ml of triethylamine, and 50 ml of chloroform which had been passed through basic alumina under nitrogen. With vigorous stirring, a solution of 3.85 g of sebacyl chloride (freshly distilled) in 25 ml of purified chloroform was added all at once. The mixture was stirred for 10 minutes and poured into 500 ml of hexane with stirring. Stirring was continued for a few minutes, the mixture was filtered, and the isolated solid was rinsed on the filter with hexane. The dried solid was washed in a blender once with 200 ml of water and once with 100 ml of acetone. The resulting sticky polymer was dried in a vacuum oven at room temperature and then washed in the blender three times with 200 ml of water. After being dried in a vacuum oven at 70°, the polymer weighed 3.20 g: inherent viscosity (0.05% in m-cresol at 25°)=0.36.
EXAMPLE 18
A Polyamide from 1,3-Bis(2,2-dimethyl-3-aminopropyl)benzene and Diphenyl Bibenzoate ##STR46##
In a 50-ml, round-bottomed flask was placed 5.0 g of 1,3-bis(2,2-dimethyl-3-aminopropyl)benzene and 7.94 g of diphenyl bibenzoate. The flask was equipped as described in Example 13 and then heated in an oil bath at 210° to 220° with the nitrogen capillary positioned above the reaction mixture. Within 10 minutes, the charge completely melted whereupon the flask was agitated to insure thorough mixing of the reactants. After 3 hrs and 20 min of heating at 210° to 220°, the capillary was lowered so that nitrogen bubbled up through the still liquid reaction mixture, and the temperature of the oil bath was raised so that after 30 min its temperature was 265°. Heating at this temperature was continued for 2 hrs 45 min, during the final hour of which the reactor was evacuated with an oil pump (˜0.5 mm). After the flask had cooled to room temperature under vacuum, the polymer was isolated: wt=9.2 g (100%). The polymer was ground up in a blender with 200 ml of water, reisolated by filtration, and finally dried in a vacuum oven at 70°. A clear, tough film was pressed at 220° and 500 lbs. The inherent viscosity (0.05% in m-cresol at 25°)=0.57.
EXAMPLE 19
A Polyamide from 1,4-Bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene and Sebacyl Chloride ##STR47##
In a 1-liter flask, equipped with a paddle stirrer, a reflux condenser, and a nitrogen bubbler, was placed 10.00 g of 1,4-bis(2,2-dimethyl-3-aminopropyl)tetramethylbenzene, 10.1 ml of triethylamine, and 125 ml of chloroform which had been passed through basic alumina under nitrogen. The reaction flask was cooled in a room-temperature water bath, and with vigorous stirring a solution of 7.85 g of freshly distilled sebacyl chloride in 50 ml of purified chloroform was added all at once. After the mixture had been stirred vigorously for another 30 minutes, 500 ml of hexane was added, and stirring was continued for 30 minutes. Then with stirring, 200 ml of water was added. Stirring was continued for a short time and the mixture was allowed to stand at room temperature overnight. The polymer was isolated by filtration, rinsed on the filter with water, and then washed in a blender once with 200 ml of water, once with 200 ml of acetone, and three times with 200 ml of water. The isolated polymer was dried overnight in a vacuum oven at 70°. There was thus obtained 9.50 g (61%) of product: inherent viscosity (0.05% in m-cresol at 25°)=0.38. A clear, colorless, brittle film was pressed at 180° and 500 lbs pressure.
EXAMPLE 20
A Polyamide from 3,3'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Sebacyl Chloride ##STR48##
In a 250-ml flask equipped with a paddle stirrer, a reflux condenser, and a nitrogen bubbler was placed 5.03 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl, 4.8 ml of triethylamine and 75 ml of chloroform which had been passed through basic alumina under nitrogen. With vigorous stirring, a solution of 3.71 g of freshly distilled sebacyl chloride in 20 ml of purified chloroform was added all at once. The mixture was stirred for 30 min and then poured with stirring into 150 ml of hexane. As stirring was continued, the total volume was increased to 350 ml with hexane. The resulting precipitate was filtered, rinsed on the filter with hexane, and then washed in a blender successively with 100 ml of water, 100 ml of acetone, and finally three times with 100 ml of water. After being dried in a vacuum oven at 70° overnight, the polymer weighed 4.80 g (63%): inherent viscosity (0.05% in m-cresol at 25°)= 0.64.
EXAMPLE 21
A Polyamide from 3,3'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Terephthaloyl Chloride ##STR49##
In a 1-liter blender was put 100 ml of distilled water, 40 ml of chloroform (which had been passed through basic alumina), 0.77 g of sodium lauryl sulfate, 3.28 g of anhydrous sodium carbonate and 5.04 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl. The mixture was stirred moderately fast until a uniform emulsion was obtained. Then a solution of 3.15 g of terephthaloyl chloride in 110 ml of purified chloroform was added in a few seconds. The mixture was stirred for 14 minutes and then 300 ml of hexane was added. After a further 7 minutes of stirring, an additional 200 ml of hexane was added with stirring. In order to more completely coagulate the polymer, the mixture was added with stirring to dilute aqueous HCl. The resulting polymer was filtered, washed in a blender successively with 100 ml of water, 100 ml of acetone, and then three times with 100 ml of water, and dried in a vacuum oven at 70°. There was thus obtained 2.76 g of colorless solid polymer: inherent viscosity (0.05% in m-cresol at 25%)=0.27.
EXAMPLE 22
A Polyamide from 3,3'-Bis-(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl Bibenzoate ##STR50##
In a 50-ml round-bottomed flask was placed 5.05 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl and 6.14 g of diphenyl bibenzoate. The flask was equipped as described in Example 13 and then heated for 30 minutes in an oil bath at about 220° with the nitrogen capillary positioned above the reaction mixture. The capillary was then lowered so that nitrogen bubbled up through the reaction mixture and the heating at 220° continued for about 4 hours. The bath was then heated more strongly so that its temperature rose to 270° in the next hour. Heating at 270° was continued for 1 hr 30 min. During the final hour of the heating period, the flask was evacuated with an oil pump. The flask was then removed from the oil bath and allowed to cool to room temperature. The flask was broken and the polymer was isolated: weight=8.2 g (˜100%) of clear, amber-colored, tough solid: inherent viscosity (0.05% in m-cresol at 25°)=0.29.
Long tough fibers could be drawn from this polymer heated on a metal block at 300° to 310°. A clear, colorless, tough film was pressed at 220° and 500 lbs pressure.
EXAMPLE 23
A Polyamide from 3,3'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl 2,6-Naphthalenedicarboxylate ##STR51##
In a 50-ml flask was placed 5.05 g of 3,3'-bis(2,2-dimethyl-3-aminopropyl)biphenyl and 5.73 g of diphenyl 2,6-naphthalenedicarboxylate. The flask was then fitted as described in Example 12, and heated in an oil bath at 220°. After 10 minutes of heating, the charge became liquid whereupon the flask was agitated to insure complete mixing of the reactants. After 2 hr 30 min of heating at 220°, the temperature of the oil bath was increased so that after 43 min the temperature was 270°. The oil bath was maintained at this temperature for 2 hr 47 min, during the last 1 hr 30 min of which the system was evacuated at 0.20 mm. The reactor was allowed to cool under vacuum and the polymer was isolated, ground up in a blender with 200 ml of water, filtered and dried in a vacuum oven at 70°: wt=7.10 g (90%): inherent viscosity (0.05% in m-cresol at 25°)=1.08.
EXAMPLE 24
A Polyamide from 2,6-Bis(2,2,-dimethyl-3-aminopropyl)naphthalene and Diphenyl Terephthalate ##STR52##
In a polymer tube (23 cm×2.5 cm), fitted with a side arm, was put 5.00 g of 2,6-bis(2,2-dimethyl-3-aminopropyl)naphthalene and 5.33 g of diphenyl terephthalate. A nitrogen capillary was positioned in the tube so that the end of the capillary was above the reaction mixture. The tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 4 hr 30 min. After 1 hr 15 min at 220°, the capillary was lowered so that the nitrogen bubbled up through the reaction mixture. The tube was then heated at 280° for 2 hrs 30 min. During the last 30 min of this heating, the tube was evacuated at about 2.5 mm. After the tube had cooled to room temperature, it was broken and 5.61 g (78%) of polymer was isolated: inherent viscosity (0.05% in m-cresol at 25°)=0.20.
EXAMPLE 25
A Polyamide from 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Sebacyl Chloride ##STR53##
In a 300-ml flask, equipped as described in Example 20, was placed 5.00 g of 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl, 4.8 ml of triethylamine and 75 ml of chloroform which had been passed through basic alumina under nitrogen. With vigorous stirring, a solution of 3.68 g of freshly distilled sebacyl chloride in 125 ml of purified chloroform was added all at once. The mixture was stirred for 10 min and then poured into 500 ml of vigorously stirred hexane. The resulting precipitate was isolated by filtration, dried on the filter and washed in a blender once with 200 ml of water, once with 100 ml of acetone, and finally three times with 200 ml of water. After being dried in a vacuum oven at 70°, the polymer weighed 6.3 g (83%): inherent viscosity (0.05% in m-cresol at 25°)=0.46.
EXAMPLE 26
A Polyamide from 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl Bibenzoate ##STR54##
In a large test tube (30 cm×3.5 cm), fitted with a 2-hole rubber stopper containing a straight glass tube and a right angle glass tube, was put 4.0 g of 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl and 4.86 g of diphenyl bibenzoate. A nitrogen capillary was fitted into the straight tube and positioned so that its end was above the reaction mixture. The right angle tube was connected to a nitrogen bubbler. The test tube was lowered into the vapor of a 220° vapor bath and heated at that temperature for 3 hrs 45 min. The tube was then heated in a 280° vapor bath for 1 hr 25 min. During the last 40 minutes the tube was evacuated with an oil pump. After the tube had cooled to room temperature, 6.5 g (99%) of polymer was isolated. Successive washings of the polymer in a blender with 100 ml of water, 100 ml of acetone, and then 3 times with 100 ml of water and then drying in a vacuum oven at 70° gave 6.16 g of product: inherent viscosity (0.05% in sulfuric acid at 25°)=0.40.
EXAMPLE 27
Polyamide from 3,3'-Dichloro-4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl Bibenzoate
When an equivalent amount of 3,3'-dichloro-4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl is substituted for the 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl in the procedure of Example 26, a polyamide with the repeating unit ##STR55## is formed.
COMPARATIVE EXAMPLES
These experiments were undertaken to compare the thermal stability of disclosed terephthalamide polymers which are derived from diamines having the formula ##STR56## wherein n is 0, 1, 2 or 4, with the terephthalamide polymers derived from diamines of the present invention which are of the formula ##STR57##
I. Preparation of 4,4'-Bis(1,1-dimethyl-3-aminopropyl)biphenyl
A. 4,4'-Bis(1,1-dimethyl-2-carboxyethyl)biphenyl ##STR58##
In a 1 liter flask equipped with a magnetic stirrer, a reflux condenser capped with a nitrogen bubbler, and an addition funnel was put 250 g of carbon disulfide, 23.1 g of biphenyl and 80 g of anhydrous aluminum chloride. To this stirred mixture, a solution of 30.0 g of β,β-dimethyl acrylic acid dissolved in 165 ml of carbon disulfide was added from the addition funnel in about 1/4 hour. The resulting mixture was stirred at room temperature for 2 hours and then heated to gentle reflux for 1 hour. After being cooled to room temperature, the mixture was poured into 1 kilogram of chopped ice with vigorous stirring, and stirred for about 16 hours.
The resulting colorless solid was filtered, rinsed in the filter with water, and then stirred for a few minutes on a hot plate with a solution of 200 ml of concentrated aqueous ammonia in 200 ml of water. The resulting suspension was filtered to remove the alumina and the solid was rinsed on the filter with water. The combined filtrate and rinsings were cooled in an ice-water bath and with stirring were acidified with concentrated HCl until no more precipitation occurred. The resulting solid was isolated by filtration, rinsed on the filter with much water, and dried in a vacuum oven at 70°; wt: 36.3 g (68%), mp=145° to 220°. This material was dissolved in 375 ml of absolute ethanol at reflux, and the hot solution was filtered through a medium sintered glass filter and cooled to 10° C.
The resulting 4,4'-bis(1,1-dimethyl-2-carboxyethyl)biphenyl, after isolation by filtration and drying, weighed 11.4 g and melted at 233.5° to 236.5°. An additional 3.75 g of product (mp=230° to 237°), was obtained by evaporating the filtrate to 150 ml. One more recrystallization from ethanol raised the melting point to 237° to 239°. Two further recrystallizations from o-dichlorobenzene at reflux (7.5 ml/gm) gave the product as essentially colorless crystals melting at 244.5° to 245°.
Anal. Calcd. for C 22 H 26 O 4 : C, 74.55; H, 7.39. Found: C, 74.82; H, 7.30; C, 75.12; H, 7.28.
B. 4,4'-Bis(1,1-dimethyl-2-amidoethyl)biphenyl ##STR59##
All equipment was dried at 135° before assembly and flushed with nitrogen after assembly. In a 200 ml flask equipped with a nitrogen stirrer, and a reflux condenser capped with a nitrogen bubbler was put 20 g of 4,4'-bis-(1,1-dimethyl-2-carboxyethyl)biphenyl, 60 ml of thionyl chloride and 2 drops of anhydrous dimethylformamide. This mixture was refluxed for 16 hours. The excess thionyl chloride was distilled off on the water pump and the resulting solid residue freed of the last trace of thionyl chloride by evacuation on the oil pump (˜0.10 mm) at room temperature. There was thus obtained 23.08 g of 4,4'-bis(1,1-dimethyl-2-chlorocarbonylethyl)biphenyl as an almost colorless crystalline solid.
All of this product was dissolved in 750 ml of anhydrous tetrahydrofuran contained in a 2-liter flask fitted with a magnetic stirrer, a gas inlet tube which extended below the surface of the solution, and a reflux condenser capped with a nitrogen bubbler. While the mixture was stirred, anhydrous ammonia was passed through the gas inlet tube until no more precipitation was evident (11/2 hours). The resulting mixture was filtered and the filter cake was rinsed with a little tetrahydrofuran. After the filter cake had been dried on the filter, it was stirred for 1/4 hour with 500 ml of water. The mixture was filtered and the solid was rinsed on the filter with water. After drying in a vacuum oven at 70°, there was obtained 16.6 g (83%) of 4,4'-bis(1,1-dimethyl-2-amidoethyl)biphenyl melting at 207° to 209°. After two recrystallizations from ethanol (181 ml/gm), the product was obtained as colorless plates melting at 214.5° to 215.5°.
Anal. Calcd. for C 22 H 28 N 2 O 2 : C, 74.96; H, 8.01; N, 7.95. Found: C, 75.55; H, 7.79; N, 7.43. C, 75.51; H, 7.87; N, 7.57.
Further recrystallization of other batches gave product melting at 215.7° to 216.7°.
C. 4,4'-Bis(1,1-dimethyl-3-aminopropyl)biphenyl ##STR60##
All equipment was dried at 135° before assembly and flushed with nitrogen after assembly. In a five-liter flask equipped with a magnetic stirrer, a dropping funnel, and a reflux condenser capped with a nitrogen bubbler, was put 25.00 g of 4,4'-bis(1,1-dimethyl-2-amidoethyl)biphenyl and 1250 ml of reagent grade toluene which had been passed through acid alumina under nitrogen directly into the reaction vessel. With stirring at room temperature, 500 ml of a 25% solution of diisobutyl-aluminum hydride in toluene was added from the dropping funnel in 1/2-1 hour. The mixture was then refluxed for about 16 hours. After the mixture had been cooled in an ice-water bath, a solution of 30 ml of water in 140 ml of methanol was added dropwise with stirring during 55 minutes. This was followed by the dropwise addition of a solution of 140 ml of water in 280 ml of methanol during 25 minutes.
The resulting mixture was stirred for two hours at ice-bath temperature and for an additional hour at room temperature. The mixture was filtered under nitrogen, the solid was washed thoroughly on the filter with toluene, and the combined filtrates and washings were distilled on the water pump. The resulting solid residue was dried on the oil pump at room temperature to remove the last traces of solvent. This residue was then sublimed at 160° to 180°/0.1 mm to give 15 g (65%) of 4,4'-bis(1,1-dimethyl-3-aminopropyl)biphenyl as a colorless crystalline solid. Another sample prepared in the same manner was analyzed:
Anal. Calcd. for C 22 H 32 N 2 : C, 81.42; H, 9.94; N, 8.63. Found: C, 80.89; H, 10.03; N, 7.89. C, 80.69; H, 10.06; N, 8.15. The infrared spectrum of this material contains bands at 2.98μ and 3.04μ (--NH 2 ), 3.37μ and 3.47μ (saturated CH), 3.28μ (═CH), 6.32μ (NH 2 deformation and/or aromatic C═C), 6.66μ (aromatic C═C) and 12.13μ (p-disubstituted aromatic).
II. A Polyamide from 4,4'-Bis(1,1-dimethyl-3-aminopropyl)biphenyl and Diphenyl Terephthalate ##STR61##
All equipment was dried at 135° and let cool in a nitrogen dry box. The loading was also done in a nitrogen dry box. In a 100-ml flask was put 6.8652 g of 4,4'-bis(1,1-dimethyl-3-aminopropyl)biphenyl and 6.7342 g of diphenyl terephthalate (weight ratio of 1.01945, molar ratio of 1.0000). The reactants were thoroughly mixed and the flask was fitted with a 15 cm extension tube and a short path still head which had a small motor driven paddle stirrer inserted into it reaching to the bottom of the flask, and a small round bottomed flask as a receiver. The assembled set-up was connected to a nitrogen bubbler and the flask was inserted into an oil bath heated to approximately 220°. The reaction mixture was then submitted to the following heating, stirring and evacuation schedule:
Oil Bath Temperature
218° to 224°--40 min--stirred during last 37 min.
224° to 232°--16 hr 40 min
232° to 268°--1 hr 22 min
268° to 270°--4 hr 15 min
270° to 263°--2 hr 55 min--evacuated at 0.10 mm.
The reactor was then allowed to cool under vacuum and the polymer was isolated. It weighed 9.5 g (99%). The polymer was ground in a micro mill sufficient to pass through a 40 mesh screen. It was then dried at 200° in a vacuum oven for about 16 hours. The inherent viscosity (0.25% in m-cresol at 25°)=0.42.
III. A Polyamide From 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl and Diphenyl Terephthalate ##STR62##
In the same set-up described in Part II, a mixture of 9.6500 of 4,4'-bis(2,2-dimethyl-3-aminopropyl)biphenyl and 9.4659 g of diphenyl terephthalate (weight ratio of 1.01945, molar ratio of 1.0000) was submitted to the following heating, stirring and evacuation schedule:
Oil Bath Temperature
210° to 220°--1 hr 2 min--stirred
220°--1 hr 7 min
220° to 300°--1 hr 25 min
300°--2 hr 10 min
300°--1 hr--evaluated at 0.2 mm.
The polymer was isolated, broken up in blender with 300 ml of water, filtered, and then dried at 70° in the vacuum oven: wt=12.70 g (93%). The sample was then ground up in Wiley Mill sufficient to pass through a 20 mesh screen. It was then dried at 200° in a vacuum oven for about 16 hours. The inherent viscosity (0.25% in m-cresol at 25°)=0.49.
IV. Comparison of Thermal Stabilities of the Terephthalamides Derived From 4,4'-Bis(1,1-dimethyl-3-aminopropyl)biphenyl and 4,4'-Bis(2,2-dimethyl-3-aminopropyl)biphenyl
Samples of the above polymers of comparable inherent viscosities were subjected to isothermal thermogravimetric analyses (TGA) under nitrogen using a Du Pont Thermo Gravimetric Analyzer Model 990-951. This established technique measures decomposition via weight loss. The test results are tabulated below.
Comparative Thermal Stabilities
__________________________________________________________________________ % Weight Loss Temperature ABAfter One Hour ##STR63##__________________________________________________________________________300° 2.5% 1.3% 92.3%350° 8.7% 4.2% 107.1%375° 26.5% 17.5% 51.4% ##STR64## ##STR65##__________________________________________________________________________
The data show that in the temperature range 300° to 375° C., polyamide A loses 50% to 107% more weight by thermal decomposition than does polyamide B. Polymer A was semimolten and collapsed and polymer B was molten at 300° C. Both polymers were molten at 350° C. and 375° C. Thus, the difference in size of the original particles cannot effect the thermal decomposition test results.
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Aromatic-aliphatic diamines of the formula ##STR1## in which Ar is an arylene or substituted arylene are useful in preparing thermally stable, rigid, polyamides, polyureas and polyurethanes having a repeating unit of the formula ##STR2## in which Ar is arylene or substituted arylene, X is --NH-- or --O--, n is 0 or 1, and R is a divalent organic radical.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to an expanded clamping band for use in a washer and a method for manufacturing a washer having an expanded clamping band.
[0002] A typical prior art washer for washing laundry includes a cabinet with an outer tub placed in the cabinet and an inner tub placed within the outer tub. This inner tub is known by various names, including as a “spin tub” or “spinner.” The spin tub contains the clothes or other laundry articles and is rotated at various points in the laundry cycles, particularly during a spin cycle used to extract water from the laundry.
[0003] It has been observed that an unbalanced load within the tub results in a lumped mass of clothes in the spin tub. This unbalanced load can exert a force on a localized region of the spin tub. The resulting force has a direct relationship to both the mass of the laundry articles and the radius of the spin tub. This force increases as the square of the angular velocity of the spin tub. Thus, the greater the velocity of the spin tub, the greater the force on localized regions of the spin tub. Also, the greater the size of the spin tub as measured by its radius, the greater the force on the localized regions of the spin tub.
[0004] The appliance industry has continued to increase the speed of the spin tubs in order to reduce overall energy consumption through improved extraction of water. This increase in speed also increases the force on localized regions of the spin tub as previously explained.
[0005] Therefore, one of the challenges in boosting the spin speed is to prevent deformation of the spin tub. This deformation can reduce the clearance between the spin tub and outer tub to the point where contact occurs. This results in numerous problems including undesirable noise that may result in a service call. Also, this type of deformation can more seriously damage the outer tub, and needs to be avoided.
[0006] The spin tub could be made more durable through enlarging the size of the spin tub. However, manufacturers attempt to provide the largest possible spin tub volume given certain constraints. One such constraint is that one industry standard for the width of a washer and dryer pair is 54 inches. Typically, each washer and dryer is 27 inches wide to allow usage of common cabinetry components on the washer and dryer. The design of the suspension system in a washer further necessitates some amount of clearance between the outer tub and cabinet to accommodate movement of the dynamic system during spin without creating cabinet hits. Further, some amount of clearance is necessary between the spin tub and the outer tub. Each of these constraints further limits the available spin tub volume.
[0007] Therefore, what is needed is a washer having a spin tub or spinner that improves upon the state of the art.
[0008] A further object, feature, or advantage of the present invention is to provide a washer with a spin tub designed to minimize deformation of the spin tub.
[0009] It is a still further object, feature, or advantage of the present invention to reinforce a spin tub without reducing spin tub volume.
[0010] Another object, feature, or advantage of the present invention is to provide a spin tub that is suitable for rotating at high speeds while still minimizing deformation due to unbalanced laundry loads.
[0011] Yet another object, feature, or advantage of the present invention is to provide a washer that can be made to an industry standard size.
[0012] A still further object, feature or advantage of the present invention is to provide a washer having a reinforced spin tub that is easy and cost effective to manufacture. Another object, feature, or advantage of the present invention is to provide a washer that reduces overall energy consumption—a significant buying criteria.
[0013] These and/or other objects, features, or advantages of the present invention will become apparent from the specification and claims that follow.
SUMMARY OF THE INVENTION
[0014] The present invention relates to an expanded metal clamping band that forms a portion of a spin tub of a washer. The expanded metal clamping band is used to reinforce the spin tub to minimize deformation when rotated at higher speeds. This higher speed rotation provides a reduction in overall energy consumption. According to one aspect of the present invention a washer includes a cabinet, an outer tub disposed within the cabinet, and a spin tub rotatably mounted within the outer tub. The spin tub includes a metal spin tub upper body and an expanded metal clamping band on an outer surface of the metal spin tub upper body. The expanded metal clamping band reinforces the spin tub in order to help minimize deformation caused by unbalanced loads that are rotated at high speeds, particularly during the water extraction process. The spin tub is formed through expanding the metal spin tub upper body and the metal clamping band together.
[0015] According to another aspect of the invention, a spin tub for use in a washer has a cylindrical metal spin tub upper body and an expanded metal clamping band on an outer surface of the spin tub upper body to reinforce the spin tub. The spin tub is formed through expanding the metal spin tub upper body and the metal clamping band together.
[0016] Another aspect of the present invention is a method of manufacturing a washer having a spin tub. The method provides for welding a metal band and a metal spin tub upper body. The metal band and metal spin tub upper body are then expanded together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of one embodiment of a spin tub disposed within a washer according to the present invention.
[0018] FIG. 2 is a sectional top view of one embodiment of the washer of the present invention showing a spin tub mounting within a washer.
[0019] FIG. 3 illustrates a front cross-sectional view of one embodiment of the upper spin tub body of the present invention.
[0020] FIG. 4 illustrates a cross-sectional view of one embodiment of the expanded metal clamp of the present invention attached to an upper spin tub body.
[0021] FIG. 5 illustrates one embodiment of the spin tub of the present invention.
[0022] FIG. 6 illustrates a top view of one embodiment of a metal clamp of the present invention prior to assembly.
[0023] FIG. 7 is a perspective view of one embodiment of a metal clamp and upper spin tub body prior to forming operations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] The present invention provides for a washer that uses an expanded clamping band on the spinner or spin tub in order to reinforce the spin tub. FIG. 1 illustrates a perspective view of one embodiment of a washer according to the present invention. The washer 10 illustrated includes a cabinet 12 . A control panel 14 is also shown as well as a lid 16 . Thus, the washer 10 shown in FIG. 1 is a top-loading washer. The present invention, however, is not limited to a specific configuration of the washing machine shown as various sizes and orientations are known.
[0025] FIG. 2 illustrates a top view of the washer 10 taken along the axis 2 - 2 of FIG. 1 . The washer 10 includes an outer tub 20 . Rotatably mounted within the outer tub 20 is spin tub assembly 32 , commonly referred to as a spin tub or spinner. The spin tub assembly 32 has an open end 18 shown. This allows laundry articles to be placed within the area 24 enclosed by the spin tub assembly 32 .
[0026] FIG. 3 illustrates a portion of a spin tub. The spin tub includes an upper spin tub body 22 . The spin tub body 22 is made of metal, preferably a stainless steel. Positioned along the top of the spin tub body 22 is a metal clamping band 26 . As shown in FIG. 3 , the metal clamping band 26 is substantially flush with the top edge of the upper spin tub body 22 . The clamping band 26 and the upper spin tub body 22 are both of a substantially cylindrical shape. The clamping band 26 and the spin tub body 22 are both in the substantially cylindrical shapes before the forming operations. Then, the metal expansion process is performed on the metal spin tub body and the metal clamping band together. The result is that the spin tub 22 is reinforced with the expanded metal clamping band 26 . This helps minimize deformation, especially when the spin tub is operated at high speeds. These high speeds help reduce overall energy consumption by extracting more moisture prior to the drying process.
[0027] FIG. 4 illustrates an enlarged view of a cross section taken along lines 4 - 4 of FIG. 3 . FIG. 4 illustrates the metal clamping band 26 and the spin tub body 22 after forming operations are performed. Note that there are a plurality of holes 30 in the spin tub body 22 . The clamping band 26 conforms to the shape of the spin tub body 22 .
[0028] FIG. 5 illustrates a complete spin tub assembly 32 with both the upper spin tub body 22 and a lower spin tub body 34 . The upper spin tub body 22 is operatively connected to the lower spin tub body 34 . The spin tub assembly 32 includes an open top end 33 and an opposite bottom end 35 .
[0029] FIG. 6 illustrates a flat metal clamping band 26 prior to assembly. The flat metal clamping band 26 has a notch 42 for assembly orientation. The flat clamping band 26 is formed into a cylinder and the ends 36 , 38 are then welded to each other. Similarly, a flat blank of upper spin tub body 22 is formed into a cylinder and welded. After the clamping band 26 has been placed on the outside of spin tub body 22 , an expansion process is performed. During expansion, the cylindrical diameters of the spin tub body 22 and clamping band 26 are simultaneously increased in a single operation. After the expansion process, the spin tub body and metal clamping band are roll-formed to create rib 40 . A spin tub is then assembled as a part of the manufacturing process for the washer. This methodology allows for the clamping band to be thin so that the addition of the clamping need not affect the size of the spin tub.
[0030] FIG. 7 is a perspective view of the flat metal clamping band 26 and upper spin tub body 22 prior to forming operations. The metal clamping band 26 and upper spin tub body 22 are both cylindrical in shape. The parts at this stage in the process are slightly smaller in diameter than they are in final form. The metal clamping band 26 is preferably positioned proximate the open top end 33 , and on the outside of the upper spin tub body 22 .
[0031] The method of manufacturing of the present invention includes providing a metal spin tub body and providing a metal band to reinforce the spin tub body. Preferably, both the metal band and the spin tub body are formed from stainless steel. The metal band and the metal spin tub body are welded to form two cylindrical parts. Preferably plasma welding is used to form a smooth and precise weld. The metal band and the metal spin tub body are expanded together to create internal stresses in the part to increase the rigidity of the assembly. Preferably the combined expanded metal clamping band and metal spin tub body can then be roll formed to provide additional strength and mechanically lock the band 26 to the spin tub body 22 . A plurality of lanced tabs 44 formed in the spin tub assembly 32 further lock the clamping band 26 to the upper spin tub body 22 .
[0032] It should be apparent that the expanded metal clamping band 26 of the present invention serves to reinforce the spin tub 22 . The present invention contemplates variations in materials, the specific configuration of the washer, and is not to be limited to the preferred embodiment shown herein.
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The present invention includes an expanded metal clamping band for reinforcing a spin tub body of a washer. A metal locking band is assembled to an outer surface of a metal spin tub body to reinforce the spin tub. The spin tub is formed through expanding the metal spin tub body and a metal clamping band together.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] None
BACKGROUND OF THE INVENTION
[0003] (1) Field of the Invention
[0004] The present invention relates to a nail polish lacquer remover which is non-toxic, non-flammable and environmentally benign. In partiuclar, the present invention relates to a composition, kit and method which comprises a liquid mixture of a hydroxylated carboxylic acid ester and a dicarboxylic acid diester which is a solvent for the lacquer.
[0005] (2) Description of Related Art
[0006] Nail polish, sometimes referred to as nail polish lacquer, must be removed from nails without damage to the nail or to health of the individual. At present, most commercial finger nail polish removers utilize acetone, which is flammable and highly volatile, as the base for a liquid formulation. A second class of removers utilize ethyl acetate as the base which is also flammable and highly volatile.
[0007] The following patents are representative of the prior art. JP 54046846 (1979) teaches the use of gamma butyrolactone, methyl acetate, water, and perfumes as the basis for the formulation. This formulation is claimed to be noncombustible. A number of other compounds are described which are different from those of the present invention. JP 57122013 (1982) claims an acetone, water, and 2-octyldodecyl oleate mixture. U.S. Pat. No. 4,735,798 (1988) claims an acetone, ethyl acetate, ethanol, water, and glycerin mixture with a claim of improved adhesion of the nail polish subsequent to use of the remover.
[0008] Two (2) U.S. patents separately describe the use of succinate or lactate esters.
[0009] In Bayless (U.S. Pat. No. 5,372,742), the solvent d-limonene which is a skin irritant is used in the formulations. In addition, ethyl acetate and cetyl acetate are claimed as essential. The present invention does not use either limonene or cetyl acetate. In Farynlarz et al (U.S. Pat. No. 5,486,305), a volatile component, acetone, is described as essential, in addition to a C 4 to C 30 diester, and water. These formulations do not include hydroxylated carboxylic acid esters (e.g. ethyl lactate) and requires that one component be a volatile solvent. Thus solvents such as acetone and limonene are required in these formulations. These components are flammable and toxic.
SUMMARY OF THE INVENTION
[0010] The present invention relates to a composition for removing nail polish lacquer which comprises as a mixture:
[0011] (a) a hydroxylated carboxylic acid ester which is liquid at STP; and
[0012] (b) a dicarboxylic acid diester which is a liquid at STP, wherein the mixture is a solvent for the nail polish lacquer.
[0013] Further, the present invention relates to a composition for removing nail polish which comprises as a mixture:
[0014] (a) ethyl lactate; and
[0015] (b) diethyl succinate, wherein the mixture is a solvent for nail polish.
[0016] The present invention also relates to a nail polish lacquer removing composition comprising as a mixture:
[0017] (a) for the lacquer 1 to 10 part by volume of ethyl lactate;
[0018] (b) 1 to 10 part by volume of diethylsuccinate; and
[0019] (c) optionally up to about 0.1 part by volume water based upon (a) and (b).
[0020] The present invention also relates to a nail polish lacquer removing composition which comprises in admixture:
[0021] (a) a liquid hydroxylated mono, di- or tri-carboxylic acid ester, wherein the hydroxylated mono- , di- or trihydroxylated acid moiety is selected from the group consisting of lactic, malic, citric and tartaric acids and mixtures thereof, and the ester moiety is lower alkyl containing 1 to 4 carbon atoms; and
[0022] (b) a liquid dicarboxylic acid diester of the formula
[0023] wherein R 1 and R 2 are lower alkyl containing 1 to 4 carbon atoms, which can be the same or different, and x is an integer of 1 to 4.
[0024] The present invention also relates to a method for removing a dried nail lacquer from the nail which comprises:
[0025] (a) applying a composition comprising as a mixture a hydroxylated carboxylic acid ester which is liquid at STP; and a dicarboxylic acid diester which is a liquid at STP, wherein the mixture is a solvent for the nail polish lacquer so as to solvate the nail polish on the nail; and
[0026] (b) removing the solvated nail polish from the nail.
[0027] The present invention also relates to a method for removing a dried nail polish lacquer from the nail which comprises:
[0028] (a) applying a composition which comprises a mixture ethyl lactate; and diethyl succinate, wherein the mixture is a solvent for nail polish to solvate the nail polish on the nail; and
[0029] (b) removing the solvated nail polish from the nail.
[0030] The present invention relates to a method for removing a dried nail polish lacquer from the nail which comprises:
[0031] (a) applying a composition comprising as a mixture 1 to 10 part by volume of ethyl lactate; 1 to 10 part by volume of diethylsuccinate; and optionally up to about 0.1 part by volume water based upon (a) and (b) to solvate the nail polish lacquer on the nail; and
[0032] (b) removing the solvated nail polish from the nail.
[0033] The present invention also relates to a method for removing a nail polish lacquer from the nail which comprises:
[0034] (a) applying a composition as a mixture which comprises a liquid hydroxylated mono, di- or tri-carboxylic acid ester wherein the acid moiety is selected from the group consisting of lactic, malic, citric and tartaric acids and mixtures thereof, and the ester moiety is alkyl containing 1 to 4 carbon atoms; and a liquid dicarboxylic acid diester of the formula
[0035] wherein R 1 and R 2 are lower alkyl containing 1 to 4 carbon atoms which can be the same or different and x is 1 to 4 to solvate the nail polish lacquer on the nail;
[0036] (b) removing the solvated nail polish from the nail.
[0037] The present invention also relates to a kit for solvating nail polish lacquer which comprises:
[0038] (a) a composition which comprises as a mixture a hydroxylated carboxylic acid ester which is liquid at STP and a dicarboxylic and diester which is liquid at STP, wherein the mixture is a solvent for the nail polish lacquer in a sealable container; and
[0039] (b) an applicator in the container which is removable from the container for applying the composition to the nail to solvate the nail polish lacquer for removal.
[0040] The present invention also relates to a kit for solvating nail polish lacquer which comprises:
[0041] (a) a composition which comprises as a mixture ethyl lactate; and diethylsuccinate, wherein the mixture is a solvent for nail polish lacquer; and
[0042] (b) an applicator in the container and removable from the container for applying the composition to the nail.
[0043] The present invention also relates to a kit for solvating nail polish lacquer which comprises:
[0044] (a) a composition which comprises as a mixture lacquer 1 to 10 part by volume of ethyl lactate; 1 to 10 part by volume of diethyl succinate; and optionally up to about 0.1 part by volume water based upon the lactate and succinate in a sealable container; and
[0045] (a) an applicator in the container which seals the container and which is removable from the container for applying the composition to the nail to solvate the nail polish lacquer for removal.
[0046] The present invention also relates to a kit for solvating nail polish lacquer which comprises:
[0047] (a) a composition as a mixture which comprises a liquid hydroxylated mono, di- or tri-carboxylic acid ester wherein the acid moiety is selected from the group consisting of lactic, malic, citric and tartaric acids and mixtures thereof, and the ester moiety is alkyl containing 1 to 4 carbon atoms; and
[0048] a liquid dicarboxylic acid diester of the formula
[0049] wherein R 1 and R 2 are lower alkyl containing 1 to 4 carbon atoms which can be the same or different and x is 1 to 4 in a sealable container; and
[0050] (b) an applicator which is removable from the container for applying the composition to the solvate the nail polish lacquer from removal.
[0051] In particular, lactate-succinate ester blends are excellent nail polish lacquer removing solvents which are non-toxic. The preferred embodiment of the invention uses ethyl lactate and diethyl succinate in equal volume proportions. These esters are miscible with each other in all proportions. In addition, some water can be added to the mixture, however, above about 10% by volume water a two phase solution will be formed which is no longer a good polish remover.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0052] The present invention uses a combination of esters homologous to lactate and succinate esters. We have particularly found that combinations of ethyl lactate with diethyl succinate are excellent nail polish removers, but are not toxic and have very low volatility and flammability. In addition, these formulations are biodegradable and possess a very small environmental impact.
[0053] Ethyl lactate and diethyl succinate are both listed as acceptable ingredients for synthetic flavorings and adjuvants in 21CFR172.515, 21CFR172 is “Food Additives Permitted For Direct Addition to Food For Human Consumption.” The LD50 data shows that very large doses are required to produce toxic results in animals. These solvents are thus the most preferred.
[0054] A ternary diagram for the system diethyl succinate, ethyl-1-lactate and water at 297° K. The reference is Uusi-Pentilla, M., R. J. Richards, P. Blowers, B. A. Torgerson, and K. A. Berglund, “Liquid-Liquid Equilibria of Selected Dibasic Ester +Water+Solvent Ternary Systems,” J. Chem. Eng. Data 1996, 41, 235-238. This diagram shows that the limit of solubility of water in the mixture is about 10%.
[0055] The dielectric constant for ethyl lactate is 16.5 and for diethyl succinate is 6.7 as reported by Uusi-Pentilla, M., R. J. Richards, B. A. Torgerson, and K. A. Berglund, “Spectroscopically Determined Dielectric Constants for Various Esters,” Ind. Eng. Chem. Res. 1997, 36, 510-512. The succinate is non-polar and the lactate is polar and thus, it is surprising that the compositions of the present invention are so effective.
[0056] The vapor pressure of ethyl lactate is 1.6 mmHg @ 20° C. and for diethyl succinate is 0.2 mmHg @ 20° C. These are very favorable for a nail polish removing lacquer.
[0057] Other hydroxylated carboxylic acid esters can be used in place of the lactates including, but not limited to, malic, citric, and tartaric. Other aliphatic carboxylic acid esters preferably containing 1 to 8 carbon atoms can be used in place of the succinates including, but not limited to, glutaric and adipic. The alcohol used to make the esters can include, but are not limited to, methanol, ethanol, n-propanol, isopropanol, isobutanol, and n-butanol which are lower alkanols containing 1 to 4 carbon atoms. Other non-solvent ingredients such as surfactants, detergents, and fragrances can be used as additives in the formulation. They can be used as adjuvants, extenders and olfactory agents.
EXAMPLE 1
[0058] A 50:50 volume percent solution of ethyl lactate and diethyl succinate was made. The resulting solution was water clear and was easily adsorbed onto a paper tissue that was subsequently used to remove finger nail polish lacquer from the finger nails of a thirteen-year-old female. The polish was completely removed with ease and no damage to the nail was observed and no damage or drying of the skin was observed.
EXAMPLE 2
[0059] A 50:50 volume percent solution of ethyl lactate and diethyl succinate was made. The resulting solution was water clear and was easily adsorbed onto a tissue that was subsequently used to remove finger nail polish lacquer from a glued-on imitation nail extender. The polish was completely removed with ease and no damage to the imitation or natural nail was observed.
[0060] A repeat patch test with the 50:50 by volume mixture of diethylsuccinate and ethyl lactate showed that there was no response. Thus the compositions of the present invention are safe for use as a nail polish.
[0061] The compounds used in the present invention can be produced from natural sources of succinic acid and lactic acid. The acids are produced by fermentation.
[0062] It is intended that the foregoing description be only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims.
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A composition which is a mixture of a hydroxylated carboxylic acid ester and a mono-, di- or tricarboxylic acid ester for solvating a nail polish lacquer for removal is described. Included are kits for compositions for and a method of using the compositions.
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TECHNICAL FIELD
[0001] The present invention relates to waveguide type optical devices, in particular, lithium-niobate-based, high-speed optical signal modulators and methods of making the same.
BACKGROUND ART
[0002] Waveguide optical devices may utilize an electro-optical crystal, such as an LiNbO 3 or an LiTaO 3 substrate in order to modulate optical signals for high-speed telecommunication systems using optical fiber networks. For optical modulators, an electric field is applied to an optical waveguide path formed inside a surface of an electro-optical crystal substrate such as LiNbO 3 or LiTaO 3 , which in turn alters the refractive index of the optical waveguide path inducing switching of optical signals traveling inside the optical waveguide path, as well as modulates the phase and intensity of the optical signals. FIG. 1( a ) schematically illustrates a cross-sectional diagram of such a single drive LiNbO 3 modulator device 100 . The voltage V applied to the two electrodes 10 , 12 separated by a gap G produces an electric field line E, which intersects the optical waveguide path 14 .
[0003] In a single drive LiNbO 3 modulator device, such as the one illustrated in FIG. 1( a ), a transparent dielectric film or buffer layer 16 , having a slightly lower refractive index than that of the optical waveguide path 14 , is often sandwiched between the optical waveguide path 14 and the electrodes 10 , 12 . The buffer layer 16 reduces the undesirable absorption of light in the optical waveguide path 14 by the electrode metal, and also helps to match velocities between the RF and optical signals because of the buffer layer's lower dielectric constant. When an electrode 10 , 12 is formed on the buffer layer 16 and the voltage V is applied to the electrode 10 , 12 , the electric field E is applied to the optical waveguide path 14 formed in the LiNbO 3 crystal substrate 18 and the refractive index of the optical waveguide path 14 changes in proportion to the intensity of the electric field E. As a result, functions, such as switching and modulation of optical signals may be performed. Therefore, accurate control of the electric field E applied to the optical waveguide path 14 is important in assuring reliability of devices 100 of this type.
[0004] Waveguide devices utilizing the above-described electric field-based modulation of an electro-optical crystal substrate include optical switches, modulators, branching filters, and polarized wave controllers. Such devices are described, for example, in “Optical Fiber Telecommunications”, Volume IIIB, edited by I. P. Kaminow and T. L. Koch, page 404, Academic Press, New York, 1997, and “Lithium Niobate for Optoelectronic Applications” by J. Saulner, Chap. CII in Materials for optoelectronics, edited by Maurice Quilec, 1996.
[0005] [0005]FIG. 1( b ) illustrates an exemplary dual drive prior art LiNbO 3 modulator device 200 . The device 200 is based on a Mach-Zehnder-type optical modulator design which is useful for ultra-high speed optical communication. The modulator device 200 is a dual-drive, traveling wave, y-branch type design, which is desirable for ensuring high modulation bandwidth and a low drive voltage operation. The modulator 200 of FIG. 1( b ) allows an electrical drive signal to propagate from input optical fiber 1 , along a transmission line along a direction of the optical waveguide path 14 , to optical output fiber 9 . One or both of the input optical fiber 1 and the optical output fiber 9 may be surrounded by a glass capillary 8 . The electrodes 10 , 12 may be made of gold strips and the buffer layer may be a sputter deposited SiO 2 layer.
[0006] A long interaction length enables the drive voltage V to be kept relatively low. A thin charge-dissipating-layer (CDL layer) including a slightly conductive material (possibly Si, nitride or oxide compound-based may optionally be added between the electrode 10 , 12 and the buffer layer 16 so as to reduce the electric charge accumulation/drift on the buffer layer 16 surface, which can cause electric field control variations.
[0007] In FIG. 1( b ), the LiNbO 3 crystal substrate 18 is cut along a certain crystallographic orientation, e.g., x-axis or z-axis, depending on the mode of operation and specific application. If the cut is made in such a manner that an x-axis of the crystal axis extends in a longitudinal direction of a chip and a z-axis extends in the direction of thickness, then the desirable electro-optical coefficient x 33 is utilized. A semi-circular optical waveguide path 14 having a greater refractive index than that of the substrate 18 and having a diameter of typically several micrometers (similar to the core size of optical fibers 1 , 9 ) is formed on a surface of the substrate 18 by either localized ion implantation of titanium or by deposition of Ti metal and controlled thermal diffusion into the waveguide regions.
[0008] [0008]FIG. 1( c ) schematically illustrates a prior art modulator structure of a single drive type, which includes an LiNbO 3 substrate 18 , a buffer oxide layer 16 , a charge dissipation layer 17 , an optical waveguide 14 , and electrodes 10 , 12 . For the purpose of preventing absorption of light propagating through the optical waveguide path 14 by the electrode 10 , 12 , the silicon dioxide (SiO 2 ) layer 16 having a specific dielectric constant of ˜4.0 and a refractive index of about ˜1.45 is deposited to a thickness of e.g., ˜0.5 micrometers over the entire surface of the waveguide substrate 18 by a film formation technique, such as sputtering or electron beam deposition, thereby forming the buffer layer 18 . The signal electrode 10 and a ground electrode 12 including a thin gold (Au) film having a width of several micrometers and a thickness of ˜10 micrometers, for example, are formed by vacuum deposition and plating at positions on the surface of the buffer layer 16 corresponding to the optical waveguide path 14 . As illustrated, the output optical fiber 9 may be aligned and locked in position by glass capillary fixture 8 .
[0009] In operation, the voltage V applied to the waveguide path 14 may change with time. As a result, the characteristics of the outgoing light signal from the modulator device 100 also varies with time. Such a phenomenon is referred to as a “DC drift” problem in LiNbO 3 waveguide devices.
[0010] This common and undesirable, time-dependent drift of the DC bias voltage should be either eliminated or minimized. Movement of ions, such as the Li + ions or Na ions, that are present inside the LiNbO 3 crystal 18 or on its surface as interstitial atoms, is considered to be one of the causes of DC drift. As the ions move or accumulate locally, the distribution of the DC electric field within the modulator device 100 changes over time and DC drift occurs. This is described in S. Yamata et al., “DC Drift Phenomenon in LiNbO3 Optical Waveguide Devices”, Japanese Journal of Applied Physics Vol. 20, No. 4, April 1881, page 733.
[0011] There are several known solutions to this problem, many focusing on immobilizing the movable ions inside and on the surface of the crystal substrate 18 in order to control DC drift. Some of these known solutions are described below.
[0012] U.S. Pat. No. 5,680,497 discloses an optical waveguide device which includes a LiNbO 3 substrate 1 and a buffer layer 3 ′. The buffer layer 3 ′ is made of a transparent dielectrical insulator of a mixture between silicon dioxide and an oxide of at least one element selected from the group consisting of the metal elements of the Groups III-VIII, Ib, and IIb elements, for example, about 5-10 atomic % of In 2 O 3 . The doping of the SiO 2 buffer layer with other oxides such as In 2 O 3 appears to help tie up or slow down the movement of the Li + ions. U.S. Pat. No. 5,479,552 discloses a waveguide-optical device which includes an LiNbO 3 or LiTaO 3 substrate, a blocking layer, and buffer layer of SiO 2 . The blocking layer, including Si, Si 3 N 4 , SiON, or MgF 2 is placed between the substrate and the buffer layer. The blocking layer blocks the diffusion of Li + ions from the substrate.
[0013] Japanese Kokai Patent Application No. Hei 6-75195 discloses an optical controller including an LiNbO 3 or LiTaO 3 substrate and a SiO 2 buffer. A blocking layer, of low ionic conductance, is also placed between the substrate and the buffer. Again, the blocking layer may include Si, Si 3 N 4 and MgF 2 . The trapping layer includes SiO 2 doped with phosphorus. The trapping layer and blocking layer may be used separately or in combination to thereby sandwich the buffer layer.
[0014] Japanese Kokai Patent Application No. HEI 5-113513 discloses a waveguide optical device which includes an LiNbO 3 substrate doped with a Group V element, such as Cl and/or P.
[0015] “Reduction of DC Drift in LiNbO 3 Waveguide Electro-optic Device by Phosphorus and SiO 2 Buffer Layer” by Suhara et al. discloses a LiNbO 3 substrate with a buffer layer of SiO 2 doped with phosphorus.
SUMMARY OF THE INVENTION
[0016] The present invention reduces DC drift in conventional electrooptic devices by providing an electrooptic device and method for making the same, wherein active ions, such as F − ions, are implanted in a buffer layer. In a preferred embodiment, the active ions react with positive ions, such as mobile Li + to form stable compounds such as LiF. The reduced number of mobile Li + ions reduces the DC drift of the associated electrooptic device.
[0017] More specifically, the ion implantation of F − ions or fluorine containing species is performed in a buffer layer, such as a SiO 2 which may be doped with other oxides such as In 2 O 3 buffer layer The F − ions or fluorine containing ions getter positive ions, such as lithium in the buffer layer. Further, the profile of the implanted ions may be adjusted to control and/or optimize the properties of the electrooptic device. Fluorine is particularly advantageous because it also lowers the dielectric constant, thereby facilitating higher frequency operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The nature, advantages and various additional features of the invention will appear more fully upon consideration of the illustrative embodiments now to be described in detail with the accompanying drawings. In the drawings:
[0019] FIGS. 1 ( a ), ( b ), and ( c ) schematically illustrate the basic structure and operation principle of prior art single and dual drive LiNbO 3 modulators;
[0020] FIGS. 2 ( a ) and ( b ) schematically illustrate cross-sectional diagrams depicting (a) a fluorine ion implanted modulator structure of a single drive type according to the present invention and (b) a fluorine implanted modulator of a dual-drive type according to the present invention;
[0021] [0021]FIG. 3 illustrates an F − ion depth profile of ion implantation into an Sio 2 buffer layer;
[0022] FIGS. 4 ( a )-( c ) schematically illustrate alternative embodiments of the F − ion implanted LiNbO 3 modulator structure according to the present invention;
[0023] [0023]FIG. 5 schematically illustrates yet another embodiment of the present invention.
[0024] It is to be understood that the drawings are for purposes of illustrating the concepts of the present invention and are not to scale.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] Referring to the drawings, FIG. 2( a ) schematically illustrates a fluorine ion (F − ) implanted modulator structure of a single drive type according to the present invention. According to the present invention, fluorine ions (F − ) are incorporated, in a blanket manner, onto the finished modulator parts with the electrode structure already formed. The implanted fluorine ions (F − ) get into the SiO 2 buffer layer 16 by penetrating the charge-dissipating layer 17 at sufficiently high ion implantation accelerating energy, and tie up mobile ions such as Li + or Na + in the SiO 2 buffer layer 16 and reduce the DC voltage drift problem. For the particular case of FIGS. 2 ( a ) and ( b ) type device configurations, the fluorine ions (F − ) are implanted only in the buffer layer 16 locations between the electrodes 10 , 12 (in the implanted gap regions 19 ).
[0026] The fluorine atoms (F − ) so introduced serve at least two functions. The first is to trap mobile ions such as Li + or Na + especially those remaining mobile ions which may not have been controlled by other means such as the use of the SiO 2 buffer layer 16 doped with In 2 O 3 and other materials. The second is to actually reduce the dielectric constant (ε) in the F − implanted gap regions of the SiO 2 buffer layer 16 , and thus enhancing the electric field concentration under the electrode 10 , 12 so as to increase the effective field of the waveguide region. The desired level of dielectric constant reduction is, for example, from 4.0 to 3.8, or from 4.0 to 3.6 if an F − 0 concentration as high as 7% is introduced.
[0027] The introduction of fluorine ions (F − ) into the SiO 2 buffer layer 16 (undoped or doped with indium oxide), according to the present invention, ties up the mobile Li + and other ions and reduces the DC bias voltage drift. When Li + and F − atoms are present together, they form a very stable compound, LiF, due to a strong thermodynamic driving force. The heat of formation (ΔH f ) for the reaction of Li + and F − to produce LiF is a very large negative value, i.e., about −290 Kcal/mole at 0° K. This is much greater than the ΔH f values for the formation of SiF 4 (−185 Kcal/mole) or InF 3 (−167 Kcal/mole). Thus the tendency of LiF formation and an Li + ion gettering effect using fluorine is very strong. Further, once the LiF compound is formed, it is difficult to separate the Li + from the LiF compound, thus the previously mobile Li + ions are converted to immobile or significantly less mobile ions.
[0028] After implantation of fluorine atoms, the buffer layer 16 may be optionally and preferably baked to facilitate the Li—F reaction to form LiF. The preferred temperature and time of such baking is 100-700° C., preferably 100-500° C., and for a duration of 0.1-1000 hours, preferably 0.5-50 hours. The atmosphere for such baking treatment can be oxygen, air or inert gas, such as argon.
[0029] In the exemplary embodiment of FIG. 2( a ), the LiNbO 3 substrate 18 is a single crystal z-cut substrate, approximately 700 μm high, where n=2.14, ε zz =30, and r 33 =31 pm/V, the SiO2 buffer oxide layer 16 is approximately 1 mm thick and indium doped, where n=1.45 and ε=4, the charge dissipation layer 17 is approximately 80 nm thick, the electrode 10 is a gold ground electrode, 15-30 μm high, the electrode 12 is a gold hot line electrode, 15-30 μm high, 6-10 μm wide, and 15-30 μm from the ground electrode 10 ., and the optical waveguide path 14 is Ti diffused, where n=2.15 and the loss is approximately 0.2 dB/cm, however, all of these parameters could be varied or applied to other embodiments of the present invention, as would be know to one of ordinary skill in the art.
[0030] Further, the fluorine ions (F − ) may be incorporated in either a single drive type or a dual drive type modulator. FIG. 2( a ) illustrates a single drive type modulator and FIG. 2( b ) illustrates a dual drive type modulator. As illustrated in FIG. 2( b ), the dual drive type modulator includes multiple waveguides 14 .
[0031] The desired dose and ion implantation energy of F − ions varies depending on the amount of mobile Li + ions present, the degree of Li + ion gettering, the thickness of the SiO 2 buffer layer 16 , etc. FIG. 3 illustrates the depth profile of implanted fluorine atoms in SiO 2 shown as a function of the position in the thickness of the SiO 2 buffer layer being implanted with fluorine. FIG. 3 is an example for the case of F − ion implantation dose of 10 17 ions/cm 2 for two different implantation energies (accelerating voltage) of 100 KeV and 200 KeV. For the given dose and 100 KeV energy, the peak in fluorine concentration occurs at a depth of ˜1300 A in SiO 2 , with a fluorine concentration of ˜8.3×10 21 atoms/cm 3 (corresponding to approximately 30 atomic % concentration). For lower doses, the concentration of implanted fluorine in the SiO 2 buffer layer decreases substantially proportionately.
[0032] [0032]FIG. 3 also illustrates that a higher accelerating energy of implantation increases the average penetration depth more or less proportionately. For a thinner SiO 2 buffer layer, lower accelerating fields may be used for smaller penetration depths. For a thicker buffer layer, a higher accelerating field may be used or multiple implantation steps with different accelerating fields, so that the various implantation depths can be superimposed to distribute the implanted fluorine atoms over more volume of the buffer layer.
[0033] For reducing the DC bias voltage drift in LiNbO 3 modulator type applications, the desired accelerating field for F − ion implantation is in the range of 5-500 KeV, preferably 20-200 KeV. The desired dose for the F-ion implantation process is 0.1-1×10 16 ions/cm 2 , preferably 0.4-3×10 16 ions/cm 2 . The desired final concentration of implanted F − atoms in SiO 2 is in the range of 0.1-20 atomic %, preferably in the range of 0.2-2 atomic %. The distribution of implanted F − atoms along the buffer layer thickness can be non-uniform as shown in FIG. 3, or can be spread more uniformly, as might be anticipated for the post-implantation baked example.
[0034] [0034]FIG. 4( a ) is an alternative embodiment of a fluorine implanted modulator structure according to the present invention. In this embodiment, a blanket implantation of F − ions 21 is carried out on the upper portion of SiO 2 buffer layer 16 , before the electrodes 10 , 12 are added. Either the as deposited (e.g., by sputtering) or the deposited and annealed (e.g., 600° C. for 5 hours in wet oxygen atmosphere to reduce defects in the asdeposited microstructure and optimize the structure, dielectric and optical properties of the SiO 2 ) buffer layer 16 can be ion implanted. If implanted onto the asdeposited SiO 2 , the subsequent buffer layer annealing treatment can also serve as a facilitating treatment for Li + and F − interaction to form the LiF compound. The electrodes 10 , 12 (e.g., gold stripes deposited and patterned) are then formed on the surface of the implanted buffer layer 16 .
[0035] [0035]FIG. 4( b ) represents an alternative embodiment in which a charge-dissipating-layer (CDL) 17 (for example, a thin layer of a very slightly conductive material such as a mixture of Si and TiN) is added between the ion implanted buffer layer 16 / 21 and the electrodes 10 , 12 . This CDL 17 serves to reduce undesirable and uncontrolled electric charge accumulation and movement, thus ensuring reproducible behavior during electro-optic operations. The implantation can be performed before the charge-dissipating-layer 17 is deposited, or alternatively, after the CDL layer 17 is deposited, by utilizing higher accelerating voltage and making the implanted ions penetrate into the buffer layer 16 beyond the thickness of the charge-dissipating-layer 17 .
[0036] The inventive F − ion implantation approach of the present invention can also be applied to other configurations of LiNbO 3 modulators, such as the one depicted in FIG. 4( c ). In this configuration, part of the base LiNbO 3 substrate 18 is selectively etched or ion milled in such a way that a ridge configuration results. The presence of grooves between the electrodes 10 , 12 serves to minimize Li + ion transport by removing the material along the part of the electric field lines emanating from one electrode 10 toward the adjacent electrode 12 , and lowers the effective dielectric constant which improves the matching of RF signal and optical signal. The accompanying decrease in the line capacitance also allows a reduction in the buffer layer 16 thickness for enhanced RF-optical signal matching. As in the case of FIG. 4( a ), the implantation can be carried out before the electrodes are deposited.
[0037] Yet another embodiment of the present invention is schematically illustrated in FIG. 5. In this case, the F − ion implantation is carried out on the surface of the LiNbO 3 substrate 18 before the buffer layer 16 and the electrodes 10 , 12 are formed. Here, the implanted F − ions combine with the Li + in the substrate 18 and forms a stable LiF compound which can serve as a barrier to slow down or stop the movement of mobile Li + ions toward the buffer layer 16 above.
[0038] It is noted that the voltage drift of electrooptic devices made in accordance with one or more embodiments of the present invention is reduced by at least a factor of 2, or more preferably by at least a factor of 5, over electrooptic devices without implanted F − ions, when the voltage drift is measured over a period of at least of one month at ambient temperature or at least 24 hours at an accelerating test temperature of 100° C.
[0039] It is understood that the above-described embodiments are illustrative of only a few of the many possible specific embodiments which can represent applications of the invention. It is further understood that various combinations of features of the above exemplary embodiments, although not expressly set forth, are also within the knowledge of one of ordinary skill in the art. Further, numerous and varied other arrangements can be made by those skilled in the art without departing from the spirit and scope of the invention.
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An electrooptic device and method for making the same, including one or more of substrate, a buffer layer, a charge dissipation layer, and electrodes are disclosed. Active ions, such as F − ions, are implanted the buffer layer. The active ions react with positive ions, such as Li + from the substrate to form stable compounds such as LiF. The reduced number of mobile Li + ions reduces the DC drift of the associated electrooptic device. The profile of the implanted ions may be adjusted to control and/or optimize the properties of the electrooptic device. Fluorine is particularly advantageous because it also lowers the dielectric constant, thereby facilitating higher frequency operation.
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RELATED APPLICATION DATA
This application is a national phase of International Application No. PCT/IB02/03034 filed Jun. 12, 2002 and published in the English language.
FIELD OF THE INVENTION
The present invention relates to a nasal delivery device for and a method of delivering a substance, in particular one of a liquid, as a suspension or solution, or a powder containing a medicament, especially systemic or topical pharmaceuticals, or a vaccine to the nasal airway of a subject.
BACKGROUND AND SUMMARY OF THE INVENTION
Referring to FIG. 1 , the nasal airway 1 comprises the two nasal cavities separated by the nasal septum, which airway 1 includes numerous ostia, such as the paranasal sinus ostia 3 and the tubal ostia 5 , and olfactory cells, and is lined by the nasal mucosa. The nasal airway 1 can communicate with the nasopharynx 7 , the oral cavity 9 and the lower airway 11 , with the nasal airway 1 being in selective communication with the anterior region of the nasopharynx 7 and the oral cavity 9 by opening and closing of the oropharyngeal velum 13 . The velum 13 , which is often referred to as the soft palate, is illustrated in solid line in the closed position, as achieved by providing a certain positive pressure in the oral cavity 9 , such as achieved on exhalation through the oral cavity 9 , and in dashed line in the open position.
There are many nasal conditions which require treatment. One such condition is nasal inflammation, specifically rhinitis, which can be allergic or non-allergic and is often associated with infection and prevents normal nasal function. By way of example, allergic and non-allergic inflammation of the nasal airway can typically effect between 10 and 20% of the population, with nasal congestion of the erectile tissues of the nasal concha, lacrimation, secretion of watery mucus, sneezing and itching being the most common symptoms. As will be understood, nasal congestion impedes nasal breathing and promotes oral breathing, leading to snoring and sleep disturbance. Other nasal conditions include nasal polyps which arise from the paranasal sinuses, hypertrophic adenoids, secretory otitis media, sinus disease and reduced olfaction.
In the treatment of certain nasal conditions, the topical administration of medicaments is preferable, particularly where the nasal mucosa is the prime pathological pathway, such as in treating or relieving nasal congestion. Medicaments that are commonly topically delivered include decongestants, anti-histamines, cromoglycates, steroids and antibiotics. At present, among the known anti-inflammatory pharmaceuticals, topical steroids have been shown to have an effect on nasal congestion. Topical decongestants have also been suggested for use in relieving nasal congestion. The treatment of hypertrophic adenoids and chronic secretory otitis media using topical decongestants, steroids and anti-microbial agents, although somewhat controversial, has also been proposed. Further, the topical administration of pharmaceuticals has been used to treat or at least relieve symptoms of inflammation in the anterior region of the nasopharynx, the paranasal sinuses and the auditory tubes.
Medicaments can also be systemically delivered through the nasal pathway, the nasal pathway offering a good administration route for the systemic delivery of pharmaceuticals, such as hormones, for example, oxytocin and calcitionin, and analgetics, such as anti-migraine compositions, as the high blood flow and large surface area of the nasal mucosa advantageously provides for rapid systemic uptake.
Nasal delivery is also expected to be advantageous for the administration of medicaments requiring a rapid onset of action, for example, analgetics, anti-emetics, insulin, anti-epileptics, sedatives and hypnotica, and also other pharmaceuticals, for example, cardio-vascular drugs. It is envisaged that nasal administration will provide for a fast onset of action, at a rate similar to that of injection and at a rate much faster than that of oral administration. Indeed, for the treatment of many acute conditions, nasal administration is advantageous over oral administration, since gastric stasis can further slow the onset of action following oral administration.
It is also expected that nasal delivery could provide an effective delivery route for the administration of proteins and peptides as produced by modern biotechnological techniques. For such substances, the metabolism in the intestines and the first-pass-effect in the liver represent significant obstacles for reliable and cost-efficient delivery.
Furthermore, it is expected that nasal delivery using the nasal delivery technique of the present invention will prove effective in the treatment of many common neurological diseases, such as Alzheimer's, Parkinson's, psychiatric diseases and intracerebral infections, where not possible using existing techniques. The nasal delivery technique of the present invention allows for delivery to the olfactory region, which region is located in the superior region of the nasal cavities and represents the only region where it is possible to circumvent the blood-to-brain barrier (BBB) and enable communication with the cerebrospinal fluid (CSF) and the brain.
Also, it is expected that the nasal delivery technique of the present invention will allow for the effective delivery of vaccines.
Aside from the delivery of medicaments, the irrigation of the nasal mucosa with liquids, in particular saline solutions, is commonly practised to remove particles and secretions, as well as to improve the mucociliary activity of the nasal mucosa. These solutions can be used in combination with active pharmaceuticals.
For any kind of drug delivery, accurate and reliable dosing is essential, but it is of particular importance in relation to the administration of potent drugs which have a narrow therapeutic window, drugs with potentially serious adverse effects and drugs for the treatment of serious and life-threatening conditions. For some conditions, it is essential to individualize the dosage to the particular situation, for example, in the case of diabetes mellitus. For diabetes, and, indeed, for many other conditions, the dosage of the pharmaceutical is preferably based on actual real-time measurements. Currently, blood samples are most frequently used, but the analysis of molecules in the exhalation breath of subjects has been proposed as an alternative to blood analysis for several conditions. Breath analysis is currently used for the diagnosis of conditions such as helicobacter pylori infections which cause gastric ulcers.
WO-A-00/51672 discloses a delivery device for delivering a substance, in particular a medicament, in a bi-directional flow through the nasal cavities, that is, an air flow which passes into one nostril, around the posterior margin of the nasal septum and in the opposite direction out of the other nostril. This bi-directional air flow advantageously acts to stimulate the sensory nerves in the nasal mucosa, thereby conditioning the subject for the delivery and providing a more comfortable delivery situation.
It is an aim of the present invention to provide improved nasal delivery devices and nasal delivery methods for providing for the improved delivery of a substance to a nasal cavity of subject.
In one aspect the present invention provides a nasal delivery device for delivering substance to a nasal airway of a subject, comprising: a nosepiece for fitting to a nostril of a subject, the nosepiece including a nozzle through which substance is in use delivered to the nasal airway, and at least one inflatable cuff member which is configured to be inflated subsequent to exhalation by the subject; and a delivery unit for delivering substance through the nozzle of the nosepiece.
In another aspect the present invention provides a nasal delivery device for delivering substance to a nasal cavity of a subject, comprising: a nosepiece including a nozzle through which substance is in use delivered to the nasal cavity, and at least one inflatable cuff member which is configured such as, when inflated, to provide a fluid-tight seal between the nosepiece and an inner wall of the nasal cavity of the subject; and a delivery unit for delivering substance through the nozzle of the nosepiece.
In a further aspect the present invention provides a nasal delivery device for delivering substance to a nasal airway of a subject, comprising: a nosepiece for fitting to a nostril of a subject, the nosepiece including a nozzle through which substance is in use delivered to the nasal airway, and at least one cuff member which is configured such as, when fitted in a nasal cavity of the subject, to engage an inner wall of the nasal cavity of the subject and direct at least a distal end of the nozzle towards a site in the nasal airway of the subject; and a delivery unit for delivering substance through the nozzle of the nosepiece.
In yet another aspect the present invention provides a nasal delivery device for delivering substance to a nasal airway of a subject, comprising: a nosepiece for fitting to a nostril of a subject, the nosepiece including a nozzle through which substance is in use delivered to the nasal airway, and at least one cuff member, at least one of the at least one cuff member including at least one lobe which, when the at least one of the at least one cuff member is fitted in the nasal cavity of the subject, extends into a region of the nasal cavity of the subject such as to at least partially obstruct the same and prevent flow thereinto; and a delivery unit for delivering substance through the nozzle of the nosepiece.
In a yet further aspect the present invention provides a nasal delivery device for delivering substance to a nasal airway of a subject, comprising: a nosepiece for fitting to a nasal cavity of a subject, the nosepiece including a first delivery outlet through which substance is in use delivered to the nasal airway of the subject, and at least one second delivery outlet through which at least one gas flow, separate to an exhalation breath of the subject, is in use delivered to the nasal airway of the subject; a delivery unit for delivering substance through the first delivery outlet of the nosepiece; and a gas supply unit for supplying a flow of gas through the at least one second delivery outlet of the nosepiece.
In yet another further aspect the present invention provides a method of delivering substance to a nasal airway of a subject, comprising: fitting a nosepiece to a nasal cavity of a subject, the nosepiece including a nozzle through which substance is delivered to the nasal airway, and at least one inflatable cuff member; inflating the at least one cuff member subsequent to exhalation by the subject; and delivering substance through the nozzle of the nosepiece.
In a still further aspect the present invention provides a method of delivering substance to a nasal cavity of a subject, comprising the steps of: fitting a nosepiece to a nasal cavity of a subject, the nosepiece including a nozzle through which substance is delivered to the nasal cavity, and at least one inflatable cuff member which is configured such as, when inflated, to provide a fluid-tight seal between the nosepiece and an inner wall of the nasal cavity of the subject; and delivering substance through the nozzle of the nosepiece.
In still yet another further aspect the present invention provides a method of delivering substance to a nasal airway of a subject, comprising the steps of: fitting a nosepiece to a nasal cavity of a subject, the nosepiece including a nozzle through which substance is delivered to the nasal airway, and at least one cuff member which is configured such as, when fitted in the nasal cavity of the subject, to engage an inner wall of the nasal cavity of the subject and direct at least a distal end of the nozzle towards a site in the nasal airway of the subject; and delivering substance through the nozzle of the nosepiece.
In a still yet further aspect the present invention provides a method of delivering substance to a nasal airway of a subject, comprising the steps of: fitting a nosepiece to a nasal cavity of a subject, the nosepiece including a nozzle through which substance is delivered to the nasal airway, and at least one cuff member, at least one of the at least one cuff member including at least one lobe which, when the at least one of the at least one cuff member is fitted in the nasal cavity of the subject, extends into a region of the nasal cavity of the subject such as to at least partially obstruct the same and prevent flow thereinto; and delivering substance through the nozzle of the nosepiece.
In a still yet another further aspect the present invention provides a method of delivering substance to a nasal airway of a subject, comprising the step of: delivering substance through a first delivery outlet and at least one gas flow, separate to an exhalation breath of a subject, through at least one second delivery outlet into the nasal airway of the subject.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described hereinbelow by way of example only with reference to the accompanying drawings, in which:
FIG. 1 schematically illustrates the anatomy of the upper respiratory tract of a human subject;
FIG. 2 schematically illustrates a nasal delivery device in accordance with a first embodiment of the present invention;
FIG. 3 schematically illustrates the delivery device of FIG. 2 inserted in a nasal cavity of a subject for operation;
FIG. 4 schematically illustrates the delivery device of FIG. 2 during actuation;
FIG. 5 schematically illustrates the delivery device of FIG. 2 following actuation;
FIG. 6 schematically illustrates a nasal delivery device in accordance with a second embodiment of the present invention;
FIG. 7 schematically illustrates the delivery device of FIG. 6 inserted in a nasal cavity of a subject for operation;
FIG. 8 schematically illustrates the delivery device of FIG. 6 during actuation;
FIG. 9 schematically illustrates the delivery device of FIG. 6 following actuation;
FIG. 10 schematically illustrates a nasal delivery device in accordance with a third embodiment of the present invention;
FIG. 11 schematically illustrates the delivery device of FIG. 10 inserted in a nasal cavity of a subject for operation;
FIG. 12 schematically illustrates the delivery device of FIG. 10 during actuation;
FIG. 13 schematically illustrates the delivery device of FIG. 2 following actuation;
FIG. 14 schematically illustrates a nasal delivery device in accordance with a fourth embodiment of the present invention;
FIG. 15 schematically illustrates the delivery device of FIG. 14 inserted in a nasal cavity of a subject for operation;
FIG. 16 schematically illustrates the delivery device of FIG. 14 during actuation;
FIG. 17 schematically illustrates a nasal delivery device in accordance with a fifth embodiment of the present invention;
FIG. 18 schematically illustrates the delivery device of FIG. 17 inserted in a nasal cavity of a subject for operation;
FIG. 19 schematically illustrates the delivery device of FIG. 17 during actuation;
FIG. 20 schematically illustrates a nasal delivery device in accordance with a sixth embodiment of the present invention;
FIG. 21 schematically illustrates the delivery device of FIG. 20 inserted in a nasal cavity of a subject for operation;
FIG. 22 schematically illustrates the delivery device of FIG. 20 during actuation;
FIG. 23 schematically illustrates a nasal delivery device in accordance with a seventh embodiment of the present invention;
FIG. 24 schematically illustrates the delivery device of FIG. 23 inserted in a nasal cavity of a subject for operation;
FIG. 25 schematically illustrates the delivery device of FIG. 23 during actuation;
FIG. 26 schematically illustrates the delivery device of FIG. 23 following actuation;
FIG. 27 schematically illustrates a nasal delivery device in accordance with an eighth embodiment of the present invention;
FIG. 28 schematically illustrates the delivery device of FIG. 27 inserted in a nasal cavity of a subject for operation;
FIG. 29 schematically illustrates the delivery device of FIG. 27 during actuation;
FIG. 30 schematically illustrates the delivery device of FIG. 27 following actuation;
FIG. 31 schematically illustrates a nasal delivery device in accordance with a ninth embodiment of the present invention;
FIG. 32 schematically illustrates the delivery device of FIG. 31 inserted in a nasal cavity of a subject for operation;
FIG. 33 schematically illustrates the delivery device of FIG. 31 during actuation;
FIG. 34 schematically illustrates the delivery device of FIG. 31 following actuation;
FIG. 35 schematically illustrates a nasal delivery device in accordance with a tenth embodiment of the present invention, illustrated in the inoperative configuration;
FIG. 36 schematically illustrates the delivery device of FIG. 35 where the driving unit is primed for actuation;
FIG. 37 schematically illustrates the delivery device of FIG. 35 inserted in a nasal cavity of a subject for operation;
FIG. 38 schematically illustrates the delivery device of FIG. 35 during actuation where the subject has commenced exhaling and the delivery device is at the point of actuation;
FIG. 39 schematically illustrates the delivery device of FIG. 35 during actuation;
FIG. 40 schematically illustrates a nasal delivery device in accordance with an eleventh embodiment of the present invention, illustrated in the inoperative configuration;
FIG. 41 schematically illustrates the delivery device of FIG. 40 where the driving unit is primed for actuation;
FIG. 42 schematically illustrates the delivery device of FIG. 40 inserted in a nasal cavity of a subject for operation;
FIG. 43 schematically illustrates the delivery device of FIG. 40 where the subject has commenced exhaling and the delivery device is at the point of actuation;
FIG. 44 schematically illustrates the delivery device of FIG. 40 where the driving unit has been actuated, the driving unit having initiated actuation of the gas delivery unit and being at the point of initiating actuation of the substance supply unit;
FIG. 45 schematically illustrates the delivery device of FIG. 40 during full actuation;
FIG. 46 schematically illustrates a nasal delivery device in accordance with a twelfth embodiment of the present invention, illustrated in the inoperative configuration;
FIG. 47 schematically illustrates the delivery device of FIG. 46 where the driving unit is primed for actuation;
FIG. 48 schematically illustrates the delivery device of FIG. 46 inserted in a nasal cavity of a subject for operation;
FIG. 49 schematically illustrates the delivery device of FIG. 46 where the subject has commenced exhaling and the delivery device is at the point of actuation;
FIG. 50 schematically illustrates the delivery device of FIG. 46 where the driving unit has been actuated, the driving unit having initiated actuation of the gas delivery unit and being at the point of initiating actuation of the substance supply unit; and
FIG. 51 schematically illustrates the delivery device of FIG. 46 during full actuation.
FIGS. 2 to 5 illustrate an exhalation breath-actuated nasal delivery device in accordance with a first embodiment of the present invention.
DETAILED DESCRIPTION
The delivery device comprises a housing 15 , a nosepiece 17 for fitting in a nasal cavity of a subject, and a mouthpiece 19 through which the subject exhales to actuate the delivery device.
The nosepiece 17 comprises a guide member 20 , in this embodiment a frusto-conical element, for guiding the nosepiece 17 into a nasal cavity of the subject, and an outlet unit 21 for delivering substance into the nasal airway of the subject. In this embodiment the nosepiece 17 is a replaceable unit.
In this embodiment the outlet unit 21 comprises a delivery channel 23 which is in fluid communication with the mouthpiece 19 such that an air flow is delivered into and through the nasal airway of the subject on exhalation by the subject through the mouthpiece 19 , and a nozzle 25 for delivering substance to the nasal airway of the subject. In this embodiment the nozzle 25 is disposed in the delivery channel 23 co-axially with the same. In this embodiment the nozzle 25 is configured to provide an aerosol spray. In an alternative embodiment, for the delivery of a liquid, the nozzle 25 could be configured to deliver a liquid jet as a column of liquid.
In this embodiment the outlet unit 21 is movably coupled to the housing 15 , here as provided by a flexible coupling, such as to allow for the positioning of the outlet unit 21 in the nasal cavity of the subject, as will be described in more detail hereinbelow.
In an alternative embodiment the outlet unit 21 could be fixed to the housing 15 , and the mouthpiece 19 instead movably coupled to the housing 15 , here as provided by a flexible coupling, such as to allow for the positioning of the outlet unit 21 in the nasal cavity of the subject.
In this embodiment at least the tip of the delivery channel 23 comprises a tubular section of a flexible, preferably resilient, material. In a preferred embodiment the material is a semi-soft plastics material, such as silicone rubber.
In this embodiment at least the tip of the delivery channel 23 has a tapering section which narrows to the distal end thereof. The delivery channel 23 , in having a narrowing taper, acts, on insertion, to expand the narrow nasal valve of the nasal cavity of the subject. In a preferred embodiment the delivery channel 23 has an elliptical section, preferably an oval section.
In a preferred embodiment the distal end of the outlet unit 21 is configured to extend at least about 2 cm, preferably at least about 3 cm, and more preferably from about 2 cm to about 3 cm, into the nasal cavity of the subject.
The nosepiece 17 further comprises at least one expandable cuff member 27 for expansion in the nasal cavity of the subject. In this embodiment the at least one cuff member 27 comprises an inflatable member.
In this embodiment the at least one cuff member 27 is in fluid communication with the delivery channel 23 , whereby the air flow generated by the subject on exhalation through the mouthpiece 19 acts to inflate the at least one cuff member 27 . In an alternative embodiment the delivery device could include a separate pump unit for inflating the at least one cuff member 27 subsequent to fitting of the nosepiece 17 , and in a preferred embodiment subsequent to, preferably in response to, exhalation through the mouthpiece 19 .
In this embodiment the at least one cuff member 27 is an inflatable member which is inflated on exhalation by the subject. In an alternative embodiment the at least one cuff member 27 could be inflated on the nosepiece 17 being located in the correct position.
In this embodiment the at least one cuff member 27 comprises a flexible balloon element which is inflated by the generation of a pressure in the delivery channel 23 , with the at least one cuff member 27 deflating on the release of pressure from the delivery channel 23 . In the alternative embodiment, where the at least one cuff member 27 is inflated by a separate pump unit, the at least one cuff member 27 could equally be deflated by the evacuation of gas therefrom using the same pump unit.
In one embodiment the at least one cuff member 27 could comprise a resilient balloon element which is inflated by the generation of a pressure in the delivery channel 23 , with the at least one cuff member 27 returning to the original, deflated configuration on the release of pressure from the delivery channel 23 .
In another embodiment the at least one cuff member 27 could comprise an inflatable sponge element, in one embodiment a foam element having an encapsulating sealing layer, which can be compressed, in this embodiment by evacuation, to adopt a compact configuration to allow for insertion into a nasal cavity of the subject and inflated, in this embodiment by breaking the vacuum, to allow for the introduction of a gas into the porous structure of the sponge element. In one embodiment such a cuff member 27 could be in selective fluid communication with the atmosphere. In another embodiment such a cuff member 27 could be in selective fluid communication with the delivery channel 23 , whereby the pressure developed in the delivery channel 23 would assist in the inflation of the cuff member 27 . In the alternative embodiment which includes a separate pump unit, the pump unit could be employed to assist in inflating such a cuff member 27 and in deflating the cuff member 27 by the evacuation of gas therefrom. In one embodiment the inflation could be triggered on exhalation by the subject. In another embodiment the inflation could be triggered on the nosepiece 17 being located in the correct position in the nasal cavity of the subject.
The at least one cuff member 27 is disposed to an outer surface of the outlet unit 21 such as, on expansion, to engage the inner wall of the nasal cavity of the subject. The at least one cuff member 27 , in being expandable, provides for the expansion of the narrow nasal valve of the nasal cavity of the subject, the sealing of the nosepiece 17 in the nasal cavity of the subject, and the positioning, in particular the direction, of the outlet unit 21 in the nasal cavity of the subject.
In this embodiment the at least one cuff member 27 comprises a single annular cuff member 27 which is located about the outlet unit 21 such as to provide a seal between the delivery channel 23 and the inner wall of the nasal cavity of the subject when inflated.
In an alternative embodiment the at least one cuff member 27 could comprise a plurality of cuff members 27 which together provide a seal between the delivery channel 23 and the inner wall of the nasal cavity of the subject when inflated.
The delivery device further comprises a substance supply unit 29 for delivering metered doses of a substance, in this embodiment an aerosol canister for delivering metered volumes of a propellant, preferably a hydrofluoroalkane (HFA) propellant or the like, containing medicament, either as a suspension or solution, which is fluidly connected to the nozzle 25 to deliver substance from the nosepiece 17 , in this embodiment as an aerosol spray.
In this embodiment the substance supply unit 29 is a multi-dose unit for delivering a plurality of metered doses of substance. In another embodiment the substance supply unit 29 could be a single-dose unit for delivering a single metered dose of substance.
The substance supply unit 29 is pre-primeable, in this embodiment by loading a resilient element, and includes a breath-actuated release mechanism 31 which, when triggered, releases the resilient element and actuates the substance supply unit 29 to deliver a metered dose of a substance through the nozzle 25 .
In this embodiment the trigger mechanism 31 is configured to cause actuation of the substance supply unit 29 on generation of a predetermined flow rate through the delivery channel 23 .
In another embodiment the trigger mechanism 31 could be configured to cause actuation of the substance supply unit 29 on generation of a predetermined pressure within the delivery channel 23 .
In a further embodiment the trigger mechanism 31 could be configured to cause actuation of the substance supply unit 29 on generation of either one of a predetermined flow rate through the delivery channel 23 or a predetermined pressure within the delivery channel 23 .
In an alternative embodiment the substance supply unit 29 could comprise a mechanical delivery pump, in particular a liquid delivery pump or a powder delivery pump, which delivers metered doses of a substance on actuation thereof.
In another alternative embodiment the substance supply unit 29 could comprise a dry powder delivery unit which delivers metered doses of a substance, as a dry powder, on actuation thereof.
In yet another alternative embodiment the substance supply unit 29 could comprise a nebulizer which delivers metered doses of a substance, as an aerosol spray, on actuation thereof.
Operation of the delivery device will now be described hereinbelow with reference to FIGS. 3 to 5 of the accompanying drawings.
Referring to FIG. 3 , the nosepiece 17 is first inserted into one of the nasal cavities of a subject until the guide member 20 abuts the nares of the nostril, at which point the distal end of the outlet unit 21 extends about 2 cm into the nasal cavity of the subject, and the mouthpiece 19 is gripped in the lips of the subject.
The subject then begins to exhale through the mouthpiece 19 , which exhalation acts to close the oropharyngeal velum of the subject and drive an air flow through the delivery channel 23 of the outlet unit 21 , with the air flow passing into the one nasal cavity, around the posterior margin of the nasal septum and out of the other nasal cavity, thereby achieving a bi-directional air flow through the nasal airway of the subject. Exhalation through the mouthpiece 19 acts to develop a pressure in the delivery channel 23 , which pressure acts to inflate the at least one cuff member 27 . As illustrated in FIG. 4 , the expansion of the at least one cuff member 27 acts to expand the nasal valve in the nasal cavity, seal the delivery channel 23 to the inner wall of the nasal cavity, and position the outlet unit 21 in relation to the nasal cavity of the subject. As will be noted from FIG. 4 , the outlet unit 21 is forced to adopt the required position by the at least one cuff member 27 , in this embodiment as accommodated by flexing of the outlet unit 21 .
In this embodiment, when the flow rate developed through the delivery channel 23 reaches a predetermined value, the release mechanism 31 is triggered to actuate the substance supply unit 29 to deliver a metered dose of a substance to the nozzle 25 and into the nasal cavity of the subject. In the alternative embodiment the release mechanism 31 could be triggered on the generation of a predetermined pressure in the delivery channel 23 .
Following exhalation, the pressure in the delivery channel 23 decreases and the at least one cuff member 27 deflates, as illustrated in FIG. 5 , at which point the mouthpiece 19 is released and the nosepiece 17 withdrawn from the nasal cavity of the subject.
In one embodiment, where the delivery device is a single-dose device, the device can be discarded.
In another embodiment, where the delivery device is a multi-dose device, the device is ready for further use following priming of the substance supply unit 29 . In a preferred embodiment, where the nosepiece 17 is replaceable, the nosepiece 17 can be replaced with a new nosepiece 17 .
FIGS. 6 to 9 illustrate an exhalation breath-actuated nasal delivery device in accordance with a second embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described first embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts
The delivery device of this embodiment differs from that of the above-described first embodiment in further comprising an oral exhalation breath-actuatable gas supply unit 33 for delivering a gas flow through the delivery channel 23 of the outlet unit 21 in response to exhalation by a subject, and in that the mouthpiece 19 is in fluid communication with the gas supply unit 33 and not the delivery channel 23 of the outlet unit 21 , whereby a gas flow is delivered to the delivery channel 23 of the outlet unit 21 , and hence the nasal airway of the subject, in response to exhalation through the mouthpiece 19 .
Operation of the delivery device is the same as for the above-described first embodiment, with a gas flow being delivered to the delivery channel 23 of the outlet unit 21 in response to exhalation through the mouthpiece 19 .
FIGS. 10 to 13 illustrate an exhalation breath-actuated nasal delivery device in accordance with a third embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described first embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described first embodiment only in that the nosepiece 17 comprises a plurality of, in this embodiment two, inflatable cuff members 27 a , 27 b . This arrangement of cuff members 27 a , 27 b enables the distalmost cuff member 27 b to have a reduced size, and thereby facilitates insertion of the outlet unit 21 through the narrow nasal valve in the nasal cavity of the subject.
Operation of the delivery device is the same as for the above-described first embodiment.
FIGS. 14 to 16 illustrate an exhalation breath-actuated nasal delivery device in accordance with a fourth embodiment of the present invention.
The delivery device comprises a housing 35 , a nosepiece 37 for fitting in a nasal cavity of a subject, and a mouthpiece 39 through which the subject exhales to actuate the delivery device.
The nosepiece 37 comprises a guide member 40 , in this embodiment a frusto-conical element, for guiding the nosepiece 37 into the nasal cavity of the subject, and an outlet unit 41 for delivering substance into the nasal airway of the subject. In this embodiment the nosepiece 37 is a replaceable unit.
In this embodiment the outlet unit 41 comprises a delivery channel 43 which is in fluid communication with the mouthpiece 39 such that an air flow is delivered into and through the nasal airway of the subject on exhalation by the subject through the mouthpiece 39 , and a nozzle 45 for delivering substance into the nasal cavity of the subject. In this embodiment the nozzle 45 is disposed in the delivery channel 43 co-axially with the same. In this embodiment the nozzle 45 is configured to provide an aerosol spray. In an alternative embodiment, for the delivery of a liquid, the nozzle 45 could be configured to deliver a liquid jet as a column of liquid.
In this embodiment at least the tip of the delivery channel 43 comprises a tubular section of a flexible, preferably resilient, material. In a preferred embodiment the material is a semi-soft plastics material, such as silicone rubber.
In this embodiment at least the tip of the delivery channel 43 has a tapering section which narrows to the distal end thereof. The delivery channel 43 , in having a narrowing taper, acts, on insertion, to expand the narrow nasal valve of the nasal cavity of the subject. In a preferred embodiment the delivery channel 43 has an elliptical section, preferably an oval section.
In a preferred embodiment the outlet unit 41 is configured to extend at least about 2 cm, preferably at least about 3 cm, and more preferably from about 2 cm to about 3 cm, into the nasal cavity of the subject.
The nosepiece 37 further comprises at least one cuff member 47 for fitting in the nasal cavity of the subject. In this embodiment the at least one cuff member 47 is a resilient member which is deformable to allow for insertion into the nasal cavity of the subject and, on insertion, expansion to adopt the required position in the nasal cavity, in which position the outlet unit 41 is correctly positioned. When so positioned, the at least one cuff member 47 provides for the expansion of the narrow nasal valve in the nasal cavity, the sealing of the outlet unit 41 in the nasal cavity, and the positioning, in particular the direction, of the outlet unit 41 in the nasal cavity of the subject. In this embodiment the at least one cuff member 47 comprises a sponge member, here a foam member. In an alternative embodiment the at least one cuff member 47 could comprise a gel-filled member, such as a silicone-filled member.
In this embodiment the at least one cuff member 47 is configured such that, when inserted in the nasal cavity, the outlet unit 41 is directed at a lower region of the nasal cavity of the subject. In preferred embodiments the at least one cuff member 47 can be configured to direct the outlet unit 41 at any region of the inferior meatus and the inferior region of the middle meatus, whereby substance can be targeted in particular at the inferior nasal concha, and the adenoids and tubal ostia in the superior region of the epipharynx.
Regions in the nasal airway adjacent the inferior meatus and the inferior region of the middle meatus represent the regions in the nasal airway which provide the path of least flow resistance therethrough. With existing nasal spray systems, the delivery is such that the delivered substance flows along the floor of the nasal cavity, with the result that the substance does not reach the adenoids or the tubal ostia.
In this embodiment the at least one cuff member 47 includes at least one lobe 54 , here a single lobe 54 , which is configured such as to extend into, and thereby obstruct, an upper region of the nasal cavity of the subject, the at least one lobe 54 acting to force the delivered flow to follow a flow path defined by the inferior meatus and the inferior region of the middle meatus. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the inferior meatus and the inferior region of the middle meatus.
In this embodiment the at least one cuff member 47 comprises a single annular cuff member 47 which is disposed about the outlet unit 41 .
In an alternative embodiment the at least one cuff member 47 could comprise a plurality of cuff members 47 which are disposed about the outlet unit 41 .
The delivery device further comprises a substance supply unit 49 for delivering metered doses of a substance, in this embodiment an aerosol canister for delivering metered volumes of a propellant, preferably a hydrofluoroalkane (HFA) propellant or the like, containing medicament, either as a suspension or solution, which is fluidly connected to the nozzle 45 to deliver substance from the nosepiece 37 , in this embodiment as an aerosol spray.
In this embodiment the substance supply unit 49 is a multi-dose unit for delivering a plurality of metered doses of substance. In another embodiment the substance supply unit 49 could be a single-dose unit for delivering a single metered dose of substance.
The substance supply unit 49 is pre-primeable, in this embodiment by loading a resilient element, and includes a breath-actuated release mechanism 51 which, when triggered, releases the resilient element and actuates the substance supply unit 49 to deliver a metered dose of a substance through the nozzle 45 .
In this embodiment the trigger mechanism 51 is configured to cause actuation of the substance supply unit 49 on generation of a predetermined flow rate through the delivery channel 43 .
In another embodiment the trigger mechanism 51 could be configured to cause actuation of the substance supply unit 49 on generation of a predetermined pressure within the delivery channel 43 .
In a further embodiment the trigger mechanism 51 could be configured to cause actuation of the substance supply unit 49 on generation of either one of a predetermined flow rate through the delivery channel 43 or a predetermined pressure within the delivery channel 43 .
In an alternative embodiment the substance supply unit 49 could comprise a mechanical delivery pump, in particular a liquid delivery pump or a powder delivery pump, which delivers metered doses of a substance on actuation thereof.
In another alternative embodiment the substance supply unit 49 could comprise a dry powder delivery unit which delivers metered doses of a substance, as a dry powder, on actuation thereof.
In yet another alternative embodiment the substance supply unit 49 could comprise a nebulizer which delivers metered doses of a substance, as an aerosol spray, on actuation thereof.
Operation of the delivery device will now be described hereinbelow with reference to FIGS. 15 and 16 of the accompanying drawings.
Referring to FIG. 15 , the nosepiece 37 is first inserted into a nasal cavity of a subject until the guide member 40 abuts the nares of the nostril, at which point the distal end of the outlet unit 41 extends about 2 cm into the nasal cavity of the subject, and the mouthpiece 39 is gripped in the lips of the subject.
The subject then begins to exhale through the mouthpiece 39 , which exhalation acts to close the oropharyngeal velum of the subject and drive an air flow through the delivery channel 43 of the outlet unit 41 , with the air flow passing into the one nasal cavity, around the posterior margin of the nasal septum and out of the other nasal cavity, thereby achieving a bi-directional air flow through the nasal airway of the subject.
In this embodiment, when the flow rate developed through the delivery channel 43 reaches a predetermined value, the release mechanism 51 is triggered to actuate the substance supply unit 49 to deliver a metered dose of a substance to the nozzle 45 and into the nasal cavity of the subject. In the alternative embodiment the release mechanism 51 could be triggered on the generation of a predetermined pressure in the delivery channel 43 .
Following exhalation, the mouthpiece 39 is released and the nosepiece 37 withdrawn from the nasal cavity of the subject.
In one embodiment, where the delivery device is a single-dose device, the device can be discarded.
In another embodiment, where the delivery device is a multi-dose device, the device is ready for further use following priming of the substance supply unit 49 . In a preferred embodiment, where the nosepiece 37 is replaceable, the nosepiece 37 can be replaced with a new nosepiece 37 .
FIGS. 17 to 19 illustrate an exhalation breath-actuated nasal delivery device in accordance with a fifth embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described fourth embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described fourth embodiment only in the configuration of the outlet unit 41 and the at least one cuff member 47 .
In this embodiment the at least one cuff member 47 is configured such that, when inserted in the nasal cavity of the subject, the outlet unit 41 is directed at a middle region of the nasal cavity of the subject. In a preferred embodiment the at least one cuff member 47 can be configured to direct the outlet unit 41 at any region of the middle meatus and the inferior region of the superior meatus, whereby substance can be targeted in particular at the middle nasal concha, the sinus infundibulum and the sinus ostia.
The middle meatus is the region of the nasal cavity located under and lateral to the middle nasal concha, with the sinus infundibulum and the sinus ostia representing the sites of the main pathologies in many very common diseases, such as chronic sinusitis, which affects about 10 to 15% of the population and has no FDA approved treatment, and nasal polyposis. The only known treatment of these conditions is the application of drops during a rigorous and complex procedure involving severe neck extension and the so-called “Mecca” position. As will be appreciated, however, owing to the complicated and often painful procedure, compliance is very poor. Existing nasal spray systems are ineffective in delivering substance to this region of the nasal cavity.
In this embodiment the at least one cuff member 47 includes upper and lower lobes 54 a , 54 b which are configured such as to extend into, and thereby obstruct, respective ones of the upper and lower regions of the nasal cavity of the subject, the lobes 54 a , 54 b acting to force a delivered flow to follow a flow path defined by the middle meatus and the inferior region of the superior meatus. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the middle meatus and the inferior region of the middle meatus.
Operation of the delivery device is the same as for the above-described fourth embodiment.
FIGS. 20 to 22 illustrate an exhalation breath-actuated nasal delivery device in accordance with a sixth embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described fourth embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described fourth embodiment only in the configuration of the outlet unit 41 and the at least one cuff member 47 .
In this embodiment the at least one cuff member 47 is configured such that, when inserted in the nasal cavity of the subject, the outlet unit 41 is directed at a superior region of the nasal cavity of the subject. In a preferred embodiment the at least one cuff member 47 can be configured to direct the outlet unit 41 at any region of the superior meatus, and in particular provide for the targeting of the superior nasal concha and the olfactory region.
The olfactory region is located in the superior region of the nasal cavity and typically has a surface area of from about 4 to 6 cm 2 . The olfactory region represents the only region where it is possible to circumvent the blood-to-brain barrier (BBB) and enable communication with the cerebrospinal fluid (CSF) and the brain. Such delivery is necessary to enable effective treatment of neurological diseases, such as Alzheimer's and Parkinson's disease, psychiatric diseases and intracerebral infections.
The olfactory region is reached through narrow slit-like passages and the delivery of substance to this region is not possible using existing nasal delivery systems.
In existing nasal spray systems, substantially all of the particles are far too large to pass through the passages in communication with the olfactory region. Indeed, such spray systems are specifically designed to deliver particles having an average diameter of greater than 10 μm in order to comply with the FDA requirements which require that the maximum fraction of particles having a diameter of less than 10 μm be 5% of the total fraction. The reason for this requirement is that, where the velum is not closed, as would be the case where a subject inhales through the nose as prescribed for delivery, particles having a diameter of less than 10 μm could escape from the nasal cavity and be inhaled into the lungs.
In addition, in existing nasal spray systems, the flow characteristics of particles delivered into the nasal cavity are not suited to enable delivery through the passages communicating with the olfactory region.
Furthermore, the sniffing action by a subject during delivery causes the particles to be drawn into the inferior and middle regions of the nasal cavity, where the flow resistance is the lowest, with only a minimal fraction, if any, of the particles being delivered to the olfactory region.
In this embodiment, by ensuring closure of the velum in delivery and optimizing both the particle size distribution so as to include a larger fraction of smaller particles, typically having a particle size of less than 10 μm, and the aerodynamic delivery conditions, the delivery device provides for the effective delivery of substance to the olfactory region. Such a delivery regime has not previously been known, and has been recognised by the present applicant as providing an improved delivery device and delivery method.
In this embodiment the at least one lobe 54 of the at least one cuff member 47 is configured such as to extend into, and thereby obstruct, a lower region of the nasal cavity of the subject, the at least one lobe 54 acting to force a delivered flow to follow a flow path defined by the superior meatus and in particular the olfactory region. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the superior meatus and in particular the olfactory region.
Operation of the delivery device is the same as for the above-described fourth embodiment.
FIGS. 23 to 26 illustrate an exhalation breath-actuated nasal delivery device in accordance with a seventh embodiment of the present invention.
The delivery device comprises a housing 55 , a nosepiece 57 for fitting in a nasal cavity of a subject, and a mouthpiece 59 through which the subject exhales to actuate the delivery device.
The nosepiece 57 comprises a guide member 60 , in this embodiment a frusto-conical element, for guiding the nosepiece 57 into a nasal cavity of the subject, and an outlet unit 61 for delivering substance into the nasal airway of the subject. In this embodiment the nosepiece 57 is a replaceable unit.
In this embodiment the outlet unit 61 comprises a delivery channel 63 which is in fluid communication with the mouthpiece 59 such that an air flow is delivered into and through the nasal airway of the subject on exhalation by the subject through the mouthpiece 59 , and a nozzle 65 for delivering substance to the nasal airway of the subject. In this embodiment the nozzle 65 is disposed in the delivery channel 63 co-axially with the same. In this embodiment the nozzle 65 is configured to provide an aerosol spray. In an alternative embodiment, for the delivery of a liquid, the nozzle 65 could be configured to deliver a liquid jet as a column of liquid.
In this embodiment the outlet unit 61 is movably coupled to the housing 55 , here as provided by a flexible coupling, such as to allow for the positioning of the outlet unit 61 in the nasal cavity of the subject, as will be described in more detail hereinbelow.
In an alternative embodiment the outlet unit 61 could be fixed to the housing 55 , and the mouthpiece 59 instead movably coupled to the housing 55 , here as provided by a flexible coupling, such as to allow for the positioning of the outlet unit 61 in the nasal cavity of the subject.
In this embodiment at least the tip of the delivery channel 63 comprises a tubular section of a flexible, preferably resilient, material. In a preferred embodiment the material is a semi-soft plastics material, such as silicone rubber.
In this embodiment at least the tip of the delivery channel 63 has a tapering section which narrows to the distal end thereof. The delivery channel 63 , in having a narrowing taper, acts, on insertion, to expand the narrow nasal valve of the nasal cavity of the subject. In a preferred embodiment the delivery channel 63 has an elliptical section, preferably an oval section.
In a preferred embodiment the distal end of the outlet unit 61 is configured to extend at least about 2 cm, preferably at least about 3 cm, and more preferably from about 2 cm to about 3 cm, into the nasal cavity of the subject.
The nosepiece 57 further comprises at least one expandable cuff member 67 for expansion in the nasal cavity of the subject. In this embodiment the at least one cuff member 67 comprises an inflatable member.
In this embodiment the at least one cuff member 67 is in fluid communication with the delivery channel 63 , whereby the air flow generated by the subject on exhalation through the mouthpiece 59 acts to inflate the at least one cuff member 67 . In an alternative embodiment the delivery device could include a separate pump unit for inflating the at least one cuff member 67 subsequent to fitting of the nosepiece 57 , and in a preferred embodiment subsequent to, preferably in response to, exhalation through the mouthpiece 59 .
In this embodiment the at least one cuff member 67 is an inflatable member which is inflated on exhalation by the subject. In an alternative embodiment the at least one cuff member 67 could be inflated on the nosepiece 57 being located in the correct position.
In this embodiment the at least one cuff member 67 comprises a flexible balloon element which is inflated by the generation of a pressure in the delivery channel 63 , with the at least one cuff member 67 deflating on the release of pressure from the delivery channel 63 . In the alternative embodiment, where the at least one cuff member 67 is inflated by a separate pump unit, the at least one cuff member 67 could equally be deflated by the evacuation of gas therefrom using the same pump unit.
In one embodiment the at least one cuff member 67 could comprise a resilient balloon element which is inflated by the generation of a pressure in the delivery channel 63 , with the at least one cuff member 67 returning to the original, deflated configuration on the release of pressure from the delivery channel 63 .
In another embodiment the at least one cuff member 67 could comprise an inflatable sponge element, in one embodiment a foam element having an encapsulating sealing layer, which can be compressed, in this embodiment by evacuation, to adopt a compact configuration to allow for insertion into a nasal cavity of the subject and inflated, in this embodiment by breaking the vacuum, to allow for the introduction of a gas into the porous structure of the sponge element. In one embodiment such a cuff member 67 could be in selective fluid communication with the atmosphere. In another embodiment such a cuff member 67 could be in selective fluid communication with the delivery channel 63 , whereby the pressure developed in the delivery channel 63 would assist in the inflation of the cuff member 67 . In the alternative embodiment which includes a separate pump unit, the pump unit could be employed to assist in inflating such a cuff member 67 and in deflating the cuff member 67 by the evacuation of gas therefrom. In one embodiment the inflation could be triggered on exhalation by the subject. In another embodiment the inflation could be triggered on the nosepiece 57 being located in the correct position in the nasal cavity of the subject.
The at least one cuff member 67 is disposed to an outer surface of the outlet unit 61 such as, on expansion, to engage the inner wall of the nasal cavity of the subject. The at least one cuff member 67 , in being expandable, provides for the expansion of the narrow nasal valve of the nasal cavity of the subject, the sealing of the nosepiece 57 in the nasal cavity of the subject, and the positioning, in particular the direction, of the outlet unit 61 in the nasal cavity of the subject.
In this embodiment the at least one cuff member 67 comprises a single annular cuff member 67 which is located about the outlet unit 61 such as to provide a seal between the delivery channel 63 and the inner wall of the nasal cavity of the subject when inflated.
In an alternative embodiment the at least one cuff member 67 could comprise a plurality of cuff members 67 which together provide a seal between the delivery channel 63 and the inner wall of the nasal cavity of the subject when inflated.
In this embodiment the at least one cuff member 67 is configured such that, when inserted in the nasal cavity, the outlet unit 61 is directed at a lower region of the nasal cavity of the subject. In preferred embodiments the at least one cuff member 67 can be configured to direct the outlet unit 61 at any region of the inferior meatus and the inferior region of the middle meatus, whereby substance can be targeted in particular at the inferior nasal concha, and the adenoids and tubal ostia in the superior region of the epipharynx.
Regions in the nasal airway adjacent the inferior meatus and the inferior region of the middle meatus represent the regions in the nasal airway which provide the path of least flow resistance therethrough. With existing nasal spray systems, the delivery is such that the delivered substance flows along the floor of the nasal cavity, with the result that the substance does not reach the adenoids or the tubal ostia.
In this embodiment the at least one cuff member 67 includes at least one lobe 74 , here a single lobe 74 , which is configured such as to extend into, and thereby obstruct, an upper region of the nasal cavity of the subject, the at least one lobe 74 acting to force the delivered flow to follow a flow path defined by the inferior meatus and the inferior region of the middle meatus. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the inferior meatus and the inferior region of the middle meatus.
In this embodiment the at least one cuff member 67 comprises a single annular cuff member 67 which is disposed about the outlet unit 61 .
In an alternative embodiment the at least one cuff member 67 could comprise a plurality of cuff members 67 which are disposed about the outlet unit 61 .
The delivery device further comprises a substance supply unit 69 for delivering metered doses of a substance, in this embodiment an aerosol canister for delivering metered volumes of a propellant, preferably a hydrofluoroalkane (HFA) propellant or the like, containing medicament, either as a suspension or solution, which is fluidly connected to the nozzle 65 to deliver substance from the nosepiece 57 , in this embodiment as an aerosol spray.
In this embodiment the substance supply unit 69 is a multi-dose unit for delivering a plurality of metered doses of substance. In another embodiment the substance supply unit 69 could be a single-dose unit for delivering a single metered dose of substance.
The substance supply unit 69 is pre-primeable, in this embodiment by loading a resilient element, and includes a breath-actuated release mechanism 71 which, when triggered, releases the resilient element and actuates the substance supply unit 69 to deliver a metered dose of a substance through the nozzle 65 .
In this embodiment the trigger mechanism 71 is configured to cause actuation of the substance supply unit 69 on generation of a predetermined flow rate through the delivery channel 63 .
In another embodiment the trigger mechanism 71 could be configured to cause actuation of the substance supply unit 69 on generation of a predetermined pressure within the delivery channel 63 .
In a further embodiment the trigger mechanism 71 could be configured to cause actuation of the substance supply unit 69 on generation of either one of a predetermined flow rate through the delivery channel 63 or a predetermined pressure within the delivery channel 63 .
In an alternative embodiment the substance supply unit 69 could comprise a mechanical delivery pump, in particular a liquid delivery pump or a powder delivery pump, which delivers metered doses of a substance on actuation thereof.
In another alternative embodiment the substance supply unit 69 could comprise a dry powder delivery unit which delivers metered doses of a substance, as a dry powder, on actuation thereof.
In yet another alternative embodiment the substance supply unit 69 could comprise a nebulizer which delivers metered doses of a substance, as an aerosol spray, on actuation thereof.
Operation of the delivery device will now be described hereinbelow with reference to FIGS. 24 to 26 of the accompanying drawings.
Referring to FIG. 24 , the nosepiece 57 is first inserted into one of the nasal cavities of a subject until the guide member 60 abuts the nares of the nostril, at which point the distal end of the outlet unit 61 extends about 2 cm into the nasal cavity of the subject, and the mouthpiece 59 is gripped in the lips of the subject.
The subject then begins to exhale through the mouthpiece 59 , which exhalation acts to close the oropharyngeal velum of the subject and drive an air flow through the delivery channel 63 of the outlet unit 61 , with the air flow passing into the one nasal cavity, around the posterior margin of the nasal septum and out of the other nasal cavity, thereby achieving a bi-directional air flow through the nasal airway of the subject. Exhalation through the mouthpiece 59 acts to develop a pressure in the delivery channel 63 , which pressure acts to inflate the at least one cuff member 67 . As illustrated in FIG. 25 , the expansion of the at least one cuff member 67 acts to expand the nasal valve in the nasal cavity, seal the delivery channel 63 to the inner wall of the nasal cavity, and position the outlet unit 61 in relation to the nasal cavity of the subject. As will be noted from FIG. 25 , the outlet unit 61 is forced to adopt the required position by the at least one cuff member 67 , in this embodiment as accommodated by flexing of the outlet unit 61 .
In this embodiment, when the flow rate developed through the delivery channel 63 reaches a predetermined value, the release mechanism 71 is triggered to actuate the substance supply unit 69 to deliver a metered dose of a substance to the nozzle 65 and into the nasal cavity of the subject. In the alternative embodiment the release mechanism 71 could be triggered on the generation of a predetermined pressure in the delivery channel 63 .
Following exhalation, the pressure in the delivery channel 63 decreases and the at least one cuff member 67 deflates, as illustrated in FIG. 26 , at which point the mouthpiece 59 is released and the nosepiece 57 withdrawn from the nasal cavity of the subject.
In one embodiment, where the delivery device is a single-dose device, the device can be discarded.
In another embodiment, where the delivery device is a multi-dose device, the device is ready for further use following priming of the substance supply unit 69 . In a preferred embodiment, where the nosepiece 57 is replaceable, the nosepiece 57 can be replaced with a new nosepiece 57 .
FIGS. 27 to 30 illustrate an exhalation breath-actuated nasal delivery device in accordance with an eighth embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described seventh embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described seventh embodiment only in the configuration of the outlet unit 61 and the at least one cuff member 67 .
In this embodiment the at least one cuff member 67 is configured such that, when inserted in the nasal cavity of the subject, the outlet unit 61 is directed at a middle region of the nasal cavity of the subject. In a preferred embodiment the at least one cuff member 67 can be configured to direct the outlet unit 61 at any region of the middle meatus and the inferior region of the superior meatus, whereby substance can be targeted in particular at the middle nasal concha, the sinus infundibulum and the sinus ostia
The middle meatus is the region of the nasal cavity located under and lateral to the middle nasal concha, with the sinus infundibulum and the sinus ostia representing the sites of the main pathologies in many very common diseases, such as chronic sinusitis, which affects about 10 to 15% of the population and has no FDA approved treatment, and nasal polyposis. The only known treatment of these conditions is the application of drops during a rigorous and complex procedure involving severe neck extension and the so-called “Mecca” position. As will be appreciated, however, owing to the complicated and often painful procedure, compliance is very poor. Existing nasal spray systems are ineffective in delivering substance to this region of the nasal cavity.
In this embodiment the at least one cuff member 67 includes upper and lower lobes 74 a , 74 b which are configured such as to extend into, and thereby obstruct, respective ones of the upper and lower regions of the nasal cavity of the subject, the lobes 74 a , 74 b acting to force a delivered flow to follow a flow path defined by the middle meatus and the inferior region of the superior meatus. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the middle meatus and the inferior region of the middle meatus.
Operation of the delivery device is the same as for the above-described seventh embodiment.
FIGS. 31 to 34 illustrate an exhalation breath-actuated nasal delivery device in accordance with a ninth embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described seventh embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described seventh embodiment only in the configuration of the outlet unit 61 and the at least one cuff member 67 .
In this embodiment the at least one cuff member 67 is configured such that, when inserted in the nasal cavity of the subject, the outlet unit 61 is directed at a superior region of the nasal cavity of the subject. In a preferred embodiment the at least one cuff member 67 can be configured to direct the outlet unit 61 at any region of the superior meatus, and in particular provide for the targeting of the superior nasal concha and the olfactory region.
The olfactory region is located in the superior region of the nasal cavity and typically has a surface area of from about 4 to 6 cm 2 . The olfactory region represents the only region where it is possible to circumvent the blood-to-brain barrier (BBB) and enable communication with the cerebrospinal fluid (CSF) and the brain. Such delivery is necessary to enable effective treatment of neurological diseases, such as Alzheimer's and Parkinson's disease, psychiatric diseases and intracerebral infections.
The olfactory region is reached through narrow slit-like passages and the delivery of substance to this region is not possible using existing nasal delivery systems.
In existing nasal spray systems, substantially all of the particles are far too large to pass through the passages in communication with the olfactory region. Indeed, such spray systems are specifically designed to deliver particles having an average diameter of greater than 10 μm in order to comply with the FDA requirements which require that the maximum fraction of particles having an average diameter of less than 10 μm be 5% of the total fraction. The reason for this requirement is that, where the velum is not closed, as would be the case where a subject inhales through the nose as prescribed for delivery, particles having an average diameter of less than 10 μm could escape from the nasal cavity and be inhaled into the lungs.
In addition, in existing nasal spray systems, the flow rate of particles delivered into the nasal cavity is too great to enable delivery through the passages communicating with the olfactory region.
Furthermore, inhalation by a subject during delivery causes the particles to be drawn into the inferior and middle regions of the nasal cavity, where the flow resistance is the lowest, with only a minimal fraction, if any, of the particles being delivered to the olfactory region.
In this embodiment, by ensuring closure of the velum in delivery and optimizing both the particle size distribution so as to include a larger fraction of smaller particles, typically having a particle size of less than 10 μm, and the aerodynamic delivery conditions, the delivery device provides for the effective delivery of substance to the olfactory region. Such a delivery regime has not previously been known, and has been recognised by the present applicant as providing an improved delivery device and delivery method.
In this embodiment the at least one lobe 74 of the at least one cuff member 67 is configured such as to extend into, and thereby obstruct, a lower region of the nasal cavity of the subject, the at least one lobe 74 acting to force a delivered flow to follow a flow path defined by the superior meatus and in particular the olfactory region. The achievement of such a flow path, allied with an optimization of the particle size distribution, provides that a much larger fraction of substance can be delivered to sites in the superior meatus and in particular the olfactory region.
Operation of the delivery device is the same as for the above-described seventh embodiment.
FIGS. 35 to 39 illustrate an exhalation breath-actuated nasal delivery device in accordance with a tenth embodiment of the present invention.
The delivery device comprises a housing 75 , a nosepiece 77 for fitting in a nasal cavity of a subject, and a mouthpiece 79 through which the subject exhales to actuate the delivery device.
The nosepiece 77 comprises a cuff member 80 , in this embodiment a frusto-conical element, for positioning the nosepiece 77 in the nasal cavity of the subject and providing a fluid-tight seal therewith, and an outlet unit 81 for delivering substance into the nasal airway of the subject.
In this embodiment the outlet unit 81 comprises a nozzle 82 from which substance is delivered into the nasal cavity of the subject, and a delivery channel 83 through which a gas flow, separate from the exhalation breath of the subject, is delivered to interact with the substance delivered from the nozzle 82 . This configuration, in interacting with the substance and altering the characteristics of the delivered substance, advantageously provides for improved delivery of the substance.
In this embodiment the nozzle 82 is configured to provide an aerosol spray. In an alternative embodiment, for the delivery of a liquid, the nozzle 82 could be configured to deliver a liquid jet as a column of liquid.
In this embodiment the nozzle 82 is disposed in the delivery channel 83 co-axially with the same. In this embodiment the delivery channel 83 is an annular channel which surrounds the nozzle 82 such as to define an annular gas flow which interacts with the substance delivered from the nozzle 82 .
The delivery device further comprises a substance supply unit 85 which is fluidly connected to the nozzle 82 such as to deliver a metered dose of a substance on actuation thereof. In this embodiment the substance supply unit 85 comprises a mechanical pump for delivering a metered dose of a substance on actuation thereof.
The delivery device further comprises a gas supply unit 87 which is fluidly connected to the delivery channel 83 for supplying a gas flow therethrough. The gas supply unit 87 comprises a cylinder 89 , a piston 91 which is movably disposed within the cylinder 89 and defines a chamber 93 forward thereof which contains a gas, with a volume of the contained gas, typically about 5 ml, being expelled from the chamber 93 on actuation of the gas supply unit 87 .
The delivery device further comprises a driving unit 95 which is actuatable to actuate the substance supply unit 85 and the gas supply unit 87 .
The driving unit 95 comprises a drive member 97 , in this embodiment a block, which is coupled, here commonly coupled, to the body of the substance supply unit 85 and the piston 91 of the gas supply unit 87 and movable between a first, rest position (as illustrated in FIGS. 35 to 38 ) in which the substance supply unit 85 and the gas supply unit 87 are in the non-actuated positions and a second, actuated position (as illustrated in FIG. 39 ) in which the body of the substance supply unit 85 and the piston 91 of the gas supply unit 87 are advanced to the actuated positions, and a return biasing element 99 , in this embodiment a resilient element, particularly a compression spring, for returning the drive member 97 to the rest position.
The driving unit 95 further comprises a load biasing element 101 , in this embodiment a resilient element, particularly a compression spring, for biasing the drive member 97 in an actuating direction when in the rest position, and a loading member 103 , in this embodiment a lever, for loading the load biasing element 101 such as to bias the drive member 97 when in the rest position with an actuation force. The loading member 103 is movable between a first, inoperative position (as illustrated in FIG. 35 ) in which the load biasing element 101 is not loaded thereby, and a second, operative position (as illustrated in FIGS. 36 to 38 ) in which the biasing element 101 , when restrained, loads the drive member 97 with the actuation force.
The delivery device further comprises a trigger mechanism 105 which is configured normally to lock the drive member 97 of the driving unit 95 in the rest position and release the same on exhalation by the subject through the mouthpiece 79 , which drive member 97 , when loaded by the load biasing element 101 , once released acts commonly to actuate the substance supply unit 85 and the gas supply unit 87 .
In this embodiment the trigger mechanism 105 is configured to cause actuation of the driving unit 95 on generation of a predetermined flow rate through the mouthpiece 79 .
In another embodiment the trigger mechanism 105 could be configured to cause actuation of the driving unit 95 on generation of a predetermined pressure within the mouthpiece 79 .
In this embodiment the trigger mechanism 105 comprises a linkage assembly 107 which includes first and second link elements 109 , 111 , and a biasing element 112 , in this embodiment a resilient element, particularly a tension spring, for biasing the linkage assembly 107 to a locking configuration (as illustrated in FIGS. 35 to 37 ) in which the linkage assembly 107 acts to lock the drive member 97 of the driving unit 95 in the rest position and prevent movement thereof when loaded by the load biasing element 101 .
One of the link elements 109 includes a pivot 113 about which the same is rotatable, and first and second arms 115 , 117 . One of the arms 115 extends into the mouthpiece 79 and, when the linkage assembly 107 is in the locking configuration, is biased to a rest position (as illustrated in FIGS. 35 to 37 ) in which the flow path through the mouthpiece 79 is substantially closed, the one arm 115 thereby providing a vane to be acted upon by the exhalation breath of the subject.
The other of the link elements 111 is pivotally coupled at one end to the distal end of the other, second arm 117 of the first link element 109 and at the other end to the drive member 97 of the driving unit 95 ; the second arm 117 of the first link element 109 being angularly positioned relative to the first arm 115 thereof such that, when the linkage assembly 107 is in the locking configuration, the second arm 117 of the first link element 109 and the second link element 111 enclose an angle of less than 180 degrees on the side opposite to the first arm 115 of the first link element 109 , whereby the second arm 117 of the first link element 109 and the second link element 111 are over-centered and support the drive member 97 of the driving unit 95 when loaded.
Operation of the delivery device will now be described hereinbelow with reference to FIGS. 36 to 39 of the accompanying drawings.
In a first step, as illustrated in FIG. 36 , the loading member 103 is operated to bias the biasing element 101 and load the drive member 97 of the driving unit 95 with the actuation force.
Referring to FIG. 37 , the nosepiece 77 is then first inserted into a nasal cavity of a subject until the cuff member 80 is fitted in the nares of the nostril, at which point the distal end of the outlet unit 81 extends about 2 cm into the nasal cavity of the subject, and the mouthpiece 79 is gripped in the lips of the subject.
The subject then begins to exhale through the mouthpiece 79 , which exhalation acts to close the oropharyngeal velum of the subject and drive an air flow over the first arm 115 of the first link element 109 of the linkage assembly 107 which extends into the mouthpiece 79 . While the flow rate developed is not sufficient to actuate the trigger mechanism 105 , the linkage assembly 107 of the trigger mechanism 105 acts to retain the drive member 97 of the driving unit 95 in the locked position, whereby the substance supply unit 85 and the gas supply unit 87 are not actuated. When the flow rate developed reaches a predetermined value, as illustrated in FIG. 38 , the rotation of the first arm 115 of the first link element 109 is such as to rotate the second arm 117 of the first link element 109 to a position in which the support provided together with the second link element 111 is unstable and collapses. Referring to FIG. 39 , this collapse of the linkage assembly 107 enables the drive member 97 of the driving unit 95 to be moved by the load biasing element 101 to the actuated position, which movement actuates the substance supply unit 85 to deliver a metered dose of a substance through the nozzle 82 and the gas supply unit 87 to deliver a metered volume of a gas through the delivery channel 83 , which gas flow interacts with the delivered substance to modify the characteristics of the delivered substance, and thereby provide for improved delivery to the nasal airway of the subject.
Following actuation, the mouthpiece 79 is released and the nosepiece 77 is withdrawn from the nasal cavity of the subject.
The loading member 103 of the driving unit 95 is then returned to the inoperative position, and the drive member 97 of the driving unit 95 is returned to the rest position by the return biasing element 99 . The return of the drive member 97 to the rest position causes the body of the substance supply unit 85 and the piston 91 of the gas supply unit 87 to be returned to the rest positions.
Following the return of the drive member 97 to the rest position, the linkage assembly 107 again adopts the locking configuration, with the linkage assembly 107 being maintained in the locking configuration by the linkage biasing element 112 . In this configuration, the delivery device is ready for further use.
FIGS. 40 to 45 illustrate an exhalation breath-actuated nasal delivery device in accordance with an eleventh embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described tenth embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described tenth embodiment only in the configuration of the driving unit 95 .
In this embodiment the drive member 97 of the drive unit 95 is not configured to commence actuation of the substance supply unit 85 and the gas supply unit 87 at the same instant as in the above-described tenth embodiment, but rather is configured such that actuation of the gas supply unit 87 is commenced prior to the actuation of the substance supply unit 85 , whereby an interacting gas flow is delivered from the delivery channel 83 of the outlet unit 81 prior to the delivery of substance from the nozzle 82 and then during the delivery of substance from the nozzle 82 such as to interact with the same.
In this embodiment the delayed actuation of the substance supply unit 85 is achieved by configuring the drive member 97 such as to be spaced from the body of the substance supply unit 85 when the drive member 97 is in the rest position, whereby the drive member 97 has to be advanced a predetermined distance, corresponding to a predetermined time period, prior to common actuation of the substance supply unit 85 and the gas supply unit 87 . In this embodiment the substance supply unit 85 includes a biasing element 119 for returning the substance supply unit 85 to the rest position following actuation. With this configuration, the interval between actuation of the gas supply unit 87 and the common actuation of the substance supply unit 85 and the gas supply unit 87 can be controlled by altering the spacing between the drive member 97 and the body of the substance supply unit 85 .
Operation of the delivery device is the same as for the above-described tenth embodiment.
FIGS. 46 to 51 illustrate an exhalation breath-actuated nasal delivery device in accordance with a twelfth embodiment of the present invention.
The delivery device of this embodiment is very similar to the delivery device of the above-described tenth embodiment, and thus, in order to avoid unnecessary duplication of description, only the differences will be described in detail, with like reference signs designating like parts.
The delivery device of this embodiment differs from that of the above-described tenth embodiment only in the configuration of the outlet unit 81 and in the integration of the substance supply unit 85 and the gas delivery unit 87 .
In this embodiment the outlet unit 81 includes a second delivery channel 120 , here an annular channel which is disposed co-axially about the nozzle 82 , through which an air flow from an exhalation breath of a subject is delivered, such as to entrain with the substance delivered from the nozzle 82 . In this embodiment the second delivery channel 120 is fluidly connected to the mouthpiece 79 downstream of the trigger mechanism, and the mouthpiece 79 includes a pressure-release valve which allows for the development of a flow above the release pressure of the pressure-release valve where a flow, or at least not a sufficient flow, cannot be developed through the nasal airway of the subject.
In this embodiment the substance supply unit 85 comprises a piston unit which is disposed within the chamber 93 of the gas supply unit 87 . The substance supply unit 85 comprises a cylinder 121 which defines a chamber 122 and into one, forward end of which a hollow needle 123 extends as an extension of the nozzle 82 . The substance supply unit 85 further comprises first and second pistons 124 , 125 which contain a volume of substance therebetween and are movably disposed within the chamber 122 .
With this configuration, the forward, piston 125 is driven forwardly on the rear, piston 124 being driven forwardly, the substance contained between the pistons 124 , 125 being substantially incompressible. The forward piston 125 is a puncturable member which is punctured by the needle 123 of the nozzle 82 on being driven onto the same, with the needle 123 of the nozzle 82 being in fluid communication with the substance contained between the pistons 124 , 125 on puncturing the forward piston 125 .
In this embodiment the forward piston 125 of the substance supply unit 85 is spaced from the needle 123 of the nozzle 82 by a predetermined distance such that the piston 91 of the gas supply unit 87 , which drives the rear piston 124 of the substance supply unit 85 , is required to be driven a predetermined distance before the forward piston 125 of the substance supply unit 85 is ruptured and substance is delivered through the nozzle 82 . In this way, actuation of the gas supply unit 87 is initiated prior to the actuation of the substance supply unit 85 , whereby an interacting gas flow is delivered from the delivery channel 83 of the outlet unit 81 prior to the delivery of substance from the nozzle 82 and then during the delivery of substance from the nozzle 82 such as to interact with the same. In this embodiment the interval between actuation of the gas supply unit 87 and the common actuation of the substance supply unit 85 and the gas supply unit 87 can be controlled by altering the spacing between the forward piston 125 of the substance supply unit 85 and the needle 123 of the nozzle 82 .
Operation of the delivery device is the same as for the above-described tenth embodiment.
Finally, it will be understood that the present invention has been described in its preferred embodiments and can be modified in many different ways without departing from the scope of the invention as defined by the appended claims.
In particular, it should be understood that features of any of the embodiments could be incorporated in any other of the embodiments. For example, the second and third embodiments could incorporate features of the first embodiment, in particular the at least one expandable cuff member 23 as in the first embodiment.
Also, in embodiments where an entraining gas flow is not required through the nasal airways of subjects, ones of the embodiments could be modified to include no such gas flow. For example, the first-described embodiment could be modified such that the outlet unit 21 includes only the nozzle 23 and no delivery channel 23 .
In the described embodiments the mouthpieces are configured to be gripped in the lips of a subject. In alternative embodiments the mouthpieces could be configured to be gripped by the teeth of a subject and sealed by the lips of the subject. In preferred embodiments the mouthpieces could be specifically configured to have one or both of a shape or geometry which allows the delivery devices to be gripped repeatedly in the same position, thereby providing for the respective nosepieces to be reliably inserted in the same position in the nasal cavity.
In preferred embodiments the delivery devices are configured to deliver substance through one nostril of a subject at such a pressure as to flow around the posterior margin of the nasal septum and out of the other nostril of the subject, thereby achieving bi-directional delivery through the nasal cavities as disclosed in WO-A-00/51672. In alternative embodiments the, delivery device could be configured to deliver substance at a reduced pressure which is not sufficient to achieve bi-directional delivery through the nasal cavities. Such embodiments are still advantageous as compared to known delivery devices in providing for velum closure and being capable of achieving targeted delivery, particularly when certain regions of the nasal cavity are obstructed by cuff members.
Also, in another modification, the delivery devices could include two nosepieces, in one embodiment configured for the simultaneous delivery to each of the nasal cavities. Such embodiments would advantageously provide for three-point fixation of the delivery devices via the nosepieces and the mouthpieces.
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The present invention relates to a nasal delivery device for and a method of delivering a substance, in particular one of a liquid, as a suspension or solution, or a powder containing a medicament, especially systemic or topical pharmaceuticals, or a vaccine to the nasal airway of a subject.
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BACKGROUND OF THE INVENTION
Cigar smoking has been known for centuries. Quality cigars are hand-made and produced to certain predetermined standards. Machine-made cigars are also produced to certain predetermined standards. These standards include the length of the cigar, which may range from about four (4) inches to nine and one-quarter (91/4) inches, but is usually between four and one-half (41/2) inches and eight (8) inches, and the girth or diameter of the cigar, which may range from about three-eighths (3/8) inch to slightly more than one (1) inch. The diameter is typically measured in sixty-fourths (1/64) of an inch, with the number of sixty-fourths being designated as the ring size. Thus, a cigar having a diameter of forty-nine sixty-fourths (49/64) of an inch would have a ring size of 49.
According to A. Bari, The Cigar Companion (Running Press: Philadelphia, Pa., 1993), at pages 44-47, there are no fewer than sixty (60) possible cigar sizes. Some Havana brands have as many as forty (40) different sizes, while most non-Havana brands have six (6) to 10 (10) sizes, according to the same source.
While many manufacturers use similar standard sizes for their cigars, they typically assign their own proprietary names for the various sizes of the cigars they make. These proprietary names, however, do not typically appear on the paper band or ring on the cigar itself. Rather, the paper band typically contains only the manufacturer's name. Table 1 lists examples of sizes and names of various cigars according to The Cigar Companion.
Each manufacturer has its own blend, and each manufacturer generally uses a different blend of tobaccos in each of the sizes of cigars it makes in its product line.
Thus, a cigar smoker who has enjoyed a particular cigar cannot use the manufacturer's name on the paper band to determine the name or size of the particular cigar. Accordingly, such a cigar smoker has no way to purchase the same cigar.
TABLE 1______________________________________Length Ring Gauge Name(s)______________________________________91/4 47 Gran Corona, Montecristo A77/8 49 Double Corona71/2 38 Especial7 47 Churchill7 36 Long Pantela61/2 42 Lonsdale61/8 52 Pyramids, Torpedo6 42 Corona Grande53/4 39 Culebras55/8 46 Corona Gorda51/2 52 Belicoso51/2 42 Corona5 50 Robusto, Rothschild5 48 Hermoso5 42 Petit Corona41/2 40 Tres Petit Corona41/2 26 Panatela4 40 Perla4 30 Demi Tasse______________________________________
SUMMARY OF THE INVENTION
One object of the invention is to permit a user to determine the length and diameter, or ring size, of a cigar. A further object of the invention is to permit a user to determine the size, and hence name, of a particular cigar within a manufacturer's product line.
A further object of the invention is to provide such a cigar measuring device in a compact and pocket-sized form.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1C show a cigar measuring device in accordance with one embodiment of the present invention.
FIG. 2 shows a cigar measuring device in accordance with another embodiment of the present invention.
FIGS. 3A-3B show a cigar measuring device in accordance with yet another embodiment of the present invention.
FIG. 4 shows a cigar measuring device in accordance with still another embodiment of the present invention.
FIG. 5 shows a cigar measuring device in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A-1C show a cigar measuring device 100 in accordance with a first embodiment of the present invention. The device 100 includes an outer case having a front portion 101 and a back portion 102. The outer case may be made from a variety of materials, including, but not limited to, brass, steel, aluminum, titanium, anodized aluminum, stainless steel, sterling silver, nickel silver, gold plated metal, plastic, exotic hardwoods, mahogany, ebony, cherry, leather, reinforced leather, and the like. The outer case is preferably made from a rigid material, such as metal, plastic, wood, and the like. The outer case is shaped so as to include a gap 103 between the front portion 101 and back portion 102 along the top portion thereof, while the bottom portion 112 is preferably closed. The outer case may be of unitary construction or the front and back portions may be joined at the bottom portion and/or at one end thereof and/or optionally by a fastening means 107, such as a screw, rivet, or the like.
The device 100 further includes plural leaves 104, rotatably mounted on a fastening means 107. The fastening means 107 has an axis of rotation perpendicular to the front portion 101 of the outer case. The plural leaves are preferably made from a rigid material, such as metal, wood, plastic, and the like. The plural leaves 104 are designed so as to fit within the gap in the outer case in a stored position as shown in FIG. 1B. The fastening means may include known tension means 113 in FIG. 1C (exploded view) to maintain the leaves 104 in the stored position. The plural leaves 104 may optionally be provided with known detents 114 in FIG. 1A along the top portion thereof so as to facilitate rotating them out of the stored position.
Each of the plural leaves 104 is provided with at least one aperture 105 having a unique diameter. Each of the plural leaves 104 may be provided with indicia 106 adjacent each aperture 105, whereby each indicium 106 denotes the ring size, or diameter in units of one sixty-fourth (1/64) inch. The indicia 106 may be engraved, embossed, imprinted, or otherwise provided on the leaves 104. In a preferred embodiment, apertures 105 would be provided to correspond to each ring size from about thirty-eight (38) to about fifty-four (54). Alternately, apertures 105 could be provided corresponding only to even ring sizes or corresponding only to odd ring sizes, so as to decrease the number of leaves 104 required.
In actual construction, it is necessary that the apertures 105 be drilled approximately one sixty-fourth of an inch larger than the corresponding ring size. Thus, an aperture 105 corresponding to ring size 49, and bearing a "49" indicium 106, would have an actual diameter of approximately fifty sixty-fourths (50/64) of an inch.
The bottom portion 112 of the front portion 101 of the outer case is provided with a zero rule 108 and optionally with one or more ruled markings 109. At least one of the plural leaves 104 is further provided with ruled markings 110 along a portion thereof, such portion being the top portion in the stored position as shown in FIG. 1B and the bottom portion in the open position, as illustrated in FIG. 1A. Such ruled markings may be at 1-inch, 1/2-inch, 1/4-inch, 1/8-inch, or, most preferably, 1/16-inch intervals. The at least one plural leaf 104 provided with ruled markings 110 is preferably further provided with indicia 111 adjacent at least one or more of the ruled markings 110, whereby each indicium indicates the length from the zero point 108 in units of one (1) inch. The indicia 111 may be engraved, embossed, imprinted, or otherwise provided on the at least one leaf 104. In a preferred embodiment, the ruled markings would extend from about four and one-half (41/2) inches to about eight (8) inches.
To use the measuring device 100, a user would rotate the leaves 180° from the stored position so that the at least one leaf 104 having ruled markings 110 is aligned with the outer case, to create a straight rule from the zero point 108 through the ruled markings 110 as illustrated in FIG. 1. The user would then align one end of a cigar with the zero point 108 and determine the length of the cigar using the ruled markings 110. To determine the diameter or ring size of the cigar, the user then passes the cigar through the apertures 105 to determine the closest fit. The cigar should not be forced, as this will strip the outer leaves from the cigar.
With knowledge of the manufacturer, the length, and the ring size of the cigar, the user can enter any tobacco shop and request the particular cigar desired.
FIG. 2 shows a cigar measuring device 200 in accordance with another embodiment of the present invention. The device 200 includes an outer case having a front portion 201 and a back portion 202. The outer case may be made from a variety of materials, as described above with regard to the embodiment of FIG. 1, and preferably is made from a rigid material, as described above. As shown in FIG. 2, the front and back portions may be joined at one end thereof, optionally by a fastening means 207, such as a hinge or the like.
The device 200 further includes plural leaves 204, rotatably mounted on a fastening means 207. The fastening means 207 has an axis of rotation parallel to the front portion 201 of the outer case. The plural leaves are preferably made from a rigid material, such as metal, plastic, wood, and the like, as described with regard to the embodiment of FIG. 1.
Each of the plural leaves 204 is provided with at least one aperture 205 having a unique-diameter. Each of the plural leaves 204 may be provided with indicia 206 adjacent each aperture 205, whereby each indicium 206 denotes the ring size, or diameter in units of one sixty-fourth (1/64) inch. The indicia 206 may be engraved, embossed, imprinted, or otherwise provided on the leaves 204. In a preferred embodiment, apertures 205 would be provided to correspond to each ring size from about thirty-eight (38) to about fifty-four (54). Alternately, apertures 205 could be provided corresponding only to even ring sizes or corresponding only to odd ring sizes, so as to decrease the number of leaves 204 required.
Again, in actual construction, it is necessary that the apertures 205 be drilled approximately one sixty-fourth of an inch larger than the corresponding ring size. Thus, an aperture 205 corresponding to ring size 49, and bearing a "49" indicium 206, would have an actual diameter of approximately fifty sixty-fourths (50/64) of an inch.
The bottom portion 212 of the front portion 201 of the outer case is provided with a zero rule 208 and optionally with one or more ruled markings 209. The bottom portion 213 of the back portion 202 of the outer case is provided with ruled markings 210. Such ruled markings may be at 1-inch, 1/2-inch, 1/4-inch, 1/8-inch, or, most preferably, 1/16-inch intervals. The bottom portion 213 of the back portion 202 of the outer case is preferably further provided with indicia 211 adjacent at least one or more of the ruled markings 210, whereby each indicium indicates the length from the zero point 208 in units of one (1) inch. The indicia 211 may be engraved, embossed, imprinted, or otherwise provided on the bottom portion 213 of the back portion 202 of the outer case. In a preferred embodiment, the ruled markings would extend from about four and one-half (41/2) inches to about eight (8) inches.
To use the measuring device 200, a user would unfold the outer case and the leaves 204, so that the bottom portion 213 of the back portion 202 of the outer case is on a flat plane with the bottom portion 212 of the front portion 201 of the outer case. The user would then align one end of a cigar with the zero point 208 and determine the length of the cigar using the ruled markings 210. To determine the diameter or ring size of the cigar, the user then passes the cigar through the apertures 205 to determine the closest fit. As mentioned before, the cigar should not be forced, as this will strip the outer leaves from the cigar.
Again, with knowledge of the manufacturer, the length, and the ring size of the cigar, the user can enter any tobacco shop and request the particular cigar desired.
FIG. 3A shows a cigar measuring device 300 in accordance with yet another embodiment of the present invention. The device 300 is of unitary construction and is preferably made from a rigid material, as described above with regard to the embodiment of FIG. 1.
The cigar measuring device 300 is provided with plural apertures 305, each of such apertures having a unique diameter. The device 300 may be provided with indicia 306 adjacent each aperture 305, whereby each indicium 306 denotes the ring size, or diameter in units of one sixty-fourth (1/64) inch. The indicia 306 may be engraved, embossed, imprinted, or otherwise provided on the device 300. In one embodiment, apertures 305 would be provided to correspond to each ring size from about thirty-eight (38) to about fifty-four (54). Alternately, apertures 305 could be provided corresponding only to even ring sizes or corresponding only to odd ring sizes, as shown in FIG. 3, so as to decrease the size of the device 300.
As before, in actual construction, it is necessary that the apertures 305 be drilled approximately one sixty-fourth of an inch larger than the corresponding ring size.
The bottom portion 312 of the measuring device 300 is provided with ruled markings 310. Such ruled markings may be at 1-inch, 1/2-inch, 1/4-inch, 1/8-inch, or, most preferably, 1/16-inch intervals. One edge of the bottom portion 312 of the device 300 may be used as the zero rule 308, or a separate zero rule (not shown) may be provided. The bottom portion 312 of the device 300 is preferably further provided with indicia 311 adjacent at least one or more of the ruled markings 310, whereby each indicium indicates the length from the zero point 308 in units of one (1) inch. The indicia 311 may be engraved, embossed, imprinted, or otherwise provided on the bottom portion 312 of the device 300. In a preferred embodiment, the ruled markings would extend from about four and one-half (41/2) inches to about eight (8) inches. The bottom portion 312 may optionally be bevelled, as shown in FIG. 3B.
To use the measuring device 300, a user would simply align one end of a cigar with the zero point 308 and determine the length of the cigar using the ruled markings 310. To determine the diameter or ring size of the cigar, the user then passes the cigar through the apertures 305 to determine the closest fit. Once again, the cigar should not be forced.
As before, with knowledge of the manufacturer, the length, and the ring size of the cigar, the user can enter any tobacco shop and request the particular cigar desired.
FIG. 4 shows a cigar measuring device 400 in accordance with a still another embodiment of the present invention. The device 400 comprises a first blade 401 and a second blade 402, each blade preferably made from a rigid material, such as metal, wood, plastic, and the like, as described above. The two blades are rotatably joined at one end thereof by a fastening means 407, such as a screw, rivet, or the like, where the fastening means 407 has an axis of rotation perpendicular to the surface of the blades. The device 400 may comprise more than two blades, in which case a third blade would be rotatably joined to the second blade, and so forth.
Each of the blades is provided with plural apertures 405, each aperture 405 having a unique diameter. Each of the blades may be provided with indicia 406 adjacent each aperture 405, whereby each indicium 406 denotes the ring size, or diameter in units of one sixty-fourth (1/64) inch. The indicia 406 may be engraved, embossed, imprinted, or otherwise provided on the blades. In one embodiment, apertures 405 would be provided to correspond to each ring size from about thirty-eight (38) to about fifty-four (54). Alternately, apertures 405 could be provided corresponding only to even ring sizes or corresponding only to odd ring sizes, as shown in FIG. 4, so as to decrease the size of the device 400.
As before, the apertures 405 must be drilled approximately one sixty-fourth of an inch larger than the corresponding ring size.
The bottom portion 412 of the first blade 401 is provided with a zero rule 408 and optionally with one or more ruled markings 409. Alternatively, the edge of the first blade 401, if squared, may be used as the zero rule (not shown). The second blade 402 is further provided with ruled markings 410 along a portion thereof, such portion being the top portion in the stored position (not shown) and the bottom portion in the open position. As before, such ruled markings may be at 1-inch, 1/2-inch, 1/4-inch, 1/8-inch, or, most preferably, 1/16-inch intervals. The second blade 402 is preferably further provided with indicia 411 adjacent at least one or more of the ruled markings 410, whereby each indicium indicates the length from the zero point 408 in units of one (1) inch. As before, the indicia 411 may be engraved, embossed, imprinted, or otherwise provided on the second blade 402. In a preferred embodiment, the ruled markings would extend from about four and one-half (41/2) inches to about eight (8) inches.
To use the measuring device 400, a user would rotate the blades 180° from the stored position to create a straight rule from the zero point 408 through the ruled markings 410. The user would then align one end of a cigar with the zero point 408 and determine the length of the cigar using the ruled markings 410. To determine the diameter or ring size of the cigar, the user then passes the cigar through the apertures 405 to determine the closest fit. As before, with knowledge of the manufacturer, the length, and the ring size of the cigar, the user can enter any tobacco shop and request the particular cigar desired.
FIG. 5 shows a cigar measuring device 500 in accordance with a still further embodiment of the present invention. The device 500 comprises a first blade 501 and a second blade 502, each blade preferably made from a rigid material, such as metal, wood, plastic, and the like, as described above. The two blades are rotatably joined at one end thereof by a fastening means 507, such as a hinge or the like, where the fastening means 507 has an axis of rotation parallel to the surface of the blades. The device 500 may comprise more than two blades, in which case a third blade would be rotatably joined to the second blade, and so forth.
Each of the blades is provided with plural apertures 505, each aperture 505 having a unique diameter. Each of the blades may be provided with indicia 506 adjacent each aperture 505, whereby each indicium 506 denotes the ring size, or diameter in units of one sixty-fourth (1/64) inch. The indicia 506 may be engraved, embossed, imprinted, or otherwise provided on the blades. In one embodiment, apertures 505 would be provided to correspond to each ring size from about thirty-eight (38) to about fifty-four (54). Alternately, apertures 505 could be provided corresponding only to even ring sizes or corresponding only to odd ring sizes, as shown in FIG. 5, so as to decrease the size of the device 500. Again, the apertures 505 must be drilled approximately one sixty-fourth of an inch larger than the corresponding ring size.
The bottom portion 512 of the first blade 501 is provided with one or more ruled markings 509. The bottom portion 513 of the second blade 502 is provided with ruled markings 510. Such ruled markings may be at 1-inch, 1/2-inch, 1/4-inch, 1/8-inch, or, most preferably, 1/16-inch intervals. One edge of the bottom portion 512 of the first blade 501 may be used as the zero rule 508, or a separate zero rule (not shown) may be provided. The bottom portion 513 of the second blade 502 is preferably further provided with indicia 511 adjacent at least one or more of the ruled markings 510, whereby each indicium indicates the length from the zero point 508 in units of one (1) inch.
To use the measuring device 500, a user would unfold the blades from the stored position, so that the blades are on a flat plane with each other to create a straight rule. The user would then align one end of a cigar with the edge of the first blade 501 and determine the length of the cigar using the ruled markings 510. To determine the diameter or ring size of the cigar, the user then passes the cigar through the apertures 505 to determine the closest fit. As before, with knowledge of the manufacturer, the length, and the ring size of the cigar, the user can enter any tobacco shop and request the particular cigar desired.
It is to be understood that the determination of the length and ring gauge of the cigar can be made in any order. And, of course, the apertures for determining the ring gauge can be chosen to represent any desired sizes and can be arranged in any pattern, on any number of leaves or blades. In the embodiments of FIGS. 1 and 2, the useful number of leaves is from about two (2) to about six (6), with four (4) or five (5) being the optimum number. In the embodiments of FIGS. 4 and 5, the useful number of blades is about two (2) to four (4), with two (2) or three (3) being the optimum number. Moreover, the ruled markings and/or the zero rule may be provided on the apertured leaves and/or on the outer case and/or on separate non-apertured leaves. Thus, for example, when the outer case is not made from a rigid material, the necessary rulings may be provided on the apertured leaves or additional non-apertured leaves may be provided for this purpose.
It is also to be understood that the above-described arrangements are merely illustrative of the many possible embodiments which represent applications of the present invention. Numerous and varied other arrangements can readily be devised in accordance with the principles of the present invention without departing from the spirit and scope thereof.
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An apparatus and method are disclosed for determining the length and diameter, or ring size, of a cigar. This information, together with the manufacturer's name, permits the user to determine the size and hence the name of a particular cigar in order to facilitate the purchase of same. The apparatus disclosed may be compact and pocket-sized.
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BACKGROUND OF THE INVENTION
This invention relates to an overedge sewing machine for cutting the edge of a fabric and sewing an overedge stitch at the same time.
The U.S. Pat. No. 4570558 discloses one known overedge sewing machine. In this prior-art overedge sewing machine, a lower knife holder supporting a lower knife crosses the fabric-feed direction at a right angle. When an adjustment knob is rotated, an external screw is engaged with an internal screw, the lower knife holder is moved, and stitch width is thus adjusted. A stitch-support member is fixed on the lower knife holder. When the stitch width is altered, the stitch-support member is moved together with the lower knife holder.
Generally, an excess amount of upper and lower looper thread is necessary for the thread to reciprocate between the needle location and the fabric edge. Excess thread in proportion to the stitch width is also necessary. In this prior art, an adequate amount of reciprocating thread corresponding to the stitch width can be obtained. However, since the stitch-support member moves together with the lower knife and the relative position of the stitch-support member with the lower knife does not change, an adequate amount of excess thread proportional to the stitch width cannot be obtained. The amount of thread is so insufficient that the stitch becomes too taut when the adjusted stitch width increases.
Another known overedge sewing machine is disclosed in the U.S. Pat. No. 4690079. In this prior-art overedge sewing machine, the lower knife holder supporting the lower knife crosses the cloth feed direction at a right angle. When the adjustment knob is rotated, a movable member is moved and the external screw is engaged with the internal screw. The lower knife holder is moved accordingly, and the stitch width is thus adjusted. The stitch-support member attached to the movable member crosses the fabric-feed direction at a right angle. After the stitch width is adjusted, the position of the stitch-support member can be finely adjusted by loosening a set screw.
In this prior art, when the stitch width is altered, the position of the lower knife holder should be adjusted, then that of the stitch-support member should be finely adjusted. On the other hand, the movable member of the lower knife holder supports the stitch-support member, so the stitch-support member moves together with the lower knife holder when the stitch width is altered. Every time the stitch width is adjusted, the position of the stitch-support member must be finely adjusted according to the type of the fabric.
SUMMARY OF THE INVENTION
One object of the invention is, therefore, to provide an overedge sewing machine where, by securing an adequate excess thread proportional to an adjusted stitch width, a stitch can be steadily formed regardless of the stitch width without increasing the tension in the threads.
Another object of the invention is to provide an overedge sewing machine where the position of the lower knife holder supporting the lower knife and that of the stitch-support member can be adjusted easily using one adjustment member.
According to the present invention there is provided an overedge sewing machine comprising:
upper and lower knives disposed on the feed side in front of a needle location for cutting an edge of a fabric (W) being fed toward the needle location;
a lower knife holder movable in a direction perpendicular to the fabric-feed direction for supporting the lower knife;
a stitch-support member near the needle location, extending away from the feed side and movable in the direction perpendicularly to the fabric-feed direction;
an adjustment member for adjusting the stitch width;
displacement means responsive to said adjustment member for
moving said lower knife holder and said stitch-support member by first and second displacement amounts respectively on movement of said adjustment member by a given amount.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be best understood by referring to the following description of the preferred embodiments of the invention and the drawings in which:
FIG. 1 is a perspective view of an overedge sewing machine for the described embodiments of the invention;
FIG. 2 is a partial front sectional view showing a lower knife holder and a stitch-support member for the embodiments;
FIG. 3A is a side sectional view of FIG. 2 for the first embodiment;
FIG. 3B is a side sectional view of FIG. 2 for the second embodiment;
FIG. 4 is a partial top view of FIG. 2;
FIG. 5 illustrates stitch formation at the edge of the fabric;
FIG. 6 is a graph showing the displacement of cam members in the first embodiment; and
FIG. 7 is a graph showing the displacement of cam members in the second embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described referring to the drawings.
As shown in FIG. 1, a sewing machine body 1 comprises an arm 2 and a bed 3. The arm 2 has a needle bar 4. A needle 5 attached to the lower edge of the needle bar 4 sews an overedge stitch S on the edge of fabric W in cooperation with a known looper provided in the bed 3. An upper knife 6 is movably attached on the operator's side in front of a needle location in the bed 3. The upper knife 6 and a lower knife 7 fixed to the bed 3 cooperate to cut the edge of the fabric W being fed toward the needle location before overedge stitch is sewed.
The structure for supporting and adjusting the lower knife 7 is now explained. As shown in FIG. 2, a lower knife holder 8 is movably attached through a pair of support pins 9 to the bed 3, and can cross the fabric-feed direction at a right angle. The lower knife 7 is fixed with a screw 10 to the right side of the lower knife holder 8. Compression springs 11 are inserted between the bed 3 and spring washers 12 fixed at the tips of the pins 9. The resilience of the compression spring 11 moves the lower knife holder 8 to the left in FIG. 2.
A needle plate 13 is fixed on the top of the bed 3 of the sewing machine body 1. As shown in FIG. 4, a stationary stitch-support member 14 is fixed near the needle location extending away from the operator. As shown in FIGS. 2 and 3A, a movable member 15 is adjacent to the lower knife holder 8. The movable member 15 is attached through a pair of support pins 16 to the bed 3, and can cross the fabric-feed direction at a right angle. A movable stitch-support tongue 17 is attached to the top of the movable member 15 near the needle location in the fabric-feed direction. As shown in FIG. 5, the movable stitch-support tongue 17 and the stationary stitch-support member 14 temporarily hold the overedge stitch S between each other. Compression springs 18 are inserted between the bed 3 and spring washers 19 provided at the tips of the pins 16. The resilience of the springs 18 moves the movable member 15 to the left in FIG. 2.
An adjustment member 20 for adjusting stitch width is rotatably attached through a shaft 21 to the bed 3 of the sewing machine body 1. On the periphery of the adjustment member 20, graduation marks 22 marking the stitch width are provided. First and second cam members 23 and 24 are respectively incorporated into each side of the adjustment member 20. The first cam member 23 comprises a horizontal-movement-producing cam and the second cam member 24 comprises a vertical-movement-producing cam. As shown in FIG. 6, in this embodiment, the displacement due to the second cam member 24 is greater than that due to the first cam member 23.
As shown in FIG. 2, a first transmission lever 25 is rotatably attached through a shaft 26 to the bed 3. One end of the first transmission lever 25 engages the first cam member 23, and the other end engages a support pin 9 supporting the lower knife holder 8. A second transmission lever 27 is rotatably attached through a shaft 28 to the bed 3. One end of the second transmission lever 27 engages the second cam member 24, and the other end engages a pin 16 supporting the movable member 15. The first and second transmission levers 25 and 27 compose a transmission means for individually moving the lower knife holder 8 and the movable member 15 of the stitch-support tongue 17 based on the displacements due to the first and second cam members 23 and 24, respectively.
In this embodiment, when the adjustment member 20 is rotated according to the graduation marks 22 indicating stitch width, the first cam member 23 operates the first transmission lever 25 causing the lower knife holder 8 supporting the lower knife 7 to cross the fabric-feed direction at a right angle. At the same time, the second cam member 24 operates the second transmission lever 27 causing the movable member 15 with the stitch-support tongue 17 to move in the same direction as the lower knife holder 8. The upper knife 6 is also moved so that it continues to cooperate with the lower knife so as to cut the fabric. The stitch width is thus adjusted. As shown in FIG. 6, the second cam member 24 is displaced more than the first cam member 23. When the stitch width changes, the stitch-support tongue 17 moves more than the lower knife holder 8.
While the upper knife 6 cuts the edge of the fabric W in cooperation with the lower knife 7, the needle 5 sews the overedge stitch S in cooperation with the known looper. As shown in FIG. 5, the overedge stitch S is temporarily held by and between the stitch-support member 14 and the stitch-support tongue 17. When the stitch width is adjusted by rotating the adjustment member 20, the stitch-support tongue 17 moves more than the lower knife holder 8, so the stitch-support tongue 17 moves apart from the stationary stitch-support member 14. An amount A of thread reciprocating the width of the stitch and an excess amount B of thread both increase. By adjusting only the adjustment member 20, the overedge stitch steadily forms without excessive tension in the thread.
Another embodiment of the present invention will be explained with reference to the drawings. A second embodiment has the same construction as the first embodiment as shown in FIGS. 1, 2, and 4. However, the configuration of the second cam member 24 in the second embodiment in FIG. 3B differs from that in the first embodiment in FIG. 3A.
In the second embodiment, as shown in FIG. 7, the first cam member 23 has a continuous displacement. The second cam member 24 is displaced by almost the same amount as the first cam member 23, but its displacements are discrete.
In operation, while the upper knife 6 cuts the edge of the fabric W in cooperation with the lower knife 7, the needle 5 sews the overedge stitch S in cooperation with the known looper. When the adjustment member 20 is rotated, the first and second cam members 23 and 24 operate the first and second transmission levers 25 and 27, and the lower knife holder 8 and the movable member 15 move at right angles to, the fabric-feed direction by almost the same amount. The stitch width is thus adjusted. When the edge of the fabric W is cut and overedge stitch S is sewn, the fabric W, held by a known presser foot assembly, stretches toward the lower knife 7. When the fabric W is released from the presser foot assembly, the fabric W contracts to regain its original length. The expansion and contraction coefficient of the fabric W varies widely with the type of the fabric W. To adjust the stitch width, the relative position between the lower knife 7 and the stitch-support tongue 17 should be finely adjusted according to the type of the fabric W.
In the second embodiment, after the adjustment member 20 is rotated according to the graduation marks 22 for the stitch width, the adjustment member 20 is finely rotated within a graduation. Then, the first cam member 23 moves the lower knife holder 8 slightly within a graduation in the direction crossing the fabric-feed direction perpendicularly. However, since the second cam member 24 is in phase with a graduation on the adjustment member 20, the movable member 15 having the stitch-support tongue 17 does not move when a fine adjustment is made within a graduation. Consequently, the relative positions of the lower knife 7 and the stitch-support tongue 17 can be adjusted precisely and easily according to the type of the fabric.
These are only two possible embodiments of the invention claimed below. These embodiments are only illustrations of the claims, and in no way restrict the scope of the claims.
For instance, the cam members could be provided separately from the adjustment member. The cam members could be operated via a drive shaft by the adjustment member. One cam member could move both the lower knife holder and the stitch-support member individually by different amounts by means of the transmission levers with different lever lengths.
Furthermore, the first cam member could be displaced discretely, and the second cam member can be displaced continuously.
Thus, this invention includes all equivalent embodiments and modifications that come within the scope of the claims.
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In this overedge sewing machine, when stitch width is adjusted, an adequate excess thread proportional to the adjusted stitch width is obtained. An overedge stitch can be steadily sewn without excessive stitch tension, even when the stitch width increases. By operating one adjustment member, the position of the lower knife holder and the stitch-support member can be easily adjusted, and the stitch width can thus be easily altered.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the priority of German Patent Application No: DE 10 2005 022 715.5, filed on May 18, 2005, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention generally relates to a circuit arrangement that may be used to generate light pulses.
Circuit arrangements of this type are used in particular as transmitting units for optical sensors. These optical sensors can be embodied as distance sensors, which typically operate based on the light transit time method. For the distance measuring, light pulses are generated with predetermined timing with the aid of the circuit arrangement of the transmitting unit. The transit time of a light pulse to the object and back to the optical sensor is evaluated as a measure of the distance between an object and the optical sensor.
To achieve a highly precise distance measurement, it is necessary to generate sequences of very short light pulses, wherein the pulse duration of a light pulse typically is approximately one nanosecond. Accordingly, light pulses of this type are also required to have extremely short rise times below one nanosecond.
Circuit arrangements of this type for generating the aforementioned short light pulses are provided with laser diodes functioning as electro-optical converters. A charge store, typically a charge capacitor, is connected to this laser diode by way of a switching element, for example, a transistor.
The charge capacitor is discharged by closing the switching element and, in the process, a current pulse is generated, which is then converted in the laser diode to a light pulse.
With ideal components for such a circuit arrangement, the resulting time history for the current pulse would correspond to a discharge of an ideal RC (resistance-capacitance) element. This would mean an infinitely rapid rise time for the current pulse and an exponential decay of the current pulse.
However, during actual operations system-related deviations occur from the ideal time history of such current pulses, wherein these deviations in particular are caused by parasitic inductances in the components used.
A first deviation is that a finite rise time is obtained for the current pulse in place of an infinitely rapid rise time. Furthermore, the time history of the current pulse takes the form known for the discharge of an RLC (resistance-inductance-capacitance) element. Accordingly, post-oscillations occur during the decay of the current pulse. These post-oscillations comprise negative undershoots which are followed by positive overshoots. The negative undershoots polarize the laser diode in non-conducting direction and result in a Zener breakdown of the pn junction for the laser diode, thereby drastically reducing its operating life.
If the positive overshoots of the current pulse exceed a specific amplitude value, additional parasitic light pulses can thus be generated in the laser diode which follow the actual light pulse and result in distorting the distance measurements.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a circuit arrangement of the aforementioned type, which makes it possible to generate light pulses with the lowest possible rise times and without interfering post-oscillations.
This object may be achieved using various embodiments of the invention, as claimed. In one embodiment, a circuit arrangement for generating light pulses, comprising: an electro-optical converter; a switching element; a charge store, wherein the electro-optical converter is connected to the charge store via the switching element, and wherein the closing of the switching element triggers a discharging process in the charge store and, in the process, generates an electrical pulse that is converted to a light pulse in the electro-optical converter; and first and second impedance matching circuits arranged, respectively, between the charge store and the switching element and between the switching element and the electro-optical converter.
The basic idea behind the invention is that super-imposed current and/or voltage waves cannot form owing to the impedance matching according to the invention with the aid of the matching circuits arranged between the charge store and the switching element, as well as between the switching element and the electro-optical converter, which is preferably a laser diode. Current and voltage waves of this type, which travel between the components of the circuit arrangement and are reflected back by these, are the main reason for the appearance of post-oscillations in the current pulses generated in the circuit arrangement.
Avoiding or at least significantly reducing the current and voltage waves systematically prevents post-oscillations in the current pulses, in particular negative undershoots that result in shortening the operating life of the laser diode functioning as electro-optical converter. Also avoided are positive overshoots, which would result in the emission of undesirable parasitic light pulses by the laser diode. Furthermore, the circuit arrangement according to the invention makes it possible to significantly shorten the rise times for the current and light pulses.
The circuit arrangement according to the invention can therefore be used particularly advantageously as a transmitting unit in optical sensors, in particular in distance sensors operating based on the light-transit time method, wherein these sensors make it possible to realize highly precise and fast distance measurements.
The matching circuits for eliminating current and voltage waves traveling between the components of the circuit arrangement have a simple layout and can be produced cost-effectively, wherein the circuit arrangement components in general can be active and/or passive components.
The components of the matching circuits are generally dimensioned such that parasitic inductances of the charge store, the switching element, and the electro-optical converter are taken into account. The matching circuits consequently simulate circuit lines with defined wave resistances and limit frequencies, which eliminate or at least strongly reduce the reflections of current and voltage waves between the charge store and the switching element, as well as between the switching element and the electro-optical converter.
According to one advantageous embodiment of the invention, a first matching circuit is provided as a separate unit for adapting the internal resistance of the charge store to the complex input resistance of the switching element. A second matching circuit is furthermore provided as separate unit for matching the impedance between switching element and electro-optical converter. With this type of embodiment, the charge store in particular can be a single charge capacitor.
According to a different, advantageous embodiment of the invention, the first matching circuit can be integrated into the charge store. In that case, the charge store preferably comprises a multiple-unit arrangement of charge capacitors which form a circuit network together with the components of the first matching circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the invention will be further understood from the following detailed description of the preferred embodiments and with reference to the accompanying schematic drawings, in which:
FIG. 1 shows a schematic representation of a circuit arrangement for generating light pulses, as disclosed in prior art;
FIG. 2 shows the time history for an ideal current pulse generated with the circuit arrangement according to FIG. 1 ;
FIG. 3 shows the time history for an actual current pulse generated with the circuit arrangement according to FIG. 1 ;
FIG. 4 shows a schematic representation of a first embodiment of the circuit arrangement according to the invention for generating light pulses;
FIG. 5 shows a detailed representation of a circuit arrangement according to FIG. 4 ;
FIGS. 6 a and 6 b illustrate the time histories for partial current flows in the circuit arrangement according to FIG. 5 ;
FIG. 6 c shows the time history for a current pulse and a light pulse generated with the circuit arrangement according to FIG. 4 ; and
FIG. 7 shows a detailed representation of a second embodiment of the circuit arrangement according to the invention for generating light pulses.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 shows a circuit arrangement 1 according to prior art for generating short light pulses. The arrangement comprises an electro-optical converter in the form of a laser diode 2 that emits laser light. To enable the laser diode 2 to emit short light pulses, preferably in the nanosecond range, the laser diode is connected via an electronic switching element 3 to a charge store, which for the present case is a charge capacitor 4 . The switching element 3 is a transistor, typically an avalanche transistor.
To generate a light pulse, an external trigger signal is used to close the switching element 3 . As a result, the charge capacitor 4 is discharged and, in the process, a current pulse i(t) is generated, which travels through the laser diode 2 and is converted in the laser diode 2 to a light pulse p(t).
FIG. 2 shows the time history of the current pulse i(t), which essentially corresponds to the time history of the light pulse p(t) if the components of the circuit arrangement 1 are ideal components. In the ideal case, the current pulse has an infinitely short rise time and an exponential decay behavior, corresponding to the characteristic of a RC element.
However, system-related inherent parasitic inductances for the components of the circuit arrangement 1 , as well as connection inductances of the transistor and the laser diode 2 , cause general deviations from this ideal time history for the current pulse i(t).
FIG. 3 shows the actual time history for the current pulse i(t) of the circuit arrangement 1 according to FIG. 1 . Parasitic inductances in the circuit arrangement 1 will result in a finite rise time of the current pulse i(t). As a result of the existing parasitic inductances, the current pulse i(t) decay behavior corresponds to that of an RLC element, and no exponential decay of the current pulse occurs, as shown in FIG. 3 . Rather, the positive current pulse i(t) is followed by a negative undershoot I, which is followed by a positive overshoot II. Undershoots of this type polarize the laser diode 2 in the non-conducting direction and cause a Zener breakdown of the pn junction, thereby considerably reducing the operating life of the laser diode 2 . In the event that positive overshoots exceed specific amplitude values, these generate additional parasitic light pulses on the light pulse generated with the current pulse i(t). If the circuit arrangement 1 is used for realizing a distance measurement according to the light-transit time method, for example, these parasitic light pulses lead to distortions in the distance measurements.
FIG. 4 illustrates the basic layout of an exemplary embodiment of the circuit arrangement 1 according to the invention, which is designed to eliminate for the most part the interfering influences caused by parasitic inductances within the circuit arrangement 1 .
Corresponding to the circuit arrangement 1 shown in FIG. 1 , the circuit arrangement 1 according to FIG. 4 also comprises a laser diode 2 with a charge capacitor 4 and a switching element 3 connected thereto. The switching element 3 can again be a transistor, for example, an avalanche transistor, a MOSFET transistor, or an IGBT transistor. A first matching circuit 5 is provided between the charge capacitor 4 and the switching element 3 to eliminate the aforementioned interfering influences. A second matching circuit 6 is furthermore provided between the switching element 3 and the electro-optical converter.
FIG. 5 shows the circuitry which can be realized for the circuit arrangement 1 according to FIG. 4 . The switching element 3 in this case is an avalanche transistor. The charge capacitor 4 is connected via a resistance 7 to a voltage supply U B . FIG. 5 furthermore shows the existing parasitic inductances 8 a - 8 d present in the circuit arrangement 1 , wherein these are attributed to the charge capacitor 4 , the switching element 3 , and the laser diode 2 as components of the circuit arrangement 1 .
The two matching circuits 5 , 6 are provided to eliminate the influence of these parasitic inductances 8 a - 8 d.
In the present case, the first matching circuit 5 comprises two RC elements R 1 C 1 and R 2 C 2 . The second matching circuit 6 also comprises two RC elements R 3 C 3 and R 4 C 4 .
The parasitic inductances 8 a - 8 d are taken into account for the dimensioning of the RC elements in both matching circuits 5 , 6 . The first matching circuit 5 consequently functions to adapt or match the inherent complex resistance of the charge capacitor 4 to the inherent resistance of the switching element 3 . The second matching circuit 6 functions to adapt the impedance between the switching element 3 and the laser diode 2 . As a result of dimensioning the first matching circuit 5 in this way, only one current or voltage wave is generated and propagates from the charge capacitor 4 in the direction of the switching element 3 when the switching element 3 is operated, meaning it closes following the triggering by an external signal. The impedance matching achieved with the first matching circuit 5 thus prevents the current or voltage wave from being reflected back from the switching element 3 to the charge capacitor 4 . The second matching circuit 6 functions to allow the current and voltage wave, which leaves the circuit element 3 , to travel without reflection to the laser diode 2 .
In general, the influences of parasitic inductances can be systematically compensated with the aid of the matching circuits 5 , 6 , thereby making it possible to eliminate or for the most part suppress current and voltage waves that travel back and forth between the components of the circuit arrangement 1 . Since the parasitic inductances are taken into consideration for dimensioning the matching circuits 5 , 6 , their influence can be compensated even if the components are encased transistors or if laser diodes 2 are used, for which the feed line inductances are extremely high.
The matching circuit 5 , 6 according to the invention thus simulates a transmission line with defined wave resistance in the circuit arrangement 1 . This not only results in a considerable shortening of the rise times for the current pulses i(t) generated in the circuit arrangement 1 , but it also leads to avoiding undershoots and overshoots during the decay of the current pulse i(t).
FIG. 6 c shows the typical time histories for the current pulses i(t), generated in the circuit arrangement 1 according to FIG. 4 and/or FIG. 5 , and thus also the light pulses p(t) generated in the laser diode 2 . The comparison to FIG. 3 shows that the matching circuits 5 , 6 according to the invention consequently exhibit a considerable improvement in the signal curves for the current pulses i(t) and therefore also the light pulses p(t).
FIGS. 6 a, b show different current-path simulations for the circuit arrangement 1 according to FIG. 5 .
FIG. 6 a illustrates a simulation of the circuit arrangement 1 as shown in FIG. 5 , wherein I and II represent the time histories of the partial current flows through the resistance R 3 and the capacitor C 3 of the RC element R 3 C 3 . The total current flow through the RC element R 3 C 3 is furthermore shown in FIG. 6 a with III, that is to say the total simulated current flow through the laser diode 2 . The measured current flow through the laser diode 2 is shown with IV.
The simulation results illustrated in FIG. 6 a show that with a suitable dimensioning of the components R 3 and C 3 of the RC element R 3 C 3 , the time history for the total current flow can be specified precisely. The two partial current flows through R 3 and C 3 add up to a steep rising edge for the total current flow while undershoots in the current flowing through R 3 , which are caused by inductive components, are compensated by overshoots in the current flowing through C 3 . The amplitudes and zero passages of the partial current flows in this case can be adjusted optimally through a careful selection of R 3 and C 3 .
FIG. 6 b shows an expanded simulation which, in addition to the current flows I, II through R 3 and C 3 , also takes into account the time constants R 2 C 2 and R 4 C 4 with V and VI as additional compensation elements in the circuit arrangement according to FIG. 5 , so as to generate the total current III which flows through the laser diode 2 . By adding these additional compensation elements, the rise time and pulse shape of the total current flow through the laser diode can be further improved as compared to the simulation in FIG. 6 a , without resulting in a worsening of the post-oscillation behavior.
FIG. 7 contains an additional exemplary embodiment of the circuit arrangement 1 according to the invention. Coinciding with the exemplary embodiment according to FIG. 5 , the circuit arrangement 1 according to FIG. 7 again comprises a laser diode 2 functioning as electro-optical converter and an avalanche transistor functioning as switching element 3 . The supply voltage U B is again conducted via the resistance 7 to the charge store. However, the charge store for the present case comprises a multiple-unit arrangement of charge capacitors 4 , wherein these charge capacitors 4 are integrated into the first matching circuit 5 . Coinciding with the exemplary embodiment according to FIG. 5 , the second matching circuit 6 forms a separate circuit between the switching elements 3 and the laser diode 2 .
The matching circuits 5 , 6 in turn function to compensate the interfering influences caused by parasitic inductances 8 b - 8 d , meaning the matching circuits 5 , 6 prevent the current and voltage waves from traveling back and forth between the charge store and the switching element 3 as well as the switching element 3 and the laser diode 2 .
For the embodiment shown in FIG. 7 , a total of five charge capacitors 4 are provided for the first matching circuit 5 , wherein these are separated by inductances 9 a , 9 b , 9 c and 9 d . Additional charge capacitors that are separated by corresponding inductances may advantageously be provided as part of the arrangement of the first three charge capacitors 4 which are separated by the inductances 9 a , 9 b . The last two charge capacitors 4 are incorporated into a network which comprises the resistances 10 a , 10 b and 10 c as further components. The first three capacitors 4 and the last two capacitors 4 may be separated by a resistance 10 a′.
The second matching circuit 6 comprises a capacitor 11 , an inductance 12 , as well as three resistances 13 , 14 , 15 .
In addition, the matching circuit 6 in the circuit arrangement 1 functions to simulate a transmission line with defined wave resistance and defined limit frequency to prevent the reflection of current and voltage waves within the circuit arrangement 1 . This embodiment of the circuit arrangement 1 consequently also provides a characteristic for the current pulses i(t) and the light pulses p(t) which corresponds to FIG. 6 c . Whereas the embodiment of the matching circuit 5 , 6 as shown in FIG. 5 has a particularly simple layout with respect to the HF circuitry, owing to the use of RC elements, the matching circuits 5 , 6 shown in FIG. 7 permit a particularly broad adaptation to the parasitic inductances 8 b , 8 c and 8 d . A minimum rise time with simultaneous control of the pulse duration and the decay time can thus be achieved for specific embodiments of the laser diode 2 and/or the switching element 3 .
The circuit arrangements 1 shown in FIGS. 4 , 5 and 7 can advantageously be used as transmitting units in optical sensors, wherein these are in particular distance sensors operating based on the light-transit time method. The sensors are furthermore provided with a receiver for receiving light pulses and an evaluation unit in which the distances to detected objects are determined in dependence on the signals received at the receiver. With a distance sensor of this type, the laser diode 2 of the transmitting unit emits sequences of light pulses with a predetermined pulse-pause ratio, wherein the light pulses p(t) have extremely short rise times, typically below one nanosecond, and pulse durations of approximately one nanosecond as a result of using the matching circuits 5 , 6 . For the distance determination, the transit time of a light pulse from the distance sensor to an object and back to the distance sensor is evaluated in each case. In the simplest case, the distance sensor emits light pulses in a fixedly predetermined direction. The distance sensor can furthermore also be embodied as a scanning sensor, for which the emitted light is periodically deflected within a flat or three-dimensional area to be monitored.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A circuit arrangement for generating light pulses includes an electro-optical converter; a switching element; and a charge store. The electro-optical converter is connected to the charge store via the switching element. The closing of the switching element triggers a discharging process in the charge store and, in the process, generates an electrical pulse that is converted to a light pulse in the electro-optical converter. First and second impedance matching circuits are arranged, respectively, between the charge store and the switching element and between the switching element and the electro-optical converter.
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FIELD OF THE INVENTION
This invention relates to the treatment, by alkaline digestion according to the Bayer process, of alumina monohydrate bauxite or boehmite, including the addition of alumina trihydrate or gibbsite.
DESCRIPTION OF RELATED ART
The Bayer process, which is widely described in the literature, constitutes the essential production technique of alumina to be transformed by igneous electrolysis into aluminum, or to be used in the hydrate state or transition, calcinated, sintered or melted alumina states, in numerous applications in the technical alumina field.
According to this process, the bauxite mineral is digested when hot by means of an aqueous liquor of sodium hydroxide at the appropriate concentration, thereby making the alumina soluble and obtaining a slurry made up of particles of non-digested residue (mud) in a sodium aluminate liquor referred to as “aluminate liquor”.
This slurry is then usually diluted so as to separate the mud from the aluminate liquor by settling. Once the liquor is “purged” of this mud, it is cooled to a temperature at which it is in a state of strong supersaturation imbalance. At this stage it is referred to as “pregnant liquor”. Particles of alumina trihydrate are then seeded in order to initiate the “crystallization” of the pregnant liquor, in other words the precipitation of the alumina in the form of alumina trihydrate. Finally, the sodium aluminate liquor, depleted in alumina as a result of the precipitation and referred to as “spent liquor”, is recycled towards the digestion stage after being concentrated by evaporation and, if appropriate, the addition of sodium hydroxide so as to constitute a liquor, known as “digestion liquor”, whose concentration is adapted to the digestion of the mineral.
Those skilled in the art are well aware that treatment conditions must be adapted to the degree of hydration and the crystallographic structure of the alumina contained in the bauxite, and to the nature and level of the impurities which it contains.
Bauxite containing alumina in the monohydrate state (boehmite, diaspore) is more difficult to digest than trihydrate bauxite and is treated according to the Bayer process at temperatures higher than 200° C., usually between 220 and 300° C. Bauxite containing alumina in the trihydrate state (gibbsite) is treated at temperatures below 200° C., usually between 100 and 170° C.
The digestion yield is defined by the ratio between the quantity of alumina dissolved in the digestion liquor and the total quantity of alumina contained in the mineral. At the present time, a digestion yield in the region of 90% is usually reached with monohydrate bauxites containing between 2 and 3% of silica.
The chief factors acting on the digestion yield of bauxite are temperature and the concentration of “free” sodium hydroxide or caustic soda, i.e. capable of dissolving alumina. Caustic soda is usually expressed by the base group Na 2 O and its concentration given in Na 2 O grams per liter (g Na 2 O/1).
In addition, the saturation or stability state of the liquors is characterized by the weight ratio: A / C = concentration in dissolved AL 2 O 3 ( in g / l ) concentration in Na 2 O caustic soda ( in g / l )
With regard to bauxites which are rich in monohydrate, the dissolution kinetics falls sharply in the course of dissolution, to such an extent that, in economically viable treatment conditions, the quantity of extracted alumina remains appreciably less than what it could be with the same quantity of caustic soda digesting alumina trihydrate. Thus, the maximum A/C attained with a monohydrate bauxite is of the order of 1.20 while a ratio of 1.40 which can be reached with a trihydrate bauxite.
This A/C weight ratio, characterising the saturation state in alumina dissolved in the liquor of the Bayer cycle, determines the productivity of the liquor during its crystallization. This productivity is defined by the quantity of alumina recovered, in the form of alumina trihydrate, after crystallization of the pregnant liquor, in relation to a given volume of pregnant liquor. The productivity is expressed in kilograms of alumina per cubic meter of liquor (kg Al 2 O 3 /m 3 ) and is obtained by multiplying the A/C variation before and after crystallization by the caustic concentration of the pregnant liquor. This concentration is usually higher in European-type Bayer processes than in American-type processes and that is the reason why a productivity at the crystallization of the pregnant liquor is considered as good when it exceeds 70 kg Al 2 O 3 /m 3 for an American-type Bayer process and when it exceeds 80 kg Al 2 O 3 /m 3 for an European-type Bayer process.
In the case of monohydrate bauxite, productivity at crystallization could be increased if it were possible to raise the dissolved alumina level and thus the A/C weight ratio, for example by addition of alumina trihydrate and dissolution during the cooling of the liquor, before separation of the red mud. The trihydrate solubility is in fact good up to approximately 100° C. in alkaline medium and such an operation would increase, at least in the first instance, the quantity of alumina dissolved to the extent that the A/C weight ratio could reach 1.25 and even 1.30.
It has occurred that such a mode of liquor supersaturation, developed during the 1950s and referred to as “sweetening”, is difficult to exploit on an industrial scale. In point of fact, it is known (YAMADA—Jl of Jap. Inst. of Light Metals—vol. 31 pp. 43-48—January 1981) that in these extreme supersaturation conditions, part of the alumina reprecipitates inopportunely before or during the separation of the red mud and is evacuated with it: this reversion is a particularly unwelcome phenomenon which is to be avoided since it reduces the extraction yield of the alumina.
Thus the sweetening implemented according to American patent U.S. Pat. No. 2,701,752, consisting in adding a certain quantity of trihydrate to the slurry during cooling after the high-temperature digestion of the monohydrate, limits the A/C after digestion to less than 1.08 with caustic concentrations not exceeding 120 g Na 2 O/l. While the risk of reversion is certainly minimized in these conditions, the productivity of the liquor suffers as a result and does not exceed 70 kg Al 2 O 3 /m 3 .
In such conditions, the sole interest of the sweetening mode lies in its ability to reduce the energy cost of the treatment, since it provides a trihydrate digestion which costs nothing in energy terms because it uses the heat supplied for the digestion of the monohydrate.
It therefore emerges clearly that the various means of the prior art, designed to limit the unwelcome effects of reversion on the extraction yield of alumina, are implemented at the expense of the productivity of the liquor which A/C weight ratio can barely exceed 1.15.
Thus alumina producers are still concerned by the development of a an effective process for the treatment of bauxites which are rich in monohydrates, particularly in view of the importance of this type of bauxites as a source of supply. Such a process must satisfy the following criteria:
total alumina digestion yield higher than 90%;
productivity of crystallization greater than 70 kg Al 2 O 3 /m 3 of liquor, being capable of exceeding 90 kg Al 2 O 3 /m 3 in a European-type Bayer process;
reduction of the quantity of energy required to dissolve the same quantity of alumina.
SUMMARY OF THE INVENTION
The process according to the invention developed by the applicant satisfies these criteria. For this purpose, a sweetening stage is included in the process but is implemented in an entirely different way.
More specifically, the invention relates to a process for treating alumina monohydrate-based bauxite by caustic and high-temperature digestion of the ground bauxite so as to form a slurry which is settled and filtered in order to separate a sodium aluminate liquor to be crystallized in the presence of seeds and an insoluble residue, the process being characterized by the following series of operations:
a) digesting the bauxite, preferably ground, at a temperature higher than 200° C., with shaking if required, with a liquor which caustic concentration is above or equal to 160 g Na2O/liter and having an A/C weight ratio between 0.45 and 0.75, for a contact time which is sufficient to extract the aluminate monohydrate and to give an A/C ratio between 1.10 and 1.20;
b) cooling and flashing the resulting slurry, then introducing alumina trihydrate in said slurry, at a temperature of less than 200° C., in order to obtain an A/C ratio of the aluminate liquor between 1.20 and 1.30 when at atmospheric pressure, the temperature being slightly below boiling temperature;
c) first diluting the slurry giving a caustic concentration between 160 and 175 g Na2O/liter;
d) settling of said slurry, preferably in the presence of a flocculant, in order to separate the insoluble residue from a sodium aluminate liquor having an A/C ratio between 1.20 and 1.30;
e) filtering the aluminate liquor;
f) lowering the aluminate liquor concentration to less than 160 g Na2O/liter, via a complementary dilution carried out before or during crystallization, in which the alumina trihydrate precipitates, one part being recycled as seed and the other part being filtered and then washed;
g) after separation of the alumina trihydrate by filtration, recycling of the spent liquor which, after concentration, for example by evaporation and possible addition of sodium hydroxide, is reused as digestion liquor with a caustic concentration above or equal to 160 g Na2O/liter.
Preferably, the alumina trihydrate in stage b) is introduced by injecting a pulp obtained by grinding, in the presence of an aliquot of the digestion liquor, an alumina trihydrate bauxite or waste containing the same.
Also preferably, the complementary dilution of the liquor, which is carried out according to the invention after the settling stage, is performed with a previously filtered fraction of a diluted liquor resulting from the washing of the red mud, possibly containing the wash water of the alumina trihydrate produced. This takes place before or during crystallization and it is important to take steps to avoid any pollution by this wash water, for example by means of a preliminary filtration. The liquor may for example be diluted, filtered and then introduced in the chain of precipitators.
Contrary to all expectations, the applicant observed that it was able to delay, at least partially, the dilution of the aluminate liquor until the start of its crystallization. This operating method, however, runs counter to the usual practice in which the specialist dilutes the slurry by adding water so as to facilitate the settling of the mud. This dilution has the twin advantage of reducing its viscosity and allowing the addition of numerous flocculants which are unstable in liquors which are too concentrated. On the other hand, it increases alumina supersaturation which favors reversion. But the precipitation kinetics are slow when the A/C does not exceed 1.10-1.15 or even 1.20, so that this risk has always been considered as minimal provided that settling times are not too long. If settling is too lengthy, the fine particles of the non-digested residue present in the slurry may in fact initiate the precipitation and an intense reversion may still develop 5 or 6 hours after the start of settling. Dilution before separation of the mud has consequently always been considered as obligatory by the specialist because it shortens settling time and preserves the stability of the flocculants.
It unexpectedly occurred to the applicant that, given the flocculants currently used—these are usually anionic polyelectrolytes, for example synthetic polyacrylates which may advantageously be combined with polysaccharide-based additive improving clarity—, it was possible to settle the insolubles in a concentrated aluminate liquor in an acceptable lapse of time, despite a very high A/C, higher than 1.20, without reversion occurring. It emerges that the delaying effect of the reversion due to the high caustic level prevails over the accelerating effect due to a slight increase in the settling time. Moreover, the strong aluminate concentration appreciably increases its boiling temperature, thereby making it possible to settle at a higher temperature and to reduce still further the risk of reversion.
In other words, despite a very high A/C, higher than 1.20, obtained by sweetening, the risk of reversion of the pregnant liquor during the separation of the insolubles is considerably reduced when the caustic concentration remains above or equal to 160 g Na 2 O/l, due to the partial transfer of the dilution until after the settling stage.
What matters here, in fact, is that part of the dilution has been postponed until after the settling. This complementary dilution of the aluminate liquor may be carried out at once, right at the start of crystallization. This simple procedure was chosen in our examples. But, with a view to further improving productivity, the crystallization chain may be arranged in such a way that dilution is carried out in several stages during crystallization. It is known (J. V. Sang et al. Light Metals 1989, pp. 33-39, FIG. 1) that the optimum caustic concentration with respect to productivity diminishes as the A/C falls. Since the A/C inevitably falls during crystallization, it is important to dilute gradually the liquor of the aluminate slurry circulating in the crystallization chain so that productivity remains constantly at an optimum level.
BRIEF DESCRIPTION OF THE DRAWINGS
A clearer understanding of the invention will emerge from the detailed description of its application based on the following figures:
FIG. 1 representing in diagram form the product flows in a digestion process according to the prior art
FIG. 2 representing in diagram form the product flows in the basic process according to the invention
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to FIG. 1, representative of the prior art, the monohydrate bauxite 1 is submitted to a humid grinding A 1 in the presence of an aliquot 20 a of digestion liquor 20 having an A/C ratio preferably between 0.5 and 0.7 and a caustic concentration between 160 and 220 g Na 2 O/l. The whole is introduced, with the other aliquot 20b of the digestion liquor 20 , in autoclaves so as to form a slurry which is heated to a temperature between 220 and 300° C. for a sufficient length of time, generally between 0.2 and 1 hour, in order to extract the alumina monohydrate. The slurry 2 resulting from this pressurized digestion A 2 is cooled and put to atmospheric pressure (Cooling/Flash B 1 ), then diluted (Dilution B 2 ). The caustic concentration after said dilution is less than 160 g Na 2 O/l, preferably between 140 and 150 g Na 2 O/l. The resulting slurry 3 is then settled C 1 in the presence of a flocculant and then to filtration C 2 in order to separate the insoluble residues 5 from the aluminate liquor 4 . After washing F with the water 7 and the wash water 13 a resulting from the crystallization, the inert residues 5 a , or mud, are evacuated for discharge G and the wash water 7 a is used for dilution B 2 of the slurry 3 before settling C 1 .
The aluminate liquor 4 , having an A/C ratio between 1.05 and 1.15 and a caustic concentration between 110 and 160 g Na 2 O/l, is then cooled and crystallized between 80° C. and 50° C. (crystallization D) in the presence of fine particles of precipitate 10 recycled to act as seed. The grains of alumina trihydrate thus obtained are classified in such a way that the largest 11 are recovered, and after washing H with water 13 , calcinated (calcination K) in order to produce the production alumina 12 , while the finest 10 remain within the recycled seeds. The spent liquor 8 , with an A/C ratio between 0.5 and 0.7, is then reconcentrated by evaporation E with a possible addition of sodium hydroxide 9 and becomes the digestion liquor 20 .
The basic procedure according to the invention illustrated in diagram form in FIG. 2 is implemented as follows:
The same monohydrate bauxite 1 , after a first humid grinding A 1 in the presence of an aliquot 20 a of digestion liquor 20 having an A/C ratio preferably between 0.55 and 0.65 and a caustic concentration between 160 and 220 g Na 2 O/l, is introduced with another aliquot 20 b of the digestion liquor 20 , in autoclaves so as to form a slurry which is heated to a temperature between 220 and 300° C. for a sufficient length of time to extract the alumina monohydrate, between 0.2 and 1 hour. The slurry 2 resulting from this first pressurized digestion A 2 , with A/C between 1.05 and 1.20, is partially cooled and flashed (Cooling/Flashing N 1 ). At a temperature of less than 200° C., a pulp 6 containing alumina trihydrate, resulting from the humid grinding L of trihydrate bauxite 13 with a third aliquot 20 c of the digestion liquor 20 , is injected under pressure (“Sweetening” N 2 ). Before being injected in the slurry 2 , the ground pulp 6 is maintained for a dwell time of between 3 and 24 hours so as to produce a predesilicatation of said pulp.
The injection preferably takes place between 190 and 130° C. in the flash tank corresponding to this temperature and ensuring a dwell time of at least two minutes. The slurry 3 a , enriched in alumina as a result of the injection of the ground pulp 6 , is then cooled and flashed to atmospheric pressure. It has an A/C ratio between 1.20 and 1.28 and its caustic concentration is between 180 and 220 g Na 2 O/l. It is submitted to a first dilution by addition of a fraction 7 b of diluted liquor resulting from washing of the mud. Its concentration is lowered to a value between 160 and 175 g Na 2 O/l. It is then submitted, at a temperature slightly below—at most 5° C. below—boiling temperature, to settling C 1 in the presence of a flocculant, and lastly to filtration C 2 in order to separate the sodium aluminate liquor 4 a from the insoluble residues 5 . After countercurrent washing by the water 7 and the wash water 13 a of the alumina trihydrate produced 11 , these inert residues 5 a , or mud, are discharged G.
The aluminate liquor 4 a is diluted (dilution M) with the filtered wash water 7 c (filtration O) of the residues 5 . The diluted liquor 4 b has a caustic concentration between 140 and 155 g Na 2 O/l. It is then cooled and crystallized (D) between 80° C. and 50° C. in the presence of fine particles of precipitate 10 serving as seed. The grains of alumina trihydrate thus obtained are classified in such a way that the largest 11 are recovered. The grains just washed 11 a are calcined K to supply the production alumina 12 , while the finest remain within the recycled seeds 10 . The spent liquor 8 is then reconcentrated by evaporation and possible addition of sodium hydroxide so as to reach a caustic concentration between 160 and 220 g Na 2 O/l. Once concentrated, the liquor is used as digestion liquor 20 .
EXAMPLES OF APPLICATION
In examples 1 (according to the prior art), 2 and 3 (according to the invention), a first monohydrate bauxite (diaspore) was digested according to an European-type Bayer process. In example 4, a monohydrate Australian bauxite (boehmite) was digested according to an American-type Bayer process.
The dry ponderal composition of the first bauxite is as follows:
element
% in weight
Al 2 O 3
56.77
Fe 2 O 3
21.58
total SiO2
2.63
TiO2
2.69
Ignition loss
16.33
and various
Example 1
According to the prior art, a 100 ton batch of said bauxite was digested at 260° C. for 1 hour with a digestion liquor concentrated at
210 g Na 2 O/l.
After flash, cooling, dilution and settling, we obtained the following results:
Liquor before crystallization
A/C: 1.15
Caustic concentration: 146 g Na 2 O/l
Liquor after crystallization
A/C: 0.58
Global digestion yield: 90.6% extracted alumina/total alumina
Productivity at crystallization: 83 Kg Al 2 O 3 /m 3
Energy necessary for the digestion of 1 kg of alumina: 3.55 MJ
Example 2
Another 100 ton batch of the same bauxite was digested according to a first mode of the invention:
Digestion at 260° C. for 1 hour with a digestion liquor concentrated at 210 g Na 2 O/l.
Cooling to 160° C.
The slurry being maintained shaken, 9.2 tons of an African bauxite rich in trihydrate (85%) was injected in slurry form, said bauxite having previously been ground in the presence of an aliquot of the digestion liquor.
The trihydrate bauxite has the following ponderal composition:
element
% in weight
Al 2 O 3
56.5
Fe 2 O 3
4.8
total SiO2
1.4
TiO2
3.7
Ignition loss
33.6
and various
This slurry is mixed with the principal slurry and the digestion is maintained for 5 minutes. the quantity of alumina dissolved is such that the A/C weight ratio of the pregnant liquor reaches 1.25.
After flash, a first dilution was carried out, leading to a concentration of 168 g Na 2 O/l, then a settling at 104° C., in the presence of flocculant CYTEC® HX 400, at the rate of 600 g/ton of insoluble residue. After separation of the insoluble residues, the aluminate liquor was again diluted to a concentration of 147 g Na 2 O/l.
After dilution, we obtained the following results:
Liquor before crystallization
A/C: 1.21
Liquor after crystallization
A/C: 0.585
Global digestion yield: 91.0% extracted alumina/total alumina
Productivity at crystallization: 91.5 kg Al 2 O 3 /m 3
Energy necessary for the digestion of 1 kg of alumina: 3.25 MJ
Example 3
Another 100 ton batch of the same bauxite was digested according to a second mode of the invention:
Digestion at 260° C. for 1 hour with a digestion liquor concentrated at 210 g Na 2 O/l.
Cooling to 130° C.
The slurry being maintained shaken, 13 tons of a Brazilian bauxite rich in trihydrate was injected in slurry form, said bauxite having previously been ground in the presence of an aliquot of the digestion liquor. The quantity of alumina dissolved is such that the A/C weight ratio of the aluminate liquor reaches 1.27/1.28.
After expansion and first dilution at 175 g Na 2 O/l, settling took place at 108° C., in the presence of flocculant CYTEC® HX 400, at the rate of 800 g/ton of insoluble residue. After separation of the residue, the liquor is diluted to a concentration of 146 g Na 2 O/l.
After dilution, we obtained the following results:
Pregnant liquor before crystallization
A/C: 1.23
Pregnant liquor after crystallization
A/C: 0.59
Global digestion yield: 91.31 extracted alumina/total alumina
Productivity at crystallization: 93 kg Al 2 O 3 /m 3
Energy necessary for the digestion of 1 kg of alumina: 3.15 MJ
Example 4
Sweetening and Partial Transfer of Dilution on an American-type Bayer Process
In this example, an Australian monohydrate bauxite (boehmite) having the following dry ponderal composition was digested:
element
% in weight
Al 2 O 3
54.22
Fe 2 O 3
12.01
total SiO2
5.6
TiO2
2.83
Ignition loss
25.34
and various
A batch of 100 tons of this Australian monohydrate bauxite was digested according to a third mode of the invention:
Digestion at 265° C. for 20 minutes with a digestion liquor concentrated at 180 g Na 2 O/l.
After partial flashing, a slurry containing 11 tons of African bauxite rich in trihydrate was injected in the slurry cooled to 180° C., said bauxite having previously been ground in a minimum of digestion liquor followed by desilicatation for 8 hours at 100° C. The quantity of alumina dissolved is such that the A/C weight ratio of the aluminate liquor reaches 1.23.
A first dilution at 160° C. Na 2 O/l is carried out before settling at 103° C. in the presence of flocculant CYTEC® HX 400, at the rate of 500 g/ton of insoluble residue, and then the liquor is diluted to a concentration of 130 g Na 2 O/l.
After dilution, we obtained the following results:
Liquor before crystallization
A/C: 1.20
Liquor after crystallization
A/C: 0.63
Global digestion yield: 88.4% extracted alumina/total alumina
Productivity at crystallization: 74 kg Al 2 O 3 /m 3
Energy necessary for the digestion of 1 kg of alumina: 3.35 MJ
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A process for treating an alumina monohydrate-based bauxite by high temperature caustic digestion includes the steps of introducing alumina trihydrate into the digested slurry at a temperature of less than 200° C., in order to obtain an aluminate liquor at atmospheric pressure having an alumina/caustic weight ratio between 1.20 and 1.30, and diluting the resultant aluminate liquor to result in a caustic concentration between 160 and 175 g Na 2 O/liter. After settling and filtration, the resulting supersaturated liquor undergoes a further dilution before or during a crystallization step. The alumina trihydrate product is filtered from the spent liquor, which is concentrated and recycled.
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GOVERNMENT INTEREST
Governmental Interest—The invention described herein may be manufactured, used and licensed by or for the U.S. Government.
FIELD OF INVENTION
Embodiments of the present invention generally relate to radio-frequency communications and, more particularly, to a method and apparatus for analyzing the spectrum of radio-frequency signals using a fiber optic recirculation loop.
BACKGROUND OF THE INVENTION
Typically, public radio-frequency (RF) communications are transmitted at a preconfigured frequency so that a receiver can tune to the particular frequency and receive the communications. In contrast, private communications are transmitted across multiple frequencies (e.g., using frequency hopping and/or spread spectrum techniques). In some instances, these private communications need to be captured by unintended receivers, e.g., law enforcement agencies, military organizations and the like. However, difficulties arise when a communication is transmitted across various frequencies, i.e., frequency hopping is employed, in the form of short RF pulses where each broadcast is on a different frequency.
Without knowing the frequency hopping pattern, a receiver must attempt to capture all signals in the relevant band. Typically, all the signals within the band are digitized and then processed using a very high speed digital signal processing (DSP) system. Such high speed DSP systems are very costly to manufacture, operate and maintain. In some instances, the band of interest is divided into sub-bands and each sub-band is digitized and processed in a corresponding DSP. Such sub-band channelization enables many signals to be quickly processed in parallel using less expensive DSP circuits (i.e., lower speed circuits). However, even a channelized, broad band receiver is very expensive to manufacture, operate and maintain.
Recently, optical systems have found use in broad band signal processing wherein the received RF signals are used to modulate a light signal and the light signal is processed using optical signal processing. Such techniques, unfortunately, are prone to noise and system instability.
Therefore, there is a need in the art for an improved a method and apparatus for analyzing the spectrum of radio-frequency signals using a fiber optic recirculation loop.
BRIEF SUMMARY OF THE INVENTION
Embodiments of the present invention relate to an apparatus comprising a fiber optical loop for conducting a first and second light, generated by a first and second light source, modulated by a radio frequency signal by a modulator to create a first and second pulse with corresponding first and second wavelengths, a first splitter for separating the first and second pulses in the optical loop into a first and second path for a small portion of the loop to introduce a predetermined time delay between the first and second pulse, a coupler for tapping a replica of the pair of pulses from the loop and an auto-correlation module, coupled to the coupler, for correlating the replica of the pair of pulses with each other.
Another embodiment of the present invention is directed to a method determining a channelized frequency spectrum from an RF signal comprising conducting, in a fiber optical loop, a first and second light generated by a first and second light source, modulating, using a modulator, the first and second light by a radio frequency signal to create a first and second pulse with corresponding first and second wavelengths, splitting, using a first splitter, the first and second pulses in the optical loop into a first and second path for a small portion of the loop to introduce a predetermined time delay between the first and second pulse, tapping, using a coupler, a replica of the pair of pulses from the loop, correlating, using an auto-correlation module, coupled to the coupler, the replica of the pair of pulses with each other and performing a Fast-Fourier Transform (FFT), using an FFT module, on a plurality of the correlated pair of pulses, generating a channelized frequency spectrum.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of 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 block diagram of an apparatus for detecting radio-frequency signals using a fiber optic recirculation loop; and
FIG. 2 is a flow diagram of method for detecting radio-frequency signals using an optical loop.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention comprise a method and apparatus detecting radio-frequency signals using a fiber optic recirculation loop, by modulating an input RF signal using two lasers of differing wavelength, and introducing a time delay between the lasers to auto-correlate the two time-delayed lasers. Light from the first and second laser with differing wavelengths are modulated using the received RF input signal, which is comprised of multiple frequencies. The modulated lights are converted into a pair of pulses of light. The pulse circulates through the optical loop a finite number of times. A split path in the loop with a time adjuster allows for introducing a customizable delay between each pulse of light, irrespective of the natural delay caused by the difference of travel time due to the difference of wavelength in the pair of pulses. For every cycle the pulses take through the fiber, a replica pulse pair is “tapped” from the loop. The tapped pulse pair is photo-detected to create two RF signals; the two RF signals are correlated with each other within an RF mixer, filtered, and then digitized. Once the loop has run multiple times, a Fast Fourier transform (FFT) is performed on the accumulated digitized signals (data points) to generate a channelized frequency spectrum representing information carried by the received RF signals.
FIG. 1 is a block diagram of an apparatus 100 for detecting radio-frequency signals using a fiber optic recirculation loop. The apparatus 100 comprises a first laser 102 , a second laser 104 , a combiner 106 , a first polarizer 108 , an optical modulator 110 , a second polarizer 112 , an optical switch 114 , an electronic time control 133 , a 2-by-2 coupler 116 , a first isolator 118 , a wavelength division multiplex (WDM) 120 , an amplifier 122 , a second isolator 124 , a splitter 126 , a filter 128 , a second combiner 130 , an optional phase shifter 132 , an electronic time control 133 , a switch 134 , a second polarizer 136 , a second splitter 138 , a first photodetector 142 , a second photodetector 144 , a second combiner 146 and a square-law RF detector 148 which form a an auto-correlation circuit (e.g., an RF electronic multiplexer) 145 , a second filter 150 , an analog to digital converter (ADC), and a computer 154 . The computer 154 comprises a processor 159 and memory 157 . The memory 157 comprises an Fast-Fourier transform module 156 and stores data points 160 .
According to an exemplary embodiment of the present invention, the apparatus 100 processes an RF input signal 101 and produces frequency spectrum 156 representing information carried by the RF input signal 101 . The RF input signal 101 is an RF signal and the first and second laser 102 and 104 are carrier wave light signals.
The RF input signal 101 may be received via a conventional RF front end (not shown) comprising, for example, an antenna, low noise amplifier and various filters. The choice of components and arrangement depends upon the nature of the signals that are to be processed. The selection of components and their arrangement is a design choice capable of being made by anyone with skill in the RF communication arts.
The lasers 102 and 104 provide laser light of wavelength λ 1 and λ 2 , respectively. The combiner 106 combines the laser lights from lasers 102 and 104 . According to an exemplary embodiment, the combiner 106 is a wavelength division multiplex (WDM) and the frequency difference between λ 1 and λ 2 is much larger than the RF microwave operation frequencies and bandwidth. In some embodiments, the laser light from lasers 102 and 104 is infrared light and the difference in wavelength λ 1 and λ 2 is approximately 100 GHz. The combined light output from the combiner 106 is optionally coupled to a polarizer 108 to polarize the light. According to an exemplary embodiment, the polarizer 108 is a fiber polarizer. The combiner 106 (or optionally the polarizer 108 ) transmits the combined light to the optical modulator 110 to modulate the laser lights by the input RF signal. The polarizer 108 may be located before the optical modulator 110 or before the optical modulator 110 according to various embodiments of the present invention.
The optical modulator 110 modulates light from the laser 102 and 104 with the RF input signal 101 , creating an RF modulated light wave. According to an exemplary embodiment, the lasers 102 and 104 are continuous wave lasers. Also according to an exemplary embodiment of the present invention, the optical modulator 110 is a Mach Zehnder modulator. The optical switch 114 (e.g., an optical gate switch) converts the modulated light into a pair of RF modulated optical pulse. Optionally, the switch 114 is a 1×2 switch in which the first output carries the pulses to a 2×2 optical coupler 116 . The second output of the switch 114 can be used to connect to another optical switch for time division multiplex cascading to additional recirculation loops to process any signals received within a large time window such as continuous wave (CW) signals as opposed to pulsed RF signals.
Once the switch 114 generates the optical pulses, the pulses enter the coupler 116 . According to an exemplary embodiment, the coupler has a coupling ratio range from 50%:50% to 1%:99%. Once the pulses enters the switch 114 , the switch 114 closes so further pulses cannot enter the loop 105 causing distortion and noise.
The optical recirculation loop 105 is formed by connecting one output of the coupler 116 , which according to an exemplary embodiment is a 2×2 coupler, to the second input of the same coupler with several optical components in the loop. According to exemplary embodiments of the present invention, the loop length generally does not affect the ability to tap out replica pulse pairs, however loops with length less than one pulse width will cause overlap and distort results. The loop 105 may be a dispersion shifted fiber where there is non-dispersion around the operating wavelength of the lights.
The optical loop contains an isolator 118 which isolates the pulses. An optional WDM 120 combines a third wavelength by forming a third loop between the WDM splitter 126 and 120 . The amplifier 122 amplifies the isolated pulse pairs from isolator 118 . Optionally, isolator 124 is placed in the loop after the amplifier 122 to allow a continuous wavelength (CW) light with the third wavelength be amplified so to keep the amplifier working in a steady state instead an unstable state when there are only short pulse to be amplified. This will further reduce any noise in the pulse pairs. According to an exemplary embodiment of the present invention, the optical amplifier 122 is an Erbium doped fiber amplifier (EDFA), though the present invention does not limit the type of optical amplifier used.
The optical amplifier 122 amplifies the pulses to compensate for the coupling loss. The isolator 118 is coupled to the loop 105 to prevent any light going in the reverse direction from causing interference in the loop 105 . The pulse pairs are then transmitted to a splitter 126 . According to an exemplary embodiment, the splitter 126 is a WDM splitter which routes the pulse pairs into a first path 127 and a second path 131 according to their wavelength λ 1 and λ 2 to introduce a preconfigured delay between the transmission of the first and second pulse. This allows for auto-correlation of the two pulses later on.
According to one embodiment of the present invention, the EDFA 122 can be replaced by two EDFAs placing in each path 127 and 131 . According to an alternate embodiment, there is a gain control attenuators in each path 127 and 131 in place of the two EDFAs to balance the intensity/power of the first and second modulated signal. The WDM splitter 126 is, according to an exemplary embodiment, implemented a two wavelength filters which filter for optical noise produced by the amplifier 122 .
Filter 128 is an optional filter for removing any further noise in the pulse traversing the first path 127 . The adjuster 120 is an optical path length adjuster for adjusting relative travelling time between the two differing wavelength pulses, i.e., the path length adjuster will increase or decrease the time it takes for a pulse travelling the first path 127 to travel through the path 127 . A combiner 130 combines the two pulses and couples the pulses to a switch 134 , which according to an exemplary embodiment is a high speed optical switch used as a time domain filter to filter out light noise outside of the switching window. The phase shifter 132 is optionally added before the switch 134 to introduce a random phase shift to prevent the residue CW light noise because resonant noise (lasing). The output of switch 134 is connected to a polarizer 136 for reducing polarization dependent effects inherent in the fiber of the loop to change the coupling ratio for the coupler 116 and then back to an input of the coupler 116 to close the loop 105 .
The electronic time control circuit 133 controls the functionality of the switch 134 , by synchronizing with control of the switch 114 . The coupler 116 outputs a replica pulse pair at its second output after each loop cycle. The splitter 138 (e.g., a WDM splitter) splits the replicated pulse pairs into individual pulses. The photodetectors 142 and 144 each convert the RF modulated optical pulses into RF modulated electronic pulse signals.
For n passes through the loop 105 , the nth pulse pair replica will have a time delay of nΔt between the two pulses due to the first path 127 having the adjuster 129 for adjusting travel time of one of the pulses, where Δt=ΔL/c. ΔL is the effective optical path difference of the two pulse wavelengths in one loop cycle. The wavelengths of the lasers 102 and 104 are customizable. Optionally, an RF phase shifter is connected to the output of the photodetector 142 to set an initial phase adjustment, for example, φ, between the two pulses of each pair.
If a single RF frequency ω signal is introduced at the input, for the n th pulse pair, the two pulse signals are represented as A cos(ωt n ) and B cos(ω(t n +nΔt)+φ], where A and B are the pulse signal amplitudes, and t n is the time that has passed as of the n th loop cycle. In an exemplary embodiment, a negative feedback control is provided for a servo 140 from the combiner 146 to control the gain of the amplifier 122 in the loop 105 , preventing over and under amplification and compensating for drift in the loop 105 .
The output RF electronic pulse signals from the photodetectors 142 and 144 are coupled to a RF electronic multiplexer circuit 145 to multiply the pulse pairs together. This is also known as an auto-correlation module. The multiplexer 145 integrates many pulses over time. The pulse pairs are auto-correlated to help in finding the presence of repeating patterns and periodic signals in the RF input 101 . According to an exemplary embodiment, the circuit 145 comprises a 2×1 RF combiner 146 connected to a square-law RF detector 148 to produce the multiplication product for the correlation process.
In an exemplary embodiment, the detector 148 is a square law RF detector such as a crystal detector (Low Barrier Schottky diode) or an RF mixer. The output of the multiplexer 145 is coupled to an optional RF filter 150 which filters the high band frequencies, i.e., a low pass filter, yielding just a baseband signal cos(ωnΔt+φ) and a DC signal. A DC block may optionally be used to filter out the DC signal. The baseband signal is coupled to an ADC 152 such that each replicated pulse pair yields a data point for autocorrelation with a different delay between the pulse pair.
These points are stored in memory 157 as data points 160 . The computer 154 (e.g., a fully programmable gate array, or the like) contains a Fast Fourier transform (FFT) module 156 in its memory 157 which performs a Fourier transformation to transform the series of pulse pairs from time domain to frequency domain, thereby obtaining the RF spectrum of the input RF pulse 101 . In an exemplary embodiment, the memory 157 may include one or more of the following: random access memory, read only memory, magneto-resistive read/write memory, optical read/write memory, cache memory, magnetic read/write memory, and the like, as well as signal-bearing media, not including non-transitory signals such as carrier waves and the like.
The FFT module 156 performs an FFT on the data points from the ADC 152 to generate a channelized frequency spectrum. The FFT module 156 converts the data points from the time domain to the frequency-squared domain, from which the frequency spectrum data 1158 is obtained using signal processing techniques known to those of ordinary skill in the art.
According to other exemplary embodiments of the present invention, an optical path length random perturbation device 132 such as an optical phase shifter or fiber stretcher is inserted in the loop 105 to reduce the resonance effect on the noise signal in the loop. An optional ring laser loop is added in the loop 105 to stabilize the optical amplifier 122 by allowing a third wavelength be constantly amplified by the EDFA and cause lasing in continuous wave (CW) mode. In other embodiments, laser 102 and laser 104 are replaced with laser transmitters with wavelength λ 1 and λ 2 . The RF input signal 101 is split and used to modulate the two laser transmitters.
According to other exemplary embodiments of the present invention, photodetectors 142 and 144 , the splitter 138 and the combiner 146 are replaced by one photodetector and an amplifier combination at the output of lop 105 at the 2×2 coupler 116 . According to this embodiment, optical pulse monitoring by the gain control serve 140 must be tapped from inside the loop as opposed to from the combiner 146 .
FIG. 2 is a flow diagram of method 200 for detecting radio-frequency signals using an optical loop. The method begins at step 202 and proceeds to step 204 , where a first and second light from a laser is modulated by an RF input signal using RF modulator 110 . At step 206 , the switch 108 generates a pair of pulses of the modulated optical signal with a first and second wavelength based on the wavelength of the first and second light. At step 208 , a replica of the pulse is tapped from the loop 105 for processing, while the remaining portion of the pulse re-circulates in the loop 105 .
At step 210 , first and second RF signals are generated from the pulse pair and then auto-correlated at step 212 . The two RF signals have a time delay between them due to the first path having an adjuster 129 embedded in it, for reducing or increasing the time a pulse takes to travel the first path 127 . At step 214 , data points are generated by the ADC 108 to digitize the auto-correlation and the digitized data points are stored in memory 132 . At step 216 , the method determines whether N points have been stored.
If N points have not been stored, the method returns to step 208 to tap more pulses from the loop 109 . If N points have been stored, the FFT module 134 performs a FFT on the N points to generate a frequency domain spectrum at step 218 . At step 220 , it is determined whether a new pulse should enter the loop. If so, the method proceeds to step 204 of modulating light from a laser with an RF input. If there are no more pulses, the method ends at step 222 . According to an exemplary embodiments, N=500, 1000 or the like.
The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the present disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as may be suited to the particular use contemplated.
Various elements, devices, modules and circuits are described above in associated with their respective functions. These elements, devices, modules and circuits are considered means for performing their respective functions as described herein. 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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An apparatus comprising a fiber optical loop for conducting a first and a second pulse having a corresponding first and second wavelength, a first splitter for separating the first and second light pulses in the optical loop into a first and second light path to introduce a predetermined time delay between the first and second light pulses, a coupler for tapping a replica of the pair of light pulses from the loop, an auto-correlation module, coupled to the coupler, for correlating the replica of the pair of light pulses with each other to produce a set of data points comprising a plurality of multiplied and correlated pair of pulses and a transform module, coupled to the auto-correlation module, for transforming the data points into a channelized frequency spectrum.
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FIELD OF THE INVENTION
This invention relates to a quick erection bridge and a method related thereto.
BACKGROUND OF THE INVENTION
Quick erection bridges are typically used for such purposes as forestry operations where temporary bridges are required. Forestry roads are frequently built only to provide temporary access during active logging operations. Once the logging operations are completed, the roads are often abandoned and bridges are removed. Thus it is highly desirable to provide bridges which may be quickly and economically erected and which can be dismantled and re-used at another point after logging operations are completed. Military operations as well require bridges which can be quickly erected with a minimum of equipment. Such bridges are also used for emergency purposes when permanent structures are washed out or collapse.
One problem associated with such quick erection bridges is the method of making the initial span across the creek, ravine or other gap to be crossed. It is possible to use cranes to position relatively heavy beams across the gap. However, this means that high load capacity cranes must be available and frequently this is not feasible or economical at remote sites. A common method used to make the initial span is to place a relatively lightweight "nose" at the leading edge of the bridge which is then moved across the distance to be spanned. The nose rests on a roller on the opposite side of the span and supports the permanent bridge structure as it is moved across the gap. The nose does not contribute to the permanent structure and is simply removed after the permanent structure spans the gap. The transport of the nose to the site and the assembly of the nose and disassembly of it are all tasks which increase the expense and time involved. U.S. Pat. No. 4,520,523 to Fitzgerald-Smith discloses a bridge module which is initially moved into place by means of a crane. Nose girders are connected to the front end of the bridge. The entire unit is then rolled over a roller beam, the nose girders being removed as they reach the far bank.
British Pat. No. 1,266,820 shows the use of rollers to reduce bending in the bottom chords of trusses while being launched.
Earlier U.S. patents of general interest include U.S. Pat. Nos. 3,491,391 to Soffge, 4,493,122 to Echtler, 4,120,065 to Sivachenko, 4,521,932 to Parramore, 3,707,011 to Launay, and 2,878,498 to Gollnow.
SUMMARY OF THE INVENTION
The invention provides a load bearing apparatus for spanning a distance between two ends thereof. The apparatus has a relatively light lower beam member having a length sufficient to span the distance and a relatively heavy upper beam member having a length generally equal to the length of the lower beam member. The upper beam member is positioned on the lower beam member. The lower beam member has sufficient strength to span the distance between the ends alone and to support the upper beam member when the upper beam member is moved across the lower beam member to span the distance. Fasteners draw together the upper beam member and the lower beam member to close any gap therebetween and to rigidly connect the upper beam member to the lower beam member along the lengths thereof so the upper beam member and the lower beam member jointly contribute to bearing the load.
The invention also provides a method of bridging a distance between two points. The method comprises the steps of providing a relatively light lower bridge portion and a relatively heavy upper bridge portion. The portions have generally a common length. The lower bridge portion is placed across the distance between the points. The upper bridge portion is then moved across the lower bridge portion so the upper bridge portion spans the distance above the lower beam portion. The upper bridge portion and the lower bridge portion are then drawn vertically together to close any gap therebetween due to differential deflection of the bridge portions. The bridge portions are connected together along the lengths thereof to form a unitary structure for supporting a load.
The method and apparatus according to the invention provide distinct advantages over the prior art. Firstly, the initial span can be made by a relatively light member which can be placed in position with a readily available low capacity crane. Furthermore, the member making the initial span is not discarded, but forms a unitary structure with the upper member to provide the necessary load carrying capacity. This reduces the amount of components that must be trucked to the site and avoids the cost and waste of time in using and spanning the distance with a member which will ultimately be discarded or returned for re-use elsewhere. Finally, the method and apparatus negate the need for expensive high capacity cranes to be on site. All work is performed by equipment more likely available, such as low capacity cranes.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an elevation showing a crane positioning a lower beam member across a distance to be spanned;
FIG. 2 is an elevational view showing the upper beam member being assembled, partly on the lower beam member;
FIG. 3 is an elevational view showing the assembled upper beam member being moved across the lower beam member;
FIG. 4 is an elevational view showing the upper beam member resting on top of the lower beam member;
FIG. 5 is a sectional view along line 5--5 of FIG. 4;
FIG. 6 is an enlarged, fragmentary elevation showing portions of the upper beam member and lower beam member and the fasteners used to close the gap therebetween;
FIG. 7 is an enlarged, fragmentary elevation showing portions of the upper beam member and wheel and guide connected thereto; and
FIG. 8 is an elevational view showing an alternative method for moving the lower beam member across the distance to be spanned.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The drawings show both a load bearing apparatus 8, shown assembled in FIGS. 4 and 5, and a method of bridging a distance between two points employing this apparatus, the steps being shown progressively in FIGS. 1-4.
The apparatus 8 has a length extending between its two ends 10 and 12, shown in FIG. 4, sufficient to span a distance between two points 14 and 16 representing bridge abutments. These points are typically on opposite sides of a depression such as creek 18 or other distance to be bridged. The apparatus has a relatively light lower beam portion 20 which, as may be seen in FIG. 5, comprises two separate and parallel box-section members 22 and 24 in this embodiment. In most instances the distance to be spanned between points 14 and 16 is too long for a single member. In such cases each of the members 22 and 24 is pre-assembled by laying identical members end to end and connecting them together by welding, bolting or riveting, or other suitable means. The members 22 and 24 are placed successively across the gap between points 14 and 16, normally employing a crane, such as crane 26 shown in FIG. 1. When positioned the members are parallel and both extend between points 14 and 16 as may be appreciated from FIGS. 1-5.
The apparatus 8 also includes a relatively heavy upper beam portion 28 which, in the preferred embodiment, is a prefabricated bridge unit employing steel beams in a braced structure as known in the prior art. The unit may be a plate girder as shown in FIG. 5 or a truss structure similar to the bridge structures used in earlier fast assembly bridges, such as those sold under the trade mark Bailey. Since the units are conventional, details of the girders or trusses are not provided other than to note that member 28 normally would be of a width suitable for highway transport and comprises one or more separate beam members, such as beam members 30 and 32 having a length suitable for highway transport. Before final assembly of the apparatus 8 the separate members 30 and 32 are abutted together and permanently connected by welding or bolting or the like as illustrated in FIGS. 2 and 3.
Although other means can be used, the illustrated embodiment incorporates one means for moving beam member 28 over beam portion 20 after the latter is in position. For this purpose a trailer hitch 36 is temporarily connected to one end of member 28. The opposite end is mounted on a dolly 38. The tractor 34 is used to move beam member 30 towards beam member 32 as shown in broken lines and illustrated by arrow 40. When members 30 and 32 are abutted together and in proper alignment they are connected together as mentioned by welding or bolting and using suitable reinforcement such as plate 42 shown in FIGS. 3 and 4.
In the preferred embodiment, as shown best in FIG. 7, a pair of wheels 43 are rotatably mounted on a pair of struts 44 (only one of each illustrated) temporarily connected to end 10 of beam portion 28 which is the end opposite trailer hitch 36. The wheels are spaced-apart such that one wheel is capable of riding on the top of box-section member 22, while the other wheel rides on top of member 24. Guides 46 extend downwardly from each of the struts below the tops of members 22 and 24 to guide the movement of upper beam portion 28 over lower beam portion 20. The guides prevent the wheels from rolling off the lower beam portion. As shown by arrow 48 in FIG. 3, the completed upper beam portion 28 is moved across the lower beam portion 20 until its ends 10 and 12 are above points 14 and 16 as shown in FIG. 4. It may be observed that the lower beam portion 20 and upper beam portion 28 have substantially the same length in this embodiment.
Lower beam portion 20, comprising the two box-section members 22 and 24, has sufficient strength to support itself when spanning the distance between points 14 and 16 and to support upper beam portion 28 as it is moved across the lower beam portion as illustrated in FIGS. 2 and 3. Both beam portions 20 and 28 deflect downwardly under their own weight, but not the same amount due to the fact that upper beam portion 28 is deeper and structurally more rigid. The deflection by bending of the beam portions is illustrated in exaggerated form in FIG. 6. It may be seen that a gap 50 results due to the greater deflection of lower beam portion 20 when compared with upper beam portion 28. This gap is closed using a plurality of threaded fasteners which, in this embodiment are in the form of nut and bolt combinations 52 which extend through a plurality of spaced-apart apertures 54 extending along the bottom edges of upper beam portion 28 and the upper edges of members 22 and 24. Gap 50 is closed by gradually tightening the nut and bolt combinations to draw the members together and thus connecting them. Once the nut and bolt combinations are tight, lower beam portion 20 and upper beam portion 28 form a unitary structure for supporting a load. It is clear to someone skilled in the design of bridges or other such structures that apparatus 8 thus formed by the bolting together of lower beam portion 20 and upper beam portion 28 has a greater load carrying capacity than the sum of the load bearing capacities of the two portions. This is due to the increased depth of apparatus 8 when compared to either lower beam portion 20 or upper beam portion 28. Thus it may be seen that the total load bearing capacity is significantly increased by utilising the lower beam portion 20 and integrating it with the bridge structure comprising upper beam portion 28. The member initially making the span is not wasted and becomes an important part of the overall structure unlike prior art bridges of the general type.
Decking 56 is placed on and connected to the top of upper beam portion 28. This may be done after the upper beam portion and lower beam portion are connected together. However, preferably the decking is placed and connected to individual beam members 30 and 32 prior to transport of these members to the job site. This is illustrated in FIG. 2. The amount of work and assembly that must be done at the site of creek 18 or other bridge location is consequently minimized.
FIG. 8 shows an alternative method of moving the lower beam portion 20 across the ravine or such gap to be spanned. The beam portion 20 is supported on a roller 70. Cables 72 and 74 are connected to opposite ends of the beam portion. The beam portion is to be moved to the left from the side of the gap where the roller is positioned. This is accomplished by pulling on cable 74 with, for example, a tractor, a truck or a winch. A winch adjacent the roller may be used by looping the cable 74 about a pulley connected to a fixed object on the opposite side of the gap. Arrow 76 denotes the direction of the pulling force on cable 74 and the direction of movement of the beam portion. Back tension is maintained on cable 72 as indicated by arrow 78 to keep the beam portion 20 under control and to prevent it moving too far and falling, for example, into the ravine or creek.
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A bridge apparatus has a relatively light lower beam portion and a relatively heavy upper beam portion. The beam portions are generally equal in length. The lower beam portion is initially placed across the point to be bridged and has sufficient strength to support itself and to support the upper beam portion as the upper beam portion is moved across the lower beam portion. The upper beam portion is placed on top of the lower beam portion and fasteners are used for drawing together the two beam portions to close any gas therebetween and to rigidly connect the beam portions together so the beam portions jointly contribute to bearing the load.
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FIELD OF THE INVENTION
[0001] The invention is directed to model human figures. More particularly, the invention is directed to a model human figure comprising a frame and joints. The invention is also directed to a model human figure comprising a frame and a wire body with joints.
BACKGROUND OF THE INVENTION
[0002] Models are widely available in an assortment of shapes, styles, and colors to represent full scale objects and/or living creatures. Human models are often used by artists and art students to draw the human form in a variety of poses. Models may also be used as toys, decorations, desk accessories, and other purposes. Many of the models available today, however, have limitations. For example, many of the available models are not capable of being posed in a standing position without the aid of a pedestal or a support rod. Many models have only limited or unidirectional movement of limbs, limiting the variety of poses they can achieve and reducing the life-likeness of those poses.
[0003] Art students often use human models to practice drawing the basic human shape. A commonly used artist model is made of wooden pieces representing human body segments and is held together by an internal wire. Such a model, however, is often unable to stand on its own and therefore must be supported by a rod or the feet must be affixed to a base in order to achieve a standing position. This may prevent the model from achieving a variety of positions, such as a sitting position, and may require the inclusion of a foreign element in the model. The wooden segments are solid and opaque, preventing the artist from seeing the opposite side and from viewing the three-dimensional shape of the model. The wooden models also have simple wooden hands that are incapable of holding items. The wooden models have joints that contain springs, making it difficult for the model to remain in a given pose without springing back to a neutral position.
[0004] Thus, there is a need in the art for a model with movable segments, that can stand or be arranged in a variety of positions, including a standing and sitting position, that enables the viewer to see through the model to the opposite side, and that has joints allowing for a four way range of motion and enabling the model to stay in a posed position.
BRIEF SUMMARY OF THE INVENTION
[0005] The invention relates to human models with an internal frame and joints to enable movement. The invention also relates to human models with an internal frame, a wire external frame, and joints to enable movement. The model may also include hands capable of holding objects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] In the accompanying drawings that form a part of the specification and are to be read in conjunction therewith, the present invention is illustrated by way of example and not limitation, with like reference numerals referring to like elements, wherein:
[0007] FIG. 1 illustrates a first example of a model of the present invention.
[0008] FIGS. 2A and 2B illustrate second examples of a model of the present invention.
[0009] FIG. 3 illustrates an example of the external frame of the model of FIG. 2A .
[0010] FIG. 4A illustrates an example of a joint of the present invention.
[0011] FIG. 4B illustrates an exploded view of the joint of FIG. 4A .
[0012] FIGS. 5A-5D illustrate the movement of the joint of FIG. 4 .
[0013] FIGS. 6A-6G illustrates the model of FIGS. 1 and 2A in a variety of poses.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The invention relates to a human model with an internal frame and joints that allow the model to be posed in a variety of life-like positions including an unaided standing position. The model may also contain a wire external frame. The model may also contain hands capable of holding objects.
[0015] As used herein, the terms below are given the definitions that follow. The definitions are supplied to provide clarity and consistency and are not intended in any way to limit the scope of the invention.
[0016] Model or Human Model: an inanimate object used to represent the human form.
[0017] Internal Frame: a structural portion of a model that provides support for the model.
[0018] External Frame, External Wire Frame, or Wire Frame: a portion of a model made of wire that represents the outside of a body and is supported by the internal frame.
[0019] Joint: a mechanism which joins together two body segments.
[0020] Square Bracket: a material formed in a generally square shape serving as the support for the hinges in a joint.
[0021] The model of the present invention includes an internal frame and several joints that mimic human joints. A wire external frame may be disposed around internal frame. Model is capable of standing on its own as well as being posed in a variety of other configurations such as sitting, kneeling, lying down, etc. Model may also contain hands capable of holding objects.
[0022] FIG. 1 illustrates an example of a first model 100 of the present invention. FIG. 1 illustrates a front view of model 100 . First model 100 can be any size provided the proportions are recognizable as human.
[0023] First model 100 generally comprises several body segments 105 representing human body segments. For example, first model 100 includes one head segment 105 a , one chest segment 105 b , one pelvis segment 105 c , two upper arm segments 105 d , two forearm segments 105 e , two hand segments 105 f, two upper leg segments 105 g, two lower leg segments 105 h, and two foot segments 105 i.
[0024] As shown in FIG. 1 , first model 100 includes an internal frame 115 . Internal frame 115 provides structure to first model 100 . Internal frame 115 is divided into several internal frame body segments 115 a - 115 i that correspond to each of the body segments 105 a - 105 i. For example, head segment 105 a contains an internal frame head segment 115 a ; chest segment 105 b contains an internal frame chest segment 115 b ; pelvis segment 105 c contains an internal frame pelvis segment 115 c ; each upper arm segment 105 d contains an internal frame upper arm segment 115 d ; each forearm segment 105 e contains an internal frame forearm segment 115 e ; each hand segment 105 f contains an internal frame hand segment 115 f; each upper leg segment 105 g contains an internal frame upper leg segment 115 g; each lower leg segment 105 h contains an internal frame lower leg segment 115 f; and each foot segment 105 i contains an internal frame foot segment 115 i.
[0025] Each internal frame body segment 115 is a support structure that acts as a “skeleton” and provides first model 100 with its basic shape. Unlike an actual human skeleton, however, internal frame 115 is not made of single bones in the center of the body part it is supporting. Instead, each internal frame segment 115 is molded in the general shape of the body part is it representing. For example, as can be seen in FIG. 1 , internal frame foot segment 115 i is molded in the general shape of a foot. Likewise, internal frame forearm segments 115 e are molded in the general shape of forearms and internal frame head segment 115 a is molded in the general shape of a head.
[0026] Internal frame foot segment 115 i is configured so that the bottom of foot segment 105 i is flat, enabling model 100 to stand on a flat surface with no additional support. Internal frame hand segment 115 f may be molded to include the shape of fingers to enable hand segment 115 f to hold small objects, such as paper, stamps, business cards, greeting cards, brochures, or any other suitable object.
[0027] Internal frame 115 can be made of any material capable of supporting model 100 . By way of example, internal frame 115 can be made of metal (such as, for example, stainless steel, iron, copper, aluminum, epoxy coated steel, vinyl coated steel, steel with an anodized finish), plastic, or any other suitable material. Internal frame 115 can retain the color of the underlying material or it can be changed to another color by painting, dying, coating, or any other means capable of changing the color.
[0028] Body segments 105 are connected by joints 400 (which are shown in more detail in FIG. 4 ), including one neck joint 400 a , one waist joint 400 b , two hip joints 400 c , two knee joints 400 d , two ankle joints 400 e , two shoulder joints 400 f, two elbow joints 400 g and two wrist joints 400 h.
[0029] Specifically, neck joint 400 a connects internal frame head segment 115 a with internal frame chest segment 115 b ; waist joint 400 b connects internal frame chest segment 115 b with internal frame pelvis segment 115 c ; each hip joint 400 c connects internal frame pelvis segment 115 c with an internal frame upper leg segment 115 d ; each knee joint 400 d connects an internal frame upper leg segment 115 d with the corresponding internal frame lower leg segment 105 e ; each ankle joint 400 e connects an internal frame lower leg segment 115 e with a corresponding internal frame foot segment 115 f; each shoulder joint 400 f connects internal frame chest segment 115 b with an internal frame upper arm segment 115 g; each elbow joint 400 g connects an internal frame upper arm segment 115 g with a corresponding internal frame forearm segment 115 h; and each wrist joint 400 h connects an internal frame forearm segment 115 h with the corresponding internal frame hand segment 115 i. Joints 400 correspond to analogous human joints except that the “waist joint” 400 b is a single joint that replaces the movement allowed by the vertebra in a living human.
[0030] FIGS. 2A and 2B illustrate examples of a second model 200 of the present invention. Second model 200 can be any size provided the proportions are recognizable as human.
[0031] Second model 200 includes all of the elements of first model 100 and an external wire frame 300 (shown in more detail in FIG. 3 ).
[0032] In second model 200 , each body segment 105 is made from a corresponding internal frame body segment 115 and may be surrounded by wire of the external frame 300 . For example, head segment 105 a contains an internal frame head segment 115 a surrounded by wire 300 ; chest segment 105 b contains an internal frame chest segment 115 b surrounded by wire 300 , pelvis segment 105 c contains an internal frame pelvis segment 115 c surrounded by wire 300 , each upper arm segment 105 d contains an internal frame upper arm segment 115 d surrounded by wire 300 , each forearm segment 105 e contains an internal frame forearm segment 115 e surrounded by wire 300 , each hand segment 105 f contains an internal frame hand segment 115 f, each upper leg segment 105 g contains an internal frame upper leg segment 115 g surrounded by wire 300 ; each lower leg segment 105 h contains an internal frame lower leg segment 115 f surrounded by wire 300 ; and each foot segment 105 i contains an internal frame foot segment 115 i surrounded by wire 300 .
[0033] External wire 300 is wrapped around internal frame foot segments 115 i in such a manner that the bottom of the foot segments 105 i remain flat, enabling model 200 to stand on a flat surface with no additional support. As shown in FIG. 2A and 2B , Internal frame hand segments 115 f may remain free of external wire 300 to allow the “fingers” to hold small objects (see FIG. 6G ). In other embodiments (not shown) internal frame hand segments 115 f may also be wrapped in wire 300 .
[0034] As shown in FIG. 2A , external wire 300 may be wrapped around internal body segments 115 but not wrapped around joints 400 . As shown in FIG. 2B , external wire 300 may be wrapped around both internal body segments 115 and joints 400 .
[0035] FIG. 3 illustrates a portion of second model 200 from FIG. 2A showing external frame 300 . External frame 300 is comprised of wire wrapped around internal frame 115 . The wire of external frame 300 can be made of any material capable of wrapping around internal frame 200 . By way of example, the wire can be made of metal (such as, for example, stainless steel, iron, copper, aluminum, epoxy coated steel, vinyl coated wire), plastic, or any other suitable material. The wire can retain the color of the underlying material or it can be changed to another color by painting, dying, coating, or any other means capable of changing the color.
[0036] External frame 300 is wrapped around each internal frame body segment 115 in such a way that it provides a general appearance of the corresponding body part of a human being. For example, as shown in FIG. 3 , external frame 300 is wrapped around internal frame lower leg segment 115 h in such a way that the resulting lower leg segment 105 h generally resembles the lower leg shape of a human being. Similarly, external frame 300 is wrapped around internal frame foot segment 115 i in such a way that the resulting foot segment 105 i generally resembles the foot shape of a human being.
[0037] External frame 300 can be wrapped around internal frame 115 by any means capable of disposing external frame 300 around internal frame 115 . By way of example, external frame 300 can be wrapped around internal frame 115 by hand or by machine or by a combination of the two.
[0038] External frame 300 may be comprised of any number of wires. For example, external frame 300 may be one continuous wire that is wrapped around all of internal frame body segments 115 . External frame 300 may include several wires, each of which is wrapped around a separate internal frame body segment 115 . External frame 300 may also be several wires and more than one wire may be wrapped around each internal frame body segment 115 . Any number of wires can be wrapped around any number of internal frame body segments 115 .
[0039] FIG. 4A illustrates one example of a joint 400 of the present invention. FIG. 4B illustrates an exploded view of joint 400 of FIG. 4A . Joint 400 is comprised of four hinges 410 , namely a first hinge 410 a , a second hinge 410 b , a third hinge 410 c , and a fourth hinge 410 d . First hinge 410 a and second hinge 410 b together make up the first hinge pair. Third hinge 410 c and fourth hinge 410 d together make up the second hinge pair. Hinges 410 are arranged around a square bracket 440 . First hinge 410 a is located across from second hinge 410 b on square bracket 440 . Third hinge 410 c is located at a 90 degree angle from first hinge 410 a and second hinge 410 b and across from fourth hinge 410 d on square bracket 440 . Fourth hinge 410 d is located at a 90 degree angle from first hinge 410 a and second hinge 410 b and across from third hinge 410 c on square bracket 440 .
[0040] In the example shown in FIGS. 4A and 4B , each hinge 410 is made from a rivet 450 installed on square bracket 440 over a portion of internal frame 115 . This configuration allows movement of internal frame 115 around rivet 450 and secures internal frame 115 to rivet 450 , thereby attaching joints 400 to model 100 and 200 (see FIGS. 1 , 2 A and 2 B). Square bracket 440 may be made of any material suitable for holding rivets 450 . By way of example, square bracket 440 may be made of metal (such as, for example, stainless steel, iron, copper, aluminum, epoxy coated steel, vinyl coated steel, steel with an anodized finish), plastic or any other material capable of holding rivets 450 . Rivet 450 may be made of any material suitable for installation on square bracket 440 . By way of example, rivet 450 may be metal (such as, for example, aluminum, stainless steel, iron, copper, aluminum, epoxy coated steel, vinyl coated steel, steel with an anodized finish), plastic (such as, for example, polyprolylene and ABS), or any other suitable material. The factory head 450 a of rivet 450 is positioned on the outside of internal frame 200 and the shop head 450 b of rivet 450 is positioned on the inside of square bracket 440 . In one example, a spacer 460 is located between factory head 450 a of rivet and internal frame 115 . Spacer 460 provides a cushion between factory head 450 a of rivet and internal frame 115 and assists in maintaining resistance between internal frame 115 and joint 400 , enhancing the ability of body segments 105 to maintain poses. Spacer 460 can be made of any material capable of cushioning joint 400 . By way of example, spacer 460 may be made of metal (such as, for example, stainless steel, iron, copper, aluminum, epoxy coated steel, vinyl coated steel, steel with an anodized finish), plastic (such as, for example, acetate or polyvinyl chloride) or any other suitable material. This particular assembly is for illustration purposes only and is not intended to limit the scope of the invention.
[0041] FIGS. 5A-5D illustrate the movement 500 of joint 400 in four directions along two axes. Specifically, FIGS. 5A-5D illustrate the movement of internal frame head segment 115 a relative to internal frame chest segment 115 b via the movement of neck joint 400 a . Neck joint 400 a is representative of all of the joints 400 in the models 100 and 200 (see FIGS. 1 , 2 A and 2 B) and is shown to illustrate how each of the joints 400 function.
[0042] FIG. 5A illustrates the movement of internal frame head segment 115 a in a forward direction 500 a along a first axis. To move in forward direction 500 a , first hinge pair (comprising first hinge 410 a and second hinge 410 b ) rotate forward while square bracket 440 and second hinge pair (comprising third hinge 410 c and fourth hinge 410 d ) remain stationary.
[0043] FIG. 5B illustrates the movement of internal frame head segment 115 a in a backward direction 500 b along first axis. To move in backward direction 500 b , first hinge pair (comprising first hinge 410 a and second hinge 410 b ) rotate backward while square bracket 440 and second hinge pair (comprising third hinge 410 c and fourth hinge 410 d ) remain stationary.
[0044] FIG. 5C illustrates the movement of internal frame head segment 115 a in a right side direction 500 c along second axis. To move in right side direction 500 c , second hinge pair (comprising third hinge 410 c and fourth hinge 410 d ) rotate to the right while square bracket 440 and first hinge pair (comprising first hinge 410 a and second hinge 410 b ) remain stationary.
[0045] FIG. 5D illustrates the movement of internal frame head segment 115 a in a left side direction 500 d along second axis. To move in left side direction 500 d , second hinge pair (comprising third hinge 410 c and fourth hinge 410 d ) rotate to the left while square bracket 440 and first hinge pair (comprising first hinge 410 a and second hinge 410 b ) remain stationary.
[0046] Thus, neck joint 410 a (and the other joints 400 , not shown) are each capable of moving in four directions—front 500 a , back 400 b , right side 400 c , and left side 400 d —along two axes (a front-back axis and a right-left axis). Each hinge pair is capable of moving along one axis—the first hinge pair (comprising first hinge 410 a and second hinge 410 b ) is capable of moving along the first axis (the front-back axis) and the second hinge pair (comprising third hinge 410 c and fourth hinge 410 d ) is capable of moving along the second axis (the right-left axis). The front-back direction of the first axis is 90 degrees from the right-left direction of the second axis.
[0047] Such range of movement allows each body segment 105 to be positioned in numerous positions, enabling the models 100 and 200 (see FIGS. 1 , 2 A and 2 B) to be configured in a variety of human like poses (see FIGS. 6A-6G ).
[0048] FIGS. 6A-6G illustrate models 100 and 200 in a variety of poses. FIG. 6A illustrates model 100 in an unaided standing position. FIG. 6B illustrates model 200 in unaided standing position. FIG. 6C illustrates model 200 in a leaning position. In FIG. 6C , model 200 is leaning against a computer monitor. FIG. 6D illustrates model 100 in a sitting position with crossed legs. In this illustration, the internal frame hand segments 115 f of hand segments 105 f are not formed into fingers, and are instead formed into a more general mitten shape. FIG. 6E illustrates model 100 in a sitting position with legs uncrossed. FIG. 6F illustrates model 200 in a sitting position with legs uncrossed. In this illustration, internal frame hand segments 115 f of hand segments 105 f are not formed into fingers, and are instead formed into a more general mitten shape. FIG. 6G illustrates model 200 in a reclined sitting position holding a paper object.
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This invention is directed to model human figures. More particularly, this invention is directed to a model human figure comprising a frame with joints. This invention is also directed to a model human figure comprising a frame and a wire body with joints.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 14/424,969, filed Feb. 27, 2015, now U.S. Pat. No. 9,624,425, issued on Apr. 18, 2017, entitled “Novel Coelenterazine Compounds and Methods of Use”, which application is a 35 U.S.C. §371 national phase application of PCT/US2013/057660 (WO 2014/036482) filed on Aug. 30, 2013, entitled “Novel Coelenterazine Compounds and Methods of Use”, which application claims the priority benefit of U.S. Provisional Application No. 61/696,136, filed Sep. 1, 2012 and entitled “Novel Coelenterazine Compounds and Methods of Use”, which is incorporated herein by reference in its entirety. Any disclaimer that may have occurred during the prosecution of the above-referenced applications is hereby expressly rescinded, and reconsideration of all relevant art is respectfully requested.
TECHNICAL FIELD
[0002] The present disclosure teaches new Coelenterazine analogs that significantly modify the color and activity of Coelenterazine utilizing luciferases, and calcium activated photoprotein light emission. The present disclosure also teaches uses for such compounds. Such uses include systems for producing visible light chemically stored within a protein dissolved in water designed to emit visible or ultraviolet light that would visually enhance (surprise, startle, dazzle, amaze, scare or otherwise entertain) the audience experience during a theatrical, cinematic, stage, or music performance created by the direct application to the audience via their clothes, hair, and the chairs, flooring materials, upholstery, and any adjacent surfaces containing calcium on that surface.
BACKGROUND
[0003] The marine environment contains many animals with minimal or poorly developed nervous systems. Many of these animals have evolved systems to emit light in response to stimulation by contact with other animals. The general mediators for this release of visible light are trans-cellular and intra-cellular calcium ion messengers.
[0004] Many marine animals use Calcium Activated Photoproteins (herein know as CAP or CAPs) that luminesce in response to a local increase in the calcium concentration allowing the calcium ion to interact with the protein. For purposes herein, the word “calcium” refers to aqueous calcium ions in their ionic +2 state.
[0005] The increase in local calcium ions applied to the protein causes a conformational change to the protein that either directly releases light energy, as is in a calcium activated photoprotein finalizing the oxidation and release of its stabilized oxidized luciferin and light, or calcium ions binding to a luciferin binding or luciferin carrier protein, causes the luciferin carrier protein to release its stored luciferin in proximity or directly complexed with its luciferase or calcium activated photoprotein, and thus generate light by the oxidation of the luciferin within the luciferase or allowing renewal of spent (oxidized) luciferin by presentation to the photoprotein.
[0006] The present disclosure teaches new Coelenterazine analogs that significantly modify the color and activity of Coelenterazine utilizing luciferases, and calcium activated photoprotein light emission. The present invention discloses the use of novel techniques utilizing CAPS to enhance visual experiences of various audiences as listed above.
SUMMARY OF THE EMBODIMENTS
[0007] The disclosure teaches a composition, comprising a calcium reactive light emitting photoprotein dissolved or suspended in calcium-free and magnesium-free purified water, or other suitable buffer(s). The calcium reactive photoprotein(s) reacts with the calcium contained in or on a person's skin, clothes, hair, and/or any nearby or adjacent calcium containing environmental surfaces; wherein the contact of the photoprotein with the surface that contains calcium produces light visible to the dark adapted human eye during a theatrical, cinematic, or any type of staged production.
[0008] The disclosure further teaches the composition of claim 1 , further comprising a combination containing a fluorescent protein, dye, or quantum dot, in order to produce color variations to the emitted light from the photoprotein as it reacts with calcium.
[0009] The disclosure further teaches a calcium activated photoprotein that has been manufactured using an analog of its naturally occurring luciferin chromophore which alters the color of the light emitted.
[0010] The disclosure further teaches delivering the composition by means of a storage reservoir connected with a water guiding apparatus, pump, or sprayer to deliver the photoprotein in a manually operated or automatic electronically controlled delivery system. The component(s) of the photoprotein system may include micro-encapsulation to alter the temporal emission of light by delaying the release of the photoprotein thereby delaying the photoprotein's contact with a calcium containing surface.
[0011] The composition is selected from natural or semi-synthetic photoproteins derived from Aequorin, Obelin, Halusterin, or Atollin, and/or any other calcium activated photoprotein that can be cloned and manufactured for use in entertainment applications. The calcium activated releasing protein can release its attached luciferin to supply additional substrate to regenerate or prolong the reaction generating emitted visible or ultraviolet invisible light. The calcium releasing protein can be manufactured containing an analog of its naturally occurring luciferin to alter the color, duration, or kinetics of the light emitted.
[0012] The disclosure further teaches Synthetic Coelenterazine analog methoxy-Coelenterazine.
[0013] The disclosure further teaches Synthetic Coelenterazine.
[0014] The disclosure further teaches Synthetic Coelenterazine analog methoxy-eCoelenterazine-Fluoride.
[0015] The disclosure further teaches Synthetic Coelenterazine analog eCoelenterazine-Fluoride.
[0016] The disclosure further teaches Synthetic Coelenterazine analog methoxy-vCoelenterazine-Fluoride.
[0017] The disclosure further teaches Synthetic Coelenterazine analog methoxy-vCoelenterazine.
[0018] The disclosure further teaches Coelenterazine analog vCoelenterazine-Fluoride.
[0019] The disclosure further teaches Synthetic Coelenterazine analog eCoelenterazine.
[0020] The disclosure further teaches the Synthetic analogs listed above used in conjunction with calcium activated photoprotein to alter the color of light generated.
[0021] The disclosure further teaches Synthetic analogs listed above used in conjunction with any coelenterazine type luciferase to alter the color of light generated.
[0022] The disclosure further teaches Synthetic analogs listed above used in conjunction with any calcium activated luciferin releasing protein to alter the color of light generated.
[0023] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with calcium activated photoprotein to alter the color of light generated.
[0024] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with any coelenterazine type luciferase to alter the color of light generated.
[0025] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein to alter the color of light generated.
[0026] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any calcium activated photoprotein to alter the color of light generated.
[0027] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any Coelenterazine utilizing luciferase to spectrally alter the color of light generated by the reaction.
[0028] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein to spectrally alter the color of light generated by releasing the analog in proximity, within 10-100 nanometers for diffusion to a Coelenterazine utilizing luciferase.
[0029] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any calcium activated photoprotein to alter the color of light generated.
[0030] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any Coelenterazine utilizing luciferase to spectrally alter the color of light generated by their reaction.
[0031] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein to spectrally alter the color of light generated by releasing the analog in proximity to a Coelenterazine utilizing luciferase.
[0032] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with any calcium activated photoprotein in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0033] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with any coelenterazine type luciferase in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0034] The disclosure further teaches Synthetic analog methoxy-eCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0035] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any calcium activated photoprotein in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0036] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any Coelenterazine utilizing luciferase in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0037] The disclosure further teaches Synthetic analog eCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein.
[0038] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any calcium activated photoprotein in proximity with a fluorescent protein to alter the color of light generated as the proteins move into proximity with one another.
[0039] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any Coelenterazine utilizing luciferase to spectrally alter the color of light generated by the reaction.
[0040] The disclosure further teaches Synthetic analog vCoelenterazine-Fluoride used in conjunction with any calcium activated luciferin releasing protein.
[0041] The compounds disclosed herein yield changes in the spectral properties of the Coelenterazine analog CTZ-v by Methoxy group modification. In addition to these spectral changes, compound V (Me-O-vCTZ-F) will also have a higher luminescent intensity with Ca2+ triggered luciferases like Aequorin.
[0042] The disclosure further teaches methods for use for novel synthetic analogs of Coelenterazine. Coelenterazine analogs can be used as a luciferin by some luciferases that also use coelenterazine as a substrate. Although coelenterazine is the natural substrate for Gaussia luciferase, it does not use the coelenterazine analogs. In circumstances where the independent use of two or more luciferases is desired, such as in the dual-luciferase reporter assays, the selective use of coelenterazine and coelenterazine analogs allows independent control of light production by different luciferases, one of which is Gaussia luciferase or a luciferase unable to use the coelenterazine analogs. One can envision the use of the analogs where the production of purple light is desirable. This includes applications where:
1) background fluorescence is attenuated or minimized by the use and production of purple light 2) the use of dyes or fluorescent proteins that are excitable by purple light and re-emit the light at a longer wavelength 3) for use where a light detector is more efficient at detecting wavelengths longer than purple and where this allow the detector to more efficiently detect shifted, longer wavelength light such as in FRET or BRET applications 4) the detection of binding events in in vitro diagnostics applications 5) in environmental and chemical sensors 6) in reporter assays 7) cell surface labeling for in vitro or in vivo visualization of cells 8) for detection of molecules in solutions or within cells 9) where the purple wavelength is able to excite membrane associated proteins to create a pore or other conformational change such as optogenetics applications of channel rhodospsin 10) where the purple wavelength is able to create a covalent binding event between two molecules such as a protein with another protein, a protein with a dye or reactive label, or any combination of organic and inorganic molecules that are able to be activated for reactions using purple light 11) where purple light generates free radicals that can be used to generate light for detection of molecular proximities or binding events; and/or, 12) where purple light generates free radicals that can be used to inactivate or destroy pathogenic cells such as cancer or pathogenic bacteria.
[0055] The disclosure further teaches a composition of a Calcium Activated Photoprotein applied to the eye containing soft contact lenses previously impregnated with calcium salts to make the contact lenses emit light. The disclosure further teaches a method of treating a contact lens a composition of a Calcium Activated Photoprotein applied to the eye containing soft contact lenses previously impregnated with calcium salts to make the contact lenses emit light.
[0056] The disclosure further teaches a composition of a Coelenterazine utilizing luciferase and Calcium activated Coelenterazine releasing protein applied to the eye containing soft contact lenses previously impregnated with calcium salts to make the contact lenses emit light. The disclosure further teaches a method of treating a contact lens with a composition of a Coelenterazine utilizing luciferase and Calcium activated Coelenterazine releasing protein applied to the eye containing soft contact lenses previously impregnated with calcium salts to make the contact lenses emit light.
[0057] The disclosure further teaches a composition of a Coelenterazine utilizing luciferase and Calcium activated Coelenterazine releasing protein photoprotein for medical visualization of the cornea for diagnostic evaluation and visualization. The disclosure also teaches a method of use of treating a contact lens with a composition of a Coelenterazine utilizing luciferase and Calcium activated Coelenterazine releasing protein photoprotein for medical visualization of the cornea for diagnostic evaluation and visualization. The disclosure further teaches a kit comprising a contact lens with a composition of a Coelenterazine utilizing luciferase and Calcium activated Coelenterazine releasing protein photoprotein for medical visualization of the cornea for diagnostic evaluation and visualization.
[0058] The disclosure further teaches a Coelenterazine pill, wherein the Coelenterazine pill is Coelenterazine or a Coelenterazine analog. The disclosure further teaches a coelenterazine pill that is water soluble. Water solubilization is taught in Bioluminescence: chemical principles and methods/Osamu Shimomura, 2006 by World Scientific Publishing Co. Pte. Ltd., page 167, herein incorporated by reference in its entirety.
[0059] The disclosure further teaches a luciferase pill. The disclosure further teaches a luciferase pill that is water soluble.
[0060] The disclosure further teaches use of water-soluble Coelenterazine and its analogues as described above to include, but are not limited to: life science research including in vitro and in vivo imaging of luciferases, diagnostic devices, novelty applications like bath tub products, foam-party products, fish-food tablets, squirt guns.
[0061] The disclosure further teaches the dispensation of water-soluble Coelenterazine and its analogues as described above in a two chambered water gun, as disclosed herein, and as described in U.S. Pat. No. 6,247,995. The disclosure further teaches adding a coelenterazine pill to the water gun, and a luciferase pill to the water gun, wherein in the activation of the water gun, the Coelenterazine and luciferase are mixed.
[0062] The disclosure further teaches a composition comprising Coelenterazine or its analogues in a water-soluble form, compressed into a quick dissolving pill/capsule format containing: a) excipients not limited to but including: Mannitol, Trehalose, Sucrose, Lactose, Glucose, Xyliol, Erythritol, Maltose, Maltitol, Sorbitol, Pullulan, Hydroxycellulose, Methylcellulose, Propylcellulose, & Poloxamer, Cycloamyloses polymers like b-Hydroxycyclodextrin, cyclodextrin, hydroxypropyl-beta cyclodextrin, alpha-cyclodextrins, other cycloamyloses, Poloxamers, Polythyleneglycol, Polyvinylpyrolidinone, and Polyvinyl alcohols, b) rapid disintegrants may include, but are not limited to, Crospovidone, Povidone, Microcrystalline Cellulose, Croscarmellose, Carboxymethylated Potato Starch, Tapioca, Inulin, Chicory Root Starch, Corn Starch, Sodium Starch Glycolate, Malic Acid, Oxalic Acid, Citric Acid, Sodium Bicarbonate, amino acid disintegrates such as L-alanine HCL, L-lysine, glycine, L-arginine, L-tyrosine. c) enzymatic activity modulators that include but are not limited to Potassium Bromide, Magnesium Bromide, Potassium Iodide, Sodium Chloride, Potassium Chloride, Sodium Iodide, and physiologic buffering agents, such as Tris Base and Tris, Sodium Phosphate, Sodium Phosphate, and d) binding agents that include but not limited to: Stearic Acid, plant saturated fatty acids, such as Cocoa Butter, Mango Butter, Shea Butter, Argan Oil, Ucuuba Butter, Acai Butter, Kokum Butter, Tucuma Butter, Capralyl Glycol, Murumuru Butter, or Illilpe Butter and/or e) Coelenterazine stabilizer, that include but are not limited to: TECP, Sodium Thiosulfate Pentahydrate, Ascorbic Acid, DTT, Tocopherol. The disclosure further teaches said composition wherein the Coelenterazine is combined with luciferases derived from Gaussia princeps or Renilla reniformis mixed with a buffer system in a pill or capsule format. The disclosure further teaches said composition, wherein the tablet format is used in a two-chambered squirt gun as described in U.S. Pat. No. 6,247,995, incorporated by reference herein in its entirety, combined with a Gaussia and/or Renilla luciferase systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] FIG. 1 is chemical structure of Methoxy-Coelenterazine (Me-O-CTZ).
[0064] FIG. 2 is chemical structure of Coelenterazine (CTZ).
[0065] FIG. 3 is chemical structure Methoxy-e-Coelenterazine (Me-O-eCTZ).
[0066] FIG. 4 is chemical structure e-Coelenterazine (eCTZ).
[0067] FIG. 5 is chemical structure Methoxy-eCoelenterazine-Fluoride (Me-O-eCTZ-F).
[0068] FIG. 6 is chemical structure e-Coelenterazine-Fluoride (eCTZ-F).
[0069] FIG. 7 is chemical structure Methoxy-v-Coelenterazine (Me-O-vCTZ).
[0070] FIG. 8 is chemical structure Methoxy-v-Coelenterazine-Fluoride.
[0071] FIG. 9 is scheme of chemical reaction producing Coelenteramide, Light & CO 2 .
[0072] FIG. 10 is chemical structure of reaction producing Coelenteramide, Light, & CO 2 .
[0073] FIG. 11 is chemical structure of metastable hydroperoxy luciferin state within calcium active site.
[0074] FIG. 12 is Coelenterazine held in “pocket” of Calcium Activated Coelenterazine Releasing Protein (CARP).
[0075] FIG. 13 is Obelin bioluminescence “rainbow” resulting from mutations of binding site residues with labeled spectral maxima.
[0076] FIG. 14 is Emission Spectrum of Renilla muelleri Luciferase with different Coelenterazine analogues.
[0077] FIG. 15 is activity of Renilla muelleri Luciferase with Me-O-eCTZF in comparison to Coelenterazine 400 a (aka Deep Blue C).
[0078] FIG. 16 is Coelenterazine E Synthesis.
[0079] FIG. 17 is eCoelenterazine F Synthesis.
[0080] FIG. 18 is vCoelenterazine Synthesis.
[0081] FIG. 19 is v Coelenterazine F synthesis.
[0082] FIG. 20 is the light spectrum photo of Me-O-eCTZ. Renilla muelleri luciferase was used as a luciferase.
[0083] FIG. 21 is luminescent activity of Renilla muelleri Luciferase with methoxy eCTZ and methoxy eCTZf. Methoxy eCTZ is showing the same emission spectrum like methoxy eCTZf with Renilla muelleri luciferase but has an approx. two-fold higher light-output when integrated over 10 sec.
[0084] FIG. 22 is the disclosure of the two chambered water gun for delivery of the Coelenterazine or analogues thereof.
DETAILED DESCRIPTION
[0085] 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”.
[0086] 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.
[0087] CAP is a phenomenon in which light energy is specifically channeled from a semi-oxidized or partially oxidized meta-stable high energy luciferin molecule contained within its folded conformation upon contact with calcium ions.
[0088] Calcium releasing proteins (herein known as CARP) are proteins that store a luciferin or synthetic luciferin analog, and upon contact with calcium ions release their stored or bound luciferin.
[0089] Many calcium activated photoproteins have been discovered since the discovery by Dr Osamu and Akemi Shimomura of the protein known as Aequorin from their early work in 1968 collecting green glowing jellyfish classified as Aequoria victoria or Aequoria funkalsrud from the docks of Friday Harbor Marine Biological Laboratory in Washington, USA.
[0090] Many other CAPs have been discovered since 1968, the most prominent ones and the ones best characterized chemically and cloned are Obelin from Obelia geniculata , Mitrocomin, Mnemiopsin, Halisturin (from a sea cucumber Halisturia ), Berovin from Beroe ovata , Atollin (from Atolla wyvillei ) are all similar in their response to a local increase in calcium ions; they release bright blue visible light when in contact with calcium ions.
[0091] CAPs are manufactured using molecular biology to engineer recombinant bacteria to produce large amounts of these proteins by those skilled in the art. The CAPS listed above and many other calcium activated photoproteins can be used in entertainment and research applications. The best known, most studied, and most stable CAPS is Aequorin.
[0092] Suitable buffers include, but are not limited to: calcium-free and magnesium-free purified water, distilled water of neutral pH, 0.0001-0.1 molar EGTA solutions, 0.0001-0.1 molar EDTA solutions, as long as the pH is within the range of CAPs activity.
[0093] Reactive calcium may be contained in or on a person's skin, clothes, hair, and/or any nearby or adjacent calcium containing environmental surfaces. The calcium concentration should reach a local threshold that will trigger the CAPs to emit light, which is in the local environment and in a range of 0.00001-0.1 molar calcium once in contact with the CAPs.
[0094] Light visible to the dark adapted human eye includes the visible spectrum, from 400-750 nanometer wavelengths.
[0095] Synthetic Coelenterazine analogs include, but are not limited to methoxy-eCoelenterazine-Fluoride, eCoelenterazine-Fluoride, methoxy-vCoelenterazine-Fluoride, vCoelenterazine-Fluoride, Fluoro-eCoelenterazine-Fluoride, and Fluoro-vcoelenterazine-Fluoride.
[0096] The most prevalent substrate luciferin molecule found in nature is a high energy dioxetanone molecule called Coelenterazine, named after the coelenterate animals they were found to be associated with. The light emitting reaction proceeds as Coelenterazine (or analog thereof) is combined with molecular oxygen to form an oxidation product, called Coelenteramide, and releases one carbon dioxide molecule and generates blue light at 480-490 nm (or a different color of light depending on analog used).
[0097] The general reaction for all Coelenterazine luciferins and their corresponding Coelenterazine utilizing luciferases is shown in FIG. 9 .
[0098] Calcium activated photoproteins (CAPs) differ from Coelenterazine utilizing luciferases in that the luciferase constantly turns over the reaction to produce a steady light with the kinetics of standard enzymatic mechanisms. Michaelis-Menton kinetics apply to these enzymatic reactions; as products of the reaction are produced they may lower the turnover by competitive inhibition with a steady drop in light production.
[0099] The light production mechanism is different with CAPs. CAPs usually release light only once upon binding with calcium ions, unless more substrate is present in their environment, then CAPs can become “pseudo-luciferases” and turnover slowly emitting light under first order Michaelis-Menton kinetics.
[0100] Within the active site of a calcium activated photoprotein the substrate Coelenterazine (or analog luciferin) is held in a metastable hydroperoxy luciferin state, and calcium ion triggers the completion of the oxidation to the amide and the release of light.
[0101] When the partially oxidized Coelenterazine (or analog) is held in this state as it slowly forms during the manufacturing process, it becomes stable. The molecule can be freeze or spray dried under appropriate reduced pressure conditions known to those skilled in the art, to obtain a very long lasting, active, dry yellowish-white powder that is quite stable for many years if kept cool and dry or frozen.
[0102] To activate the dried CAP, the CAP is dissolved in distilled water, or calcium and magnesium free water that is substantially free of inhibitors. More preferably, the water is at a pH between pH 7 and pH 8 for a highly active light emitting solution. The reaction is retarded and the light output is prolonged using competition with magnesium salts, usually Magnesium Chloride (MgCl 2 ) added to the solution to compete for the calcium binding sites on the CAP and delay the light emission over time; however, this will also diminish the brightness.
[0103] Retarding the reaction is achieved by lowering the environmental concentration of calcium ions that would come into contact with the CAP. Divalent metal ion chelators can be used such as ethylenediamine-tetracetate (EDTA), Ethyleneglycoltetracetic acid, (EGTA), and phosphates that would irreversibly bind calcium. Any molecules that lower the concentration and/or availability of calcium ions preventing their interaction with the calcium binding domains of the CAP will work.
[0104] The present disclosure teaches that the color of the reaction is altered by using an analog of Coelenterazine, used in the manufacture of the CAP which imparts desirable changes to the brightness and temporal kinetics of the light produced. Certain CAPs manufactured with different analogs may retard the reactivity of the CAP to environmental calcium, as in the case of Coelenterazine-Iodide which prolongs light emission, by delayed “spring-opening” of the CAPs to prolong the light output for longer duration of time, over tens of minutes. As can be seen from the chart below, not only can color be altered, but also the time for half of all the available light energy to be released can be altered, changing the brightness of the light perceived by the human observer. A partial listing is included here in Table 1.
[0000]
TABLE I
Coelenterazine
Em
Relative
Half-Rise
Analog
(nm)
RLC*
Intensity†
Time‡ (ms)
native
466
1.00
1
6-30
cp
442
0.63
28
2-5
f
472
0.80
20
6-30
h
466
0.75
16
6-30
hcp
445
0.65
500
2-5
n
468
0.25
0.15
6-30
[0105] As seen from Table 1, blue or red color shifts are made by substituting synthetic Coelenterazine analogs for the naturally occurring Coelenterazine. These may also be used favorably to that change the response times upon contact with calcium ions which can substantially change relative intensity and brightness or the quality of the light generated upon contact with a calcium containing surface.
[0106] In nature, marine animals change the color of the light they produce by complexing the light producing protein, e.g. luciferase, or CAP, with a Fluorescent Protein designed to accept the light energy from the oxidation of Coelenterazine and transfer that excited state to an acceptor Fluorescent Protein that emits the light energy of the color desired by the animal.
[0107] In coastal waters where there indwelling light passes through a lot of green algae, the light reaching the bottom is much greener in color than areas of open-ocean where the light is predominantly blue. Marine animals have evolved to produce light of a color that maximally penetrates the water if they are using the light to attract other predators to themselves when they themselves are being grazed upon hoping to attract a larger predator at some distance to investigate and rid them of the grazer. In order to do this, and for other reasons still unknown, many sea pens, soft corals, and jellyfish, make specialized bioluminescent systems incorporating several proteins combined to make light of a certain color under nervous control.
[0108] Fluorescent Proteins have been well studied; are barrel proteins that contain a hydrophobic region that excludes water wherein the fluorescent chromophore resides. These molecules are designed to fit neatly in a complex with a CAP and produce light by the release of light energy from the CAP, without transmission of a blue photon intermediate, into the Fluorescent Protein directly; which evolved to obtain the color desired for the local conditions of the animal's residence.
[0109] In the Sea Pansy, Renilla species, the animal has a specialized photogenic area that contains a complex of Luciferase, Green Fluorescent Proteins, and recently cloned and fully described Calcium Activated Coelenterazine Releasing Protein. Calcium binding causes release of the substrate Coelenterazine, its luciferin, in proximity to its luciferase, causing the light emitting reaction to occur by the release of calcium under changes in membrane permeability or by direct nervous controlled release of calcium ions by the animal.
Calcium Activated Releasing Protein
[0110] As originally described by Charbonneau and Cormier in 1979, they discovered that the luciferin, Coelenterazine, isolated from the Renilla (Sea Pansy) was associated with an 18,500 MW protein recently cloned and crystallography reveals a dimeric protein of 186 amino acids containing four calcium binding EF-hand elements. Each subunit releases a Coelenterazine molecule upon binding with two (2) calcium ions. Coelenterazine is held in a protected and stabilized state to prevent it from being oxidized by the environmental oxygen.
[0111] Coelenterazine held in the “pocket” of the Calcium Activated Coelenterazine Releasing Protein (CARP) in the historical literature called this protein by different names; for the embodiments mentioned herein, we refer to any protein that stores Coelenterazine (or analog) and releases it into the environment upon contact with a Calcium Activated Coelenterazine Releasing Protein (CARP). For entertainment purposes this protein will only be used as a carrier of the Coelenterazine (or analog) in order to use the fact that the light emission can be turned on only under the control of environmental calcium and is not being used as a straight mixed luciferase-luciferin reaction as described in literature.
[0112] CARPs can be used to both control and extend the lifetime of the light emitting reaction between CAP and environmental calcium ion by creating a “pseudo-luciferase” out of the CAP. Once calcium enters the CAP binding sites the CAP starts to oxidize the luciferin and generate light.
[0113] Coelenterazine (or analog) can be added to the CARP at the same time the CAP is made by making a mixture of the two proteins in calcium free solutions and adding Coelenterazine (or analog) to the mixture and allowing the hydroperoxy-Coelenterazine CAP to form.
[0114] In the same calcium free solution and at the same time the CARP binds and holds the Coelenterazine (or analog) and CARP folds around the Coelenterazine. The completed reaction is determined by careful addition of Coelenterazine (or analog) and hourly luminometer testing. As the CARP or CAP incorporates Coelenterazine, the free Coelenterazine in solution goes down. The amount of Coelenterazine combined with CAPs and CARPs can be determined, with a 1 milligram/milliliter solution of Renilla or Gaussia Luciferase to monitor the absorption of Coelenterazine (or analog) as the CARP and CAP remove them from solution during folding and formation, the amount of light generated on mixing the solution in a luminometer will go down, indicating that the free Coelenterazine has been taken up by the CARP or CAP formation.
[0115] Different colors can be made at the same time by the addition of Fluorescent
[0116] Proteins to the mixture and drying. During manufacturing in calcium free solutions, the CAP and the CARP are mixed together at the same time and then the mixture is freeze or spray dried. The resultant composition can be encapsulated as part of, or after the drying process, and different types of delays in light release are made by altering the thickness of the encapsulating film if chosen.
EXAMPLES
[0117] The following examples are provided for illustrative purposes only and are not intended to limit the scope of the invention.
Example 1 Using Coelenterazine Analogs for Unusual Color Effect
[0118] The qualities of the CAP as it is contemplated for use in any entertainment application would be empirically determined by experimentation. A scene from a space setting would require a shower of stars in deep blue; the natural analog of Coelenterazine would be used.
[0119] The next scene of the movie require a red rocket effect or firework effect a red fluorescent protein manufactured with the CAP substituted with vCoelenterazine-Fluoride would be used to splash onto the audience to make it appear to the people being entertained that they have been “fired” upon.
[0120] The duration of the theatrical effect can be prolonged by adding magnesium ions or adding small amounts of EDTA or EGTA solutions such as from 0.0001-0.005 molar EDTA to the CAPs or CARPs solution to delay the binding of calcium ions that activate the light emitting reaction.
Example 2: Mutations Made to CAPs to Alter Color Effect
[0121] To further alter the color of emitted light from the CAP is to use a mutated CAP in which amino acid substitutions have been made to modify the sequence of amino acids in the CAP protein itself.
[0122] As can be immediately realized from inspection of FIG. 13 , a selection of colors is obtained using a library of Coelenterazine analogs and known CAP mutations. Many colors, hues, and useful light emitting properties are screened for visually or by optical spectral scanners or color cameras recording the signals for analysis from an array of mixtures to determine which CAP-Coelenterazine analog mixture is ideal.
Example 3 Fluorescent Protein Combined with CAPs to Alter Color
[0123] Currently the list of known Fluorescent Proteins is quite large, and many colors are available on the commercial market. These would be selected based upon their known published properties and combined either by making a fusion protein of the Fluorescent Protein to a linker and then combining that with the nucleic acid sequence of the CAP, or using direct synthesis of the new gene and manufacturing the desired CAP-FP fusion protein utilizing recombinant bacteria. Another method is simply freeze-drying a mixed calcium free solution of the CAP with the desired Fluorescent Protein in the correct molar ratios.
Example 4 CARP and CAP Entertainment Applications
[0124] When this mixture of CAP and CARP is applied to the audience during a movie, the environmental calcium ions found on the audience person's clothes, skin, hair, will immediately react with the CAP to release a bright shower of light, and simultaneously the CARP releases the Coeleneterazine (or analog) upon absorption of calcium ions too. This makes the Coelenterazine available to the CAP which has already bound calcium locked within its calcium binding domains, causing it to function as a weak “pseudo-luciferase” emitting a low background of light for as long as the un-oxidized Coelenterazine (or analog) is present.
[0125] This can be used to create some very interesting effects, because the CARP can be made with a different analog of Coelenterazine and added to the calcium free mixture of CAP and freeze dried together.
[0126] Once this mixture is sprayed on the audience, as the CAP initially reacts with calcium ions on the audience it will create bright light corresponding with the Coelenterazine analog it was manufactured with. As the calcium ions are also picked up by calcium on the audience they begin to release their bound different Coelenterazine analog which begin to alter the color of the light produced as the “pseudo-luciferase” starts reacting with the free Coelenterazine (or analog) released nearby from the CARP.
Example 5 CARP and Coelenterazine Utilizing Luciferases
[0127] Another embodiment is the use of Coelenterazine Utilizing Luciferases not limited to but for example luciferases such as Gaussia Luciferase (native Coelenterazine), Renilla sp Luciferase (multiple analog use), Oplophorus Luciferase, Pleuromamma Luciferase, Periphylla Luciferase, and mutants that are known or unknown as long as they utilize Coelenterazine or Coelenterazine analogs they are to be known herein as Coelenterazine Utilizing Luciferases (or coelenterazine utilizing luciferases the capitalization is of no consequence for this patent). Suppose the Director of the movie wished to have a prolonged light emission emanating from one portion of the Audience or Stage in a particular color and another brief reaction or “splash’ of light emanating from another portion or wall of the theater, stage, or Audience; this can be achieved by manufacture of the combination of a CARP and Coelenterazine Utilizing Luciferase and freeze drying them mixed together in solution.
[0128] Just prior to the performance or starting the movie, the mixture is reconstituted with calcium free water, and loaded into the designating ceiling apparatus above the section where the continuous light is desired.
[0129] In the other section of the theater, where the brief “splash” of light is desired, the CAP is sprayed on the Audience and a bright flash ensues, while at the other end the calcium activated Coelenterazine releasing protein is becoming active and gradually releasing the Coelenterazine (or analog) to create the longer lasting effect.
[0130] The area of the theater that is to release very bright light (the “splash”) can have an application of Calcium Chloride (CaCl 2 ) pre-applied and dried so that when the CAP in solution mixes with it in that designated area, a rapid release of light occurs, especially bright if the proper Coelenterazine analog is chosen based upon published characteristics of the analog and CAP.
[0131] This disclosure results from an accidental discovery from a splash of CAPs that occurred during manufacture in our laboratory. Some CAP solution landed directly into a lab workers eye. The lab worker went for the bathroom and noticed something glowing from his eye in the mirror. Distracted, he looked into the mirror to find his eye was glowing very brightly with blue light emitting directly from his soft contact lens. Upon hearing of this, the inventor recalled cartoons seen on TV from his youth where the bats in the cave or the monster in the cave had glowing eyes and prompted the thinking to develop this process for theater applications.
Example 6 Glowing Eyes
[0132] Another embodiment is the application of CARP and CAP in solution loaded in a eye wash bottle and just before the scene the Actor can use the eyewash and soak the lenses then walk out upon the stage as the lights are off and have glowing eyes.
[0133] The color of the light produced for the effect in the eye can be modulated by using a different analog of Coelenterazine during manufacture of the CAP, or a photoprotein mutation as described in the prior examples, or a CARP manufactured with a Coelenterazine analog producing the desired effect.
Example 7 Medical Ophthalmologic Eye Examination
[0134] Diagnosis of conjunctiva pathology and corneal scratches and other acute ocular emergencies such as foreign objects is best performed using an ultraviolet lamp and fluorescein dye. However there are situations, such as camping, or in poorer nations where electricity and ultraviolet lamps are not available. Another embodiment of this invention is a kit containing fluorescein dye, and a CARP manufactured using a ultraviolet producing Coelenterazine analog such as 400 a or better because it is much brighter, is methoxy-eCoelenterazine analog contained and stabilized within a freeze dried CARP which can be used for eye examinations in the field.
[0135] Denuded and scratched corneal surfaces should release more calcium then a sealed intact healthy cornea and a CAP may be used alone or in conjunction with fluorescein dye to reveal the exact location of the foreign body or severity of the ocular corneal scratch. Multiple sets of Coelenterazine applied directly in Rabbit conjunctiva, even at high concentrations, failed to produce any ocular injury.
Example 8 Warm Water and CAPs Leave No Spots on Clothes
[0136] This disclosure teaches intentional testing of CAPs in theater situations at home. Test subjects watching a movie were splashed with a CAP solution.
[0137] Using warm water of a temperature that when it lands on the audience will not make them feel a cold splash. CAPs in solution should land at skin temperature or slightly warmer to be acceptable to the Audience. CAPS bind absorb calcium from clothes; and does not leave watermarks or marks of any kind on even the finest silks tested, a fortuitous discovery for commercialization.
[0138] After binding with calcium CAPS protein release Coelenteramide which is clear to slightly cloudy white in solution but colorless when dry.
Example 9 Fluorescent Protein Mixed with CAPs
[0139] Another interesting teaching discovery was made while incorporating fluorescent proteins into CAPs mixtures; unlike most pigments and fluorescent dyes commercially available, Fluorescent Proteins can be chosen that dry perfectly clear and can only be seen under very specific illumination conditions when dry. Fluorescent Proteins can be chosen that do not stain the audience's clothes, but still retaining their fluorescent function when dry.
[0140] This has the added benefit that after the Audience that has been splashed in a 3D, 4D, or otherwise average regular movie theater fitted with a simple apparatus for delivering the CAPs, CARP, and/or Fluorescent Protein combination onto the Audience, it will not anger the Audience at the end of the show by staining their clothes.
[0141] The CAPS and CARP compositions will be empirically chosen by experimentation to achieve the cinematic effect desired by the Director and also become invisible after drying upon the theater fixtures, and audience while exiting.
Example 10 Theater Egress Entertainment Scare Tactic
[0142] Unknown to the Audience at the time, (part of the CAP composition applied during the performance), as the Audience leaves the theater to walk out the exit, the exits are equipped with special light sources designed to excite the dried Fluorescent Proteins on their clothes, hair, and skin and make the Audience think they have been “infected” by the interaction with the movie.
[0143] Renilla Green Fluorescent Protein (R-GFP) is an excellent vehicle for this effect, it dries clear, and when dry can fluoresce under blue light as the Audience is leaving the theater. It would be possible for the Audience to experience different colors on their clothes in the theater or upon leaving the theater so that some members of the Audience glow in one color and other members of the Audience glow in other colors. This example can also be used for desired effects during the performance or showing of the movie, by equipping the theatre with the light sources of the correct wavelength to excite the applied Fluorescent Proteins.
[0000] Apparatus for Equipping the Theater with a CAP and CARP Delivery System.
[0144] Theater owners are very cost sensitive to changes made to their theaters. To make a commercially viable venture they have to be willing to modify their theater to accommodate the delivery of CAPS. There are many ways to do this, simple or elaborate; the easiest and least expensive is to simply hang thin walled vinyl tubing over a designated splash zone in the theater (which can be sprayed or dusted prior to performance with calcium chloride). Perforations are made in the tubing over the seats, and the tubing is blown out after each performance because cold water is to be avoided, also drying prevents bacterial growth, CAPs and CARPS are proteins and are suitable growth media for bacteria. The lines will have to be periodically rinsed with an antibacterial agent, such as mild hypochlorite solution, or 70% ethanol.
[0145] Prior to the start of the movie, or in advance of the scenes in which the CAPs are to be sprayed, the projectionist has a bottle of pre-weighed out dry CAPs proteins and precise aliquot of hot distilled water. These are mixed, then drawn up into a large 100-200 ml syringe and pushed into the perforated tubing by manually injecting the solution into the tubing system at the appropriate time since the movie, or performance, is tagged by the Director in a way to tell the projectionist or theater personnel to apply the CAP at a selected moment.
[0146] More sophisticated devices can be used and installed. Current 4D theaters are already equipped with individual seat sprayers. In this case a mechanical device such as peristaltic, rotary lobe or other pump can be “Y” tube inline mixed and used to spray the CAPs at the Audience. In this case the system must be pre-purged with calcium free water or EDTA solution to remove any calcium on the walls of the tubing. These can be electronically triggered by the movie as it is played, or by signal to the projectionist.
[0147] The amount of CAP used is based on the duration and brightness of the effect desired; CAPs store an extremely large amount of light energy in a small weight of protein. The dose range will depend on the quality of the CAPs protein and its storage condition. As little as 0.0001 mg/ml to as much as 1.0 mg/ml is enough to achieve the desired effect.
[0148] 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.
[0149] While the invention has been particularly shown and described with reference to a number of embodiments, it would be understood by those skilled in the art that changes in the form and details may be made to the various embodiments disclosed herein without departing from the spirit and scope of the invention and that 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.
Example 11
Coelenterazine Pill:
[0150] Add 0.1-150 mgs Coelenterazine to 1.0-150 milliliters anhydrous 100% Methanol and warm until completely dissolved, add Polyethylene Glycol, (1,000-10,000 average MW), and warm over steam until all ingredients dissolved and slowly stir in lactose, 20-2,000 milligrams until a paste like consistency is formed, then add Anhydrous Malic Acid, Oxalic, or Citric Acids 1-500 milligrams, and Anhydrous Sodium Bicarbonate at 3-2000 milligrams. Add 1-5% plant butter as binding agent and compress into desired pill form using a standard pilling machine. Adjust compression empirically based on time required to dissolve the pill in water and maintain pill shape for handling and packaging.
Example 12
Luciferase Pill
[0151] Luciferase Pill: Mix 1-100 mgs lyophilized Gaussia , or Renilla Luciferase powder with 100-2,000 milligrams Lactose, 10-100 mgs Microcrystalline cellulose, 5-200 mgs Potassium Bromide, 1-50 milligrams L-Alanine, 1-50 milligrams L-Lysine, 0.1-50 milligrams Stearic acid, 10-200 milligrams Poloxamer, 1-200 milligrams Mango butter and compress into desired pill size and shape. Adjust compression empirically based on time required to dissolve the pill in water and maintain pill shape for handling and packaging.
[0152] Luciferase Pill designed for different color of light output: Mix 1-100 mgs lyophilized Gaussia , or Renilla Luciferase powder with 2-300 milligrams of Lyophilized Fluorescent Protein, 100-2,000 milligrams Lactose, 10-100 mgs Microcrystalline cellulose, 5-200 mgs Potassium Bromide, 1-50 milligrams L-Alanine, 1-50 milligrams L-Lysine, 0.1-50 milligrams Stearic acid, 10-200 milligrams Poloxamer, 1-200 milligrams Mango butter and compress into desired pill size and shape. Adjust compression empirically based on time required to dissolve the pill in water and maintain pill shape for handling and packaging.
Example 13
Kit for the Water Soluble Coelenterazine
[0153] A kit containing a reagent that contains a buffer for the Coelenterazine (Buffer A) and for the Gaussia luciferase (Buffer B).
[0154] The kit may further include Vitamin C (25-30 uM) together with Coelenterazine and the solubilizing polymer. Everything will be dissolved and then dried to a powder to prolong shelf-life. Buffer A is mixed to this Coelenterazine containing powder. The buffer itself will not contain any Vit. C only after it is mixed with the dried Coelenterazine. Further containing KI (Potassium Iodine) which reduces the background luminescence. in Buffer B as approximately 50 mM concentration. This Buffer contains no Coelenterazine. It will only come in contact with the Coelenterazine in the luminometer. The final Coelenterazine concentration will be between 10-100 uM. The concentration may be 50 uM.
[0155] The above examples include the use of Coelenterazine or analogs as described herein.
[0156] The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. The scope of the present invention is limited only by the scope of the following claims. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment described and shown in the figures was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.
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Calcium reacting photoproteins are a class of self-illuminating proteins that emit light upon contact with calcium. Fluorescent Proteins are small proteins that change the color of light when excited. Fluorescent Proteins and Calcium Activated Photoproteins can be used to enhance, dazzle, amaze, startle, and otherwise entertain an audience by their direct application on to the audience, surroundings, the actors, or sprayed on settings as in the newer 4D movies. The disclosure comprises novel Coelenterazine compounds and methods of use, including a simple delivery device for the photoprotein to create unique and novel cinematic, theatrical, stage, movie and musical concert optical effects by their luminous reaction upon contact with surfaces that contain calcium. Calcium is ubiquitous in and on most surfaces and in the environment; it is this unique property of calcium that makes this a novel use of the photoproteins for entertainment.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a coffee maker and more particularly refers to a new and improved electric coffee maker with a fresh water container, a convection heater, a coffee filter and a coffee pot in the shape of a thermos jug.
2. Description of the Prior Art
Known electric household coffee makers of this kind show a housing base with a support surface for the thermos jug and an electric flow-through heater disposed below the support surface. The fresh water container is arranged on the housing base adjacent to the support surface. The riser tube for the hot water goes upward from the housing base through the fresh water container or adjacent to it to a coffee filter which is supported by the fresh-water container or the coffee pot. In the known coffee makers of this kind, the circulating heater is arranged a bit below the lowest level of the fresh water container, so that the water pressure in it is sufficient to operate it as a tubular convection heater with the tube heating element disposed alongside of it. It must be taken into consideration that in this type of construction of a flow-through heater, the heat is applied to the ususally rather thin-walled water tube along a line and not around the circumference of the water tube. Consequently, heating is uneven with portions of the water tube intensively heated and this can easily lead to undesirable formation of steam bubbles in the hot water portion of the convection heater. The degree of formation of steam bubbles depends to a large extent on the water pressure.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an efficient electric coffee maker of this type constructed to produce a more compact form.
With the foregoing and other objects in view, there is provided in accordance with the invention an electric coffee maker comprising
(a) a coffee pot in the form of a Dewar flask
(b) a shock-proof outer housing supporting and surrounding the coffee pot
(c) a electric flow-through heater disposed below the top of the Dewar flask in the shock-proof outer housing surrounding the coffee pot
(d) a fresh water container disposed above the coffee pot
(e) a coffee filter disposed above the coffee pot
(f) fresh water conduit means connecting the fresh water container with the flow-through heater for the passage of fresh water from the fresh water container to the heater, and
(g) hot-water conduit means connecting the flow-through heater to the top of the coffee filter for the passage of hot water from the heater to the filter.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in an electric coffee maker, it is nevertheless not intended to be limited to the details shown, since various modifications may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, however, together with additional objects and advantages thereof will be best understood from the following description when read in connection with the accompanying drawings, in which:
FIG. 1 is a vertical section of a coffee maker in accordance with the invention, taken along line I--I of FIG. 2
FIG. 2 is a sectional view taken along line II--II of FIG. 1
FIG. 3 is a modification of the embodiment illustrated in FIG. 1, in which the upper portion of the coffee maker is shown in section
FIG. 4 is another modification illustrated in FIG. 1 showing the upper portion of the coffee maker in section.
DETAILED DESCRIPTION OF THE INVENTION
The circulating heater in the outer jug-housing is preferably in the space of the bottom rounded portion of the Dewar flask or vessel. A coffee maker constructed along this line has the advantage that it utilizes the dead space which is for technical reasons available in thermos jugs. If the fresh water container and the coffee filter are placed on top of the thermos jug a very compact coffee maker results. This is of considerable importance because of the numerous available household and kitchen appliances which usually have to be placed upon a kitchen table. An electric coffee maker wherein the fresh water container and the coffee filter are removably arranged above a thermos jug is known from German Petty Patent (Gebrauchsmuster) No. 70 25 972. However, the construction form proposed there with the convection heater arranged in the fresh water container cannot be compared with the construction according to the present invention, because for the reasons given the heating and circulating of the water is a problem, due to the low water pressure available in the convection heater.
To achieve the purpose of the invention an out-flow port of the fresh water container, preferably a bottom port, is connected with a seal to a connecting tube which leads down through the housing below the top of the jug into the convection heater. Preferably said connecting tube is disposed at the housing of the jug, i.e. made in one piece with the latter.
The riser tube through which brewing water flows can be arranged to go through the handle of the jug.
Furthermore, the housing or shell of the jug can be expanded to receive the fresh water container and/or the coffee filter. This expanded portion may be a support only for attaching, i.e. securing the fresh water container and the coffee filter, or it can enclose the fresh water container and/or coffee filter to a great extent. The first type of construction has the advantage that the coffee pot size can be made smaller by removing the fresh water container and/or the coffee filter before the coffee is served; the second solution has the advantage that the whole coffee maker has the form of a coffee jug of pleasing appearance and that also no further manipulation is required after preparing the coffee and serving it. Also no problems arise with drops of water continuing to drip after the filter is removed. For expanding the housing of the jug, the housing is preferably elongated above the upper edge of the Dewar vessel.
Since the Dewar flask is round for manufacturing reasons, it is practical to provide at the side of the outside shell in the region of the handle a vertical bulge containing a fresh water tube or conduit between the convection heater and the connection tube. The bulge can also serve for housing an electrical connector and/or electrical switching elements, as for example an on-off control.
In another advantageous embodiment of the coffee maker according to the invention, the coffee filter in the form of a flat filter is preferably arranged above the Dewar vessel or extends into the latter. The fresh water container is for its greater part above the coffee filter. This has the advantage that after removal of the fresh water container, the remaining part of the coffee maker is small and the riser tube need not be made either in parts, i.e. sections, or telescoping in order to obtain a small shape. An advantageous further development is to shape the bottom side of the fresh water container as a hot water (brewing water) leader, for example, as an overflow tube which functions as a distributor of the brewing water. This form of construction is very effective for space-saving, as well as saving material, and the hot water leader which is always fixed to the bottom of the fresh water container is well protected and does not require any special manipulation. The above-described arrangements of filter and fresh water container to each other, and the utilization of the bottom of the fresh water container as device for conducting the hot water have significance beyond the frame of this application for similarly constructed coffee makers without a Dewar vessel and achieve the objects of space-saving, material saving and simple construction.
In the following the invention is further explained with the aid of schematic drawings of embodiment examples shown in FIGS. 1-4.
In the middle portion of an outer housing 2 the coffee maker illustrated in the FIGS. 1 and 2 is shown having an inward turned flange 4 for receiving an elastic sealing ring 6, against which presses the upper edge of a Dewar vessel 8. The housing 2 extends beyond the Dewar flask 8 which occupies the lower part of the outer housing 2. The outer housing 2 of the jug is made in one piece with a handle 10, which is connected at its lower portion to a bottom part 12. In the middle portion of the bottom part 12 of outer housing 2 the Dewar vessel 8 is a large opening with threaded edges 14 into which is threaded a holding part 16 for supporting and securing the Dewar vessel 8.
Due to the semi-spherical shape of the Dewar vessel 8 a hollow space 18 is formed around the holding part 16. A convection heater 20 is disposed in hollow space 18 and secured by means of the spring brackets 22 to the ribs 24 which extend from the bottom part 12. In the lower part of the handle 10 is inserted a plug-in terminal 26 for connection to an electric source of power. The connection of terminal 26 to the convection heater 20 is not shown. A riser tube 28 leads from the convection heater 20 through the handle 10 to an overflow tube 30 in the upper end portion of the jug housing 2. A fresh water tube 32 connects the convection heater 20 with a connection tube 36 which is formed in the horizontal part of the rib 4 of the housing 2 of the jug. A removable filter 42 is snapped into the fresh water container 38 and extends down the bottom 40 of the fresh water container 38. A fresh water container 38 has a drain-tube 44 which is detachably plugged into the connecting tube 36. The outer housing 2 of the jug above the fresh water container 38 with the filter 42 inserted both above the Dewar vessel 8, is closed by a cover 46 which has a slideable spout closure 48 and a baffle rib 50 which serves to interrupt the flow of water coming out of the overflow tube 30 and direct it toward filter 42.
The outer housing 2 of the jug has a bulge 52 in the zone of the jug handle 10 which extends over its entire height, wherein the connecting tube 36 for mating with the draintube 44 of the fresh water container 38 is disposed.
In the embodiment according to FIG. 3 the outer housing 56 of the jug reaches only up to the zone of the upper edge of the Dewar vessel 8, and is adjacent to a flange 58 into which the seal 6 is inserted. Flange 58 is shaped to form a supporting spout 60 and a connecting tube 62. In addition, the flange 58 has a ring connection 63 which extends a short distance upward, approximately in continuation of the outer housing 56, and into which the lower portion of a fresh water container 64 is inserted. The fresh water container 64 has a bottom opening with a ring seal 70 into which a filter shaped insert member 68 is fitted. A sliding closure 72 can be arranged along the lower region of the side wall of the container and can function together with the pouring spout 60. A jug handle 74 which extends above the inserted fresh water container 64 is formed in the housing 56 of the jug. The riser tube 28 is carried through the handle 74. A cover 76 which opens to an overflow tube 78 at the jug handle 74 closes the filter 66 and the fresh water container 64 on top. In a coffee maker of this type the fresh-water container 64 with the wedge or conical-shaped filter 66 and filter-shaped insert member 68 can be taken off to make the coffee pot smaller, and the remaining coffee pot is covered by another cover with some closing means, not shown. The handle of the coffee maker or jug with the riser tube 28 arranged in it extends to the side of the jug. This could be avoided by arranging the handle in the lower portion of the jug alongside the Dewar vessel and providing a collapsible riser tube in known manner by making the tube telescopic so that section of the tube can slide into each other and conversely can be pulled out upward.
In the variation shown in the embodiment of FIG. 4 a handle which extends above the remaining jug after the fresh water container is removed, is avoided. The jug housing 80 is formed in one piece with the flange 82 which corresponds to flange 58 in FIG. 3, and is further made in one piece with jug handle 84 which reaches to its upper edge. A riser tube 86 extends through the handle 84 to a horizontal overflow tube 88. A connecting tube 100 is positioned slightly to the back of the plane of the section. A flat filter 102 extends from the top a distance into the Dewar vessel 8 just above its maximal coffee filling level. Filter 102 seats on the horizontal part of flange 82 where it protrudes inward with positioning arms 104 which are provided at the filter side extending star-like. A fresh water container 106 seats with a small shoulder 108 of its side wall on the upper edge of flange 82 of the housing 80, and extends in continuation of the jug housing a distance upward where it is closed by a cover 110. The cover 110 fits the remaining jug when the fresh water container 106 is removed and the cover 110 is provided for this purpose with a closure lug 112. Opposite the closure lug 112, outward and slightly slanted up, extending beyond the wall of the fresh water container 106 is handle 114. Handle 114 functions together with jug handle 84 when the cover is used as cover for the pot, and for pouring swings easily upward in the spout closure 112 when pressure with the thumb is applied to it. The bottom 116 of the fresh water container 106 extends down around the flat filter 102 for better utilization of available space, with the exception of a saddle which remains in the region of the overflow tube 88. An overflow tube 118 is formed at the bottom 116 with a chamber 120 for distributing the brewing water at its end. Even in the case of a rather sharp cornered transition between side wall and bottom of the Dewar vessel, because of the required centering and holding means which are disposed in the bottom region, enough space is available at the bottom of the Dewar vessel for installing a convection heater according to the invention.
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An electric coffee maker having a coffee pot in the form of a Dewar flask supported in a shock-proof outer housing surrounding the flask. A fresh water container and a coffee filter are disposed above the coffee pot. An electric flow-through heater is disposed in the housing below the top of the Dewar flask. Fresh water conduit means are conducted from the fresh water container through the interior of the housing to the flow-through heater. The hot-water conduit means from the heater to the top of the filter are routed through a handle formed from the housing.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a method for recovering petroleum, especially viscous or heavy petroleum from subterranean formations by injecting hot fluids into the formation including low quality steam which is a mixture of liquid and gaseous phase components. More specifically, this invention concerns a method for injecting steam or mixture of steam and other additives into the formation in such a manner that the tendency for steam vapors to channel through the upper portion of the formation, bypassing substantial portions of the petroleum in the lower portion of the formation, is minimized.
2. Description of the Prior Art
Steam injection or steam flooding has gained substantial recognition in the art as a preferred method for recovering viscous or heavy oil from subterranean formations. For the purpose of the present application, it is meant by use of the term "heavy oil", petroleum which has an API gravity less than about 12° API. Steam injection is generally applied to subterranean formations which have a low potential for production, e.g. less than about 10 percent of their initial petroleum by primary means, involving penetrating the formation with a well and pumping the petroleum contained therein to the surface of the earth without applying any treatment to formation petroleum to reduce its viscosity.
Steam may be used for oil recovery purposes in at least two general methods. In the first, steam is injected into one or more wells for a period of time, after which steam injection is terminated and petroleum is allowed to flow to the surface of the earth through the same well or wells as were used for injecting the steam in the formation. This cyclical procedure, sometimes referred to as "push-pull" steam stimulation, is an efficient method for simulating production from a well, but it is not satisfactory for exploiting a large aerial extent of a formation because the effect of steam injection diminishes in a push-pull sequence with distance from the point of injection due to heat losses and an ever increasing volume of depleted formation which must be saturated with steam before any new portion of the formation is contacted.
The second basic approach to steam injection is a well-to-well throughput process in which at least two wells are drilled into the formation and steam is injected into one well to pass through the permeable formation, displacing petroleum toward a remotely located well. This process has the advantage of being a continuous process in which petroleum production is not interrupted periodically as it is in the cyclical push-pull process. Moreover, the heating effect of steam is combined with the displacement phenomena similar to that employed in water flooding, which causes the creation of an oil bank between the wells which moves toward the production well and effectively displaces a substantial portion of the petroleum from the zone through which the steam moves in the formation.
When a well-to-well throughput steam injection process is applied to a thick reservoir, i.e. a subterranean petroleum saturated formation having vertical thickness of 50 feet or more, the vertical conformance of the steam process is relatively low. By vertical conformance, it is meant the portion of the vertical thickness of a formation through which the injected displacement fluid passes. Because steam is generally injected in a two phase form, at least a substantial portion being in the vapor phase, there is a strong tendency for the vapor phase component of steam to migrate to the upper portion of the petroleum reservoir. Horizontal vapor movement thereafter is confined to the upper portion of the formation, with the result that only a small percentage of the total vertical thickness of the formation is contacted by the vapor phase steam. Since the heat content of the vapor phase portion of steam is substantially higher than the liquid phase content it frequently occurs that only a small portion of thermal energy present in the injected fluid is used for decreasing the viscosity of petroleum and for recovering petroleum from the formation. Thus, it can occur in a throughput steam injection process that live, vapor phase steam exits from the production well, and yet a substantial portion of the formation between the wells, specifically the lower portions of the formation, has not been contacted by steam vapor.
In view of the foregoing discussion, it can be appreciated that there is a substantial, unfulfilled need for a method of conducting a well-to-well throughput steam injection oil recovery method in a manner which results in improved vertical conformance.
SUMMARY OF THE INVENTION
I have discovered, and this constitutes my invention, that the vertical conformance of a well-to-well throughput steam injection oil recovery process can be improved substantially by separating the steam into two fractions, one of which is substantially all liquid phase and the other of which is substantially all in the gaseous phase, and injecting the gaseous phase portion at or near the bottom of the petroleum saturated formation while the liquid portion of the steam is injected at or near the top of the petroleum formation. While both fractions are moving in a horizontal direction away from the injection well and toward the production well, the gaseous phase portion is also moving upward in the formation while the liquid portion is moving downward into the formation. This results in the injected steam mixing and contacting the formation more efficiently, while moving the point where steam vapor contacts exclusively the upper portion of the formation, farther away from the point of injection. The separation process can be accomplished on the surface, with separate injection strings being run from the surface to the two points in the formation where injection is to take place. A convenient method involves injecting the gaseous phase fraction into a centered tubing string while injecting the hot water liquid fraction down the annular space between the tubing string and the well casing. This has the advantage of minimizing the effects of heat losses from the injection well into the formation. Alternatively, the two phase steam fluid may be injected to a point near the formation and then subjected to phase separation downhole by means of a steam separator located in the injection well casing, with the liquid portion then being injected into the upper portion of the formation and the gaseous phase component being injected into the lower portions of the formation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in cross sectional view, an oil recovery method being subjected to steam flooding by conventional means, wherein the gas phase and liquid phase components are injected simultaneously into the same points in the formation, with resultant channeling of steam vapor into the upper portion of the formation, which causes poor vertical conformance to be experienced in the oil recovery method.
FIG. 2 illustrates a similar oil formation being subjected to the improved steam flooding technique in the present invention, with surface facilities for separating steam into liquid and gaseous phase components, the gaseous phase portion being injected into the lower portion of the formation and the liquid phase portion being injected into the upper portion of the formation with resultant improved vertical conformance.
FIG. 3 illustrates a means for separating two phase steam into the desired two separate phases downhole by means of a downhole steam separator, with gaseous phase steam being injected into the lower portion of the formation and liquid phase steam being injected into the top of the formation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Briefly, the oil recovery process of my invention involves a throughput, well-to-well steam flooding method in which saturated steam is generated on the surface, separated into one component which is essentially all liquid phase and another component which is substantially all gaseous phase, and the liquid phase portion is injected at or near the top of the oil formation with the gaseous phase component being injected at or near the bottom of the oil formation. Separation can be accomplished on the surface with separate injection means from the surface to the injection points, or a downhole separator may be located in the injection well near the injection point.
The process described briefly above may be employed in a viscous petroleum recovery method which involves injecting steam only into the formation, or it may be incorporated with other known techniques described in the art involving the injection of steam and other components into the formation. For example, a minor amount of an alkalinity agent such as sodium or potassium hydroxide included with the liquid portion of the steam is sometimes effective for increasing the oil recovery efficiency in viscous petroleum formations. The presence of the alkalinity agent is believed to stimulate oil recovery by inducing the formation of a low viscosity oil-in-water emulsion, which moves more readily through the subterranean porous formation than does the viscous petroleum itself. Another variation of the steam recovery method involves the injection of a substance which is immiscible with steam and miscible with the formation petroleum, i.e. an effective solvent, simultaneously with injection of steam. The solvent is preferably liquid in the phase at reservoir conditions, and will ordinarily be liquid phase at the temperature and pressure at which steam is injected into the formation. Thus the solvent material would ordinarily be injected with the liquid phase fraction of steam, into the upper portion of the formation.
In applying steam flooding to subterranean formations having relatively low permeability and/or very high viscosity petroleum, an example of which is the tar sand deposits such as are found in the western United States and northwestern Canada, it is sometimes beneficial to incorporate an inert substance into the steam, which substance remains substantially all in the gaseous phase in the formation, thereby precluding the loss of steam or other fluid transmissibility due to cooling of the injected steam and condensation thereof, in the tight formation flow channels. Nitrogen, low molecular weight normally gaseous hydrocarbons such as methane and ethane, as well as carbon dioxide are effective for this purpose. These substances will generally be gaseous at the conditions of steam injection, and so will move with the vapor phase portion of steam and be injected at or near the bottom of the oil reservoir.
In one other embodiment of steam flooding which may be successfully incorporated with the process of my invention, a mixture of air and steam is injected into a subterranean, viscous petroleum-containing formation, which mixture of steam and air initiates a low temperature controlled oxidation reaction within the formation, which is in some instances more effective in displacing the very viscous petroleum such as the asphaltic or bituminous petroleum found in tar sand deposits than is either the more conventional high temperature combustion or steam flooding alone. Since the reaction occurs only in the portion of the formation contacted by the vapor phase components, this is another instance where application of my process will improve the vertical conformance of the oil recovery method. Air and the vapor phase components of steam are injected into the lower portion of the formation while the liquid fraction of steam is simultaneously injected into the upper portion of the formation.
With these preliminary remarks in mind, the process is better understood by referring now to the drawings, in which FIG. 1 illustrates a subterranean, permeable, porous oil formation containing viscous petroleum being subjected to conventional steam flooding. Formation 1 is penetrated by injection well 2 and production well 3, each well being in fluid communication with the central portion of the formation by means of perforations 4 and 5. Steam is injected into well 2 and passes out into formation 1 by means of perforations 4. In this instance, the steam being injected into the formation is saturated, which simply means that there is present both a liquid phase and a gaseous phase simultaneously at the point of injection. Ordinarily saturated steam is defined in terms of quality by specifying the weight fraction which is in the vapor phase. Thus, 80 percent quality steam means that 80 percent of the steam on the basis of weight is vapor with the remaining 20 percent being liquid phase. Oil recovery operations usually involve saturated steam injection because of the high cost expense of generating superheated or all vapor phase steam. In addition, there are always substantial temperature losses throughout the full length of the injection well bore between the surface of the earth and the point of injection, so even if superheated steam is injected into the injection well at the surface, the steam entering the formation will likely be saturated steam because of the heat lost throughout the full length of the injection well.
As the two phase steam enters the portion of formation 1 immediately adjacent to perforations 4 in well bore 2 of FIG. 1, the vapor phase fraction of the steam begins migrating in an upward direction toward the top of the reservoir because of the difference in specific gravity between steam vapor and formation fluids. This occurs simultaneously with a horizontal motion caused by the pressure differential between injection well 2 and production well 3, with the result that vapors move horizontally and upwardly at the same time. This causes the characteristic slanting interface 6 between the steam swept zone and the unswept portion of the formation. It is not uncommon for steam to be channeling only through the upper 30 percent or less of the formation by the time the fluid reaches well bore 3. Once steam has broken through at well 3, continued injection of steam accomplishes little additional oil recovery, since the steam swept portion of the formation 1 above dotted line 6 in FIG. 1, will offer substantially less resistance to the flow than will that portion of the formation below dotted line 6 because of the difference in oil saturation. While there is some vertical movement of heat downward due to conduction, it is very small compared to convective movement upward. Steam injection can, therefore, be continued well past the point where steam vapor is flowing into production well 3, but little or no additional oil will be recovered and a substantial portion of formation 1 will not have been affected by injection of steam into the formation.
These and other problems associated with steam injection can be circumvented if the process is conducted in accordance with my invention as is shown in FIG. 2, in which formation 7 is penetrated by injection well 8 and production well 9. On the surface, a steam generator 10 is positioned near injection well 8 and operated so as to produce 85 percent quality steam. The output of generator 10 is sent directly to a steam separator 11, which separates the saturated steam into two separate phases, one being substantially all liquid and one being substantially all gaseous in phase. Ordinarily the gaseous phase will be essentially pure vapor phase water unless the oil recovery method being employed involves injection of other normally gaseous substances simultaneously with steam injection. The liquid component will very likely have appreciable amounts of salts dissolved therein as a consequence of the concentration effect which occurs when feed water having a nominal concentration of salts dissolved therein is passed through a steam generator, since all of the salts remain in the portion of the feed water which is not vaporized and thus they are concentrated in a ratio about equal to the ratio of the liquid component produced to the vapor phase component. In this instance, the presence of salts dissolved in the injection water is not objectionable so long as they do not cause injectivity problems adjacent the production well. Particulate matter should be removed from the feed water by filtering or other means before the water enters steam generator 10 in order to alleviate any formation plugging problems associated therewith.
The vapor phase portions of steam separated in separator 11 passes into tubing 12, which is terminated near the bottom of injection well 8. Perforations 13 in the bottom portion of well 8 permit the vapor phase steam to exit from the well and enter the formation. These perforations should be near the bottom portion of the formation, and will ordinarily be from about 5 to about 25 percent of the total vertical thickness of the formation.
The liquid portion of the separated steam passes through annular space 14 between tubing 12 and well casing 8. Packer 15 isolates the annular space, the packer being about midway between upper perforations 16 and lower perforations 13. The packer insures that substantially all of the liquid phase components separated from the steam which pass down annular space 14, exit through perforations 16 into the upper portion of oil formation 7.
The casing adequately cemented in place in well 9 should be perforated throughout a substantial portion of the viscous petroleum saturated interval, with production of petroleum and other fluids occurring by means of well 9.
It should be pointed out that while the two flow paths necessary in FIG. 8 to inject the liquid phase and gaseous phase components of steam into the formation in the desired points of entry are shown in FIG. 2 as employing a concentric tubing 12 with the annular space 14 between the well casing and the well tubing being utilized for liquid injection, which is the preferred method, parallel tubing strings or other arrangements may be employed, or the roles can be reversed, with liquid passing through the tubing and gaseous phase materials passing through the annular space. The arrangement shown is desirable, however, because it minimizes the effects of heat loss from the injection well to the portion of the overburden above the oil formation. Since phase change will occur and appreciable heat is lost from the gaseous phase materials, it is desirable to minimize the heat losses from the line carrying the gaseous phase component through well 8, such as by placing the gaseous phase in the inner concentric conductor.
If the injection is to be accomplished in a particularly deep formation, it may be desirable to increase the temperature of the gaseous phase materials after separation, so the material entering the formation will be substantially all in the gaseous phase at the point of entry at the bottom of the formation. This can be accomplished by an afterheater located between separator 11 and the well head of well 8, or a downhole heater may be utilized in some instances.
If the oil recovery method is to involve the injection of another material which is gaseous at injection conditions simultaneously or intermittently with steam vapor injection, the material can be mixed with the vapor phase component of steam in tubing 12 by means of suitable connections on the surface. Similarly, if a material which will be liquid at injection conditions, such as a solvent, is to be injected simultaneously and/or intermittently with steam, a connection with the line connecting steam separator 11 with the annular space of well 8 can provide for easily controlled addition of the additional substance.
In a slightly different embodiment, the saturated steam is not separated into liquid and gaseous components on the surface, but rather passes into the well bore through a single tubing string. A separator such as that shown in FIG. 3 is connected to the end of the tubing string, which permits a separation of saturated steam into separate gas and liquid phases. One means for accomplishing this involves a helix or helical shaped portion of the tubing with orifices located along the outer periphery of the helix. As the two phase fluid moves through the helical portion of the flow path, centrifical force will cause the liquid fraction to be located on the outside of the helix with the gaseous phase being confined to the inner portion. The small orificies permit the liquid portion to exit from the helix without any portion of the gaseous phase material passing therethrough. The bottom end of the helix then passes through a packer 18 which separates the annular phase below which is in fluid communication with perforations 19 at or near the bottom of the well formation from the perforations in the upper portion of the casing 20 at or near the top of the formation.
FIELD EXAMPLE
For the purpose of additional disclosure of a preferred method of employing the process of my invention to a particular set of field conditions, but without intending that it be in any way limitative or restrictive of my invention, the following pilot field example is furnished.
A subterranean, viscous petroleum reservoir is situated at a depth of 1800 feet. The average thickness of the petroleum reservoir is 90 feet. The petroleum contained in the reservoir has an API gravity of about 11° API, which is so high that little primary recovery can be achieved in this reservoir.
Two wells are drilled 250 feet apart to a depth about 5 feet below the bottom of the oil formation, and casing is set to the full formation depth and cemented at the bottom. A tubing string is run to about the midpoint of each casing. The production well is perforated from a point about 10 feet above the bottom of the formation to a point about 10 feet below the top of the formation. A 20 × 10 6 BTU/hr steam generator is located on the surface of the earth, with the output being fed to a steam separator capable of separating 85 percent quality steam into two streams, one of which is substantially all liquid phase and one of which is substantially all gaseous phase. The liquid phase output of the separator is connected to the annular space of the injection well between the production tubing and the casing, and the vapor phase output of the separator is connected to the tubing string. The injection well is perforated from a point about 5 feet above to a point about 15 feet above the bottom of the oil formation, and another set of perforations are formed from a point 15 feet below to a point 5 feet below the top of the formation. A packer is set isolating the annular space between the tubing string and the casing wall at a point just above the end of the tubing. As completed, the vapor phase portion of the generated steam is injected into the tubing which permits introduction of steam into the lower portion of the formation with the liquid phase portion being injected via the annular space into the formation through the perforations at the top of the formation.
Eighty-five percent quality steam is generated by the steam generator, which is fired by natural gas or other available fuel. To avoid initial fracturing or channeling, quantity is maintained initially at an injection pressure below fracturing pressure, usually at a rate below the steam generator capacity, gradually increased over a 10 day period until the final capacity of the generator, 20 × 10 6 BTU per hour and water equivalent of approximately 1500 barrels per day is reached, and the steam injection rate is held at or near the capacity of the generator thereafter. Steam vapor is injected exclusively into the bottom of the formation and hot liquid into the top. Steam injection is continued until production is obtained at the production well, and steam injection continued thereafter with oil production being maintained fairly constant, at about 150 to 250 barrels of oil per day with the water-oil ratio being about 6 to 10.
After the water-oil ratio has risen to about 100, it is determined that steam flood has recovered all of the oil that is economically feasible to recover by this method. Based on the projected aerial sweep in this pilot two well pattern, it is calculated that about 80 percent of the oil originally present in the full thickness of the area swept by the injected fluid has been recovered, which indicates the average vertical conformance could exceed 85 percent. This is considered quite satisfactory and substantially greater than would be expected if both liquid and vapor phase components of steam were injected into the formation in a conventional manner as a two phase fluid.
Thus, I have disclosed that it is possible to increase the vertical conformance of a well-to-well, steam injection throughput process by separating the steam into liquid and gaseous components and injecting the gaseous fraction into the bottom of the formation and the liquid portion into the top of the formation. The tendency for steam to channel quickly into the upper portion of the formation, bypassing a substantial portion of the oil near the bottom of the formation is thus greatly reduced, and the vertical conformance of the process is greatly improved.
While my invention has been described in terms of a number of illustrative embodiments, it is not so limited since many variations thereof will be apparent to persons skilled in the art of oil recovery, and particularly thermal oil recovery methods, without departing from the true spirit and scope of my invention. Similarly, while mechanisms have been proposed for purposes of explaining the improved benefits resulting from application of the process of my invention, this has been offered only for additional disclosure and it is not my intention to be restricted to any particular explanation of the mechanism or theory of operation of my invention. It is my desire and intention that my invention be limited and restricted only by those limitations and restrictions as appear in the claims appended hereinafter below.
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Viscous oil recovery methods employing well-to-well throughput steam injection are frequently less successful than anticipated because the process experiences poor vertical conformance, meaning that only a portion of the full vertical thickness of the oil saturated reservoir is contacted by the injected steam. Because the specific gravity of the vapor phase portion of saturated steam is substantially less than the specific gravity of formation petroleum fluids, the vapor phase steam channels across the upper portion of the formation and only contacts and displaces petroleum present in said upper portion of the formation, bypassing substantial amounts of petroleum in the lower portion of the formation. By separating saturated steam into two components, one predominantly liquid phase and one predominantly gaseous phase, and injecting the hot liquid into the upper portion of the formation and the vapor into the lower portion of the formation, substantially greater amounts of formation petroleum are contacted and recovered by steam. Steam may be separated into liquid and vapor phase components on the surface and injected by a separate flow path into separately completed intervals, or the separation may be accomplished in a downhole separator. The process may be applied using steam alone, or other gaseous and/or liquid phase additives to steam may be injected in the same manner.
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BACKGROUND OF THE INVENTION
The invention relates to rotary drilling tools, for use in drilling subsurface formations, of the kind comprising a tool body having a shank for connection to a drill string, and a plurality of cutters mounted on the tool body and formed with cutting edges defining a cutting profile.
The "cutting profile" of the drilling tool is an imaginary surface of revolution swept out by the cutting edges of the cutters as the tool rotates (with zero rate of penetration).
The invention is particularly, but not exclusively, applicable to drilling tools in which some or all of the cutters are preform (PDC) cutters each formed, at least in part, from polycrystalline diamond. One common form of cutter comprises a tablet, usually circular or part-circular, made up of a superhard table of polycrystalline diamond, providing the front cutting face of the element, bonded to a substrate which is usually of cemented tungsten carbide.
The tool body may be machined from solid metal, usually steel, or may be moulded using a powder metallurgy process in which tungsten carbide powder is infiltrated with metal alloy binder in a furnace so as to form a hard matrix.
The invention is particularly applicable to drill bits, and will be particularly described in relation thereto. However, it is to be understood that the invention is also applicable to other forms of drilling tools, such as hole openers and eccentric hole openers.
While PDC bits have been very successful in drilling relatively soft formations, they have been less successful in drilling harder formations and soft formations which include harder occlusions or stringers. Although good rates of penetration are possible in harder formations, the PDC cutters suffer accelerated wear and bit life can be too short to be commercially acceptable.
Studies have suggested that the rapid wear of PDC bits in harder formations is due to chipping of the cutters as a result of impact loads caused by vibration, and that the most harmful vibrations can be attributed to a phenomenon called "bit whirl". Bit whirl arises when the instantaneous axis of rotation of the bit precesses around the central axis of the hole when the diameter of the hole becomes slightly larger than the diameter of the bit. When a bit begins to whirl some cutters can be moving sideways or backwards relatively to the formation and may be moving at much greater velocity than if the bit were rotating truly. Once bit whirl has been initiated, it is difficult to stop since the forces resulting from the bit whirl, such as centrifugal forces, tend to reinforce the effect.
One method which has been employed to overcome bit whirl is to design the drill bit so that it has, when rotating, an inherent lateral imbalance force which is relatively constant in direction and magnitude. The gauge of the bit body then includes one or more low friction bearing pads which are so located as to transmit this lateral imbalance force to the part of the formation which the bearing pad is for the time being engaging. The low friction bearing pad thus tends to slide over the surface of the formation which it engages thereby reducing the tendency for bit whirl to be initiated.
In an alternative approach, bits have been designed in a manner to provide a structure which constrains the bit to rotate truly, i.e. with the axis of rotation of the bit coincident with the central axis of the borehole. One such approach is described in a paper titled "A new PDC cutting structure improves bit stabilisation and extends application into harder rock types", Paper No. SPE/IADC 25734 by G. E. Weaver and R. I. Clayton, Society of Petroleum Engineers, SPE/IADC Drilling Conference, Amsterdam, 23-25 Feb. 1993.
In PDC bits the cutters are normally arranged in spiral arrays with respect to the central axis of rotation of the bit so that the path swept by each cutter during each rotation overlaps the paths swept by other cutters disposed at slightly greater and slightly smaller radial distances from the bit axis. This provides an essentially smooth cutting profile to ensure that no part of the formation at the bottom of the borehole remains uncut. By contrast Weaver and Clayton proposed a cutter formation where the cutters, instead of being located in spiral formations, are disposed in concentric radially spaced arrays centred on the axis of rotation of the bit. In such an arrangement the cutters in each circular array sweep through essentially the same cutter path and the cutter paths of adjacent arrays do not overlap but are spaced apart in the radial direction. Consequently, the cutters define a series of concentric annular grooves in the cutting profile. As a result the cutters in each circular array cut a deep groove in the formation at the bottom of the borehole with annular ridges of uncut formation extending upwardly between the adjacent circular arrays of cutters.
The annular ridges increase significantly the vertical contact between the cutters and the formation so that any lateral force acting on the bit, whether externally generated or from cutting structure imbalance, is distributed over a larger contact area. This reduces the unit stress on the formation and the result of lower unit stress is said to result in less tendency for a cutter to bite laterally into the formation and initiate bit whirl.
However, such arrangements depend, in operation, on the upstanding annular ridges of formation between the cutter arrays eventually breaking off when they reach such a height that they cannot withstand even the lower unit lateral stress applied to them. In order to ensure that this occurs, it is necessary for the annular ridges to be of narrow radial width. It also means that the point at which an annular ridge breaks off may be unpredictable since it will depend on the nature of the formation in the ridge and the lateral force which happens to be applied to the ridge during drilling. If a ridge breaks off when it is comparatively low in height, it will not provide a useful contribution to inhibiting lateral displacement of the bit and inhibiting the initiation of bit whirl. On the other hand, if a ridge does not break off until it has reached a considerable axial depth, the ridge may bear on and abrade the surface of the bit body between the adjacent arrays of cutters, resulting in wear of the bit body, an increase in the frictional restraint to rotation of the bit, and the necessity of increasing the weight-on-bit in order to continue drilling at the same rate of penetration.
International Patent Application No. WO 93/13290 (Dresser Industries Inc.) describes various drill bits of the above-mentioned kind, including arrangements where means are provided to assist removal of the tops of the ridges as drilling progresses.
The present invention relates to improved designs of rotary drill bit in which the above-mentioned disadvantages may be overcome.
SUMMARY OF THE INVENTION
According to the invention there is provided a rotary drilling tool comprising a tool body having a shank for connection to a drill string, a plurality of cutters mounted on the tool body and formed with cutting edges defining a cutting profile, the cutters including at least two concentric radially spaced arrays of primary preform polycrystalline diamond cutters where the cutters in each array are spaced circumferentially apart around the central axis of rotation of the tool and are so disposed radially as to define between primary cutting edges of the two arrays an annular groove in the cutting profile, the deepest portion of said groove in the cutting profile being defined by secondary cutting edges on secondary preform polycrystalline diamond cutters located at a radial distance from the tool axis which is intermediate the radial distances from said axis of the primary cutting edges in said two cutter arrays respectively.
Preferably said secondary cutting edges are of greater width, in a radial direction, than said annular groove in the cutting profile defined between said primary cutting edges.
In the above-mentioned arrangement proposed by Weaver and Clayton the deepest part of each annular groove in the cutting profile is defined by the tool body with the disadvantageous results previously referred to. According to the present invention, however, the deepest part of the groove in the cutting profile is at least partly defined by cutting edges of preform polycrystalline diamond cutters. Consequently, the upper free extremity of the or each annular ridge of formation formed during drilling is positively cut by the secondary cutting edges before it can engage the tool body. In view of this, the concentric arrays of cutters can be spaced more widely apart in the radial direction so that the annular ridge of formation can be much thicker in relation to its height. The arrangement may thus be such that the ridge does not break off as a result of lateral forces but remains whole all the time its upper edge is being cut or abraded. Thus, not only does the ridge of formation not abrade the tool body itself, but it is constantly in position to resist lateral displacement of the drilling tool and is unlikely to suffer premature breaking off which might otherwise allow lateral displacement to occur.
Each circular array of cutters may comprise a plurality of cutters of similar width located at substantially the same radial distance from the tool axis. Alternatively, each array may include a plurality of cutters located at different radial distances from the tool axis. In this case the radial width of the array is determined by the width of the total path swept by the combination of cutters in the array, during one revolution.
The secondary cutting edges may be provided on one or more secondary arrays of cutters located at least in part radially between the primary cutter arrays.
In the case where one or more secondary arrays of cutters are provided, each secondary array may also comprise cutters spaced circumferentially apart around the central axis of rotation of the drill bit and having cutting edges disposed at substantially the same radial distance from said axis. Again, each secondary array may comprise similar width cutters at the same radial distance from the bit axis, or cutters at different radial distances from the tool axis.
Preferably the aforesaid annular groove in the cutting profile is wholly defined by the cutting edges of the primary cutters and the cutting edges of the secondary cutters. For example, the sides of the groove may be defined by the cutting edges of the primary cutters in the first said arrays, and the bottom of the groove defined by the cutting edges of cutters in the secondary array or arrays.
In the latter case the cross-dimension of each secondary array of cutters, measured radially, is preferably greater than the radial spacing between the cutting edges of the primary cutters so that a cutting edge of each secondary cutter extends across the whole width of the annular groove in the cutting profile.
The secondary cutters may be substantially similar to the primary cutters. For example they may be in the form of circular or part-circular tablets.
At least some of the secondary cutters may be associated with a respective primary cutter, substantially all of said associated secondary cutters being circumferentially spaced by a substantially equal circumferential distance from their respective primary cutters. Each such associated secondary cutter may be spaced either frontwardly or rearwardly of the associated primary cutter with respect to the normal direction of rotation of the tool.
Back-up elements may be associated with at least some of the primary cutters, and/or at least some of the secondary cutters, each back-up element being located at substantially the same radial distance from the bit axis as its associated primary or secondary cutter but being spaced circumferentially therefrom, the back-up element being spaced inwardly of the portion of the cutting profile defined by its associated primary or secondary cutter.
The back-up element may be spaced forwardly or rearwardly of its associated primary or secondary cutter with respect to the normal direction of rotation of the drilling tool.
The back-up element may comprise a further cutter substantially similar to its associated primary or secondary cutter, or it may comprise an abrasion or depth stop element.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic end elevation of a prior art PDC drill bit designed to improve stabilisation while drilling,
FIG. 2 is a diagrammatic section through a radial line of cutters in the drill bit of FIG. 1 showing part of the bottom hole pattern cut in the formation by the cutters,
FIG. 3 is a diagrammatic end view of one form of drill bit in accordance with the present invention,
FIG. 4 is a sectional view showing the bottom hole pattern cut by a line of cutters in the drill bit of FIG. 3,
FIGS. 5 and 6 are similar views to FIG. 4 showing alternative cutter configurations in accordance with the invention,
FIG. 7 is a diagrammatic section taken along a circumference of a drill bit showing one arrangement of the primary and secondary cutters,
FIG. 8 is a similar view to FIG. 7 showing an alternative arrangement of primary and secondary cutters,
FIG. 9 is a similar view showing a primary cutter with a back-up element,
FIG. 10 is a diagrammatic end view of a further form of drill bit in accordance with the invention,
FIG. 11 is a diagrammatic sectional representation of the cutting pattern of a line of cutters in the drill bit of FIG. 10,
FIG. 12 is a diagrammatic end view of another form of drill bit in accordance with the present invention,
FIG. 13 is a sectional view showing the bottom hole pattern cut by a line of cutters in the drill bit of FIG. 12,
FIG. 14 is a diagrammatic end view of a further of drill bit in accordance with the present invention, and
FIG. 15 is a sectional view showing the bottom hole pattern cut by a line of cutters in the drill bit of FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the prior art arrangement shown in FIGS. 1 and 2, the end face 10 of the bit body 11 is formed with a number of blades 12, a series of PDC cutting elements 13 being spaced apart side-by-side in a generally radial direction along each blade. For the purposes of illustration, three such blades 12 are shown in FIG. 1 but it will be appreciated by those skilled in the art that any number of blades may be employed and the blades may carry different numbers of cutters.
In accordance with the principles previously mentioned, it has hitherto been the usual practice for the cutters 13 to be so located on their respective blades that the path swept out by each cutter overlaps the paths swept out by two or more other cutters which are located at slightly greater or lesser radial distances from the axis 14 of rotation of the bit. According to the prior art arrangement of FIGS. 1 and 2, however, the cutters are divided into a number of concentric radially spaced circular arrays of cutters, The cutters in each array are mounted on different blades 12 and are thus spaced circumferentially apart around the axis 14, the cutters in each circular array being disposed at substantially the same radial distance from the axis 14 so that all of the cutters in each circular array sweep out essentially the same circular path.
As a result, the cutting profile of the drill bit comprises a series of concentric annular grooves and, during drilling, as best seen in FIG. 2, each array of cutters 13 cuts an annular groove 15 in the formation 16, leaving an annular upstanding ridge 17 of formation between adjacent arrays of cutters. As previously described, the ribs 17 tend to inhibit lateral displacement of the drill bit during drilling.
However, the free upper extremities of the ribs 17 must eventually break off to allow further downward penetration of the cutters 13 into the formation 16. The point at which each rib breaks off may vary depending on the precise composition of the formation in the rib, its thickness, and the lateral force applied to the rib by the adjacent cutters. It will be appreciated of course that the spacing of the arrays of cutters must be sufficiently small so that the ribs 17 are sufficiently narrow in thickness to ensure that they eventually break off. As illustrated in FIG. 2 some ribs, such as indicated at 17a, may break off at a point where it no longer provides much lateral restraint to the bit. Other ribs, such as is indicated at 17b, may not break off until the rib has engaged the surface of the blade 12 or bit body on which the cutter is mounted so that the upper extremity of the rib must be worn away by the surface of the blade or bit body. This in turn will cause abrasive wear of the bit body, increase the frictional restraint to rotation of the bit, and necessitate an increase in the weight-on-bit in order to continue drilling at the same rate of penetration.
FIGS. 3 and 4 are similar views to FIG. 1 and 2 showing an arrangement according to the present invention. In this case, by way of example, the end face 18 of the bit body 19 is again formed with three generally radial blades 20 each of which carries a line of primary cutting elements 21 arranged side-by-side along the blade. As in the prior art arrangements the cutters 21 are arranged in a series of concentric arrays, the cutters in each circular array being disposed at substantially the same radial distance from the bit axis 22. In this case, however, there is also mounted on each blade 20 a line of secondary cutters 23. The secondary cutters 23 are also arranged in concentric circular arrays so that each secondary cutter on each blade 20 is at the same radial distance from the axis 22, and sweeps out the same circular path as the corresponding secondary cutter on each of the other two blades. However, the secondary cutters 23 are spaced from the axis 22 by radial distances which are intermediate the radial distances from the axis 22 of adjacent primary cutters 21, so that the circular path swept out by each secondary cutter 23 overlaps the circular paths swept out by two primary cutters 21 in adjacent circular arrays.
Each secondary cutter 23 is so mounted on the blade 20 that it is spaced inwardly from the parts of the cutting profile defined by the adjacent primary cutters 21.
As in the previous arrangement, during drilling each primary cutter 21 forms an annular groove 24 (see FIG. 4) in the formation 25 and due to the spacing of the arrays of primary cutters 21 this forms between each array an upstanding rib of formation as indicated at 26 in FIG. 4. Contrary to the arrangement of FIGS. 1 and 2, however, the upper extremity of each rib 26 is not required to break off to allow further penetration of the primary cutters 21 into the formation, but instead the upper extremity of each rib is positively cut away by the cutting edge of a secondary cutter 23. This has two important advantages when compared with the prior art arrangement.
Firstly, since the upper extremity of each rib 26 is always positively cut away by a secondary cutter 23, there is no possibility of it rubbing on the surface of the blade 20 or bit body to cause abrasive wear and frictional restraint to rotation of the drill bit. Secondly, since the upper extremity of each rib 26 is always positively cut away, it is not necessary for the ribs 26 to be sufficiently thin to ensure that they break off eventually. Consequently, the spacing of adjacent arrays of primary cutters 21 can be greater to form a thicker rib 26 which will then provide far stronger and more consistent restraint to lateral displacement of the bit than is possible with the thin ribs 17 of the arrangement of FIGS. 1 and 2.
Although FIGS. 3 and 4 show only a single secondary cutter overlapping the paths swept out by two primary cutters 21 in adjacent circular arrays, each secondary cutter 23 might be replaced by two or more secondary cutters, the secondary cutters being at different radial distances from the axis 22 so that the paths swept out by the secondary cutters overlap each other as well as the overlapping paths swept out by the associated primary cutters 21. Such an arrangement is shown in FIGS. 12 and 13, where the primary cutters are referenced 63 and the secondary cutters are referenced 64.
Similarly, each single primary cutter 21 might be replaced by two or more circumferentially spaced primary cutters which are at different radial distances from the axis 22 so that the paths they sweep out during rotation overlap. The radial width of each primary array is then equal to the overall width of the overlapping paths of the individual primary cutters. Such an arrangement is shown in FIGS. 14 and 15 where the primary cutters are referenced 65 and the secondary cutters are referenced 66.
Although in the arrangements of FIGS. 3 and 4 the secondary cutters 23 are shown as the same diameter as the primary cutters 21 they could be larger or smaller or of different shape. Although the secondary cutters 23 are shown as being located in concentric radially spaced arrays, in similar fashion to the primary cutters 21, this is also not essential and the secondary cutters could be distributed in any fashion over the face of the drill bit provided that their contribution to the overall cutting profile is to define the deepest parts of the annular grooves in the cutting profile which form the ribs 26.
Instead of the secondary cutting edges which remove the tops of the ribs 26 being provided by separate secondary cutters 23, the primary cutters themselves may be so shaped as to provide the secondary cutting edges. FIG. 5 shows such an arrangement.
In the arrangement of FIG. 5 the primary cutters 27 are again located in concentric circular arrays so that all the cutters in each array sweep out the same path. In this case, however, the cutters 27 are shaped so as to taper inwardly as they extend away from the bit body or blade 28 and are so located radially of the bit that the wider portions 29 of the cutters have overlapping paths and the narrower portions 30 of the cutters are spaced apart. (It will be appreciated that the cutters 27 will have to be circumferentially, as well as radially spaced, to allow their paths to overlap as shown.) Again, therefore, the cutting profile defined by the cutters 27 comprises a number of concentric annular grooves resulting in the formation, during drilling, of annular upstanding ribs 31 in the formation 32 being drilled. In this case as drilling proceeds the upper edges of the ribs 31 are constantly being removed by the secondary cutting edges provided by the wider portions 29 of the cutters 27.
FIG. 6 shows an arrangement in which there are provided concentric arrays of tertiary cutters 33 in addition to arrays of primary cutters 34 and secondary cutters 35. In this case the tertiary cutters 33 are located even further away from the formation than the secondary cutters 35 and both the secondary cutters 35 and tertiary cutters 33 are arranged in concentric radially spaced arrays. As drilling proceeds the primary cutters 34 form concentric annular grooves 36 in the formation 37 to form annular ribs 38. The free extremities of the annular ribs 38 are positively cut away by the secondary cutters 35 in similar manner to that described in relation to FIG. 4. In this case, however, if drilling continues until the primary cutters 34 are totally worn away, the secondary cutters 35 will take over as the primary cutters of the formation. Since the secondary cutters 35 are also located in concentric spaced arrays, they too will form annular grooves in the formation separated by upstanding annular ribs of formation which will extend between the adjacent arrays of secondary cutters 35 and have their free extremities positively cut away by the tertiary cutters 33. Further rows of cutters may be provided, if required.
Although, for purposes of illustration in FIGS. 3, 4 and 6, the primary cutters in the different circular arrays are shown as being mounted side-by-side along a generally radial line, this is not essential to the invention and the primary cutters in different circular arrays could equally well be circumferentially spaced from one another around the bit, provided that the cutters in each array maintain the same radial distance from the axis of rotation of the bit. The same applies to the secondary cutters.
FIG. 7 is a circumferential section through part of one of the blades 20 of the arrangement of FIG. 3 and shows a typical arrangement whereby a secondary cutter 23 may be mounted inwardly of the part of the cutter profile (shown dotted at 39) defined by an associated primary cutter 21. In each case the cutting element 21 or 23 is a PDC cutter comprising a thin cutting table of polycrystalline diamond 40 bonded in a high pressure, high temperature press to a substrate 41 of hard material such as tungsten carbide. The cutter 21 is brazed to a suitably inclined surface on a stud or post received in a socket in the blade 20.
In the arrangement of FIGS. 3 and 7 the secondary cutters 23 follow the primary cutters 21 on the blade 20 with respect to the normal direction of rotation of the drill bit. However, according to another aspect of the present invention, there may be advantage in reversing this arrangement, as shown in FIG. 8, so that each secondary cutter 23 is mounted on the blade 20 so as to be ahead of the associated primary cutters 21 with respect to the normal direction of rotation. Thus, the arrangement of FIGS. 3 and 7 may suffer from the disadvantage that the primary cutters 21, since they project further from the bit body than the secondary cutters 23, may prevent adequate flow of drilling fluid to the secondary cutters. Consequently, there may be inadequate cleaning and cooling of the secondary cutters leading to their deterioration and eventual ineffectiveness. Due to inadequate cleaning, there may also be "bailing" of formation cuttings around the secondary cutters 23, leading to a reduction in their effectiveness.
In the arrangement of FIG. 8, on the other hand, the cutting elements 23, being on the leading side of the blade 20, will be exposed to the full cooling and cleaning action of the drilling fluid. At the same time, since the primary cutters 21 project further from the bit body than the secondary cutters 23 they too will receive an adequate flow of drilling fluid for purposes of cleaning and cooling.
In the arrangement of FIG. 8 it may be desirable to provide increased relief behind each primary cutter 21 to reduce the area of wear flat which develops behind the cutting edge as the cutter wears down.
In order to increase the resistance of the drill bit to displacement by lateral forces, there may be associated with at least certain of the primary cutting elements back-up elements which are arranged at the same radial distance as each primary cutting element so as to enter the groove cut in the formation by the primary cutting element. FIG. 9 shows such an arrangement. In this case the primary cutting element 42 is again mounted on a post 43 received in a socket in the blade 44 on the bit body and there is also mounted in a socket in the blade 44 an abrasion element 45 which is located at the same radius from the axis of the bit as the cutting element 42.
The abrasion element 45 may be in the form of a tungsten carbide stud which may have natural or synthetic diamond embedded therein. Preferably the abrasion element 45 is of essentially the same width as the cutting element 42, as measured in a radial direction, so that it generally fits within the groove cut in the formation by the cutting element 42. Preferably, however, the abrasion element 45 extends away from the bit body to a lesser extent than the cutting element 42 so that during normal drilling it does not bear on the bottom of the groove cut by the cutting element 42.
The abrasion element 45, in addition to providing restraint against lateral forces on the drill bit, also serves as a depth stop to limit the extent of penetration of the primary cutter 42 into the formation, and may also serve as a back-up cutter should the cutter 42, or indeed any other primary cutter at the same radius, suffer catastrophic failure.
Although in FIGS. 7-9 the secondary cutters and back-up elements are each sown as being mounted on the same blade as the respective associated primary cutter, it will be appreciated that the secondary cutter or back-up element might also be mounted on a different blade from its associated primary cutter.
In the arrangement of FIG. 9 the abrasion element 45 is shown on the leading side of the primary cutter 42, and this gives the cooling and cleaning advantages described above in relation to the arrangement of FIG. 8. However, it will be appreciated that the abrasion element might also be located rearwardly of the primary cutter 42 with respect to the normal direction of rotation of the bit.
The arrangements of FIGS. 8 and 9, where a secondary cutter or abrasion element is located on the leading side of the primary cutter, is particularly applicable to the present invention where the primary cutters are arranged in concentric circular arrays with the advantages given thereby, as previously discussed. However, it will be appreciated by those skilled in the art that placing a secondary cutter or abrasion element on the leading side, instead of the trailing side, of an associated primary cutter may also have advantage in other forms of PDC drill bit since the advantages of adequate cleaning and cooling will apply regardless of the arrangement of the primary cutters on the bit body.
In the arrangement of FIG. 9 the composition of the back-up elements 45 may be varied according to their location on the drill bit. For example, the composition of the back-up elements at the nose of the bit may be selected to give good wear resistance, whereas elements at the gauge of the bit may be formed from a composition selected to give greater impact resistance.
FIG. 10 shows in greater detail a typical drill bit designed according to the present invention and FIG. 11 shows diagrammatically one half of the bottom hole pattern cut by the drill bit of FIG. 10.
Referring to FIG. 10, the bit body 46 is formed with six blades 47-52. Each blade has mounted thereon four primary cutters 53 extending side-by-side along the blade from the outer extremity thereof. Corresponding primary cutters 53 on each blade are disposed at the same radial distance from the central axis of rotation 60 of the bit so as to provide four concentric radially spaced circular arrays of cutters, each array comprising six circumferentially spaced primary cutters 53.
Each blade also carries, spaced in front of the four primary cutters 53, three secondary cutters 54 which are set closer to the bit body than the primary cutters 53, the arrangement being similar to that shown in FIG. 8.
The secondary cutters 54 are arranged in three concentric circular arrays, each array again comprising six circumferentially spaced cutters 54 arranged at the same radial distance from the axis 60. The radial distance of each array of secondary cutters from the axis 60 is intermediate the radial distances from the axis of the two adjacent circular arrays of primary cutters.
FIG. 11 shows one half of the cutting profile defined by the cutters on the bit. The portions of the profile defined by the four circular arrays of primary cutters 53 are indicated at 53' and the portions defined by the three circular arrays of secondary cutters 54 are indicated at 54'. The cutters therefore act on the formation in similar manner-to that shown in FIG. 4 so as to form upstanding concentric annular ribs in the formation around the outer portion of the bottom of the borehole.
All of the blades of the drill bit carry a further cutter 55 spaced radially outwardly of the secondary cutters. In addition blade 52 carries a single further cutter 56 spaced radially inwardly of the secondary cutters 54 on that blade, and blades 47 and 50 each carry four further cutters 57 spaced side-by-side along the blade radially inwardly of the secondary cutters 54. The cutters 56 and 57 are disposed at various radial distances from the axis 60 and are not grouped in concentric spaced circular arrays as is the case with the primary and secondary cutters. The paths swept out by the cutters 56 and 57 therefore overlap in more conventional manner to provide a cutting profile as indicated generally at 58 in FIG. 11.
An arrangement according to the invention, and generally of the kind shown in FIGS. 10 and 11, allows the production of a heavy-set drill bit without necessarily requiring an increase in the number of blades on which the cutters are mounted. In certain circumstances it is considered desirable to keep the number of blades to a minimum to reduce the possibility of "bailing".
In conventional manner, the end surface of the bit body, between the blades, is formed with a number of nozzles 61 (six in the arrangement of FIG. 10) which deliver drilling fluid to the surface of the bit from an internal passage for the purpose of cooling and cleaning the cutters. In arrangements according to the present invention it may be advantageous for at least some of the nozzles to be so located and orientated that the jets of drilling fluid emerging from the nozzles impinge on the formation within one or more of the annular grooves formed by the primary cutters. The drilling fluid will then tend to flow along the grooves to reach not only the primary cutters which are cutting the grooves, but also the associated secondary cutters. The grooves in the formation thus serve to distribute the drilling fluid over the face of the drill bit.
In FIG. 11 the nozzles are indicated diagrammatically at 61' and the lines 62 indicate the direction of the centreline of the jet of fluid which emerges from each nozzle.
In the above embodiments the invention has been described as applied to a drill bit for drilling a new hole in subsurface formations. However, as previously mentioned, the invention is also applicable to drilling tools of other types, such as hole openers and eccentric hole openers.
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A rotary drilling tool has a plurality of cutters mounted on the tool body and formed with cutting edges defining a cutting profile. The cutters include at least two concentric arrays of primary preform polycrystalline diamond cutters which are radially spaced so as to define an annular groove in the cutting profile, between the two arrays. The deepest part of the groove in the cutting profile is defined by secondary preform polycrystalline diamond cutters located at a radial position which is intermediate the radial positions of the two arrays of primary cutters, so that in use the secondary cutters remove the tops of annular ridges of formation left between the arrays of primary cutters.
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BACKGROUND OF THE INVENTION
The present invention relates to a method of pre-treating secondary fibers prior to bleaching.
It is known when bleaching secondary fibers to allow the pulp to pass through a disperser in order to disperse any ink particles or like particles that may remain. After having passed through the dispersion stage, the pulp is transported to a bleaching stage, in which the bleaching chemicals peroxide, alkali and silicate are added. This known process consumes a large amount of the relatively expensive peroxide. It is also known to bleach secondary fibers by supplying oxygen to the system.
The known bleaching processes in which oxygen is used are relatively complicated. The oxygen treatment process is effected in a separate bleaching stage, in a pressurized reactor with a reactor residence time as long as at least ten minutes. The oxygen treatment process is also effected under alkaline conditions and at high pressure. One kilogram of peroxide is about ten times the price of oxygen. It is therefore desirable to keep the consumption of peroxide down to the lowest possible level and to replace peroxide with, for instance, oxygen to the greatest possible extent. Normally, it is not difficult to achieve desired pulp brightness when bleaching. When problems concerning brightness occur, it may be because the secondary paper contained a large percentage of mechanical pulp, large quantities of printing ink or not readily bleached ink or colors. Consequently, it is not only important to maintain a low peroxide consumption level, but also to increase brightness of the pulp in the bleaching process. EP-A-557 651 discloses a process for treatment of secondary fibre pulp. This known process is adapted to clean and treat secondary fibers of various qualities in one single process. This document discloses a screw digester, i.e. a digester which comprises a feeding screw and in which the pulp is subjected to chemical pulping. During the chemical pulping, usual chemical additives, i.e. NaOH, H 2 O 2 and O 2 , are added. The pulping takes place under high pressure, 70-135 psi (490-950 kPa) and at a temperature of 70-110° C. The residence time in the pulper is at least 30 min. The purpose of the feeding screw of the screw digester disclosed is to transport the pulp from the inlet and to the outlet end and not to mechanically process or mix the pulp. Furthermore, it is not mentioned in EP-A-557 651 that the treatment in the screw digester would result in a uniform distribution of the ink particles or the added oxygen in the secondary fibre pulp.
U.S. Pat. No. 4,909,900 discloses the treatment of a fibre pulp mixture, which may include secondary fibers, by means of a disperser. Example 1 refers to reductive bleaching by sodium dithionite and example 2 to oxidative bleaching by hydrogen peroxide. It is not mentioned that oxygen may be used together with the bleaching technique disclosed in this document. In example 2 it is more closely disclosed that a solution comprising one percent of hydrogen peroxide is delivered to the pulp by means of a nozzle in a feeding conduit from which the pulp is introduced to a feeding screw transporting the pulp to the disperser. Thus, the hydrogen peroxide is added to the pulp at a position upstream the disperser in which the mechanical treatment of the pulp takes place.
U.S. Pat. No. 5,234,544 discloses the inking and bleaching of secondary fibre pulp by means of oxygen and particularly that the pulp is brought into contact with alkali, oxygen and a surfactant in a pressurized reaction zone. The residence time in the reaction zone is relatively long. In Example 1 it is disclosed that the pulp is supplied to the reactor at a relatively low consistency of 10% and that the pulp is retained in the reactor and periodically mixed therein by means of a high shear mixer.
SUMMARY OF THE INVENTION
The object of the present invention is therefore to provide a simple method which will enable secondary fibers to be bleached more effectively.
This object is achieved in accordance with the aforesaid method by virtue of supplying oxygen in accordance with the proposal set forth in the characterizing clause of claim 1, and in accordance with the aforesaid arrangement having the characteristic features set forth in the characterizing clause of claim 7.
Thus, the present invention enables the brightness of the bleached pulp to be maintained while making large savings in peroxide consumption; alternatively, the brightness of the pulp can be further enhanced with maintained peroxide consumption. In other words, the present invention enables both oxygen and peroxide to be used in a very simple and a very effective manner when bleaching secondary fibers. This is of the greatest significance, since the combination of peroxide and oxygen when bleaching secondary fibres results in a synergistic effect whereby a further increase in pulp brightness is obtained. Since oxygen is now supplied in an existing process stage for mechanical treatment and mixing of the pulp, no additional, separate reactor is required for supplying the oxygen. Furthermore, the oxygen treatment process need not be carried out at the high pressure that prevails in such a separate reactor, since the mechanical treatment and mixing of the pulp that takes place in the mechanical treatment apparatus is sufficient to distribute the oxygen uniformly and finely throughout the pulp. It will be understood that all this makes the process equipment simpler. The process time can also be kept shorter, since the admixture of oxygen with the pulp in a separate reactor requires a long residence time, whereas the admixture of oxygen in the pulp in the mechanical treatment apparatus is effected relatively quickly as a result of the vigorous, powerful, mechanical treatment and mixing processes that take place.
Claims 2-6 and 8-11 define advantageous embodiments of the inventive method and of the inventive apparatus respectively. Claims 3 to 6 define the conditions in the mechanical pulp treatment apparatus by means of which the good pulp bleaching results are achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 shows a schematic illustration of dispersion and bleaching stages; and
FIG. 2 shows a graph of change in pulp brightness versus charge of peroxide.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In brief, the recycling process can be applied to convert secondary or recycled paper to useful pulp in the following way. The secondary paper is delivered to a high concentration slusher, or pulper, together with such chemicals as NaOH and hydrogen peroxide, for instance. The paper is pulped at a temperature of about 15° C., whereafter the pulp is screened, washed and de-inked in different stages with the aid of mutually different, known methods. After having been subjected to these process stages, the concentration of the pulp is increased to a higher level, for instance to a concentration of 20 and 40% in a double-wire press, for example. The pulp is then heated in a steam, or vapor, mixer to a temperature of between 60 and 100° C., and then transported to a disperser. No chemicals are normally added in this stage of the process. After the dispersion process, the pulp is transported with the aid of a screw feeder, to which bleaching chemicals, for instance H 2 O 2 and auxiliary chemicals, and steam are delivered. The pulp is transported by the screw feeder to the bleaching tower, where it is kept for a given period of time. After being discharged from the bleaching tower, the pulp is neutralized to a suitable pH prior to being transported to a pulp silo and to the paper mill.
When practicing the inventive method, the pulp m is supplied, in a first process-stage, to a slushing device. Thereafter the pulp is exposed to a de-inking treatment in one or more stages according to known technique. After such a treatment, in which at least a part of the ink particles is removed, the pulp m is transported to a press 2, for instance, in which it has been pressed to a concentration of between 15 and 50%, preferably 20 to 40%, and then particularly to about 30%. Therefrom the pulp m is transported to a steam mixer 3, for instance in the form of a screw conveyor. The pulp m is heated to a high temperature of between 60 and 100° C., preferably between 80 and 95° C., and then particularly to 90° C., with the aid of steam delivered to the screw conveyor through the medium of supply lines 9. The thus heated pulp having the aforesaid relatively high dry solids content, i.e. with the high pulp consistency, is then delivered to a disperser 1.
The disperser 1 is a device which refines, mixes and works the pulp mechanically. The purpose of the device is to disperse throughout the pulp any ink particles that may remain, so that these remaining ink particles will scatter light more effectively and thus make the pulp appear brighter, while also making the ink particles more accessible to the bleaching agent and therewith responsive to reaction therewith. In the case of the illustrated embodiment, there is used a disc disperser 1 which includes two mutually opposing discs which rotate in opposite directions relative to one another and which are identified in the drawing by reference numerals 13 and 14. The pulp m is delivered to the centre of the disperser, between its mutually rotating discs 13, 14 and is there subjected to vigorous, powerful, mechanical treatment and mixing over a short period of time, such that the pulp will not lose its mechanical strength properties. This treatment process involves mixing the pulp and disintegrating large agglomerations or clumps. It will be obvious to those skilled in this art that other types of dispersers may also be used. The disperser may, for instance, have the form of an appropriate grinding, attrition, refining or shredding device.
According to the embodiment of the invention a delivery line 5 is opening out into the centre of the disperser. Through this line 5 gaseous oxygen is delivered from an oxygen source 12 directly into the pulp m present in the centre of the disperser 1. The oxygen is delivered at a pressure of between 0 and 10 bars, preferably about 2-6 bars, and in an amount corresponding from 2 to 20 kilogram per ton of dry pulp, preferably about 7-10 kilogram per ton pulp. As will be understood, remaining ink particles in the pulp are finely dispersed as a result of the vigorous, powerful mechanical working of the pulp in the disperser 1, and the oxygen is also finely distributed uniformly throughout the pulp m. As before mentioned, the pulp m, delivered from the steam mixer 3, is transported into the disperser 1 by means of a screw conveyor 6, for instance. The risk of the oxygen supplied flowing back in a direction reverse to the process direction is very slight, since the pulp m is pressed into the disperser 1. The atmosphere in the disperser 1 is saturated with steam, which enhances the reliability, or security, of the process. As the pulp m leaves the disperser 1 through the outlet device 15, the pulp is conveyed by a screw conveyor 7 to a bleaching tower 8. Steam is delivered to the pulp in the screw conveyor 7 via the delivery device 10, whereas bleaching chemicals such as peroxide, alkali and silicate are delivered through the delivery device 11.
There is described in the following an experiment in which it was possible to evaluate the effect that oxygen delivered to the disperser 1 had on the brightness of the bleached pulp m. The tests were carried out in accordance with the process described above in which the supply of oxygen and other chemicals were the sole changes in the process. The amount of peroxide delivered to the system was decreased as the brightness of the pulp increased after the bleaching process.
The tests included
a) a reference test in which no oxygen was supplied;
b) tests in which oxygen was supplied;
c) tests which included a combined supply of oxygen and sodium hydroxide; and
d) tests which included a combined supply of oxygen, sodium hydroxide and hydrogen peroxide to the disperser.
It was endeavoured to achieve a bleached pulp of desired brightness in all of the tests, in this case a brightness of 80-84% ISO. The total amount of sodium hydroxide supplied was not changed in tests c) and d), and the supply of sodium hydroxide was instead decreased to a corresponding extent in the bleaching stage. It will be noted, however, that there is a relationship between the supply of peroxide and the supply of NaOH in the bleaching stage. Neither were NaOH and hydrogen peroxide delivered directly into the disperser, but were delivered instead to the steam mixer located upstream of the disperser in the process. The process conditions varied radically during the course of the tests, mainly due to changes in the incoming pulp, the brightness and bleachability of which varied greatly. Generally, the variations observed during one calendar day were smaller than the variations that occurred from one day to the next. The brightness of the de-inked pulp and the supply of peroxide thereto were kept at a constant level during the first days of the test. After having supplied oxygen to the process, the brightness was found to have increased by three units. Thus, the brightness of the pulp was doubled by the bleaching process, i.e. from three units to six units. The supply of peroxide was decreased during the following days of the test, while commencing the oxygen supply at the same time. Data relating to brightness changes when bleaching in the absence of oxygen is available.
The mean values of the daily mean values are given in Table 1, which shows that the supply of oxygen alone provides the best result, with more than a doubling in the brightness of the pulp with each kilogram of peroxide supplied. A supply of sodium hydroxide or peroxide+sodium hydroxide upstream of the disperser did not improve on the results obtained with oxygen. The difference is relatively small, which can thus be taken as an indication that there is no difference at all when oxygen is supplied alone or together with part of the bleaching chemicals. This is somewhat surprising. One explanation may be that no true reaction takes place with the oxygen in the disperser. The delivery of oxygen to the disperser results in an effective mixture of oxygen bubbles in the pulp of high concentration, so that the oxygen becomes uniformly and finely distributed in the pulp. When the pulp then reaches the bleaching chemical mixer in which peroxide is added, the mixture of oxygen and peroxide constitutes the active bleaching components. In order to confirm the improvements achieved with oxygen still further, data was chosen in another way; see Table 2. In this case, data was excluded when the brightness of the incoming de-inked pulp was low or high. Thus, data was also calculated when the resultant brightness of the bleached pulp lay above or beneath the range 80-84% ISO. It is also evident from this alternative method that the addition of oxygen results in improved peroxide bleaching, and that the amount of peroxide consumed for a given increase in brightness is roughly half the amount of peroxide that is consumed when no oxygen is added.
The graph, or diagram, illustrated in FIG. 2 shows how brightness of the pulp varied with the supply of peroxide in the different tests.
As will be seen from the diagram in FIG. 2, when bleaching pulp with peroxide, the brightness of the pulp increases when oxygen is added thereto. Whether oxygen is supplied together with alkali or peroxide would seem to make no difference.
TABLE 1______________________________________Bleached brightness 80-84%Deinked Bleached Δ Brightbright- H.sub.2 O.sub.2 -charge bright- Δ Bright- ness/ness (%) (kg/t) ness (%) kg H.sub.2 O.sub.2______________________________________Ref 78.3 9.4 81.9 3.6 0.38O.sub.2 5.8 82.8 0.86O.sub.2 + 77.7 6.2 82.5 0.77NaOHO.sub.2 + 77.9 5.8 82.3 0.76NaOH +H.sub.2 O.sub.2______________________________________
TABLE 2______________________________________Lowest & highest values of incoming brightness excluded.Deinked Bleached Δ Brightbright- H.sub.2 O.sub.2 -charge bright- Δ Bright- ness/ness (%) (kg/t) ness (%) kg H.sub.2 O.sub.2______________________________________Ref 78.3 9.4 81.9 3.6 0.38O.sub.2 7.0 83.5 0.77O.sub.2 + 77.7 6.3 82.4 0.75NaOHO.sub.2 + 77.9 5.8 82.3 4.4 0.76NaOH +H.sub.2 O.sub.2______________________________________
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A method of bleaching secondary fibers. A secondary fiber pulp is first slushed and then transferred at a consistency of 20-40% to a disperser. In the disperser, the secondary fiber pulp is mechanically treated and mixed so that ink particles in the secondary fiber pulp are dispersed throughout the secondary fiber pulp. While the secondary fiber pulp is being treated and mixed in the disperser, oxygen is delivered to the disperser so as to distribute the oxygen within the secondary fiber pulp.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of pending application Ser. No. 12/741,742, filed Jun. 30, 2010, which claims the benefits, under 35 U.S.C.§119(e), of U.S. Provisional Application Ser. No. 60/987,044 filed Nov. 10, 2007 which is incorporated herein by this reference.
TECHNICAL FIELD
[0002] The invention relates to the field of freight shipping containers, portable shelters and more particularly collapsible portable shelters having both rigid frame and flexible fabric sections which collapse to a rigid shipping container for transporting.
BACKGROUND
[0003] Collapsible portable shelters which can be transported through ISO container shipping channels are useful for military or civilian projects of short duration or projects which are sufficiently remote that on-site construction is uneconomical. The present applicant has developed a collapsible portable containerized shelter sold commercially under the trade-mark MECC (“Mobile Expandable Container Configuration”) which is the subject of prior U.S. Pat. No. 5,761,854 issued Jun. 9, 1998 and which is incorporated herein by reference. That patent discloses a portable, collapsible shelter comprising a) a rigid, hollow container having opposed vertical sides, and a horizontal top and bottom, the container having the dimensions and characteristics which satisfy the standards for ISO shipping containers; b) at least one of the vertical sides comprising a pivoting wall portion hinged along the lower edge thereof to pivot between a closed vertical position and an open horizontal position; c) means for releasably securing the pivoting wall portion in the vertical position; d) means for releasably maintaining the pivoting wall portion in the horizontal position; e) a flexible fabric cover adapted to be extended above said pivoting wall portion while the pivoting wall portion is in the lowered horizontal position; and f) means for supporting the fabric cover above the hinged vertical side while the pivoting wall portion is in the lowered horizontal position.
[0004] The MECC container can be transported through the usual ISO shipping channels, whether ship, rail or truck. It is stacked or loaded using forklift or crane. While the expanded MECC container has three times the floor area of the standard ISO container, its height remains the same, namely 2.6 m. (8.5 feet) or 2.9 m. (9.5 feet). For some applications it would be desirable to have a shelter which can be shipped as a standard ISO container but can be expanded into a shelter or storage facility with increased height in addition to or instead of increased floor area.
[0005] The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
[0006] The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
[0007] The present invention provides a standard ISO shipping container which can be extended in height when not in transit. The invention further provides a collapsible portable containerized shelter which can be extended in height when not in transit. The present invention modifies standard shipping container structures to provide one or more fold-down side walls which extend the floor space of the container and are provided with a retractable fabric cover to enclose the extended space, as well as providing a roof with extended height. Means is provided for reversibly extending the corner supports to thereby raise the roof. A flexible fabric cover is adapted to be extended above the hinged vertical side while the hinged vertical side is in its lowered horizontal position, and means is provided for supporting the fabric cover above the hinged vertical side while the hinged vertical side is in the lowered horizontal position.
[0008] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
[0010] FIG. 1 is a perspective view of the invention in collapsed state ready for shipping;
[0011] FIG. 2 is a perspective view of the invention with sides lowered;
[0012] FIG. 3 is a detail of the hydraulic control shown in FIG. 2 ;
[0013] FIG. 4 is a perspective view of the invention with roof raised and cover deployed;
[0014] FIG. 5 is a cross-sectional view taken along lines A-A of FIG. 1 ;
[0015] FIG. 6 is a detail view showing an intermediate support;
[0016] FIG. 7 is a detail perspective view showing the opening of the side latches and insertion of the winch handle;
[0017] FIG. 8 is a detail perspective view showing the opening of a side;
[0018] FIG. 9 is a further detail end view showing the opening of a side;
[0019] FIG. 10 is a detail perspective view showing the leveling of a side;
[0020] FIG. 11A-C are plan views of a corner jack;
[0021] FIG. 12 is a perspective view of the invention in collapsed state with corner jacks in place;
[0022] FIG. 13 is a detail view of a leveling extension for the pivoting side walls;
[0023] FIG. 14 is a perspective view of the invention with side walls in the horizontal position;
[0024] FIG. 15 is a perspective view of the corner locking pin;
[0025] FIG. 16 is a perspective view of the roof support frame elements in disassembled state;
[0026] FIG. 17 is a perspective view of the invention with the roof partly raised and lowered side walls removed for ease of illustration and showing the roof cover frame in position for raising;
[0027] FIG. 18 is a perspective view of the invention with the roof fully raised and roof panels removed for ease of illustration and showing the roof cover frame in partly raised position;
[0028] FIG. 19 is a detail perspective view of a roof cover frame in fully raised position;
[0029] FIG. 20 is a detail view showing the roof cover frame hinge locks;
[0030] FIG. 21 is a detail view showing the joining of the roof cover frame to the wing extension;
[0031] FIG. 22 is a cross-sectional view taken along lines B-B of FIG. 1 ;
[0032] FIG. 23 is an exploded view of the corner post and hydraulic cylinder assembly; and
[0033] FIG. 24 is an exploded view of the corner post and hydraulic cylinder assembly.
DESCRIPTION
[0034] Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
[0035] With reference to FIG. 1 , in its collapsed state the present invention forms a shipping container 10 conforming to ISO (International Organization for Standardization) standards, of dimensions either 6.1 m. (20 feet) or 12.2 m. (40 feet) in length and 2.44 m. (8 feet) in width and 2.6 m. (8.5 feet) or 2.9 m. (9.5 feet) in height. The width dimension may be as great as 3.05 m. (10 feet). The ISO and related standards applicable to the construction of the freight containers may be found in the following publications:
ISO 1161 Series 1 freight containers—corner fittings—specification ISO 1496-1 Series 1 freight containers—Specification and testing—Part 1: General cargo containers for general purposes ISO standards 9000 through 9004—quality standards International Union of Railways (U.I.C.) Transport International des Routiers (T.I.R.) Convention for Safe Containers (C.S.C.)
[0042] The container 10 has rigid sides 11 formed of pivoting side walls 12 , roof 14 and ends 16 , all of which surfaces may be insulated. While both sides 11 are preferably formed of pivoting side walls 12 , only one of the sides could have a pivoting side wall 12 . Metal bottom side rails 20 , top side rails 21 , metal cross members 22 , metal vertical rails 24 and corner fittings 26 provide reinforcement of the structure during shipping. Pockets 28 are provided to receive the forks of a fork lift vehicle. A flooring 19 is provided on the bottom 18 of the container ( FIG. 2 ). A mechanical system 29 can be pre-installed in the floor or walls or elsewhere in the container 10 .
[0043] Preferably roof 14 is a standard container roof of mild steel or Corten. Corner fittings 26 are manufactured of cast steel, and other frame members are of mild steel. End walls 16 and side walls 11 are formed of sections of steel panels surrounding rigid insulation foam. Flooring 19 is preferably plywood with a vinyl top layer, while the upper surface of side walls 12 is plywood with a linoleum upper layer. Floor and wall insulation is rigid polyurethane or polystyrene foam while fibreglass batt insulation is used for the roof 14 .
[0044] The two side walls 12 are hinged along the base thereof at 42 to allow them to pivot from a vertical position as shown in FIG. 1 , where it is retained by latches 40 , to the horizontal position shown in FIG. 2 . The hinge and wall construction can be as described in U.S. Pat. No. 5,761,854. Latches 40 lock the side walls 12 in a vertical position to provide a rigid structure for shipping purposes which can be lifted through pockets 28 or the ISO corner fittings 26 . Latches 40 may be anti-racking rotating locking bars as shown in FIGS. 1 and 7 , or other suitable latch arrangement.
[0045] The invention is preferably deployed on a hard surface such as tarmac, concrete or compacted soil, using a forklift or crane. As shown in FIGS. 11 and 12 , corner leveling jacks 46 are attached to the vertical rails 24 and corner fittings 26 . The body 48 of each jack 46 is slid down over the foot/base plate extension 50 ( FIG. 11A ). The bolt head 52 of the jack is pushed through a keyhole 54 on the corner vertical rail 24 and the jack is slid down to lock it in place. The jack 46 is then rotated towards the rail 24 and twist-lock 56 is inserted into the hole in corner fitting 26 and twisted 90 degrees to lock ( FIG. 11B ), and pin 57 inserted to lock. The foot baseplate 58 is then dropped to the ground and pin 59 inserted to lock the extension 50 . Referring to FIG. 12 , handles 60 are inserted into sockets of the jacks 46 and the handles are cranked to level the container, cranking two jacks at a time.
[0046] Prior to lowering sides 12 , intermediate supports 62 are installed on the lower rails 20 at the locations 64 shown in FIG. 5 to permit large loads to be supported in the shelter. The foot 63 of support 62 is threaded so that it can be extended by rotation of nut 65 . Cribbing 66 is used where the corner posts are more than 3 inches above grade.
[0047] The sides 12 are then lowered as shown in FIGS. 7 and 8 and using a winch as described in U.S. Pat. No. 5,761,854. The winch (not shown) may be hand operated by a handle 68 as shown in FIG. 7 , or may be operated by an electric motor. The winch raises and lowers sides 12 by winding up or releasing a cable or wire rope 70 attached to the upper corners of sides 12 and run over one or more pulleys and down to the winch which is attached to the fixed wall of the container. The winch may have a braking mechanism to prevent sudden slippage of the wire rope. Handle 68 is inserted into the winch drive sot 69 . locking bars 40 are rotated and slid down to release side 12 . The side 12 is then winched down until safety strap 72 ( FIG. 9 ) is almost taut. Safety strap 72 is then unhooked and the side 12 lowered until close to the ground. The side is then leveled either using a threaded foot plate 74 ( FIG. 10 ) or an extension 76 ( FIG. 13 ) which fits in collar 78 on side 12 and is retained by pin 79 in one of the holes 80 in extension 76 .
[0048] Once the sides are lowered and leveled the roof can be raised as follows. Lock pins 82 at each of the four corners are disengaged ( FIG. 15 ). Lock pins 82 are located on the inner surface of cross members 22 adjacent each corner vertical rail 24 and control spring bolts 114 ( FIG. 23 ). The hydraulic pump is turned on ( FIG. 3 ) using on switch and controlled using hand control 33 . The roof is then raised slightly as shown in FIG. 14 , for example 18 inches (500 mm). FIG. 16 illustrates the disassembled elements of a hinged frame for supporting the fabric cover 90 . It comprises offset pivot parts 84 , hinged T arch assembly 85 , hinged X arch assembly 86 , spacers 87 , ridge poles 88 and truss frames 89 . The hinged frame is assembled and connected to the roof as shown in FIG. 17 . The offset pivot parts are attached to the upper rail 21 at each corner 101 and have a pivoting piece 103 to which the T-arches 85 are attached. The roof is then raised by the hydraulic control to its full 4-foot extension, thereby raising the cover frame to the position shown in FIG. 18 . The hinges on each vertical leg are then locked as shown in FIGS. 19 and 20 and studs 100 on the lower ends of the vertical frame members 102 positioned in cups 104 in the floor of the pivoting floor wing extensions 12 ( FIG. 21 ), thereby forming a rigid cover-supporting frame 91 .
[0049] A fabric cover 90 as shown in FIG. 4 is then secured over frame 90 . Cover 90 may be made of a waterproof PVC-coated polyester or the like, which may be insulated. Cover 90 is attached along the edges of side wall 12 and along the edges of the rails 24 , 22 . The fabric cover 90 thus provides a waterproof seal over the floor area formed by the wing extensions. Fabric cover 90 may be provided with a zippered opening 96 for entrance and exit purposes and/or windows and screens. Vehicle ramps 95 may be provided to permit entry of a vehicle. The end openings 92 formed by the raised roof have a permanently attached fabric cover 94 which folds into the interior of the container when the roof 14 is lowered. A standard door 17 may also be used as an entrance/exit.
[0050] To collapse the structure to its shipping configuration, the foregoing steps are reversed. The fabric cover 90 is removed, hinges on frame 91 are unlocked, the roof is lowered hydraulically to the position shown in FIG. 17 , the frame 91 is disassembled and removed, the roof is fully lowered, locking pins 82 are engaged, and side walls 12 are raised by winches to a vertical position. Side walls 12 are then latched in the vertical position by anti-racking latch bars 40 . The container can then be shipped by truck, rail, ship, helicopter or airplane as a standard ISO shipping container.
[0051] Further details of the hydraulic system for extending the corner rails to raise the roof are shown in FIG. 22-24 . Inner posts 110 slide telescopically within the hollow interior 111 of outer rails 24 , centered by contact with Ultra-High Molecular weight pads 112 . Hydraulic cylinders 116 are activated by the hydraulic control 33 to extend as in FIG. 24 , or retract as in FIG. 23 , and have hydraulic connection 9 and are attached to the inner post at 2 and the outer post at 3 . Spring bolt 114 is controlled either by a lock pins 82 or a central handle 115 as shown in FIG. 23 controlling two spring bolts 114 . Spring bolt 114 either prevents the inner post from extending or releases it to extend under the force of hydraulic cylinders corner rails are shown in FIG. 15 .
[0052] The foregoing extendible height structure can also be applied to containers not having one or more pivoting sides or fabric cover. In that case sides 12 may be fixed, without hinges. The extending container roof would operate otherwise as described above. Fixed covers could be provided for the lengthwise openings formed when the roof is extended in the same way as provided for the openings 92 at the end of the container described above. In this way a container's interior space can be expanded for storage when not in shipment and retracted to standard ISO dimensions for shipment.
[0053] While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the invention be interpreted to include all such modifications, permutations, additions and sub-combinations as are within its true spirit and scope.
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An extendible height container is provided in which the corner elements telescope to extend the height of the container from standard ISO dimensions. An enlarged shelter can be formed from the container by providing sides which fold down to form the floor of the shelter and a flexible cover supported above the floor thus created.
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FIELD OF THE INVENTION
The present invention relates generally to locks and security devices, and more specifically to an apparatus providing for the lockable securing of cargo retainers or load locks on an exterior surface of a vehicle.
BACKGROUND OF THE INVENTION
Oftentimes in the trucking industry, an occasion arises when a partial load must be transported from one point to another. When only part of the total volume of a trailer or the van portion of a truck is filled, the load is subject to shifting into the unloaded portion of the volume due to vibration, acceleration, braking and turning forces, etc. On some occasions, the shift of cargo or freight can be so great as to create an unstable load and cause the truck and/or trailer to tip.
As a result, truckers generally use load locks to secure partial loads of cargo within a trailer or van. Load locks are elongated, extendible poles which may be installed transversely (or vertically in a covered space) between the walls of an enclosure and wedged therebetween, to prevent cargo or freight from shifting past the installed load locks. Normally, a trucker will carry two or more load locks with him or her when on a trip, in order to secure such cargo loads. When the load locks are not in use, they are often stored on the exterior of the back of the cab of the tractor, particularly in the event that the truck is "deadheading" with no attached trailer.
Most truckers find it convenient to wedge their load locks between the aerodynamic cab extenders immediately behind the rear of the tractor cab, if the tractor is so equipped. While this is convenient for the trucker. the lateral force of the load locks often spreads and damages the side extenders to the point that they require repair or replacement. which is not an inexpensive consideration for the trucking company or the independent trucker. Consequently, various racks or brackets have been developed for the storage of load locks on the exterior of the rear wall of a truck tractor cab.
However. such relatively lightweight and easily portable devices are subject to being readily moved from one truck or trailer to another and as a result it can be difficult for a trucker to retain a specific set of load locks for his/her vehicle. This is not generally a serious problem if the trucking company supplies such equipment. but since such devices are readily removable from the exterior of a truck or from an open trailer and are easily transportable. they are of course subject to theft. Accordingly many, if not most, trucking companies do not supply load locks and the drivers are forced to purchase their own. Securing such devices to the exterior of a tractor cab without any locking or securing means may prevent damage to the side extenders, but leaves the load locks vulnerable to theft.
The need arises for an apparatus providing for the lockable security and storage of cargo load locks on the exterior of a vehicle. The apparatus must provide complete lockable security for one or more load locks. yet must provide easy access to the load locks without the expenditure of undue time or effort on the part of the user of the apparatus. Moreover, the apparatus must be relatively inexpensive to purchase and install, and must be adaptable to various different makes and models of trucks, or other surfaces as may be desired.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 1,712,869 issued to James M. Clark, Sr. on May 14, 1929 discloses a Detachable Luggage Carrier attachable between the front bumper and grille or bodywork of an automobile. The device is not universally adaptable, considering the intergration of bumpers and bodywork on modern automobiles, and moreover is essentially nothing more than a tray with no further securing means disclosed for articles carried thereon.
U.S. Pat. No. 3,278,149 issued to Henry J. Brucker on Oct. 11, 1966 discloses a Shelving Assembly having a plurality of vertical and horizontal members which cooperate with specially formed attachments which provide support for crossmembers. The attachments do not secure to the wall itself, as in the case of the present invention, and no locking means for the crossmembers fitted therein is disclosed.
U.S. Pat. No. 3,831,892 issued to David M. Herman on Aug. 27, 1974 discloses a Jack Lock comprising plural brackets installable on a wall, as on the inner wall of a pickup truck box. The device is open ended, i.e., an elongate article could be removed by withdrawing it from one end, even with the securing brackets installed. A locking member must be installed through a passage in the jack itself, whereas the present invention surrounds the ends of the elongate member secured therein. Moreover, only a single article can be installed therein, unlike the plural capacity of the present invention.
U.S. Pat. No. 3,893,568 issued to William H. Lile on Jul. 8, 1975 discloses a Tool Holder installable in the box of a pickup truck. Again, the elongate tools can be withdrawn from the open end of the holder; the only retaining means is the tailgate structure of the pickup box. If the tailgate is opened, the tools may be removed from the holder even though the holder is locked.
U.S. Pat. No. 4,723,880 issued to Charles W. Stumpf, Jr. on Feb. 9, 1988 discloses a Shoring Beam Storage Rack for use in securing load locks (called shoring beams in the Stumpf, Jr. patent). The device operates similarly to the jack lock of the Herman patent discussed above. in that a padlock must be secured through the end of a tongue which is passed through a passage in the shoring beam. Moreover, only a single beam may be secured by the Stumpf. Jr. device, whereas the present invention provides for the storage of plural load locks.
U.S. Pat. No. 4,756,504 issued to Lewis W. Chamberlain on Jul. 12, 1988 discloses a Utility Locking Hook which may be used plurally to secure the ends of elongate articles. The device is open ended. however. which would allow any articles secured therein to be removed by withdrawing them from the end, unlike the present invention.
U.S. Patent No. 4,782,624 issued to James R. Head on Nov. 8, 1988 discloses a Fisherman's All Purpose Boat Mounted Stand, intended primarily for the storage of fishing rods. No locking means is disclosed, and moreover an article held therein may be withdrawn from the open upper end of the device, unlike the present invention.
U.S. Pat. No. 4,869,377 issued to David Mercado on Sep. 26, 1989 discloses a Storage Rack For Load Locks. The device uses a signal lock to secure plural load locks, but requires separate clamps for each load lock installed therein. Moreover, the device is open ended, as in the case of all of the other devices discussed herein; a load lock installed therein may be removed by withdrawing it from one end of the rack.
U.S. Pat. No. 5,052,601 issued to Ralph E. Carter et al. on Oct. 1, 1991 discloses a Truck-Mounted Rack For Cargo Holders. The device is installable upon various areas of the truck tractor or trailer, but again it is open ended and an elongate device could be withdrawn from one end of the rack. The only means for retaining such load locks or cargo holders within the rack, is by using some other components as end plates for the rack (e.g., the tractor cab side extenders) or by using cargo holders with relatively wide ends which cannot be withdrawn. The present invention provides for the storage of any configuration of rigid, elongate load lock(s) or other rigid, elongate article(s).
U.S. Des. Pat. No. 330,180 issued to applicant on Oct. 13, 1992 discloses a design for a Storage Kit For Cargo Load Locks. The design discloses means for securing the opposite ends of load locks therebetween. but no locking means is disclosed. Moreover, the diagonal configuration would require the load locks to be at least partially extended in order to extend from one bracket to the diagonally opposite bracket, unlike the present invention which provides for the storage of collapsed load locks.
French Patent No. 1,333,750 to Norbert E. P. Deroux and published on Jun. 24, 1963 discloses an interior baggage storage rack for use in truck cabs. The device comprises an open rack with hooks providing for the suspension of the rack from an overlying structure. No permanent installation is disclosed, nor is any means disclosed for locking an article therein.
Finally, British Patent No. 1,093,767 to Eric E. T. Sanders and published on Dec. 6, 1967 discloses Venetian-Blind Mounting Brackets having an open front and a hinged side plate securable by means of a slidable extension cooperating with a passage on an adjacent side. No locking means is disclosed, nor does the device appear to be adaptable for use in the environment of the present invention.
None of the above noted patents, taken either singly or in combination, are seen to disclose the specific arrangement of concepts disclosed by the present invention.
SUMMARY OF THE INVENTION
By the present invention, an improved securing apparatus for cargo load locks is disclosed.
Accordingly, one of the objects of the present invention is to provide an improved load lock securing apparatus which provides for securing one or more load locks with a single locking device.
Another of the objects of the present invention is to provide an improved load lock securing apparatus which is installable on the exterior wall of the rear of a truck tractor cab.
Yet another of the objects of the present invention is to provide an improved load lock securing apparatus which is adaptable for use to existing attachment points on a variety of different truck tractor cabs.
Still another of the objects of the present invention is to provide an improved load lock securing apparatus which includes two opposed members serving to secure the ends of one or more load locks therein.
A further object of the present invention is to provide an improved load lock securing apparatus in which one of the opposed members includes a signal open side and the other includes an oppositely spaced open side and a second lockable opening through which load locks may be inserted or withdrawn.
An additional object of the present invention is to provide an improved load lock securing apparatus which may be constructed of a variety of materials, such as aluminum, standard or stainless steel or relatively tough plastics of high density.
Another object of the present invention is to provide an improved load lock securing apparatus which precludes damage to the rear of a truck tractor cab upon which the apparatus is installed.
A final object of the present invention is to provide an improved load lock securing apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purpose.
With these and other objects in view which will more readily appear as the nature of the invention is better understood, the invention consists in the novel combination and arrangement of parts hereinafter more fully described, illustrated and claimed with reference being made to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the present invention. showing its installation and use on the exterior of the rear wall of a truck tractor cab.
FIG. 2 is a perspective view of opposed members of the present invention, with each member being a different embodiment due to the different mounting flange arrangements on each.
Similar reference characters denote corresponding features consistently throughout the several figures of the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now particularly to FIG. 1 of the drawings, the present invention will be seen to relate to an apparatus 10 for securing cargo load locks L to a wall, as to the exterior rear wall W of a truck tractor cab C. The load lock securing apparatus 10 of FIG. 1 comprises two spaced apart, oppositely installed enclosures 12 and 14, preferably installed respectively near the first and second edges E1 and E2 of the rear wall W of the cab C. Enclosures 12 and 14 are each essentially in the form of a hollow box, with each box having one open side: the wall W to which enclosures 12 and 14 are secured also serves as one of the sides of each of the enclosures 12 and 14.
The first enclosure 12 is defined by first and second spaced apart, opposite first and second end plates 16 and 18 with an outwardly facing interconnecting wall 20 therebetween. Second enclosure 14 includes equivalent spaced apart opposite first and second end plates 22 and 24, with an outwardly facing interconnecting wall 26 extending therebetween, as in the manner of the end plates and interconnecting wall 16, 18 and 20 of the first enclosure 12. However, it will be seen that the two enclosures 12 and 14 are installed with their outwardly facing walls 20 and 26 facing away from each other, and with an open side 28 of the first enclosure 12 and an open side 30 of the second enclosure 14 facing one another. The purpose of this arrangement will be explained in detail further below.
First and second enclosures 12 and 14 each further respectively include a cover 32 and 34, which covers 32 and 34 form the final closed sides of the two enclosures 12 and 14. While the cover 34 of the second enclosure 14 extends completely across the space between the first and second end plates 22 and 24 to connect those end plates 22 and 24 together in the manner of outwardly facing wall 26, cover 32 of the first enclosure 12 extends only partially thereacross, terminating at an edge 36 which is spaced apart from the first end 16. The space or opening 38 between the end 36 of the first enclosure cover 32 and the first enclosure first end 16 is selectively covered or closable by means of a pivotable locking plate 40.
Cover 32 includes a flange 42 extending partially into the open side 28; cover 34 may optionally include a like flange 44, as desired. While the flange 44 of the second enclosure may extend completely between the first and second ends 22 and 24, the flange 42 of the first enclosure extends only to the end 36 of the cover 32. Cover plate 40 includes a similar flange 46 having an extension 48, which extension 48 is pivotally secured to the flange 42 of the cover 32 by means of a fastener 50, e.g., pin, bolt, rivet, etc, which passes through cooperating passages (not shown for clarity) in the flange 42 and cover plate flange extension 48.
Additional cooperating lock passages 52 are formed in flange 42 and extension 48, which passages 52 provide for the locking closure of cover plate 40 when they are aligned. Once passages 52 are aligned, the cover plate 40 will be in coplanar alignment with the cover 32 of the first enclosure 12, essentially providing an unbroken cover comprising cover 32 and cover plate 40 extending from the first end plate 16 to the second end plate 18. Locking means, such as the hasp of a padlock P, may then be passed through the cooperating passages 52 and locked to preclude the unauthorized opening of the cover plate 40.
Preferably, the first and second enclosures 12 and 14 are installed on a wall W by means of mounting flanges 54, 56, 58, and 60 and fasteners 62 (e.g., bolts, rivets, etc.), with the opposite outwardly facing walls 20 and 26 spaced apart a slightly greater distance D1 than the minimum length D2 of the collapsed load locks L. Additional base flanges 55 and 57 may be included respectively along the lower edges of outwardly facing walls 20 and 26, and extending respectively between the mounting flanges 54 and 56, and flanges 58 and 60. As load locks L are extendible, they are also collapsible to a minimum length. One or more load locks L may then be placed within the first and second enclosures 12 and 14 by unlocking and opening the locking or cover plate 40 (if locked), placing one end of the load lock(s) L within the second enclosure 14 by means of the open side 30, and inserting the opposite end(s) of the load lock(s) L into the open space 38 provided when the cover or locking plate 40 is opened. The cover or locking plate 40 may then be secured by means of the lock hasp being passed through the aligned lock passages 52 to securely close the opening 38.
It will be seen that the distance D3 between the facing flanges 42 and 44 is somewhat less than the collapsed length D2 of the load lock L. Hence. any load locks L contained between the first and second enclosures 12 and 14 cannot be removed when locking cover plate 40 is locked in place, due to the wall W to which the first and second enclosures are secured; the opposite outwardly facing sides 20 and 26; the ends 16, 18, 22 and 24; and the two covers 32, 34 and the cover plate 40 of the two enclosures 12 and 14. Further, by providing sufficient depth between the edges of the covers 32 and 34 and the respective outwardly facing walls 20 and 26 of the first and second enclosures 12 and 14, and a sufficiently short span between the first and second ends 16, 18 and 22, 24. the diagonal dimension between opposite ends of the open sides 28 and 30 adjacent diagonally opposed ends 16, 24 and 18, 22 will also be shorter than the collapsed length D2 of load locks L or other similar articles secured by the present invention, thereby precluding the removal of those articles by manipulating one end diagonally opposite the other. Yet, the removal of any load locks L secured therein is easily accomplished by unlocking any lock means P used to secure the cover plate 40, pivoting the cover plate 40 outward to provide an opening 38, and withdrawing the end(s) of the load lock(s) L retained within the first enclosure 12. Once those end(s) are removed and clear of the outwardly facing wall 20, the opposite end(s) can be withdrawn from the open side 30 of the second enclosure 14.
FIG. 2 discloses alternative embodiments of the present invention. The two oppositely spaced apart enclosures 12a and 14a have essentially the same basic structure and provide essentially the same function as the two opposite enclosures 12 and 14 of FIG. 1. However, enclosures 12a and 14a include different shapes and/or arrangements of end plates and covers, in order to adapt to various types of truck tractors and their different provisions for the attachment of such enclosures and storage of load locks. While the two enclosures 12a and 14a of FIG. 2 have different arrangements of end plates and covers, it will be apparent that each of the enclosures may be provided with a "mirror image" enclosure (with the exception of the partial cover and openable cover plate on one of the two mirror image enclosures). The two different arrangements shown in FIG. 2 serve to show two of the variations possible in the present invention without resorting to an excessive number of drawing sheets and figures.
The first enclosure 12a of FIG. 2 will be seen to include generally the same components as the first enclosure 12 of FIG. 1, i.e., first and second ends 16a and 18a; an outwardly facing wall 20a and a cover 32a, with a gap or space 38a between the edge 36a of the cover 32a and the first end 16a; and a locking cover plate 40a having a flange 46a with an extension 48a which is secured to a cover flange 42a by means of a pivot 50a. Lock passages 52a are provided in the flange 42a and the cover plate flange extension 48a which, when aligned, ensure that the cover plate 40a and cover 32a are in coplanar alignment to close the space or opening 38a between the edge 36a of cover 32a and the first end 16a, in the manner discussed above for the first enclosure 12 of FIG. 1. The difference between the first enclosure 12 of FIG. 1 and the enclosure 12a of FIG. 2, is in the shape of the first and second ends. While the first and second ends 16 and 18 of the first enclosure 12 (and the first and second ends 22 and 24 of the second enclosure 14) are generally rectangular and provide an overall shape for the enclosures 12 and 14 which is that of a right parallelepiped or rectangular solid, the two ends 16a and 18a of the enclosure 12a of FIG. 2 each have truncated inwardly facing edges 64 and 66, with base edges 68 and 70 which are somewhat longer than the first and second end cover edges 72 and 74 which respectively meet with the locking cover plate 40a and the cover 32a. The two ends 16a and 18a may each further include a plurality of mounting or attachment holes 76 adjacent the two longer base edges 68 and 70, which attachment holes 76 provide for securing the enclosure 12a to another surface or brackets thereon. As in the case of the enclosures 12 and 14 of FIG. 1, enclosure 12a may include a flange 55a along the lower edge of the wall 20a and extending between the base edges 68 and 70 of the two ends 16a and 18a. A second enclosure (not shown) may be provided which is essentially a mirror image of enclosure 12a, with the exception of having a continuous, fixed cover in the manner of the cover 34 of the second enclosure 14 of FIG. 1.
The second enclosure 14a of FIG. 2 provides an additional variation on the embodiments discussed above. Enclosure 14a comprises first and second ends 22a and 24a, and an outwardly facing wall 26a and cover 34a each extending between the first and second ends 22a and 24a. The cover 34a may also include a flange 44a extending completely therealong, in the manner of the flange 44 of the second enclosure of FIG. 1, and a flange 57a along the lower edge of the wall 26a and extending between the two opposite ends 22a and 24a. The first end 22a of enclosure 14a has a form similar to that of the first and second ends 16a and 18a of enclosure 12a, and includes an attachment flange 54a with attachment holes 76a, in the manner of the attachment flange 54 of the first enclosure of FIG. 1 and the mounting or attachment holes 76 shown in the first enclosure 12 a of FIG. 2. However, with certain installations, a full width second end including mounting or attachment means may not be necessary. In the case of the second enclosure 14a of FIG. 2, both the second end 24a and the cover 34a are relatively narrow, providing only sufficient width to preclude the withdrawing of a collapsed load lock L past the second end 24a and cover 34a. Thus, the second enclosure 14a of FIG. 2 will be seen to function in the same manner as the second enclosure 14 of FIG. 1. A first enclosure (not shown) having the same shape and general configuration as that of enclosure 14a may be provided, by shortening the length of the enclosure 34a and flange 44a and providing a cover plate with a cover plate flange and extension, in the manner of the first enclosures 12 and 12a of FIGS. 1 and 2. The restriction of removal of articles secured within any of the embodiments of the present invention by means of diagonally manipulating the articles within the first and second enclosures is still valid for each of the embodiments assuming that the dimensions of the critical features (cover and end width, cover length, and spacing between enclosures) is adjusted properly.
Thus. the various embodiments of the present invention provide for the secure and lockable storage of load locks and/or other relatively rigid, elongate articles by securing such locks and articles between first and second enclosures, with one of the enclosures including a closable and lockable opening. While a variety of materials may be used to construct any of the embodiments of the present invention, preferably a durable metal is used in order to provide resistance against damage due to attempted theft, wear and tear, etc. A relatively heavy gauge of aluminum is suitable, but other metals (e.g., standard or corrosion resistant steel) may be used, as well as certain plastics having relatively tough and durable qualities in a sufficiently heavy gauge.
It is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims.
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An apparatus providing for the lockable securing of cargo load locks for the trucking industry is disclosed. Load locks comprising extendible, rigid elongate poles are installed laterally within trailers or vans to secure partial loads, and due to their portability are subject to loss or theft. The present invention is installable upon the exterior surface of the rear of a truck tractor cab, and comprises two opposed box-like structures having facing open sides. One of the structures is completely closed on all other sides when installed, requiring the end(s) of the load lock(s) to be inserted into the facing open side. The opposite structure includes an adjacent side opening into which the other end(s) of the load lock(s) may be inserted. The adjacent side opening may then be closed by a pivotable plate which locks in place with a single padlock to lock the end(s) of the load lock(s) within the two opposed boxes.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The invention relates to condum drainage devices.
2. Description of Prior Art
Although there have been a number of devices proposed in prior art literature for superceding the condom catheter for effecting external catheter drainage of urine, none has solved the acute problems inherent in this type of device, as hereinafter more fully set forth, and none, to applicant's knowledge, has been successfully used in medical practice. Accordingly, the condom drainage device is the only one currently in general use.
A separate prior art statement is being prepared herein, pursuant to C.F.R. 197 and 198.
The penis is a delicate organ covered by thin epithelium and is particularly susceptible to injury or damage occurring by available means of attachment of the catheter and by inadequate drainage, which expose this epithelium to direct trauma and irritation secondary to urine remaining in contact therewith. These conditions may result in obstruction of venous outflow from the penis, resulting in venous stasis, which may in turn result in increased susceptibility of the epithelium to damage, and even possibly result in the occurrence of venous thrombosis of the penis. Attachment of the catheter over a localized or limited area may result in increased likelihood of direct pressure-induced trauma to the penile epithelium. The exposure of the penis to urine, especially when the urine is infected, frequently results in epithelial injury. As a direct result of such injury to the epithelium, there frequently occurs the problem of contusion of the penis, maceration of the penile epithelium, and actual epithelial infection. In the common condom catheter, the penis is obscured from view, and developing injury and infection may go undetected. The foregoing sequence of events makes continued external catheter drainage impossible and results in two possible and less favorable medical alternatives: allowance of urinary incontinence, with its attendant problems, and resort to internal catheter bladder drainage, which is fraught with serious medical problems.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an external catheter drainage device of the character described which may be simply and readily applied and which will apply a substantially uniform securing pressure over substantially the entire organ, thus providing unobstructed arterial blood supply to the penis throughout its entire length and, similarly, a free venous outflow from the penis, thus avoiding venous engorgement, discomfort and a condition known as priapism, a serious medical problem of the penis.
Another object of the present invention is to provide an external catheter drainage device of the character above in which an end of the drainage tube is snubbed into substantial abutment and registration with the urethral meatus, thus effecting a direct drain-off of the urine and substantially eliminating any substantial exposure or contact of the penile epithelium with urine.
A further object of the present invention is to provide an external catheter drainage device which, when in place on the penis, will permit direct viewing of the epithelium to provide early detection of any damage or infection.
The invention possesses other objects and features of advantage, some of which of the foregoing will be set forth in the following description of the preferred form of the invention which is illustrated in the drawings accompanying and forming part of this specification. It is to be understood, however, that variations in the showing made by the said drawings and description may be adopted within the scope of the invention as set forth in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an external catheter drainage device constructed in accordance with the present invention.
FIG. 2 is a cross-sectional view taken substantially on the plane of line 2--2 of FIG. 1.
FIG. 3 is a side elevation of a modified form of the device.
FIG. 4 is a cross-sectional view taken substantially on the plane of line 4--4 of FIG. 3.
FIG. 5 is a side elevation partially in section of a further modified form of the invention.
FIG. 6 is a cross-sectional view taken substantially on the plane of line 6--6 of FIG. 5.
FIG. 7 is an enlarged fragmentary cross-sectional view of a portion of the device shown in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
The external catheter drainage device of the present invention comprises, briefly, a drainage tube 11; a pair of elongated inner and outer coterminus, impervious members 12 and 13 joined at their opposite ends 16 and 17 to define an air chamber 18 therebetween, the members being joined at ends 17 directly at and to one end 19 of tube 11 with the air chamber 18 contiguous to and extending longitudinally from tube end 19 and with the tube in registration with the interior of inner member 12; inner member 12 being formed of flexible material and being dimensioned together with air chamber 18 to surround and closely conform to the peripheral shape of the penile glans 21 and shaft 22; and chamber 18 being formed for pressurizing to thereby apply a substantially uniform encapsulating pressure on the exterior of the penile glans and shaft and to anchor tube end 19 in substantial abutment and in registration with the urethral meatus 23.
The inflatable nature of the device affords ease of application and removal, and the applying of a uniform pressure over the exterior of the penile glans and shaft maintains a free arterial inflow throughout the length of the penis and a free venous outflow, thus avoiding discomfort and venous engorgement which results in the application of a restricted inflatable cuff, which causes an increase of venous pressure and, potentially, a condition known as priapism, a serious medical problem of the penis. In other words, by applying a more or less uniform pressure around the penis over a large portion of its length and, particularly, uniformly out to the tip, no venous engorgement will take place. The importance here is the avoidance of a limited banding action which would invariably result in an elevation of the venous pressure in the penis distal to the constriction. This problem is avoided by applying uniform pressure from some proximal position on the penile shaft as far out as the arterial blood supply (end of the penis). For purposes of securement and comfort, the device is preferably dimensioned for enclosing and applying a uniform pressure to substantially the entire length of the penis up to the body wall 30.
When the device may be quickly and easily positioned on the penis and inflated and with the device so installed on the penis, the entire organ, with the exception of the urethral meatus, is covered to shield the epithelium from contact with urine. The device thus affords a comfortable, sealed, external drainage system. The large area of contact with the penile shaft and glans assures firm positioning of the device, and the continuation of the area of contact over the penile glans precludes the forming of a reservoir for urine accumulation and contact with the penile epithelium. Snubbing of the end 19 of drainage tube 11 against the urethral meatus and in registration therewith assures the direct and immediate drainage of urine away from the penis.
As a further feature of the present invention, members 12 and 13 are formed of transparent material for visual inspection through the members and air chamber of the penile epithelium. This may be accomplished, as here shown, by forming the members of thin, flexible sheets of transparent plastic. As here shown, these sheets are in tubular form defining an elongated air chamber 18 therebetween. An air inlet valve 26 is here provided on member 13 to provide inflation of the air chamber. A lure lock adapted for receipt of a standard hypodermic-type inflation device may be used. The thin flexible sheet construction of the device affords a convenient rolling up of the device for subsequent convenient unrolling onto the penis up to the body wall 30.
A modified form of the invention is illustrated in FIGS. 3 and 4, including means for relieving pressure on the urethral canal and providing an alternate and convenient form of attachment. In this form of the invention, inner and outer chambers 12a and 13a are formed with separable sections 27 and 28 at their end portions 31 for receiving and wrapping around the penile shaft, the sections preferably having an adjacent closed portion 32 into which the penile glans and adjacent shaft may be inserted. Flexible banding means 33 may be placed in encircling position to sections 27 and 28 to hold them in their wrapped-around position, as seen in FIGS. 3 and 4. The banding means may comprise a simple flexible strip secured at one end to one of the sections 27-28 and having means of attachment such as a Velcro pad 34 on the other section. Members 12a and 13a are here again formed of thin, flexible sheets of transparent material, enabling the opening out of sections 27 and 28 for receiving and wrapping around the penis to facilitate attachment and to permit subsequent inspection of the penile epithelium for injury or infection.
The means for relieving the pressure on the urethral canal 35 here comprises the open portion 31 between the confronting ends of sections 27 and 28, which are spaced apart for straddling the urethral canal so that the latter is located within the open portion 31 for minimizing pressure on the canal. Additionally, the banding strap 33 provides adjustment of the banding pressure on the penile shaft.
A further embodiment of the invention is illustrated in FIGS. 5, 6 and 7, wherein a normally closed one-way check valve 36 is mounted interiorly of inner member 12b at end 19b of tube 11b and constructed to open in response to urethral discharge pressure. Valve 36 may comprise a simple membrane mounted across and closing tube end 19b, as seen in FIGS. 5 and 7, and being formed with a normally closed slit 37, the membrane flexing in response to urethral discharge pressure to open slit 37 for one-way urine discharge.
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An externally applied penile catheter providing an inflatable air chamber extending over and around the penile glans and shaft and applying a uniform pressure thereto for holding the catheter in place and being connected to one end of the drainage tube, the structure additionally co-functioning to anchor the end of the drainage tube in substantial abutment with and in registration with the urethral meatus.
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FIELD OF INVENTION
[0001] The present invention pertains to the field of automatic transmissions for motor vehicles and, more particularly, to a friction element load sensor that directly measures torque transmitted by a friction element of an automatic transmission.
BACKGROUND OF THE INVENTION
[0002] A step-ratio automatic transmission system in a vehicle utilizes multiple friction elements for automatic gear ratio shifting. Broadly speaking, these friction elements may be described as torque establishing elements although more commonly they are referred to as clutches or brakes. The friction elements function to establish power flow paths from an internal combustion engine to vehicle traction wheels. During acceleration of the vehicle, the overall speed ratio, which is the ratio of a transmission input shaft speed to a transmission output shaft speed, is reduced during a ratio upshift as vehicle speed increases for a given engine throttle setting. A downshift to achieve a higher speed ratio occurs as an engine throttle setting increases for any given vehicle speed, or when the vehicle speed decreases as the engine throttle setting is decreased.
[0003] Various planetary gear configurations are found in modern automatic transmissions. However the basic principle of shift kinematics remains similar. Shifting a step-ratio automatic transmission having multiple planetary gearsets is accompanied by applying and/or releasing friction elements to change speed and torque relationships by altering the torque path through the planetary gearsets. Friction elements are usually actuated either hydraulically or mechanically.
[0004] In the case of a synchronous friction element-to-friction element upshift, a first pressure actuated torque establishing element, referred to as an off-going friction element, is released while a second pressure actuated torque establishing element, referred to as an on-coming friction element, engages in order to lower a transmission gear ratio. A typical upshift event is divided into preparatory, torque and inertia phases. During the preparatory phase, an on-coming friction element piston is stroked to prepare for its engagement while an off-going friction element torque-holding capacity is reduced as a step toward its release. During the torque phase, which may be referred to as a torque transfer phase, on-coming friction element torque is raised while the off-going friction element is still engaged. The output shaft torque of the automatic transmission typically drops during the torque phase, creating a so-called torque hole. When the on-coming friction element develops enough torque, the off-going friction element is released, marking the end of the torque phase and the beginning of the inertia phase. During the inertia phase, the on-coming friction element torque is adjusted to reduce its slip speed toward zero. When the on-coming friction element slip speed reaches zero, the shift event is completed.
[0005] In a synchronous shift, the timing of the off-going friction element release must be synchronized with the on-coming friction element torque level to deliver a consistent shift feel. A premature release leads to engine speed flare and a deeper torque hole, causing perceptible shift shock for a vehicle occupant. A delayed release causes a tie-up of gear elements, also resulting in a deep and wide torque hole for inconsistent shift feel. A conventional shift control relies on speed measurements of the powertrain components, such as an engine and a transmission input shaft, to control the off-going friction element release process during the torque phase. A conventional torque phase control method releases the off-going friction element from its locked state through an open-loop control based on a pre-calibrated timing, following a pre-determined off-going friction element actuator force profile. This conventional method does not ensure optimal off-going friction element release timing and therefore results in inconsistent shift feel.
[0006] Alternatively, a controller may utilize speed signals to gauge off-going friction element release timing. That is, the off-going friction element is released if the controller detects a sign of gear tie-up, which may be manifested as a measurable drop in input shaft speed. When a release of the off-going friction element is initiated prematurely before the on-coming friction element develops enough torque, engine speed or automatic transmission input shaft speed may rises rapidly in an uncontrolled manner. If this so-called engine speed flair is detected, the controller may increase off-going friction element control force to quickly bring down automatic transmission input speed or off-going friction element slip speed. This speed-based or slip-based approach often results in a hunting behavior between gear tie-up and engine flair, leading to inconsistent shift feel. Furthermore, off-going friction element slip control is extremely difficult because of its high sensitivity to slip conditions and a discontinuity between static and dynamic frictional forces. A failure to achieve a seamless slip control during the torque phase leads to undesirable shift shock.
[0007] In the case of a non-synchronous automatic transmission, the upshifting event involves engagement control of only an on-coming friction element, while a companion clutching component, typically a one-way coupling, automatically disengages to reduce the speed ratio. The non-synchronous upshift event can also be divided into three phases, which may also be referred to as a preparatory phase, a torque phase and an inertia phase. The preparatory phase for the non-synchronous upshift is a time period prior to the torque phase. The torque phase for the non-synchronous shift is a time period when the on-coming friction element torque is purposely raised for its engagement until the one-way coupling starts slipping or overrunning. This definition differs from that for the synchronous shift because the non-synchronous shift does not involve active control of a one-way coupling or the off-going friction element. The inertia phase for the non-synchronous upshift is a time period when the one-way coupling starts to slip, following the torque phase. According to a conventional upshift control, during the torque phase of the upshifting event for a non-synchronous automatic transmission, the torque transmitted through the oncoming friction element increases as it begins to engage. A kinematic structure of a non-synchronous upshift automatic transmission is designed in such a way that torque transmitted through the one-way coupling automatically decreases in response to increasing oncoming friction element torque. As a result of this interaction, the automatic transmission output shaft torque drops during the torque phase, which again creates a so-called “torque hole.” Before the one-way coupling disengages, as in the case previously described, a large torque hole can be perceived by a vehicle occupant as an unpleasant shift shock. An example of a prior art shift control arrangement can be found in U.S. Pat. No. 7,351,183 hereby incorporated by reference.
[0008] A transmission schematically illustrated at 2 in FIG. 1 is an example of a prior art multiple-ratio transmission with a controller 4 wherein ratio changes are controlled by friction elements acting on individual gear elements. Engine torque from vehicle engine 5 is distributed to torque input element 10 of hydrokinetic torque converter 12 . An impeller 14 of torque converter 12 develops turbine torque on a turbine 16 in a known fashion. Turbine torque is distributed to a turbine shaft, which is also transmission input shaft 18 . Transmission 2 of FIG. 1 includes a simple planetary gearset 20 and a compound planetary gearset 21 . Gearset 20 has a permanently fixed sun gear S 1 , a ring gear R 1 and planetary pinions P 1 rotatably supported on a carrier 22 . Transmission input shaft 18 is drivably connected to ring gear R 1 . Compound planetary gearset 21 , sometimes referred to as a Rayagineaux gearset, has a small pitch diameter sun gear S 3 , a torque output ring gear R 3 , a large pitch diameter sun gear S 2 and compound planetary pinions. The compound planetary pinions include long pinions P 2 / 3 , which drivably engage short planetary pinions P 3 and torque output ring gear R 3 . Long planetary pinions P 2 / 3 also drivably engage short planetary pinions P 3 . Short planetary pinions P 3 further engage sun gear S 3 . Planetary pinions P 2 / 3 , P 3 of gearset 21 are rotatably supported on compound carrier 23 . Ring gear R 3 is drivably connected to a torque output shaft 24 , which is drivably connected to vehicle traction wheels through a differential and axle assembly (not shown). Gearset 20 is an underdrive ratio gearset arranged in series with respect to compound gearset 21 . Typically, transmission 2 preferably includes a lockup or torque converter bypass clutch, as shown at 25 , to directly connect transmission input shaft 18 to engine 5 after a torque converter torque multiplication mode is completed and a hydrokinetic coupling mode begins. FIG. 2 is a chart showing a clutch and brake friction element engagement and release pattern for establishing each of six forward driving ratios and a single reverse ratio for transmission 2 . During operation in the first four forward driving ratios, carrier P 1 is drivably connected to sun gear S 3 through shaft 26 and forward friction element A. During operation in the third ratio, fifth ratio and reverse, direct friction element B drivably connects carrier 22 to shaft 27 , which is connected to large pitch diameter sun gear S 2 . During operation in the fourth, fifth and sixth forward driving ratios, overdrive friction element E connects turbine shaft 18 to compound carrier 23 through shaft 28 . Friction element C acts as a reaction brake for sun gear S 2 during operation in second and sixth forward driving ratios. During operation of the third forward driving ratio, direct friction element B is applied together with forward friction element A. The elements of gearset 21 then are locked together to effect a direct driving connection; between shaft 28 and output shaft 26 . The torque output side of forward friction element A is connected through torque transfer element 29 to the torque input side of direct friction element B, during forward drive. The torque output side of direct friction element B, during forward drive, is connected to shaft 27 through torque transfer element 30 . Reverse drive is established by applying low-and-reverse brake D and friction element B.
[0009] For the purpose of illustrating one example of a synchronous ratio upshift for the transmission of FIG. 1 , it will be assumed that an upshift will occur between the first ratio and the second ratio. On such a 1-2 upshift, friction element G starts in the released position before the shift and is engaged during the shift while low/reverse friction element D starts in the engaged position before the shift and is released during the shift. Forward friction element A stays engaged while friction element B and overdrive friction element E stay disengaged throughout the shift. More details of this type of transmission arrangement are found in U.S. Pat. No. 7,216,025, which is hereby incorporated by reference.
[0010] FIG. 3 depicts a general process of a synchronous friction element-to-friction element upshift event from a low gear configuration to a high gear configuration for the automatic transmission system of FIG. 1 . For example, the process has been described in relation to a 1-2 synchronous ratio upshift above wherein friction element C is an oncoming friction element and low/reverse friction element D is an off-going friction element, but it is not intended to illustrate a specific control scheme.
[0011] The shift event is divided into three phases: a preparatory phase 31 , a torque phase 32 and an inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked (not shown) to prepare for its engagement. At the same time, off-going friction element control force is reduced as shown at 34 as a step toward its release. In this example, off-going friction element D still retains enough torque capacity shown at 35 to keep it from slipping, maintaining transmission 2 in the low gear configuration. However, increasing on-coming friction element control force shown at 36 reduces net torque flow within gearset 21 . Thus, the output shaft torque drops significantly during torque phase 32 , creating a so-called torque hole 37 . A large torque hole can be perceived by a vehicle occupant as an unpleasant shift shock. Toward the end of torque phase 32 , off-going friction element control force is dropped to zero as shown at 38 while on-coming friction element apply force continues to rise as shown at 39 . Torque phase 32 ends and inertia phase 33 begins when off-going friction element D starts slipping as shown at 40 . During inertia phase 33 , off-going friction element slip speed rises as shown at 41 while on-coming friction element; slip speed decreases as shown at 42 toward zero at 43 . The engine speed and transmission input speed 44 drops as the planetary gear configuration changes. During inertia phase 33 , output shaft torque indicated by profile 45 is primarily affected by on-coming friction element C torque capacity indirectly indicated by force profile 46 . When on-coming friction element C completes engagement or when its slip speed becomes zero at 43 , inertia phase 33 ends, completing the shift event.
[0012] FIG. 4 shows a general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element D is released prematurely as shown at 51 compared with the case shown in FIG. 3 . When off-going friction element D is released, it breaks a path between automatic transmission input shaft 18 and automatic transmission output shaft 24 , depicted in FIG. 1 , no longer transmitting torque to automatic transmission output shaft at the low gear ratio. Since on-coming friction element C is yet to carry enough engagement torque as indicated by a low apply force at 52 , automatic transmission output shaft torque drops largely, creating a deep torque hole 53 which can be felt as a shift shock. At the same time, engine speed or transmission input speed rapidly increases as shown at 54 , causing a condition commonly referred to as engine flare. A large level of engine flare can be audible to a vehicle occupant as unpleasant noise. Once on-coming friction element C develops sufficient engagement torque as indicated by a rising control force at 55 , automatic transmission input speed comes down and the output torque rapidly moves to a level at 56 that corresponds to on-coming friction element control force 55 . Under certain conditions, this may lead to a torque oscillation 57 that can be perceptible to a vehicle occupant as unpleasant shift shock.
[0013] FIG. 5 shows a general process of a friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element release is delayed as shown at 61 compared with the case shown in FIG. 3 . Off-going friction element D remains engaged even after on-coming friction element G develops a large amount of torque as indicated by a large actual control force at 65 . Thus, transmission input torque continues to be primarily transmitted to output shaft 24 at the low gear ratio. However, large on-coming friction element control force 65 results in a drag torque, lowering automatic transmission output shaft torque, creating a deep and wide torque hole 63 . This condition is commonly referred to as a tie-up of gear elements. A severe tie-up can be felt as a shift shock or loss of power by a vehicle occupant.
[0014] As illustrated in FIGS. 3 , 4 , and 5 a missed synchronization of off-going friction element release timing with respect to on-coming friction element torque capacity leads to engine flare or tie-up. Both conditions lead to varying torque levels and profiles at automatic transmission torque output shaft 24 during shifting. If these conditions are severe, they result in undesirable driving experience such as inconsistent shift feel or perceptible shift shock. The prior art methodology attempts to mitigate the level of missed-synchronization by use of an open loop off-going friction element release control based on speed signal measurements. It also attempts to achieve a consistent on-coming friction element engagement torque by an open-loop approach during a torque phase under dynamically-changing shift conditions.
[0015] FIG. 6 illustrates a prior art methodology for controlling a friction element-to-friction element upshift from a low gear configuration to a high gear configuration for automatic transmission 2 in FIG. 1 . The prior art on-coming control depicted in FIG. 6 applies to a conventional torque phase control utilized for either a synchronous or non-synchronous shift. In this example off-going friction element D remains engaged until the end of torque phase 32 . Although the focus is placed on torque phase control, FIG. 6 depicts the entire shift control process. As shown the shift event is divided into three phases: a preparatory phase 31 , a torque phase 32 and an inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked (not shown) to prepare for its engagement. At the same time, off-going friction element control force is reduced as shown at 34 as a step toward its release. During torque phase 32 controller 4 commands an on-coming friction element actuator to follow a prescribed on-coming friction element control force profile 64 through an open-loop based approach. Actual on-coming friction element control force 65 may differ from prescribed profile 64 due to control system variability. Even if actual control force 65 closely follows prescribed profile 64 , on-coming friction element engagement torque may still vary largely from shift to shift due to the sensitivity of the on-coming friction element engagement process to engagement conditions such as lubrication oil flow and friction surface temperature. Controller 4 commands enough off-going element control force 61 to keep off-going element D from slipping, maintaining the planetary gearset in the low gear configuration until the end of torque phase 32 . Increasing on-coming friction element control force 65 or engagement torque reduces net torque flow within the low-gear configuration. Thus, output shaft torque 66 drops significantly during torque phase 32 , creating so-called torque hole 63 . If the variability in on-coming friction element engagement torque significantly alters a shape and depth of torque hole 63 , a vehicle occupant may experience inconsistent shift feel. Controller 4 reduces off-going friction element actuator force at 38 , following a pre-calibrated profile, in order to release it at a pre-determined timing 67 . The release timing may be based on a commanded value of on-coming friction element control force 62 . Alternatively, off-going friction element D is released if controller 4 detects a sign of significant gear tie-up, which may be manifested as a detectable drop in input shaft speed 44 . Inertia phase 33 begins when off-going friction element D is released and starts slipping as shown at 67 . During inertia phase 33 , off-going friction element slip speed rises as shown at 68 while on-coming friction element slip speed decreases toward zero as shown at 69 . Transmission input speed 44 drops as the planetary gear configuration changes. During inertia phase 33 , output shaft torque 66 is primarily affected by on-coming friction element torque capacity or control force 65 . The shift event completes when the on-coming friction element comes into a locked or engaged position with no slip as shown at 70 .
[0016] FIG. 7 illustrates another prior art methodology for controlling torque phase 32 of a synchronous upshift process from the low gear configuration to the high gear configuration. In this example, controller 4 allows off-going friction element D to slip during torque phase 32 . Although the focus is placed on torque phase control, FIG. 7 depicts the entire shift event. During preparatory phase 31 , an on-coming friction element piston is stroked to prepare for its engagement. At the same time, off-going friction element control force 86 is reduced as a step toward its slip. During torque phase 32 , on-coming friction element control force is raised in a controlled manner. More specifically, controller 4 commands on-coming friction element actuator to follow a prescribed on-coming friction element control force profile 87 through an open-loop based approach. An actual on-coming friction element control force 88 may differ from the commanded profile 87 due to control system variability. Even if actual control force 88 closely follows commanded profile 87 , on-coming friction element engagement torque may still vary largely from shift to shift due to the sensitivity of on-coming friction element engagement process to engagement conditions such as lubrication oil flow and friction surface temperature. Increasing on-coming friction element control force 88 or on-coming friction element engagement torque reduces net torque flow within the low-gear configuration. This contributes to output shaft torque 99 being reduced during torque phase 32 , creating a so-called torque hole 85 .
[0017] If the variability in on-coming friction element engagement torque significantly alters the shape and depth of torque hole 85 , the vehicle occupant may experience inconsistent shift feel. A deep torque hole may be perceived as an unpleasant shift shock. During torque phase 32 , off-going friction element control force is reduced as shown at 82 to induce an incipient slip 83 . Controller 4 attempts to maintain off-going friction element slip at a target level through a closed-loop control based on off-going friction element speed 96 which may be directly measured or indirectly derived from speed measurements at pre-determined locations. A variability in off-going friction element control force 82 of off-going element slip torque may alter the shape and depth of torque hole 85 , thus affecting shift feel. If controller 4 inadvertently allows a sudden increase in off-going friction element slip level, automatic transmission input speed or engine speed 90 may surge momentarily, causing the so-called engine speed flair or engine flair. The engine flair may be perceived by a vehicle occupant as an unpleasant sound.
[0018] Controller 4 initiates off-going friction element release process at a predetermined timing shown at which may be based on a commanded value of on-coming friction element control force 93 . Controller 4 lowers off-going friction element control force, following a pre-calibrated profile 94 . If a release of off-going friction element D is initiated prematurely before on-coming friction element C develops enough torque, engine speed or input shaft speed may rise rapidly in an uncontrolled manner. If this engine speed flair 90 is detected, controller 4 increases off-going friction element control force to delay off-going friction element release process. Alternatively to the pre-determined off-going friction element release timing, controller 4 may utilize speed signals to determine a final off-going friction element release timing. When a sign of significant gear tie-up, which may be manifested as a measurable drop in input shaft speed, is detected, off-going friction element D is released following a pre-calibrated force profile. Inertia phase 33 begins when off-going friction element torque capacity or control force drops to non-significant level 95 . During inertia phase 33 , off-going friction element slip speed rises 96 while on-coming friction element slip speed decreases 97 toward zero. The transmission input shaft speed drops as shown at 98 as the planetary gear configuration changes. During inertia phase 33 , the output shaft torque 99 is primarily affected by on-coming friction element torque capacity, which is indicated by its control force 100 . When on-coming friction element C becomes securely engaged at 101 , the shift event completes.
[0019] In summary, a prior art methodology, which is based on an open-loop on-coming friction element control during a torque phase, cannot account for control system variability and dynamically-changing shift conditions during the torque phase, resulting in inconsistent shift feel or unpleasant shift shock. A pre-determined off-going friction element release timing with a pre-calibrated control force profile cannot ensure an optimal timing under dynamically changing shift conditions, resulting in inconsistent shift feel or unpleasant shift shock. The alternative approach to gauge off-going friction element release timing based on speed signals often results in a hunting behavior between gear tie-up and engine flair, leading to inconsistent shift feel. Furthermore, off-going friction element slip control is extremely difficult because of its high sensitivity to slip conditions. In addition, a large discontinuity exists between static and dynamic friction coefficients, introducing a large torque disturbance during an incipient slip control. A failure to achieve a seamless off-going friction element slip control during the torque phase leads to undesirable shift shock.
[0020] As can be seen from the above discussion the controllability of both off-going friction element and on-coming friction element is desirable in order to deliver a consistent and seamless shift quality. The prior art does not have a cost effective design solution to the problem of directly measuring torque passing through either a multiple disc clutch or a band brake and therefore is a need in the art for a transmission control system that minimizes shift shock during a gear ratio change that does not rely solely on traditional speed signal measurement or a predetermined open-loop control and instead relies on measuring friction element load level in either a multiple plate clutch or a band brake for consistently controlling its torque level through a closed loop approach;
SUMMARY OF THE INVENTION
[0021] The present invention is directed to a load sensor assembly for measuring an amount of torque transmitted, through a torque establishing element of an automatic transmission. The assembly comprises a core mounted on a transmission housing and a load sensor mounted on the core and positioned against a portion of the torque establishing element whereby a portion of the amount of torque transmitted through the torque establishing element travels through the load sensor and is measured by the load sensor assembly. Preferably, a cable is connected to the load sensor for transmitting a signal representative of the amount of torque to a transmission controller. A cover or sleeve extends over the core and the sensor.
[0022] In a preferred embodiment, the torque establishing element is a multiple disk friction element including an end plate and a spline connection between the transmission case and the end plate. The connection has teeth that extend from the transmission case and cooperate with teeth extending from the end plate. The load sensor assembly is mounted on the transmission housing between two spline teeth extending from the end plate and in a location where a spline tooth would normally be located. Preferably, the core is made of metal and the sleeve is made from one Of rubber, plastic and metal. The sensor may have several different configurations. In One configuration, a pin is fixed to the end plate and the load sensor is placed against the pin. In another configuration, the force sensor is a load-resistive elastomer deposited on a thin film and the core is a tooth of a friction element plate. An example of such a thin film force sensor can be found in U.S. Pat. No. 6,272,936, which is incorporated herein by reference. In yet another configuration, the core is a metal beam securely anchored to the transmission case and the load sensor is a strain sensor that measures an amount of strain on the beam caused by the torque.
[0023] In another embodiment the torque establishing element is a band brake including an anchor bracket and a band brake strap. The core may engage the strap in many ways. In one configuration, the band brake strap has a block extending therefrom and the core passes through the transmission housing and engages the block. The load sensor is located between the core and the block. In another configuration, the band brake strap has a hook extending therefrom formed by punching a hole in the strap. The core passes through the transmission housing and engages the hook and the load sensor is located between the core and the hook. In yet another configuration, the anchor bracket has a pin extending therefrom. The core passes through the transmission housing and engages the pin. The load sensor is located between the core and the pin. Preferably, a cushion is located between the load sensor and the cover.
[0024] In yet another embodiment, the torque establishing element is a band brake including an anchor bracket and a band brake strap while the core is an anchor pin, which does not necessarily have a cover, mounted in the transmission case. The anchor pin extends out of the transmission case and engages the anchor bracket. The load sensor is mounted between the anchor pin and the transmission case whereby torque is transferred to the band strap, pushes on the anchor pin and is sensed by the load sensor. Preferably, a cushion is located between the load sensor and the anchor pin. The core includes an anchor pin mounted in the transmission case. The core extends out of the transmission case and is connected to an anchor strut which, in turn, engages the anchor bracket. The load sensor is mounted between the anchor pin and the transmission ease. Torque is transferred to the band strap where it pushes on both the anchor strut and pin, with the torque being sensed by the load sensor. Preferably, the transmission housing includes a hole for supporting the anchor pin. A nut is mounted in one end of the hole and secures the anchor pin to the housing. A plug and a support are located between the nut and the anchor pin. With this arrangement, torque passing through the friction elements of a transmission may be directly measured and shift shock and engine flair may be reduced.
[0025] Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings, wherein like reference numerals refer to corresponding parts in the several views.
BRIEF DESCRIPTION OF DRAWINGS
[0026] FIG. 1 is a schematic diagram of a gearing arrangement for an automatic transmission system according to the prior art;
[0027] FIG. 2 is a chart showing a clutch and brake friction element engagement and release pattern for establishing each of six forward driving ratios and a single reverse ratio for the transmission schematically illustrated in FIG. 1 ;
[0028] FIG. 3 is a plot of a general process of a Synchronous friction element-to-friction element upshift event from a low gear configuration to a high gear configuration for the prior art automatic transmission system of FIG. 1 ;
[0029] FIG. 4 is a plot of the general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which the off-going friction element is released prematurely compared with the case shown in FIG. 3 ;
[0030] FIG. 5 is a plot of the general process of a synchronous friction element-to-friction element upshift event from the low gear configuration to the high gear configuration in which off-going friction element release is delayed compared with the case shown in FIG. 3 ;
[0031] FIG. 6 is plot of a prior art synchronous friction element-to-friction element upshift control from a low gear configuration to a high gear configuration based on speed measurements of powertrain components for the automatic transmission system in FIG. 1 wherein an off-going friction element remains locked during the torque phase;
[0032] FIG. 7 is plot of a prior art synchronous friction element-to-friction element upshift control from a low gear configuration to a high gear configuration based on speed measurements of powertrain components for the automatic transmission system in FIG. 1 , wherein an off-going friction element is slipped during the torque phase;
[0033] FIG. 8 is a schematic diagram of a gearing arrangement for an automatic transmission system including load sensor locations in accordance with a first preferred embodiment of the invention;
[0034] FIG. 9 is a plot of a synchronous friction element to friction element upshift control from a low gear configuration to a high gear configuration for the automatic control system in FIG. 8 based on direct measurements or estimates of torsional load exerted onto an off-going friction element in accordance with a preferred embodiment of the invention;
[0035] FIG. 10 is a flow chart showing an on-coming friction element control method in accordance with a preferred embodiment of the invention;
[0036] FIG. 11 is a flow chart showing an off-going element release control method in accordance with a preferred embodiment of the invention;
[0037] FIG. 12 is a plot of the process used to determine an ideal release timing of the off-going friction element in accordance with first preferred embodiment of the invention;
[0038] FIG. 13 is a flow chart showing a shift control method in accordance with a preferred embodiment of the invention;
[0039] FIG. 14 is a plot of a synchronous friction element-to-friction element upshift from a low gear configuration to a high gear configuration for the automatic transmission control system in FIG. 8 based on the direct measurements or estimates of torsional load exerted onto an off-going friction element and an on-coming element in accordance with another preferred embodiment of the invention;
[0040] FIG. 15 is a flow chart showing an on-coming friction element shift control method in accordance with another preferred embodiment of the invention;
[0041] FIG. 16A depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed between two teeth of a endplate of a friction element for measuring a relative load level on the friction element;
[0042] FIG. 16B depicts the load sensor assembly of FIG. 16A installed in a transmission case;
[0043] FIG. 17A depicts a load sensor assembly in accordance with another preferred embodiment of the invention placed against a pin extending from an endplate of a friction element for measuring a relative load level on the off-going friction element;
[0044] FIG. 17B depicts the load sensor assembly of FIG. 17A installed in a transmission case;
[0045] FIG. 18 depicts a load sensor in accordance with another preferred embodiment of the invention formed of a thin film-type load sensor and attached to a tooth for measuring a relative load level on the off-going friction element;
[0046] FIG. 19 depicts a load sensor assembly in accordance with another preferred embodiment of the invention formed of a metal beam for measuring a relative load level on the off-going friction element;
[0047] FIG. 20 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0048] FIGS. 21A-21C depict a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0049] FIGS. 22A and 22B depict a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0050] FIG. 23 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0051] FIG. 24 depicts a chart in accordance with another preferred embodiment of the invention;
[0052] FIG. 25 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0053] FIG. 26 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0054] FIG. 27 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element;
[0055] FIG. 28 depicts a load sensor assembly in accordance with another preferred embodiment of the invention installed on a band brake type friction element for measuring a relative load level on the friction element; and
[0056] FIG. 29 depicts a chart in accordance with another preferred, embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0057] With initial reference to FIG. 8 , there is shown an automotive transmission employing the invention. As this automatic transmission arrangement is similar to the one schematically illustrated in FIG. 1 all the same parts have been indicated with corresponding reference numbers and therefore a duplicate discussion of these parts will not be made here. Instead, of particular importance is the addition of a torque sensor 120 located in friction element C, a load sensor 130 located in friction element D, and a torque sensor 131 located in transmission output shaft 24 , all connected to controller 4 for controlling various functions of transmission 2 as will be more fully discussed below.
[0058] FIG. 9 shows a torque phase control method according to a preferred embodiment of the invention for a synchronous friction element-to-friction element upshift from a low gear configuration to a high gear configuration for the automatic transmission system in FIG. 8 . The on-coming friction element control method illustrated here is also applicable to non-synchronous shift control. The shift event is divided into 3 phases: preparatory phase 31 , torque phase 32 and inertia phase 33 . During preparatory phase 31 , an on-coming friction element piston is stroked to prepare for its engagement. At the same time, off-going friction element control force or its torque capacity is reduced as shown at 404 as a step toward its release. During torque phase 32 , on-coming friction element control force is raised in a controlled manner as shown at 405 . More specifically, controller 4 commands on-coming friction element actuator to follow a target on-coming friction element engagement torque profile 406 through a closed-loop control directly based on the measurements of on-coming friction element engagement torque 407 during torque phase 32 . On-coming friction element torque 407 may be directly measured using a load sensor according to this invention as more fully described below. On-coming friction element engagement torque directly affects transmission output torque that is transmitted to the vehicle wheels. This torque-based close-loop control eliminates or significantly reduces the undesirable effects of on-coming friction element engagement torque sensitivity to hardware variability and shift conditions, achieving a consistent shift feel, regardless of shift conditions.
[0059] Alternatively to the direct measurements, on-coming friction element torque can be determined from the measurements of transmission output shaft torque using torque sensor 131 depicted in FIG. 8 . Mathematically, on-coming friction element torque T OCE can be described as a function of measured output shaft torque T OS as:
[0000] T OCE ( t )= G OCE T OS ( t ) Eq. (1)
[0000] Where G OCE can be readily obtained based on a given gear set geometry.
[0060] Yet alternatively, on-coming friction element torque T OCE can be estimated through the following Eq. (2), based on a slight change in transmission component speeds ω i at pre-determined locations (i=1, 2, . . . , n),
[0000] T OCE ( t )= F trans (ω i ,t ) Eq. (2)
[0000] where t indicates time and F trans represents a mathematical description of a transmission system. More specifically, as on-coming friction element engagement torque rises 407 , torque levels transmitted through various transmission components change. This creates small, but detectable changes in ω i . A transmission model, F trans , can be readily derived to estimate on-coming friction element engagement torque when off-going friction element remains locked during torque phase 32 .
[0061] Controller 4 commands enough off-going friction element control force 408 to keep it from slipping, maintaining the planetary gearset in the low gear configuration during torque phase 32 . As on-coming friction element engagement torque 407 increases, a reaction torque goes against a component that is grounded to a transmission case. More specifically, in this case, torque transmitted through off-going friction element or torsional load 409 exerted onto off-going friction element D decreases proportionally. Off-going friction element load level 409 can be directly monitored using a torque sensor such as is more fully discussed below. Alternatively, off-going friction element load level T OGE 409 can be calculated from measured or estimated on-coming friction element engagement torque T OCE 407 when off-going friction element remains locked during torque phase 32 according to:
[0000] T OGE ( t )= F OCE/OGE ( T OCE ( t )) Eq. (3)
[0000] where F OCE/OGE represents a torque ratio between on-coming friction element C and off-going friction element D at the low gear configuration and can be obtained based on gear set geometry. According to this invention, off-going friction element D is released at an ideal timing when torque load exerted onto off-going friction element D becomes zero or a near-zero level. Transmission controller 4 initiates a release process of off-going friction element D as shown at 410 as off-going friction element load 409 approaches zero at 411 . Off-going friction element torque is dropped quickly as shown at 412 with no slip control. Since no off-going friction element slip control is involved, the method is insensitive to off-going friction element break-away friction coefficient variability. In addition, the quick release of off-going friction element D shown at 412 induces little disruption in output shaft torque at 413 because off-going friction element load level is near zero as shown at 411 at the moment of release. Off-going friction element D starts slipping 411 once its control force reaches a non-significant level. During inertia phase 33 , a conventional control approach may be utilized based on on-coming friction element slip measurements. Off-going friction element slip speed increases as shown at 415 while on-coming friction element slip speed decreases as shown at 416 . The transmission input speed drops as shown at 417 as the planetary gear configuration changes. During inertia phase 33 , output shaft torque 418 is primarily affected by on-coming friction element torque level 419 . Alternatively to the conventional control, a closed loop control that is based on measured or estimated on-coming friction element torque may continue to be employed. When on-coming friction element C completes engagement or when its slip speed becomes zero as shown at 420 , the shift event completes.
[0062] FIG. 10 shows a flow chart of closed-loop on-coming friction element engagement torque control during the torque phase depicted in FIG. 9 . Step 430 is the beginning of torque phase 32 . Controller 4 chooses a desired on-coming element torque at step 431 and measures or estimates an actual torque at step 432 . At step 433 , the on-coming friction element actuator is then adjusted by controller 4 based on the difference between the measured/estimated torque level and the actual torque level. At step 434 , controller 4 determines if torque phase has ended and if so controller 4 starts inertia phase 33 at 436 .
[0063] FIG. 11 shows a flow chart of an off-going friction element torque control process during torque phase 32 depicted in FIG. 9 . The process starts at step 440 at the beginning of torque phase 32 . A load transmitted through locked off-going friction element D is directly measured or estimated at step 441 . At step 442 , when its load level drops below a predetermined level, off-going friction element D is promptly released at step 444 . The control process ends at step 445 at the end of torque phase 32 .
[0064] Alternatively to the measurements or estimates of absolute load levels, FIG. 12 illustrates the process to determine the ideal release timing of off-going friction element D based on relative load measurements or estimates according to this invention. FIG. 12 depicts an actual load profile 451 exerted on off-going friction element D and a relative load profile L(t) 452 measured by torque sensor 130 during the upshift event in FIG. 9 . The preferred embodiment requires only relative load profile L(t) 452 . Relative load profile L(t) 452 is preferably constructed from uncalibrated sensor output that reflects actual load profile 451 , but not its absolute levels. This feature eliminates the need of a full sensor calibration across the entire load range. It also makes the preferred embodiment insensitive to sensor output drift over time. However, the preferred embodiment relies on knowledge of sensor measurement L 0 453 which corresponds to zero off-going friction element load level 454 . Sensor measurement L 0 453 can be readily identified, as often as required, by sampling sensor output while vehicle transmission 2 is in a neutral or a similar condition where no load is exerted onto off-going friction element D. Transmission controller 4 collects relative load data 455 during torque phase 32 to dynamically construct relative load profile L(t) 452 . Then, controller 4 extrapolates L(t) to predict t 0 457 where L(t 0 )=L 0 . Once t 0 457 is obtained in advance, controller 4 predicts when to initiate an off-going friction element release process. Specifically controller 4 starts the release process at a time equal to t 0 -Δt shown, at 458 , where At is the time required to quickly drop off-going friction element control force to zero. In this way, off-going friction element D starts slipping at or near ideal timing t 0 457 when the actual off-going friction element load level is at or close to zero as shown by reference numeral 454 .
[0065] FIG. 13 presents a flow chart of the new upshift control method according to this invention. During preparatory phase 31 at step 461 of a synchronous upshift event, off-going friction element torque capacity or apply force is reduced to a holding level without allowing any slip at step 462 while on-coming friction element piston is stroked at step 463 . During torque phase 32 , transmission controller 4 measures at step 465 a relative load level exerted onto off-going friction element D at a pre-specified sampling frequency using torque sensor 130 described further below. Controller 4 repeats this measurement step 465 until enough data points are collected at step 466 for dynamically constructing a relative load profile at step 467 that shows load as a function of time L(t). Once relative load profile L(t) is obtained, controller 4 predicts the ideal off-going friction element release timing t 0 at step 468 so that L(t 0 )=L 0 where L 0 corresponds to a substantially zero load level on off-going friction element D. Controller 4 initiates an off-going friction element release process at t 0 -Δt as shown as step 469 where Δt is a pre-specified time required to quickly drop off-going friction element apply force to zero. Alternatively, controller 4 may initiate the off-going friction element release process at t thres such that L(t thres )=L thres where L thres is a predetermined threshold. No slip control is required for off-going friction element D during torque phase 32 . Inertia phase 33 starts when off-going friction element D is released. The control methodology illustrated in FIG. 10 is preferably applied to on-coming friction element C during torque phase 32 . A conventional on-coming friction element control may be applied during inertia phase 33 based on speed signals. When on-coming friction element C becomes securely engaged at step 473 , the shift event completes at step 474 .
[0066] FIG. 14 illustrates another preferred embodiment of the invention relating to a transmission system with an on-coming friction element actuator which may not have a sufficient control bandwidth compared with a sampling time of load measurements. At the beginning of torque phase 32 , a transmission controller raises on-coming friction element actuator force based on a pre-calibrated slope 480 over a time interval Δt between t 0 and t 1 as shown at interval 481 . During interval 481 , on-coming friction element load is either measured or estimated with a sampling time finer than Δt to construct an engagement torque profile 482 . If the measured or estimated torque profile 482 indicates a slow rise compared with a target torque profile 483 , controller 4 increases a slope of commanded on-coming friction element control force for a next interval 485 between t 1 and t 2 . On the other hand, if the actual torque is rising faster than a target profile, controller 4 reduces a slope of commanded on-coming friction element control force. For example, during interval 485 between t 1 and t 2 , on-coming friction element load is either measured or estimated with a sampling time finer than Δt to construct an engagement torque profile 486 . The measured or estimated slope 486 of the engagement torque is compared against a target profile 487 to determine a slope 488 of commanded force profile for the following control interval. This process is repeated until the end of torque phase 32 . The off-going friction element release control remains the same as that shown in FIG. 9 .
[0067] FIG. 15 shows a flow chart of alternative closed-loop on-coming friction element engagement torque control during torque, phase depicted in FIG. 14 . The start of torque phase 32 is shown at step 520 . Following path 521 , the off-coming friction element torque is measured or estimated at step 522 and torque profile 482 is created therefrom at step 523 . The method may have to go through several iterations as shown by decision block 524 and return loop 525 . Torque slope profile 486 or an average derivative of torque profile 482 is calculated at 526 and while a desired target slope profile 487 is calculated at 527 and compared with torque slope profile 486 at 528 . The actuator force Slope is increased 529 or decreased 530 and the process continues 531 , 532 until the end of torque phase 32 . The process then proceeds to inertia phase 33 at 533 .
[0068] While the shift control has been discussed above, attention is now directed to the structure of the various load sensor assemblies. FIGS. 16A , 16 B, 17 A, 17 B, 18 and 19 depict several preferred embodiments of load sensor assemblies for measuring a relative load level exerted on off-going friction element D or on-coming element C according to preferred embodiments of the invention. FIG. 16A shows a cross-sectional view of a load sensor assembly 601 design according to a preferred embodiment. In FIG. 16A , sensor assembly 601 is installed between two teeth 602 , 603 of an end plate 604 of off-going friction element D. Assembly 601 includes a core 605 , a load sensor 606 and a sleeve 607 . Core 605 is preferably made from a metal, such as steel or aluminum, and is securely grounded to a transmission case 608 through anchor bolts 609 . Load sensor 606 is preferably a film-type sensor constructed with a pressure-resistive material. Sensor 606 generates an electrical signal that corresponds to a relative level of loading force 610 . Sleeve 607 , which protects sensor 606 , is preferably made from rubber, plastic or metal. While cover 607 is referred to as either a sleeve or a cover, it is to be understood that the terms are interchangeable. FIG. 16B illustrates an installation of sensor assembly 601 in transmission case 608 . Sensor assembly 601 is securely positioned in a location where a spline tooth is normally located otherwise. When off-going friction element plates are installed, end plate 604 fits snugly around sensor assembly 601 , providing a preload to sensor 606 . That is, sensor 606 preferably indicates non-zero output L 0 even when no load is exerted on off-going friction element D or its end plate 604 . When the torque load is exerted as shown by arrow 610 during a shift event, the output from sensor 601 provides a relative measure of the load on off-going friction element D. When this embodiment is employed to measure relative load exerted onto an off-going friction element such as when torque sensor 130 is used to measure the load on friction element D, it is readily understood that optimal friction element release timing is identified when the sensor output level approaches to Lo corresponding to zero load level.
[0069] FIGS. 17A and 17B depict another sensor assembly 611 which has a similar structure to assembly 601 in FIG. 16A . Assembly 611 includes a grounded core 612 , a force sensor 613 and a sleeve 614 . However, as illustrated in FIG. 17A , assembly 611 is placed against a pin 615 that is fixed to an end plate 616 of off-going friction element D. Sensor 613 is preloaded against pin 615 , providing non-zero output in the absence of torque load on off-going friction element end plate 616 ( FIG. 17B ). When a torque load is exerted on off-going friction element D, pin 615 is pressed with a force 617 against sensor 613 across sleeve 614 . This enables sensor 613 to provide the relative measure of torque load on off-going friction element D. FIG. 17B shows a view of sensor assembly 611 and off-going friction element end plate 616 with pin 615 in a transmission case 618 .
[0070] FIG. 18 shows another potential embodiment of this invention wherein a thin film-type force sensor 621 is directly attached to a tooth 622 of a friction element plate 623 , covered with a protective sleeve 624 . Sleeve 624 is preferably made from rubber, plastic or metal. When plate 623 is installed into a transmission case 625 , sensor 621 directly measures contact load 626 between friction element tooth 622 and a spline 627 through sleeve layer 624 , providing a relative measure of the load exerted onto off-going friction element D.
[0071] FIG. 19 shows another preferred embodiment of the invention wherein a metal beam 631 , which is securely anchored to a transmission case 632 , is installed and positioned between two teeth 633 , 634 of an off-going friction element plate 635 . As a load level 636 exerted on plate 635 varies, a strain level of beam 631 changes. The level of the strain is detected through a strain sensor 637 , providing a relative measure of torque load exerted on off-going friction element D. Optionally, a cover may be added to protect strain sensor 637 .
[0072] FIGS. 20 , 21 A, 21 B, 21 C, 22 A, 22 B and 23 - 29 show various preferred embodiments of the invention relating to directly measuring torque in a friction element. More specifically, FIG. 20 shows a partial view of a band brake system 700 with a load sensing assembly 731 . Brake system 700 includes an anchor end of a band strap 732 , a pin or a hook 733 , and an anchor bracket 734 . Band strap 732 is preferably either a single-wrap or double-wrap type. Load sensor assembly 731 includes an assembly core 735 , a load sensing unit 736 and a protective sleeve or cover 737 . Assembly core 735 is made of a metal and securely mounted to a transmission case 738 with a bolt 739 or any other means. Cover 737 may be made of metal, rubber, plastic or any other materials. Cover 737 protects sensor unit 736 from direct contact with pin or hook 733 for reduced sensor material wear. Cover 737 may be made of a thermally-insulated material to protect sensor 736 from heat. Cover 737 also acts as a protective shield against any other hostile conditions that include electro-chemical reaction with transmission oil. Load sensing unit 736 , which may be a pressure resistive film-type, is positioned between core 735 and cover 737 . The tip of sensor 736 is positioned against pin 733 across cover 737 . When a band engagement is commanded, strap 732 is pulled by a hydraulic servo (which is described below) in the direction shown with an arrow 740 . Band strap 732 stretches slightly, pushing pin or hook 733 against load sensor 736 . Load sensor 736 generates an electrical signal according to a magnitude of the contact force. That is, sensor 736 provides a relative measure of band tension at the location of pin 733 . The electrical signal is transmitted to a data acquisition unit (not shown) and then to controller 4 through an electrical cable 741 .
[0073] FIGS. 21A , 21 B and 21 C depict band strap designs in detail. In FIG. 21A , a band strap 732 has a part punched out and bent to form a pin or a hook 753 and a hole 752 . Hole 752 also acts as an oil drain during band engagement. In FIG. 21B , a small pin or a block 754 is riveted, screwed or welded to strap 732 . Alternatively, a pin or a hook 755 can be formed as apart of an anchor bracket 734 as shown in FIG. 21C . A pin 755 is attached to a band anchor bracket 734 instead of a strap 732 . Sensor assembly 731 is positioned against the pin 755 . Since bracket 732 is stiffer than the strap 732 , its strain is smaller under loaded conditions during both holding and engagement. Thus, a level of force exerted onto a load sensor 736 through a micro displacement of pin 755 is reduced significantly. The lower stress level improves the life of the sensor assembly 731 while enabling the use of a sensor 736 rated for a lower maximum force.
[0074] FIG. 22A illustrates sensor functions during a band engagement process. When the engagement is initiated, transmission controller 4 sends an electrical signal I(t) to raise and regulate a hydraulic force 761 applied to a servo piston 762 . As servo piston 762 is stroked, a servo rod 763 pulls one end 764 of band strap 732 . Tension around strap 732 builds up, squeezing out lubrication oil 766 from a band-drum interface. During the engagement, brake torque from strap 732 to a drum 767 is partly transmitted through viscous shear across oil 766 . The brake torque is transmitted through a mechanical frictional force once strap 732 makes physical contact with drum 767 . According to a conventional analysis, the relationships between engagement torque T eng , band tension at a pin F pin 733 and band tension at a servo F servo 769 can be written as follows, assuming a Coulomb friction model as a primary torque transfer mechanism between band strap 732 and drum 767 :
[0000] T eng =F servo R ( e μβ −1) Eq. (4)
[0000] F pin =F servo e μβ Eq. (5)
[0000] where R=drum radius, m=a Coulomb friction coefficient, b=a band wrap angle 770 assuming that pin 733 is positioned sufficiently close to an anchor 734 . Drum 767 rotates in the same direction 772 as the hydraulic force 761 . Substituting Eq. (5) into Eq. (4) yields:
[0000]
T
eng
=
F
pin
R
(
1
-
-
μβ
)
or
F
pin
=
T
eng
R
(
1
-
-
μβ
)
Eq
.
(
6
)
[0000] Since the electrical output signal S pin from the sensor is approximately linear with band tension F pin :
[0000] S pin =kF pin Eq. (7)
[0000] where k is a proportional constant. Substituting Eq. (7) into Eq. (6) yields:
[0000]
S
pin
=
k
R
(
1
-
-
μβ
)
T
eng
=
k
′
T
eng
or
S
pin
t
=
k
′
T
eng
t
Eq
.
(
8
)
where
k
′
=
k
R
(
1
-
-
μβ
)
Eq
.
(
9
)
[0000] According to Eq. (8), the sensor output S pin provides a relative measure of band brake engagement torque T eng .
[0075] This embodiment provides a relative measure of T eng and its derivative (dT eng /dt) that enables a closed loop control of on-coming friction element engagement process during torque phase 32 . It significantly improves band engagement control, mitigating a sudden rise of band brake torque known as “grabbing” behaviors. Alternatively, the sensor signals may be utilized to adaptively optimize open-loop calibration parameters such as a rate of pressure rise as a function of oil temperature in order to achieve a consistent (dT eng /dt). The similar analysis can be applied to the so-called “de-energized” band engagement where the drum spins in the opposite direction of the servo.
[0076] FIG. 22B illustrates sensor functions while band strap 732 is securely engaged around drum 767 under a holding condition without any slippage. In this case, the band tension F pin at pin 733 reflects both the level of the band tension F servo 784 at the servo and the level of torque load T load 785 exerted onto band 732 and drum 767 from the adjoining components (not shown). It is important that one should clearly differentiate T load from T eng which is brake torque exerted from the band to the drum under slipping conditions.
[0077] According to a conventional analysis, the relationships between F pin , F servo and T load can be algebraically written as:
[0000]
F
pin
=
F
servo
+
T
load
R
or
T
load
=
R
(
F
pm
-
F
servo
)
Eq
.
(
10
)
[0000] Substituting Eq. (10) into Eq. (7), the sensor output S pin can be described as a function of F servo and T load as:
[0000]
S
pin
=
kF
pin
=
kF
servo
+
k
R
T
load
Eq
.
(
11
)
[0000] Note that F servo is a function of an electrical signal I commanded to a hydraulic control system from a transmission controller. That is:
[0000] F servo =F servo ( I ) Eq. (12)
[0000] Substituting Eq. (12) into Eq. (11) results in:
[0000]
S
pin
=
kF
pin
=
kF
servo
(
I
)
+
k
R
T
load
Eq
.
(
13
)
[0000] In the absence of T load , Eq. (13) becomes:
[0000] S pin =kF servo ( I )= S pin noload ( I ) Eq. (14)
[0000] where s pin noload is defined as the sensor output measured under no load condition for a given level of I. In practice S pin noload can be readily obtained, as required, by sweeping the servo actuator with a varying level of I while a vehicle is in a stationary condition. Substituting Eq. (14) into Eq. (13) yields.
[0000]
S
pin
-
S
pin
noload
(
I
)
=
k
R
T
load
Eq
.
(
15
)
[0000] Thus, S pin −S pin noload (I) provides a relative measure of torque load T load for a given electrical input I. The optimal timing to release off-going friction element during a synchronous shift is when the load exerted onto off-going friction element or T load becomes zero. This can be readily determined by sampling S pin and evaluating S pin −S pin noload (I) for a given electrical signal I. The use of the load sensor assembly according to this embodiment significantly improves band release controllability during a synchronous shift under all the operating conditions.
[0078] FIG. 23 shows a cross-sectional view of another sensor assembly 811 including a cushion element 812 inserted between a load sensor 813 and a pin or a block 814 that is attached to a band strap or an anchor bracket. Cushion element 812 is preferably made of a rubber. Alternatively, cushion element 812 may be made of a metal in the form of a spring such as a disk spring or a conical spring. A protective cover 815 is preferably positioned between cushion element 812 and block 814 . Cover 815 is readily slidable at a nominal force under loaded conditions. The loading force is transmitted from block 814 to load sensor 813 by deformation of cushion element 812 . Accordingly, cushion element stiffness is used to specify a force range at sensor 813 for a given range of loading force at block 814 . The force transmitted to load sensor 813 becomes limited once the cushion element surface becomes flush with surface 817 of the assembly core. This non-linear characteristic indicated at 818 enables high resolution force measurement for a targeted load range 819 as shown in FIG. 24 while protecting sensor 813 from excessive loading.
[0079] FIG. 25 shows an alternative embodiment of this invention. In this design, a load sensor 821 is placed at the bottom of a band anchor pin 822 inside a transmission case 823 . Electrical cable 824 attached to sensor 821 is routed outside through case 823 . The tip of pin 822 is inserted into an anchor bracket 826 , which is attached to band strap 825 . When the band brake system is actuated, strap 825 is hydraulically or mechanically tightened around a drum such that anchor bracket 826 pulls pin 822 in the direction of anchor load 828 as represented by an arrow. Accordingly, load sensor 821 directly measures an anchor load 828 exerted onto pin 822 from the anchor bracket 826 . A cushion element 831 is preferably placed between the bottom of an anchor pin 822 and load sensor 821 . Note that the sensing area of sensor 821 is smaller than the surface area of cushion element 831 . The anchor load supported by pin 822 is distributed over the surface of cushion element 831 . Accordingly, only part of the anchor load is transmitted to load sensor 821 . This enables the use of a sensor rated for a lower maximum force.
[0080] In FIG. 26 , a strut 841 is inserted between an anchor bracket 826 and an anchor pin 843 . Strut 841 enables the flexible placement of anchor pin 843 with respect to band strap 825 and transmission case 823 . Also, an angle 845 between strut 841 and pin 843 may be adjusted to optimize a level of the axial loading that bracket 876 exerts onto pin 843 through strut 841 . Cushion element 831 and the reduced axial loading allow the use of a sensor 821 rated for a lower maximum force. Alternatively, angle 845 may be adjusted to reduce the side loading onto pin 843 to minimize sensor output hysteresis caused by sticky pin displacement under the loaded conditions.
[0081] The embodiment of the invention in FIG. 27 shares many of the same features described in connection with the embodiment in FIG. 26 . First, anchor pin 853 is inserted into an unthreaded hole 852 inside transmission case 823 . Its large head 854 prevents pin 853 from falling through hole 852 . A cushion element 836 and a load sensor 821 are placed against pin head 854 . Cushion element 836 may be made of a rubber and act as a seal to protect the sensor 821 from transmission oil. Behind sensor 821 and cushion element 836 is a sensor support dish 857 , which may be made of a metal. Sensor support dish 857 is backed by a large plug 858 inserted into a threaded hole 859 . The position of plug 858 may be adjusted and locked with a nut 860 in order to set anchor pin 853 to a desirable position with respect to anchor bracket 826 and strut 841 .
[0082] The embodiment of the invention shown in FIG. 28 shares features with the embodiment for FIG. 27 . Specifically, a load sensor 821 is placed behind a cushion element 872 inside support dish 874 with a raised retaining wall 873 . Cushion element 872 is preferably made of rubber. Alternatively, cushion element 872 may be made of metal in the form of a spring such as a disk or a conical spring. Under a no load condition, the surface of cushion element 872 is in contact with that of a pin 875 , while the end of retaining wall 873 is away from the surface of pin 875 . When the anchor load is below a predetermined level, the entire load is transmitted to sensor 821 through the elastic deformation of cushion element 872 . As the anchor load increases, cushion element 872 becomes compressed. Once the surface level of cushion element 872 becomes flush with the end of retaining wall 873 , retaining wall 873 starts supporting the load exerted on pin 875 , limiting the load on sensor 821 .
[0083] As shown in FIG. 29 , cushion element stiffness determines where the sensor output starts leveling off at 876 . This embodiment of the invention enables the sensor performance to be targeted for a specific load range, maximizing a measurement resolution 877 . In addition, sensor output voltage at limiting load level 876 and at zero load level 878 can be used to auto-calibrate sensor 821 for enabling absolute load measurements. That is when the sensor output reaches its maximum plateau, a transfer function between sensor output voltage and load level can be mapped based on two point calibration. This feature is extremely useful, especially if sensor characteristics drift over time or vary under different operating conditions. This load-limiting feature also protects the sensor from overloading, preventing its failure.
[0084] Based on the above, it should be readily apparent that the present invention provides numerous advantages over prior friction element control during a torque phase of gear-ratio changing. The preferred embodiments provide a consistent output shaft torque profile for a powertrain system with a step-ratio automatic transmission system during a synchronous friction element-to-friction element upshift, which reduces shift shock. Also, there is a significant reduction in shift feel variability for a powertrain system with a step-ratio automatic transmission system during a synchronous friction element-to-friction element upshift. The preferred embodiments of the invention permit the use of either absolute or relative load levels which are directly measured or estimated. The use of a relative load profile, instead of absolute load levels, eliminates the need of full-sensor calibration, while the use of a relative load profile only requires one point sensor calibration that corresponds to zero load level and improves robustness against sensor drift over time. The preferred embodiments also provide for reduced output shaft torque oscillation at the beginning of the inertia phase due to the release of the off-going friction element at or near the ideal release timing where its load level is zero or close to zero and robustness against the variability of off-going friction element breakaway friction coefficient by means of a quick release of the off-going friction element at the ideal synchronization timing.
[0085] Further advantages include a consistent output shaft torque profile and significant reduction in shift feel variability for a powertrain system with a step-ratio system during a torque phase of a synchronous friction element-to-friction element upshift and during a torque phase of a non-synchronous upshift with an overrunning coupling element. Further, the system provides robustness against the variability of off-going friction element breakaway friction coefficient by means of a quick release of an off-going friction element at an ideal synchronization timing during a synchronous shift and against the variability of a friction element actuation system for both synchronous and non-synchronous shifts.
[0086] A clutch load sensor assembly provides a relative measure of torque load exerted to the clutch while it is engaged. A band brake load sensor assembly provides a relative measure of engagement torque (brake torque) and its derivative during an engagement process while a band slips against a drum and a relative measure of torque load exerted onto a band and a drum while the band is securely engaged to the drum without slippage. Sensor output may be calibrated with respect to a command signal to a band servo actuator while torque load is zero. Use of a protective cover in the sensor assembly prevents a direct contact between a load sensing material and the pin for reduced sensor material wear; and shields the sensor from hostile conditions that include heat and electro-chemical interaction, such as with transmission oil.
[0087] Although described with reference to preferred embodiments of the invention, it should be understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. For example, the invention could be extended to a doubles-wrap band brake system. In general, the invention is only intended to be limited by the scope of the following claims.
|
A load sensor assembly for measuring an amount of torque transmitted through a torque establishing element includes a core mounted on a transmission housing and a load sensor mounted on the core. The load sensor is positioned against a portion of the torque establishing element whereby a portion of the amount of torque transmitted through the torque establishing element travels through the load sensor and is measured. A cable is connected to the load sensor for transmitting a signal representative of the amount of torque to a transmission controller.
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This is a continuation of application Ser. No. 813,491, filed July 7, 1977, now abandoned.
BRIEF DESCRIPTION OF THE INVENTION
This invention relates to an automatic sewing machine which stitches various stitch patterns including zigzag stitches, super zigzag stitches, buttonhole stitches and intermittent stitches. A single buton, selected with an operator's slight finger pressure, causes the sewing machine to automatically and rapidly adjust various elements in preparation for the desired stitches by means of a power means. Such adjustable elements and parameters are: feed amplitude, lateral amplitude, lateral amplitude pattern, feeding amount, feed dog height, needle hole shape in the needle plate, presser foot pressure, needle position, stitching speed, and if necessary, thread tension, and an automatic stopping machanism.
In the prior art, when stitch patterns are changed over from one to another, it has been necessary to manually adjust many control knobs of the sewing machine in their proper order. Since such adjustments are complex, errors are often made, and considerable efforts are required when there are many kinds of stitch patterns available. In general, many shortcomings are involved in the prior art.
The present invention has been devised to overcome the shortcomings of the prior art.
It is a primary object of the invention to cause the adjustable elements of the sewing machine to be set for stitching the selected pattern by one operation of a single control button.
It is a second object of the invention to automatically determine the proper set positions of the adjustable elements automatically by one manual operation of the single button.
It is a third object of the invention to hold the main shaft of the sewing machine free from rotation during selection of the patterns by the button operation.
Many other features and operating advantages of the invention will be apparent from the following description of embodiments according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the outer appearance of an automatic sewing machine according to the present invention;
FIGS. 2 and 3 are front elevation views showing arrangements of cams of the invention;
FIG. 4 is a plan view, partially in section, of the embodiments in FIGS. 2 and 3;
FIG. 5 is a front elevational view of a cam driving machanism of the invention;
FIG. 6 is a plan view, partially in cross section, of a cam portion of the invention;
FIG. 7 is a front elevational view, partially in cross section, of a main shaft driving mechanism;
FIGS. 8 and 10 are side elevational views of a main shaft engaging and disengaging mechanism of the invention;
FIG. 11 is a button hole finish stitching mechanism;
FIG. 12 is an explanatory view of a manual-automatic exchanging device for the feed control;
FIG. 13 is an electric circuit for the first embodiment of this invention;
FIG. 14 shows main parts of the sewing machine, in outline, showing a second embodiment of the invention;
FIGS. 15-16 are side elevational views of the parts of FIG. 14;
FIG. 17 is a circuit for driving the machine motor including a power source circuit for controlling the sewing machine;
FIG. 18 is a control circuit of the embodiment in FIG. 23;
FIG. 19 is a detailed switching cam for pattern selecting cams;
FIG. 20 is a detailed view of a switching cam for a releasing cam and an automatic-manual switching cam;
FIG. 21 are graphs of signals in the control circuit;
FIG. 22-A is a controlling circuit of a third embodiment of the invention;
FIG. 22-B is a switching part of the control circuit;
FIG. 23 shows main parts of a fourth embodiment of this invention in outline;
FIG. 24 shows a control circuit for the fourth embodiment of this invention;
FIG. 25 is a detailed view of a switching cam for a releasing cam and an automatic manual switching cam, and a switch relative thereto;
FIG. 26 is a detailed view of a switch for selecting cams and switchs relative thereto; and
FIG. 27 is a cross section taken along line VII--VII of FIG. 23.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, reference numeral 01 denotes the head of the sewing machine, 02 denotes a top plate, 03 denotes a needle plate which enables the separator to alter the shape of a needle dropping hole, 04 denotes a presser foot secured to the lower end of a presser bar 05, 06 denotes a thread tension control, and 24' denotes a flywheel provided at the right side end of a main shaft 24 (see FIG. 7). 11 collectively shows a series of electric pushbutton switches 11a through 11k for selecting patterns, and each of these switch buttons, as is shown in FIG. 13, controls two circuits. When any one of the switches is slightly pushed with a finger, the other switches are automatically turned OFF by means of a suitable mechanical mechanism, and simultaneously the two circuits are operated. One of the circuits is operative only while the button is pressed, while the other circuit continues to operate until another button is pushed to release the previously pushed button. These electric switches 11a through 11k may have associated semiconductor switching elements, each such element being arranged to close one circuit in response to manual operation of a selected one of the push buttons. R indicates a reverse button for reversing the feeding drive of the sewing machine. When this button R is pushed, a switch SW 3 in FIG. 13 is closed. Switches 21 and 22 are respectively, automatic and manual switches. The automatic switch causes all the stitch adjusting elements (the feeding device, the needle bar swinging device, the needle hole, the presser device, and the stitching speed) to be automatically adjusted in accordance with the patterns selected by the buttons 11a to 11k. The manual switch enables the machine operator to manually adjust the needle swing adjusting device (48 in FIG. 2) and the feed adjusting device (52 in FIG. 11) by manually operating a feed control dial 07 and an amplitude control dial 08 provided on the top plate and thus vary an automatically adjusted stitch, such as the zigzag stitch. SW 0 is a switch for turning the machine on and off. LED collectively shows lamps indicating the operation of the push buttons. In FIGS. 2-4, reference characters A through G denote shafts which are provided between two frame plates 09, which are fixedly provided on both sides of the main shaft 24. These plates are located above the main shaft and rotatably support many cams and their corresponding followers. A numeral 1 indicates a set of pattern generating cams driven at a reduced speed by the main shaft 24 via a reduction gear. 2 indicates a plurality of followers, each rotatably mounted on the shaft F and engaging corresponding cams 1. W indicates a rod which transmits swinging movements of the followers 2 to a needle bar via a zigzag amplitude adjusting device 48. P (in FIG. 12) indicates a rod which transmits the swinging movements of the followers 2 to a feed control device 52 (in FIG. 11). 63 indicates a plurality of locking members which are rotatably mounted on a shaft arranged in parallel with the shaft F. The locking members will each engage, at one end 9, corresponding selecting cams 4 on the shaft B, and at the other end can engage the corresponding followers 2. When end 9 of locking member 63 engages the recess of the corresponding selecting cam 4 during rotation of the cam 4, the other end of the locking member is turned to lock the corresponding followers 2, so that the followers 2 can transmit the swinging movements from the pattern generating cams 1 to the needle bar swing adjusting device 48 or to the feed adjusting device (52 in FIG. 11). The followers 2 may be replaced by a single follower which is displacable along the shaft F to select a desired one of the pattern cams 1. The pattern cams 1 and the followers 2 may be replaced by a solid state or magnetic tape pattern memory and actuators connected to the pattern memory, the actuators taking out a selected pattern from the memory as a mechanical output through magnetic solenoids.
RS represents a group of switches which are operated by the rotation of switching cams 10 or switching cams 20 in FIG. 4. In the embodiment shown in FIG. 4 and FIG. 13, there are illustrated 18 combinations of the switches and cams, though FIG. 13 shows rotary switches for the sake of convenience, and shows contact elements 1 of the switches being operated by the switching cams. Switches RS 1 and RS 2 are operated by the switching cams 10-1 and 10-2, switches RS 3 and RS 4 are operated by cam 20, and switches RS 5a through RS 5k and RS 6 , RS 7 , and RS 8 are operated by cam 10-2.
In FIG. 5, the numerals 6, 7, and 8 indicate solenoids. SW 2 indicates a microswitch which is closed if any one of the solenoids is energized. 88 indicates a rotation cams which is provided on a shaft E and rotated together with a motor 5. The cam 88 is, as is shown in FIG. 6 and FIG. 7, provided coaxially with a bevel gear meshing with a bevel gear coaxial with a flat gear 23" which is in mesh with a flat gear portion 23' of a belt wheel 23 that is connected to motor 5 via a belt 5'.
When the solenoid 8 is energized, a follower 91-2 is brought into engagement with one of the cams 88 through a rod 93-8 and a link 92-8. As the result, a ratchet pawl 90-2 is continuously reciprocated to intermittently rotate a ratchet wheel 89-2. Therefore, the switching cams (20 in FIG. 4) which are integral with the ratchet wheel, are rotated counterclockwise on the shaft C.
The switching cam 20 and mechanical switching cams 18 and 19 are connected to each other by means of gears 18' so that these cams may be rotated together. When the solenoid 6 is energized, a ratchet wheel 81-3 on a shaft D is intermittently rotated, releasing cams 3 and the switching cams 10-1 and 10-3 are rotated stepwise with the same timing. When the solenoid 7 is energized, follower 91-1, pawl 90-1 and ratchet wheel 89-1 become effective, and the switching cams 10-2 on the shaft C, the pattern selecting cams 4 on the shaft B and limiting cams 49-1 on the shaft D are rotated with the same timing. 16 and 17 denote cams for controlling the needle swinging device and the feeding device via manual operation of the dials 07, 08 on the top plate of the sewing machine.
In FIGS. 7 to 10, 24" is a timing belt pulley fixed on the main shaft 24, and connects a lower shaft (not shown) of the sewing machine and the main shaft 24 by means of a timing belt (not shown). 27 indicates a bushing secured to the main shaft 24 and having a flange 27' with an engaging notch 27". 23 indicates a belt wheel rotatably mounted on the bushing 27, and driven in direction RO by the machine motor 5. 25 indicates a clutch pawl for rotating the main shaft, rotatably mounted on a shaft 25' which is provided on the belt wheel 23 parallel to the main shaft 24. The clutch pawl 25 is biased by a spring 25" so that its end point contacts the flange 27' of the bushing 27.
31 indicates a stopper cam body mounted on the bushing 27 and limited relative to the bushing 27 via a buffer spring 28. Adjacent to the flange portion 27' of the bushing 27, the cam body 31 is formed with a cam edge 26 for disengaging the clutch pawl 25 from the notch 27" of the bushing 27 against the action of the spring 25" when the stopper cam body 31 is rotated relative to the bushing 27. The cam body 31 is also formed with a portion 29 of small diameter and an inclined part 30 which are engaged by an end of a stopper 33.
32 denotes a weak return spring which provides mutual rotation between a flywheel 24' secured to the main shaft 24 and the stopper cam body 31. 9 indicates a solenoid. 35 denotes a stopper actuating arm pivoted at 38 on the machine housing together with a holding arm 37. Stopper 33 is pivoted on the machine housing and has its actuating end biased towards the center of the stopper cam 31 by means of a biasing spring 34. The holding arm 37 is, as shown in FIG. 9 and 10, rotatable within a limited range defined by a pin 39 on the actuating arm with respect to the actuating arm 35, and is biased clockwise by a spring 36. If solenoid 9 is energized together with the motor 5 when the stopper 33 is held as shown in FIG. 10 while the sewing machine is operating, the holding end of the holding arm 37 is rotated upwardly around the pivot 38, and the stopper 33 is moved, (as shown in FIG. 9) to a position stopping the sewing machine. When the controller (CL, FIG. 13) is released from stepping, the motor is deenergized and stopped, solenoid 9 is simultaneously returned, and an end 40 of the arm 35 contacts a center arm 33a of the stopper 33 (as shown in FIG. 9) to shift the stopper end of the stopper 33 out of the small diameter portion 29 of the stopper cam 31 and to move it to the position where it engages the inclined cam edge 30' of the stopper cam 31 which is rotated by the spring 28 relative to the main shaft 24.
Therefore, if a weak driving force still remains in the motor 5 at that time, the motor cannot rotate the main shaft and completely stops, and the sewing machine is automatically stopped in place. Subsequently, when the controller CL in FIG. 18 is stepped to rotate the motor 5 with a strong driving force (but a low speed) and solenoid 9 is simultaneously energized, the stopper end of the stopper 33 is released from the cam edge 30' to a position where it engages the inclined part 30, and the stopper end of the stopper 33 is then shifted out of the stopper cam body 31 by the inclined part 30 of the cam body 31 as is shown in FIG. 10.
A further reference will be made to an electric circuit shown in FIG. 13. M indicates the machine motor 5, one end of which is connected to a power source V via a switch SW 0 , and the other end of which is connected to the power source V via a controller CL when a later mentioned speed changing rotary switch RS 6 is positioned at a high speed side H, and is connected to the power source V via a diode D 1 and the controller CL when switch RS 6 is positioned at a low speed side L, and further is connected to the power source V via a diode D 2 and the controller CL when said switch RS 6 is at an intermittent stitching side Ba. p indicates a connector. La indicates a lamp for the sewing machine. SW 1 indicates a switch for the lamp. C 0 indicates an anti-interference capacitor. Solenoid 9, as mentioned above, moves the stopper 33 between its effective and ineffective positions. The solenoid 9 is connected to a full wave rectifying circuit RS 1 which is connected to the power source V via intermittent stitching side Ba of the rotary switch RS 6 . In this embodiment, the solenoid, (when it is supplied with more than a predetermined voltage,) is operated to release the clutch pawl 25 to its ineffective position, so that the main shaft 24 and the controller CL are pressed to a position between the initial stepping position and the maximum stepping position by the force of the motor 5. 6 represents a solenoid for rotating the releasing cam 3 (shown in FIGS. 2, 4, and 5.) This solenoid 6 is connected at one end to a full wave rectifying circuit SR 2 and is connected at the other end, via a thyristor SCR, to a contact m of the rotary switch RS 1 and is further connected to the contact 1 of a rotary switch RS 2 .
The contacts 1, 1 of switches RS 1 and RS 2 are switched over, closed or opened by rotation of the cams 10-1, and 10-3 (in FIG. 4) which are rotated with the releasing cams 3. The other end of solenoid 6 is connected to the contact n of the releasing side of the switch RS 2 . 7 represents a solenoid associated with the selecting cams 4 and the cams 10-2. One end of solenoid 7 is connected to the full wave rectifying circuit SR 2 and the other end is connected to the contacts m of the selecting rotary switches RS 5 a to RS 5 k which are in turn switched over by the cams 10-2, which cams are each associated with one of the respective eleven pattern selecting switches 11a to 11k. The contacts n of the switches RS 5 a to RS 5 k are connected to the contact 1 of the switch RS 2 . The switches RS 5 a to RS 5 k are operated in synchronism with the rotation of the selecting cams 4. 8 represents a solenoid for the automatic-manual switching cam 20. One end of solenoid 8 is connected to the full wave rectifying circuit SR 2 and the other end is connected to the terminal n at the solenoid side of a first rotary switch RS 3 and to the terminal m at the solenoid side of a second rotary switch RS 4 . The contacts 1, 1 of these switches RS 3 , and RS 4 are operated by rotation of the switching cam 20. A contact 1 of the speed changing rotary switch RS 6 is operated by the rotation of the selecting cam 4. SW 2 is a switch which is closed when any one of the solenoids 6, 7, or 8 is energized. One end of the switch SW 2 is connected to a terminal Ba of the intermittent stitching side of the rotary switch RS 6 and the other end of the switch is connected to the power source V. When the switch SW 2 is closed, the machine motor 5 is driven at a low speed via the diode D 2 independently of the controller CL. A low AC voltage is supplied to the full wave rectifying circuit SR 2 via voltage reducing transformer T. 46 denotes a solenoid for adjusting the feed direction changing device 47 in FIG. 11, and is connected to the full wave rectifying circuit SR 2 . SW 3 is a switch which energizes the solenoid 46 while the reverse button R is pushed. The diodes D 3 , D 4 , and D 5 connected in parallel with the solenoids, 7, 8 and 46 energize solenoids for a predetermined period of time, even if the solenoids are disconnected from the power source, in order to prevent the switch SW 2 from being temporarily opened when the rotary switches operate. This also protects the contacts of the rotary switches on disconnection. Numerals 11a and 11k indicate the pattern selecting switches, each connected at one end to the terminal m at the switch side of the first rotary switch RS 3 and to the terminal n at the switch side of the second rotary switch RS 4 . The pattern selecting switches are each connected at their other ends to the respective contact elements 1 of the rotary selecting switches RS 5 a to RS 5 k via connecting leads a' to k'. 21 represents a switch for permitting manual setting of the feeding device and the needle swinging device. 22 indicates a switch for providing an automatic setting of these devices. The switches 21 and 22 are each connected at one end to the contact n at the releasing side of the releasing rotary switch RS 1 , and are connected at the other end to contact elements 1 of the first and second rotary switches RS 3 and RS 4 respectively. SW 4 is a switch which is closed only when any one of the switches 11a to 11k, 21 or 22 is closed. However the switch SW 4 is instantly opened. When the switch SW 4 is closed, the thyristor SCR is triggered via a resistor R 1 . R 2 denotes a resistor for protecting the gate of the thyristor SCR.
LED collectively indicates light-emitting diodes to indicate that the switches 11a to 11k, 21 and 22 and SW 0 have been individually operated and closed. R 3 , R 4 and R 5 indicate protective resistors for the light-emitting diodes.
In this electric circuit, when the power source switch Sw 0 , the manual setting switch 21 and any one of the pattern selecting switches 11a to 11k (for example the switch 11d in FIG. 18) are closed, the switch SW 4 is temporarily closed and the thyristor SCR becomes conductive. Since the contact 1 of the rotary switch RS 1 in association with releasing cams 3 has been moved to position m after the preceding operation of the circuit, the releasing solenoid 6 is energized. Thus, the switch SW 2 (in association with the solenoid 6) is closed to energize the releasing solenoid 9 to disconnect the motor 5 and the main shaft 24. When the switch SW 2 is closed, the motor 5 is rotated at a low speed via the diode D 2 , independently of the controller CL. While the solenoid 6 is energized, the releasing cams 3 are intermittently rotated to shift the contacts 1 of the switch RS 1 from contact m to contact n. Thus, the solenoid 6 is deenergized. Concurrently, the contact element 1 of the rotary switch RS 2 is shifted to contact n from contact m. Since contact 1 of the switch RS 1 has been shifted to contact n, the selecting solenoid 7 is enerized via the cam selecting rotary switch RS 5 d (which is associated with the selecting cams 4 and corresponds to the pattern selecting switch 11d) the switch 11d, the switch RS 3 (associated with the manual-automatic switching cam 20), the manual setting switch 21, and the switch RS.sub. 1.
Thus, the pattern generating cams 1 corresponding to the pattern selecting switch 11d are selected by solenoid 7, and contact 1 of the switch RS 5 d is simultaneously shifted from contact m to contact n and deenergizes the solenoid 7. At this time, solenoid 6 is again energized via the switches RS 2 , RS 5 d, 11d, RS 3 , 21, and RS 1 to cause the releasing cams 3 to release, and contact 1 of switch RS 1 is concurrently shifted from contact m to contact n and contact 1 of switch RS 2 is shifted from contact m to contact n. Then the switch RS 1 is once again in the position it was in prior to operation of the pattern selecting switch 11d, but since the thyristor SCR has been deenergized, the solenoid 6 is not energized. Therefore, the selection of the pattern cams 1 is completed. In FIG. 2, the disengagement of the followers 63 from the corresponding followers 2 and the selective engagement of the followers 63 with the followers 2 is completed. The switch SW 2 then is opened, the solenoid 9 is deenergized, and the motor 5 is stopped.
When the automatic setting switch 22 is closed as is shown in FIG. 18, the manual setting switch 21 is opened and the thyristor SCR becomes conductive. When contact 1 of switch RS 1 in association with the releasing cams 3 is shifted to contact n, the solenoid 8 is energized via the switch RS 4 , and the automatic setting switch 22, the switch RS 1 , and the manual-automatic switching cam 20 come into play. The contacts 1, 1 of the respective switches RS 3 and RS 4 are then shifted from the respective contacts m, m to contacts n, n respectively, and the solenoid y is then energized via the switch RS 4 to select the pattern cams 1. This is different from the case in which the manual setting switch 21 is closed. Since the switching cam 20 comes into play, the cloth feeding amount and/or the needle swinging amplitude and the other adjustable parts of the sewing machine will be automatically adjusted in accordance with the selected pattern cams 1. However, when the manual setting switch 21 is closed, such adjustments are manually set by the manual dials 07 and 08 with respect to the feeding amount and the needle swinging amplitude in accordance with the selected pattern cams 1.
When a new switch other than the pattern selecting switch 11d is pushed, the switch 11d is thereby opened, and new pattern cams 1 corresponding to the pattern selecting switch 11 are selected in the same manner as mentioned above. The pattern cams 1 which have been previously selected are rendered inoperative by the selecting cams 4 which are rotated during selection of the new pattern cams, and simultaneously contact 1 of the switch RS 5 d is returned to contact m.
When the pattern selecting switch 11c is closed, intermittent stitching is selected and the contact 1 of speed changing switch RS 6 is moved to contact Ba, and the sewing machine is driven at a low speed via the controller CL, the switch RS 6 and the diode D 2 . Solenoid 9 is energized to operate the stopper 33 and stops the main shaft 24 of the sewing machine at a predetermined angular position corresponding to the upper dead point of the needle. When releasing the controller, the solenoid 9 is deenergized to make the stopper 33 inoperative, but the stopper 33 engages the inclined part 30 of the stopper cam 31 at the stopping position of the main shaft 24. Therefore, with the subsequent stepping of the controller, the stopper 33 is displaced out of the rotation path of the stopper cam 31, and the motor 5 is connected with the main shaft 24 to drive the shaft until the main shaft makes one complete rotation.
FIGS. 14-22 show a second embodiment of this invention. In FIGS. 14-16, the reference numeral 122 indicates a cam which is rotated by a gear 104 coaxially secured to the belt wheel 23. A cam follower 123 engages a cam face 122' formed on one side of the cam 122.
FIG. 16 is a side elevational view seen along the arrow IV in FIG. 19, and shows conditions in which the solenoid 9 is deenergized. In this condition, the drive shaft 116 is rotated, and a lever 124 fixed thereto is turned counterclockwise against compression spring 125 to hold the cam follower 123, (which is axially movable on a support shaft 126) at a position where the follower is disengaged from the cam face 122' of the cam 122. At the same time, the solenoid 9 renders the stopper 33 inoperative so that the motor 5 may be connected to the main shaft 24 via the clutch pawl 25, as will be understood from FIG. 15. When the solenoid 9 is energized, the follower 123 is released and engages the cam face 122' of the cam 122.
The reference numeral 127 indicates a swing link which is secured to a swing shaft 126. The swing link 127 has a lateral pin 127' which engages the follower 123 in such a manner that the follower 123 can be displaced on the shaft 126 relative to the pin 127' as shown in FIG. 16. The swing link 127 is biased counterclockwise by a spring 128. A pawl member 129 is, at one end, pivotally mounted on the swing link 127. Therefore, when the belt wheel is rotated by the machine motor, the cam 122 is rotated to reciprocate the pawl member 129. Since the swing shaft 126 is swung, the swing links 127A and 127B as shown at B and C in FIG. 14, (which are all secured to the common swing shaft 126) are swung and therefore pawl members 129' and 129", (which are respectively associated with swing links 127A and 127B) are longitudinally reciprocated.
Numeral 130 denotes a stopper for limiting the movement of swing link 127. 131, 132, and 133 denote solenoids which are energized and deenergized to selectively and respectively shift pawls 129, 129', and 129" between an effective position and an ineffective position. In the effective position, a pawl member 129, 129', and 129" can engage a respective one of the cam rotating ratchets 141, 142, and 143 to intermittently rotate them, and in the ineffective position the pawl members are spaced from the ratchets. These cam rotating ratchets are, respectively, rotatably mounted on support shafts 134, 135, and 136. 137 indicates an operating link for adjusting the cloth feeding mechanism (not shown). When the solenoid is energized, the operating link adjusts the feeding mechanism to feed the sewn material in reverse. 138 indicates a switch for opening and closing a switch of the machine motor controller and is operated when solenoid 133 is energized.
FIG. 17 shows a motor driving circuit and a power source circuit for controlling the operation of the motor, in which SM indicates a power switch provided at the outer side of the sewing machine. M indicates a machine motor. CONT indicates a controller. 121 denotes a switch for the motor, and its contact 121' is positioned at the side of the controller CONT when the clutch solenoid 9 in FIG. 15 is not energized and is positioned at the side of the electric source when solenoid is energized. The switch 138 operates to cut the controller circuit off from the machine motor M when the solenoid 133 is energized. +10 V, +20 V are DC supplies for the control source and the solenoid driving source as is shown in FIG. 18.
FIG. 18 shows a control circuit, in which Sa to So indicate pattern selecting switches provided on the outer side of the sewing machine, each corresponding to the stitch patterns sewn by the sewing machine, and each being normally opened. The switches Sg and So serve, respectively, for selecting a first half step of a buttonhole composed of a first bar tack stitch and a left side line tack stitch, and a second half step of the buttonhole composed of a second bar tack stitch and a right side line tack stitch. The marks h and p (which are exluded from the switch indications) are, as will be described herein, made to correspond to the left line tack stitch and the right line tack stitches which are mechanically selected without operating the selecting switches. L indicates a latch circuit, having input terminals P1-P4 which receive inputs from the switches Sa to So, which inputs are encoded by NAND gates NA1 to NA4. When any one of the switches is operated, a transistor Trs becomes conductive to connect the input side of an inverter IN1 and to deliver a pulse to the trigger terminal Cp to latch the encoded data, so that the latch circuit L continues to issue signals from the respective outputs Q1 to Q4. C indicates a counter. The exclusive OR gates EX OR1 to EX OR4 are discriminators which discriminate whether or not the sinals Q'1 to Q'4 of the counter C are in accord with the output signals Q1 to Q4 of the latch circuit L. The output of EX OR1 is connected to NAND gate NA6 via NAND gate NA5, and the outputs of EX OR2 to EX OR4 are connected to NAND gate NA6 via NOR gate NOR1. NAND gate NA7 and NA8 constitute a reset flip-flop circuit, and NA7 receives power from source +10 V via a delay circuit composed of the resistor R 1 and condenser C 1 . When the power source +10 V is connected before the pattern selecting switches Sa-So are operated, the input of the NAND gate NA8 becomes high via the inverter IN2, and the output of the NAND gate NA7 becomes high while the output of the NAND gate NA8 is low. The output of NAND gate NA8 is connected to AND gates AND 0 and AND 3 for selectively energizing the solenoids 9, 131, 132, and 133. The outputs of NAND gate NA7 and AND gate AND3 are connected to OR gate OR3 to energize the solenoid 131, to open the controller switch 138 so as to isolate the rotation of the motor M from the operation of controller CONT. Tr0 to Tr3 denote solenoids for, respectively, switching solenoids 9, 131, 132, and 133. D 1 to D 1 denote protective diodes for these solenoids. Va is a varistor for peaking the response of these solenoids when they are deenergized, by absorbing reverse EMF. The output of NAND gate NA8 is connected to the input of NA 10 of a reset flip-flop circuit that is composed of NAND gates NA9, NA 10. The input of the NAND gate NA9 is connected to the power source +10 V, and the output of NA9, which goes low when the power source +10 V is switched on, is connected to the input of NAND gate NA6. Since the NAND gate NA8 is under the control of transistor Trs, the input of the NAND gate NA8 becomes low when any one of the pattern selecting switches Sa-So is operated, and the flip-flop circuit of the NAND gates NA7 and NA8 is inverted. At this time, a flip-flop circuit composed of NAND gates NA9 and NA 10 is not inverted (as will be mentioned hereinafter). AND gate AND 0 receives the output of NAND gate NA6 via OR gates OR4, OR5, and OR1, and a low output at NAND gate NA9 energizes the clutch solenoid 9, independently of the status of the exclusive OR gates EX OR1 to EX OR4. Energization of the solenoid 9 operates the motor switch 121 to drive the motor M, independently of the controller CONT. At the same time, the stopper 33 shown in FIG. 15 is moved to its effective position to disconnect the main shaft 24 of the sewing machine from the belt wheel 104 and to rotate the cam 122 at a low speed. 151, 152 and 153 indicate switching cams for the selecting cams, the releasing cams and the automatic-manual switching cams. Cams 151, 152 and 153 are rotatably mounted on respective support shafts 134, 135, and 136 and are respectively, intermittently rotated by pawl wheels 141, 142, and 143 when the solenoids 131, 132 and 133 are selectively energized as shown in FIG. 14.
The switch cam 152 for the selecting cams has, as shown in FIG. 19, a recess A', corresponding to the basic zigzag stitches a in the patterns to be selected, and like projections B', each corresponding to the stitches b to p. These projections are divided in a like fashion. The portions not corresponding to the patterns a-p are defined by intermediate recesses N. A follower pawl 140, which is secured to a swing shaft 139, engages the switch cam 152. The follower 140 engages each of the patterns a-p during two steps of rotation of the switch cam 152 which are effected by the cooperation of the ratchet 142 and the pawl member 129'. The motion of the follower 140 is transmitted to a contact ct2 of switch S 2 through shaft 139. When the follower 140 engages recess A', the contact A is grounded. When the follower engages any one of the projections B', a contact B is grounded. When the follower engages any one of the intermediate recesses N, contacts A, B are not grounded. The switching cams 151, and 153 for the releasing cams and for the automatic-manual switching cams are each, as is shown in FIG. 20, formed with a recess A' and a projection B' opposed 180° to the recess, and are further formed with intermediate parts N as shown. Each of these switch cams 151, and 153 cooperate with switches S 1 , and S 3 which are identical to switch S2. The contact B of switch S 1 operated by the switching cam 151 is connected to one of the inputs of an AND gate AND4, the other input being connected to the output of OR gate OR5. The output of the AND gate AND4 is connected to the input of OR gate OR 2 , the output of which is connected in turn to the input of AND gate AND1. The contact B is connected to the power source +10 V. As is shown in FIG. 18, when the contact element Ct 1 is in an intermediate position the releasing solenoid 31 is energized, so that OR gate OR4 and NAND gate NA8 are both high to drive the ratchet 141, when the contact element Ct 1 of the switch S 1 contacts the contact B. In other words, contact B is grounded to stop the ratchet 141. The contact A of switch S 1 is connected to the power source +10 V and is connected to NAND gate NA11 via inventer IN3, and the output of NAND gate NA11 is connected to the input of NAND gate NA 5. In this case the contact A has no bearing on the high condition of OR gate OR4. The pawl wheel 141 is associated with the releasing cams, which are coaxially mounted on support shaft 134. When contact B of switch S 1 is grounded, the ratchet 141 drives the releasing cams to cause the pattern selecting cams (which are mounted on the shaft 135 coaxially with the ratchet 142) to select the pattern generating cams (or a pattern generating signal carrier). Further, since contact B of switch S 1 is connected to AND gates AND2 and AND3 via inverter IN4, it energizes the cam selecting solenoid 132 to drive the pawl wheel 142. The contact A of switch S 2 receives power from the source +10 V and is connected to an input of NAND gate NA9. When contact A is opened, the high state of NAND gate NA8 does not invert NAND gate NA9, if the latter has previously gone low. However, when the contact Ct 2 reaches contact A it inverts the output of NAND gate NA9 to bring that output high. Then, NAND gate NA6 operates discriminators EX OR1 to EX OR4. Further, contact A of switch S 2 is connected to the reset terminal R of the counter C via inverter IN5. Therefore, when contact A is grounded, the falling signal at the terminal R resets the counter C to make the output signals Q'4, Q'3, Q'2 and Q'1 equal to 0000. Subsequently, when contact A is opened, the reset of the counter C is released. Contact B of switch S 2 receives power from the source +10 V, and contacts A, B of switch S 2 are connected to the inputs of NAND gate NA 12, the output of which is connected to the trigger terminal Cp of the counter C via a monostable multivibrator composed of a resistor R 2 , a capacitor C 2 , and an inverter IN6. Therefore, the output of NAND gate NA 12 is made low by the rising signal generated when either of contacts A or B is opened, and the falling signal at the inverter IN6 during a predetermined time interval causes the counter C to count up. The counting up is performed during the increasing pulse width of inverter IN6, which pulse width is narrower than the width of a low state of NAND gate NA 12 as shown in FIG. 21, before the next pattern (b for example) becomes effective. When, for example, pattern selecting switch S 2 is operated, the outputs Q 4 , Q 3 , Q 2 and Q 1 of the latch circuit L are equal to 0000, and counter C brings NAND gate NA6 low without counting up after the resetting. The counter C is, as mentioned, counted up each time contact A or contact B of switch S 2 is opened, until the counter C reaches that code of the latch circuit L which corresponds to a selected pattern. When the pattern selecting cams are rotated and the selection of a pattern generating cam or cams has been made in response to any one of the pattern selecting switches Sa to So, NAND gate NA6 goes low. The output of NAND gate NA 12 is connected to an input of NOR gate NOR2, the output of which is connected to one of the inputs of OR gate OR4. The output of NAND gate NA6 is connected to another input of NOR gate NOR2 via the monostable multivibrator composed of the inverter IN7, resistor R3, and capacitor C3.
During the low state of the NAND gate NA12 after the counting up has ceased, capacitor C 3 is charged. While the capacitor C 3 is charging, it stops the ratchet 142 for a while. When the capacitor has been charged up, it rotates the ratchet 142 again until the NAND gate NA12 becomes high. At the subsequent stop position of the ratchet 142, the pattern generating cams are selected. Hence, the selected pattern generating cam or cams are engaged by corresponding cam follower or followers. The output of OR gate OR5 is connected to one of the inputs of AND gate AND5 via inverter IN8, and the other input of AND gate AND5 is connected to contact A in association with the switching cam 151, and the output of gate AND5 is connected to the input of OR gate OR1 and is also connected to the input of OR gate OR2 via a delay circuit composed of resistor R4 and capacitor C 4 . When OR gate OR4 is low, and contact A of switch S 1 is opened, the output of AND gate AND5 becomes high and the low status of OR gate OR2 is maintained while the capacitor C 4 charges. Thus, when NAND gate NA12 is high due to the stationary condition of the selecting cams, (which, in association with switch cam 152, are at a predetermined angular position) the solenoid 131 is energized to rotate the pawl wheel 141, to cause the releasing cams to render the pattern generating cams effective by engaging the cam followers with the pattern operating cams. OR gate OR4 is high until NAND gate NA12 goes high after re-rotation of the pawl wheel 142, but during the delay time caused by the delay circuit which includes the capacitor C 4 the pawl wheel 141 does not operate. Solenoid 131 is energized to rotate the pawl wheel 141 during predetermined time interval, and contact B of switch S 1 is opened but AND circuit AND1 is high. When contact A is grounded, AND gate AND5 is lowered and the capacitor C 4 discharges through diode D 2 , and solenoid 131 is then deenergized to stop the pawl wheel 141. In this stopped position, the releasing cams cause the pattern generating cams to be operated.
A further reference will be made to driving of the pawl wheel 143 for the automatic-manual switching cams. A contact MAN of the manual side of AUTO-MANUAL switch S 4 , provided on the outside of the sewing machine, is connected to contact A of switch S 3 which is operated by switch cam 153, and contact AUTO of the automatic side is connected to contact B. Contact element Ct 4 of switch S 4 receives power from the source +10 V and is connected to the inputs of AND gate AND3 and OR gate OR5. When contact Ct 3 is in the intermediate position as shown in FIG. 18, the solenoid 9 is energized via AND gate AND0, and solenoid 133 is energized via AND gate AND3 so that contact B of switch S 2 is not grounded. When contact Ct 4 is grounded, the switching cam 153 is stopped to switch to the automatic or manual setting of the sewing machine depending on the switched position of the automatic-manual setting switch S 4 . Thus, the feeding amount and the needle swinging amplitude of the sewing machine, for example, can be automatically or manually adjusted in accordance with the selected pattern cam.
An explanation will be given for back stitching to generate checking stitches on termination of stitching. A normally opened switch S 5 on the outside of the sewing machine is ineffective if it is operated during the selection of the pattern generating cams. The output of AND gate AND0 is grounded via a delay circuit composed of the resistor R 5 , capacitor C 5 , inverter IN9, and switch S 5 , and the grounded side of switch S 5 is connected to the input of OR gate OR2. The switch S 5 energizes the solenoid 131 to move a link 137 in FIG. 14 upwardly and to operate the feed changing mechanism (not shown). However, when AND gate AND0 is high during the energization of the solenoid 9, inverter IN9 becomes instantly low via diode D 3 and nullifies the operation of switch S 5 . After AND gate AND 0 becomes low, condenser C 5 is not instantly discharged and therefore, during certain time interval, the input of OR gate OR2 raised and solenoid 131 is then energized. Since the capacitor C 5 is charged during the stitching operation of the sewing machine, actuation of switch S 5 instantly generates back or checking stitches.
Button hole stitching will now be discussed. Switching from the bar tack stitches to the line tack stitches of the first half of a buttonhole is mechanically carried out after a predetermined number of bar tack stitches have been made. At this changeover of the stitches the switching cam 152 is rotated to open or close the contact B of the switch S 2 so that the counter C advances one count. As a result, the lower three bits of outputs Q' 3 , Q' 2 and Q' 1 of counter C are 1 1 1. The, contact A of switch S 1 is grounded, via the inverter IN 3 , (while the pattern generating cams have been selected) and renders both NAND gate NA11 and OR gate OR 4 low. For this purpose, the operation of the buttonhole selecting switches Sg, So sets the code at 1 1 0.
In this case, when the power source switch SM in FIG. 23 is closed, the control power source +10 V and the solenoid driving power source +20 V become effective. Referring to FIG. 18, the inverter IN2 then goes high, NAND gate NA7 goes high and NAND gate NA9 goes low. NAND gate NA7 energizes AUTO-MANUAL switching solenoid 133 only to open the controller switch 138 and isolate the circuit of the controller CONT from the motor M. When, for example, switch Sc of the pattern selecting switches Sa to So is operated, the code 0 0 1 0 corresponding to the switch Sc is latched at the output sides Q 4 to Q 1 of the latch circuit L, NAND gate NA7 simultaneously goes low. (NAND gate NA8 is high already.) NAND gate NA9 going low makes the output of OR gate OR4 high, and clutch solenoid 9 is energized to actuate the motor switch 121 to drive the motor M, independently of controller CONT. As a result, the stopper 33 shown in FIG. 15 is moved to its effective position to separate the main shaft 100 from rotating belt wheel 104. The solenoid 9 turns the lever 124 shown in FIG. 16 clockwise to engage the follower 123 with the cam 122. As a result, the driving pawls 129, 129' and 129" are reciprocated. When the contact Ct 1 of switch S 1 is in its intermediate position as shown in FIG. 18, NAND gate NA4 is made high to energize releasing solenoid 131 and drive the ratchet 141. When the contact Ct 1 is shifted, contact B becomes low to stop the ratchet 141. Thus, the selection of the pattern cam is possible. A low at contact B of contact Ct 1 energizes the cam selecting solenoid 132 via inverter IN4 to drive the ratchet 142. When the contact Ct 2 of switch S 2 reaches the contact A to lower it, the NAND gate NA9 is inverted to high, and NAND gate NA6 renders the discriminators EX OR1 to EX OR4 effective. Concurrently, the counter C is reset to make outputs Q' 4 , Q' 3 , Q' 2 and Q' 1 0 0 0 0.
Subsequent operations will be discussed in reference to FIG. 21. A lateral axis t indicates a time in which the belt wheel is rotated with a predetermined speed. 129' shows the operation of the cam selecting drive pawl. The rising portions of a curve are intervals for rotating the ratchet 142, and the falling portions are stopping intervals of the ratchet 142 while the driving pawl 129' returns downwardly. The rising portions in the two stepwise rotations of the ratchet 142 correspond to the setting portions a to p of the pattern enerating cams. 52A, 52B are contacts of the switch S 2 . H and L show the logical levels of signals. The reset of counter C is carried out at falling time t R where the contact 152A becomes low. At this time, the output of latch circuit L and the output of the counter C are not congruant. Therefore, OR gate OR4 stays high, the pawl wheel 142 continues to rotate and the contact Ct 2 opens contact A. Afterward, contact B is repeatedly opened and closed. Each time the contact B is opened, inverter IN6 issues a pluse of width t 2 under the influence of the resistor R 2 and condenser C 2 , and counter C is counted up while the pulse falls. In this case, with two counts, the outputs Q' 4 , Q' 3 , Q' 2 and Q' 1 become 0 0 1 0 to make NAND gate NA6 low, and NAND gate NA12 deenergizes solenoid 132 during the charging time of the capacitor C 3 in the lower period of the gate NA12 after the second count. Thus, the ratchet 142 is stopped until it is rotated again by reenergization of the solenoid 132. The ratchet 142 is stopped when the OR gate OR 4 becomes low on the rising pulse of the NAND gate NA12. This stopped position of the ratchet 142 corresponds to that condition in which the pattern cams are ready to be selectively engaged by the corresponding followers. The rise time of NAND gate NA12 is slightly ahead of the rise of the curve 129' where the stepwise rotation of the ratchet 142 for the pattern C is finished, and it stops the driving pawl 129' precisely during the subsequent rest period of the ratchet. Since the contact Ct 1 of the switch S 1 is on contact B, a low at OR gate OR4 energizes the releasing solenoid 131 to rotate the ratchet 141 after the delay time caused by resistor R 4 and the condenser C 4 , after the pattern cams have been stopped in their predetermined angular positions. The pawl wheel 141 is stopped when the contact Ct 1 is at contact A, solenoid 116 is deenergized, and the controller CONT begins to operate. At this time, the releasing cams engage the followers with the pattern cams selected for the pattern C, and the selection of the pattern cams is completed.
The operation of the control circuit for forming the second half of the buttonhole will now be discussed. When the pattern selecting switch S 0 is operated, the outputs Q 4 , Q 3 , Q 2 and Q 1 of the latch circuit L are made 1 1 1 0, and the counter C counts 14 counts for selecting the corresponding pattern cam for bar tack stitches. When a predetermined number of bar tack stitches have been stitched, the right side line tack stitches are formed with an automatic mechanical adjustment without the operation of solenoids 9, 131, 132 and 133. This mechanical adjustment for the line tack stitches causes the switch cam 152 to make the pattern 9, so as to make the counter C count one step up. Thus the outputs Q' 4 , Q' 3 , Q' 2 and Q' 1 are made 1 1 1 1. Therefore the exclusive OR gate EX OR1 is made high but since contact A of switch S 1 is low, NAND gate NA11 becomes low and NAND gate NA5 becomes high and OR gate OR4 becomes low. Therefore, the buttonhole stitching is performed without driving solenoids 9, 131, 132 and 133.
FIG. 22A shows a third embodiment of this invention which employs a microprocessor instead of the controlling circuit in FIG. 18. TMS 1000 is here a 4-bit microprocessor made by Texas Instruments Inc., and sold as Model No. TMS-1000. The pattern selecting switches Sa to So are connected as shown, and receive storage signals issued from terminals R 0 to R 5 . The outputs of the switches Sa to So are connected to the terminals K 1 , K 2 , K 4 , and K 8 of the microprocessor TMS 1000 via OR gate OR 6 to OR 8 or directly. OR9 and OR10 indicate OR gates. INIT indicates a reset terminal which resets the microprocessor TMS 1000 when the control power source +10 V is energized. C 6 and R 6 indicate a capacitor and a resistor which are components of a clock pulse generator provided for clocking the microprocessor. La to Lo are indicating lamps each responsive to operation of the pattern selecting switches. The microprocessor TMS 1000 is so programmed as to perform the same controls as in the control circuit in FIG. 24 and is operated in the same manner as has been described in reference to FIG. 18.
FIG. 24 is a control circuit showing a fourth embodiment of this invention where V is an AC power source. SM indicates a power source switch provided on the outer side of the sewing machine. M indicates a machine motor. CONT indicates a controller. 221 indicates a motor switch whose contact 221' is at the side of the controller CONT when the clutch solenoid 9 is not energized. The contact 221' is shifted to the side of the power source when the solenoid 9 is energized. SR indicates a full-wave rectifying circuit whose positive side is connected to ends of solenoids 9, 131, 132 and 133, and whose negative side is connected to cathodes of thyristors SCR A to SCR H of circuit groups C A to C H (enclosed within double-dotted lines) which are in parallel and other (per available patterns A to H) and which connected to these solenoids. The negative side of the full-wave rectifying circuit SR is also connected to the cathodes of a plurality of diodes D 1 to D 1 which are connected in series with solenoids 9, 131, 132 and 133 to power the solenoids independently of the thyristors after the selection of the patterns has been completed. The group of diodes D 1 to D 1 has a forward voltage drop greater than that of each of the thyristors SCR A to SCR H . Therefore, when these thyristors conduct through solenoids 216, 231, 232 and 233, electric current flows in the thyristors prior to flowing in diodes D tl D 1 . D 2 to D 2 denote protective diodes for diodes D 1 to D 1 , and Va is a varistor which absorbs energy generated when the solenoids are deenergized, to peak response by absorbing reverse EMF. With respect to the switches S 1 , S' 1 , S" 1 , contact Ct 1 of switch S 1 is connected to the other end of solenoid 9 via diode D 3 and to the other end of solenoid 131 via diode D 4 and switches 138 and 139. The contact elements Ct' 1 and Ct" 1 of switches S1 and S' 1 are, respectively, connected to the other ends of solenoids 132 and 133. The switch cams 151, 151' and 151" are normally in the angular positions shown, and the contacts a 1 , a' 1 and a" 1 of the respective switch cams are opened. The contact Ct 1 is connected to a contact a' 1 of a switch S' 1 via the diode D 5 . In FIGS. 23 and 25, the switching cam 151 and switch cams 151' and 151" have respective recesses 251B and 251'B opposed by 180° and are rotated on the common shaft 134 by the ratchet 141 for the releasing cams. Therefore, the ratchet 141 is driven by energization of the solenoids 9 and 131, as mentioned above. The angular positions of these switching cams 151, 151' and 151" in FIG. 24 show that the releasing cams (not shown) keep the followers engaged with the pattern cams selected. These followers are released from the cams when the switching cams have been rotated 180°. Contact a 1 is connected to the anode sides of the diodes D 1 to D 1 . The switches S 2 A to S 2 H have contacts Ct A to Ct H connected to the contact a' 1 of a switch S' 1 . The structure of the switches is, as shown in FIGS. 26 and 27, such that the contacts Ct 2 and the terminals a' to h' are commonly closed and connected to the terminal a' 1 in FIG. 24. When the contacts Ct' 2 rotated around the shaft 135 contacts a specific contact, (e.g. a of contacts a to h), a corresponding contact a' of contacts a' to h' is opened, and the contact Ct' 2 is connected to the contact Ct 2 . The group of contacts Ct 2 , Ct' 2 corresponds to the contact elements Ct A to Ct H in FIG. 24. Then, any one of the contacts a to h of the gate sides of the thyristors SCR A to SCR H (corresponding to the patterns A to H) is selectively connected to contact a' 1 and opens the others. The opened condition of the other contact elements closes the contacts a' to h' of the anode sides of the thyristors SCR A to SCR H . The contact element C't 2 is rotated by the ratchet 142 and the resultant operation of the switches depends upon the energization of the solenoids 9 and 132. When the contact elements Ct A to Ct H of the contacts a to h are closed, the pattern A, for example, is selected, and the follower is ready to engage the pattern cam selected. S A to S H indicate pattern selecting switches to be operated on the outer side of the sewing machine. R 1 , R A1 to R H1 and R A2 denote electric current limiting resistors for the gate sides of the thyristors SCR A to SCR H . LED A to LED H indicate light-emitting diodes selectively lighted by the conduction of the respective thyristors to indicate the selected patterns A to H. R 2 and R A3 to R H3 show protective resistors for the light-emitting diodes. D A1 to D H2 , D A2 to D H2 denote diodes. R 3 and C indicate a resistor and a condenser for preventing the thyristors SCR A to SCR H from accidental firing. The contacts Ct 3 , Ct' 3 of switches S 3 , S' 3 are connected to the contact Ct 1 of switch S 1 via the contact a" 1 of the switch S" 1 and the diode D 6 . The contact a 3 of a switch S 3 is connected to the automatic side contact AUTO of AUTO-MANUAL setting switch S 4 which is to be operated on the outer side of the sewing machine, and the contact a' 3 of a switch S' 3 is connected to the manual side contact MAN of the AUTO-MANUAL setting switch. The switching cams 153 and 153' rotated with the AUTO-MANUAL setting switch ratchet 143 on the shaft 236 have different recesses 151B, and 151B' opposed by 180° as shown in FIG. 25. As shown in FIG. 24, the contact Ct 3 is opened if the contact Ct 4 of switch S 4 , connected to the diodes D 1 to D 1 , is on the AUTO side, and is closed if the contact element Ct 4 is on the MANUAL side. Furthermore, the contact element Ct' 3 is closed if the contact element Ct 4 is on the side of AUTO side, and is opened if the element Ct 4 is on the MANUAL side of the Automatic-Manual setting switch S 4 . The rotation of these switching cams 153 and 153' is controlled by energization of solenoids 9 and 133. When the AUTO-MANUAL switching cam (not shown) is rotated 180°, contact element Ct 4 is shifted to the MANUAL side. S 5 indicates a switch to be operated on the outer side of the sewing machine. Switch S 5 is for the checking stitches on the termination of stitching and is normally opened. The switch S5 opens and closes between solenoid 131 and the diodes D 1 to D 1 . While the switch is pressed, the checking stitches are sewn.
FIG. 33 shows that the pattern A has been selected. When the electric source switch SM is closed, the thyristor SCR A of the thyristors SCR A to SCR H forms the gate circuit, but the anode circuit is opened, and the respective solenoids 9, 131, 132 and 133 do not form main circuits via respective solenoids or diodes D 1 to D 1 , and the respective switches are maintained as shown, (where the pattern A is selected) and the switch 121 turns the controller CONT on. Therefore, when the controller is operated, the sewing machine is operated to sew stitches. The light-emitting diode LED A is lighted by the full wave rectifying current via the thyristor SCR A to indicate the pattern A.
When a pattern selecting switch S B is pushed to select a pattern B, the thyristor SCR B is ignited to cut off the gate current of the thyristor SCR A and to turn off the light-emitting diodes LED A , and to turn on the light-emitting diode LED B . Solenoids 9 and 131 are energized and the conduction of the thyristor is maintained by their inductance. The clutch solenoid 9 causes the switch 121 to drive the motor M, independently of the controller CONT. At the same time, the stopper 33 shown in FIG. 15 is operated to separate the main shaft 200 from being driven by the belt wheel, in order to rotate the belt wheel relative to the main shaft.
At the same time, solenoid 9 turns the lever 124 in FIG. 16 clockwise, and allows the cam follower 123 to engage the cam 222. The pawls 129, 129' and 129" in FIG. 23 are longitudinally reciprocated. The releasing solenoid 131 engages the pawl member 129 with the ratchet 141 to rotate the ratchet 141. When switching cams 151, 151' and 151" rotate 180°, the releasing cams (not shown) move to their releasing positions to accomplish the pattern selection, and contact Ct' 1 simultaneously contacts the contact a' 1 to energize the selecting solenoid 132, whereby the switch 238 is opened and the ratchet 141 stops. Solenoid 132 drives the ratchet 142 and contact Ct A of the switch S 2A closes the contact a'. Then the contact Ct B of the switch S 2B is moved to contact b from contact b', and solenoid 132 is deenergized to stop the movement. At the switch-over of these contacts, the gate of thyristor SCR B is turned on to light up the light-emitting diode LED B . The pattern selecting cams (not shown) have already been rotated to come into a pattern selecting relation with the pattern cams. When the solenoid 132 is deenergized, the switch 238 is again opened, and solenoid 131 is energized via switch S 1 and the diodes D 1 to D 1 , and switching cams 151, 151' and 151" are further rotated 180° to the position shown in FIG. 24. Then, switch S 1 is opened to deenergize solenoids 9 and 131, in order to stop the switching cams 251, 251' and 252", and the releasing cams (not shown) set the pattern cams (not shown) for stitching, and the switch 121 is operated to enable the controller CONT to finish the pattern selection.
When the contact Ct 4 of AUTO-MANUAL setting switch S 4 is switched to contact MAN from the condition shown in FIG. 24, solenoids 9, 131 are energized, and the switching cams 151, 151', 151" are rotated 180° to close the switches S 1 , S' 1 and S" 1 . Then the solenoid 133 is energized via the switches S" 1 , S' 3 and S 4 and the diodes D 1 to D 1 , and the switch 239 deenergizes the solenoid 131 and rotates the switching cams 153, 153' 180° to open the switch S' 3 , in order to deenergize solenoid 133. At the same time the solenoid 131 is energized, to rotate the switching cams 151, 151' and 151" to the positions shown in FIG. 24. Thus the sewing machine is ready to be manually set in accordance with the selected pattern.
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An automatic pattern stitch sewing machine is disclosed in which groups of cams act to engage and disengage cam followers from a plurality of pattern cams and including change-over switches opened and closed in a predetermined sequence when one of the groups of cams reaches a position selecting position.
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This is a continuation of U.S. application Ser No. 08/041,643 filed Apr. 1, 1993, now U.S. Pat. No. 5,376,884.
FIELD OF THE INVENTION
This invention relates to determination of nuclear magnetic resonance properties of substances, and has particular application to determination of nuclear magnetic resonance properties of earth formations surrounding a borehole.
BACKGROUND OF THE INVENTION
There have been various prior approaches suggested and/or implemented for measuring nuclear magnetic resonance ("NMR") properties of earth formations surrounding a borehole to obtain evidence of the substances present.
It is well recognized that any particles of a formation having non-zero magnetic spin, for example protons, have a tendency to align with a magnetic field imposed on the formation. Such a magnetic field may be naturally generated, as is the case for the earth's magnetic field, B E . When a second magnetic field B 1 , transverse to B E , is imposed on the protons by a logging tool electromagnet, the protons will align with the vector sum of B E and B 1 after a sufficient polarization time has passed. If the polarizing field B 1 is then switched off, the protons will tend to precess about the B E vector with a characteristic Larmor frequency ω L which depends on the strength of the earth's field B E and the gyromagnetic constant of the particle. Hydrogen nuclei precessing about a magnetic field B E of 0.5 gauss have a characteristic frequency of approximately 2 kHz. If a population of hydrogen nuclei were made to precess in phase, the combined magnetic fields of the protons can generate a detectable oscillating voltage in a receiver coil. Hydrogen nuclei (protons) of water and hydrocarbons occurring in rock pores produce NMR signals distinct from signals induced in other rock constituents.
A further NMR approach employs a locally generated static magnetic field, B 0 , which may be produced by one or more permanent magnets. Nuclear spins align with the applied field B 0 with a time constant of T 1 . The angle between the nuclear magnetization and the applied field can be changed by applying an RF magnetic field B 1 perpendicular to the static field B 0 . The frequency of the RF field must be (4.258 kHz/Gauss)·B 0 . The angle of nutation (tilt) obtained between the nuclear magnetization and the static field is proportional to the product of B 1 and the duration of the RF pulse. At the end of the RF pulse, the nuclear spins precess around the static field B 0 at the Larmor frequency (4.258 kHz/Gauss)·B 0 . The rotating component of the nuclear magnetization decays with a time constant T 2 which is less than T 1 . Various measurements, known in the art, can be made to determine parameters of these phenomena, from which earth formation characteristics can be inferred.
For the type of operation just described, it is desirable to have the RF field, B 1 , perpendicular to the static field, B 0 , to have the static field, B 0 , as large as possible, and to have a static field intensity variation, as a function of position, be as small as possible in the measurement region so that a larger "resonant volume" will contribute to the measurements.
One prior art approach is described, for example, in U.S. Pat. No. 5,055,788, which discloses a nuclear magnetic resonance logging device having permanent magnets and an RF trough antenna mounted in a pad or skid that contacts the borehole wall. Measurements are made on the side of the borehole wall that the pad or skid faces. Relatively powerful rare-earth magnets can be used, and are arranged to obtain a static and substantially homogeneous magnetic field in a given volume of the formation directed to one side of the body. The trough antenna that generates the RF field is electromagnetically shielded and is directed toward the given volume of formation.
Another approach, described, for example, in U.S. Pat. No. 4,710,713, uses one or more cylindrically arranged permanent magnets in a centralized tool with a generally circumferential region of investigation around the borehole. An RF coil is wound around the outside of the magnets, and produces an RF field that is indicated as being perpendicular to the static field produced by the permanent magnets. A limitation of this centralized approach is that the RF magnetic field produced by the coil needs to pass through the magnet material, and the '713 Patent indicates that it is essential that the magnet material be non-conductive, such as a ferrite.
It is among the objects of the present invention to provide a nuclear magnetic resonance measuring apparatus that has a generally circumferential region of investigation, and overcomes limitations of prior art approaches.
SUMMARY OF THE INVENTION
The present invention is directed to a nuclear magnetic resonance measurement apparatus that can be utilized in a logging device which operates generally centrally in a borehole, and has a generally circumferential region of investigation, but which permits usage of relatively powerful permanent magnets, such as rare-earth magnets, that are not permeable to the RF magnetic field. This is achieved by employing side-by-side spaced apart elongated magnets, and an RF current loop (or plurality of loops, as in a coil) in the region between the magnets.
In accordance with an embodiment of the invention, there is provided an apparatus for measuring a nuclear magnetic resonance property of formations surrounding an earth borehole. A logging device, moveable through the borehole, is provided. First and second elongated magnets, preferably rare-earth permanent magnets, are disposed in the device in side-by-side spaced-apart arrangement. An RF current loop is disposed in the region between the magnets. Means are provided for coupling RF energy to the RF current loop. Means are also provided for detecting RF signals induced in the RF current loop.
In a disclosed embodiment of the invention, the magnets are each in the shape of a segment of a cylinder, and the respective axes of elongation of the magnets are parallel. In this embodiment, the magnets have respective casings with electrically conductive surfaces, and the RF current loop includes at least a portion of the conductive surfaces of the magnet casings. Also in this embodiment, the RF current loop includes a conductor coupled between conductive surfaces of respective magnet casing surfaces, and further includes at least one capacitor coupled between conductive surfaces of respective magnet casing surfaces.
In accordance with a further feature of the invention the permanent magnets extend longitudinally beyond both longitudinal extremes of the RF current loop. This helps ensure that the static magnetic field is relatively constant with respect to the longitudinal (generally, vertical) position in the region of investigation, and also reduces or eliminates any spurious NMR signal contribution from the borehole fluid beyond the longitudinal ends of the magnets.
Further features and advantages of the invention will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram, partially in block form, of an apparatus in accordance with an embodiment of the invention.
FIG. 2 is a cross-sectional partially broken-away and schematic view of the logging device of the FIG. 1 apparatus.
FIG. 3 is another cross-sectional, partially broken away and schematic view of the FIG. 1 apparatus.
FIG. 4 is a cross-sectional view as taken through a section defined by arrows 4--4 of FIG. 3.
FIG. 5 is a diagram showing two z-independent dipolar fields that are everywhere orthogonal.
FIG. 6 is a simplified top view of the logging device of the FIG. 1 embodiment, illustrating representative field lines of the RF magnetic field.
FIG. 7 illustrates a partially broken-away view of the exterior of an embodiment of the logging device of FIG. 1.
FIG. 8 is a block diagram of circuitry that can be utilized in an embodiment of the invention.
FIG. 9 is a cross-sectional view through a layered magnet casing, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown an apparatus in accordance with an embodiment of the invention for investigating subsurface formations 31 traversed by a borehole 32, which can be used in practicing embodiments of the invention. The borehole 32 is typically filed with a drilling fluid or mud which contains finely divided solids in suspension and a mudcake 39 is shown on the walls of the borehole.
An investigating apparatus or logging device is suspended in the borehole 32 on an armored cable 33, the length of which substantially determines the relative depth of the device 30. The cable length is controlled by suitable means at the surface such as a drum and winch mechanism (not shown). In the illustrated embodiment, the logging device comprises an elongated cylindrical sonde 40, which can be provided with centralizing arms (not shown). The top portion thereof, 42, can contain electronics and telemetry equipment. Measurement signals can be processed and/or stored downhole, using a downhole processor, but it will be understood that some or all signals could be transmitted uphole for processing and/or storage. Electronic signals indicative of the information obtained by the logging device can be transmitted through the cable 33 to uphole telemetry equipment 80, uphole processor 85, and recorder 95. Depth information to the recorder 95 and processor 85 can be provided from a rotating wheel 96 that is coupled to the cable 33. The processor 85 will typically include associated memory, timing, input/output, display, and printing functions, none of which are separately shown. Although the logging device is shown as a single body, it may alternatively comprise separate components, or may be a tool that is combinable with other logging tools. Also, while a wireline is illustrated, alternative forms of physical support and communicating link can be used, for example in a measurement while drilling system.
The lower portion of the logging device 40, represented at 45 in FIG. 1, is shown, partially schematically, in FIG. 2. Elongated permanent magnets 110 and 120, are mounted in side-by-side spaced apart arrangement within a housing 150, shown broken away in FIG. 2. The longitudinal axes of the magnets are parallel and, in the present embodiment, are also parallel to the longitudinal axis of the sonde 40, which will generally be approximately parallel to the borehole axis. In the present embodiment, and as described further hereinbelow, the magnetic material of the permanent magnets is part of a magnet assembly that includes a casing with a surface having one or more layers. The magnets are preferably rare earth magnets, such as Sm-Co magnets, which are relatively powerful permanent magnets, but which are conductive and are not permeable to the RF magnetic field. The rare earth magnetic material is relatively brittle, and is difficult to make in large pieces, so it is conventionally made by packaging a number of small pieces of the rare earth magnetic material in a relatively strong magnet casing. In the present embodiment the magnet casing material is preferably a non-magnetic metal such as titanium or monel. In the illustrated embodiment, each of the magnet casings is in the shape of a segment of an elongated cylinder. The magnetization directions of the magnets, represented by the arrows in the Figure, are aligned, and are perpendicular to the longitudinal axis of the magnets and the sonde. The magnetization directions are also perpendicular to the radial direction of the gap between the magnets.
In a form of the invention, the magnet casings constitute part of an RF current loop that is used to transmit and receive the RF magnetic field. In the embodiment illustrated in FIG. 2 (and with reference now also to FIGS. 3 and 4) a conductor 125, for example a copper cable, plate, or wires, is coupled across the magnet casings, preferably at a longitudinal position below the longitudinal centers of the magnets, and above the lower ends of the magnets. At least one capacitor, represented in FIGS. 2-4 by capacitors 135, is coupled across the magnet casings, preferably at a longitudinal position above the longitudinal centers of the magnet casings, and below the top ends of the magnet casings. The capacitor(s) 135, which function as parallel resonating tuning capacitors, in conjunction with the RF short 125 and the magnet casings, provide a resonant RF loop in the longitudinal central region of the magnet casings. The magnet casings (and the magnets therein) extend substantially above and below the resonant region of the RF loop. A ferrite core 155 (not shown in FIG. 2, for ease of illustration), which may either be a ferrite permanent magnet or an unmagnetized ferrite with high magnetic permeability, but must be permeable to the RF magnetic field, can be provided in the region between the magnets, as shown in FIGS. 3 and 4. Conductors from the RF transmitter/receiver, represented at 111, are coupled to the magnet casings, as shown in FIGS. 2 and 3, and with the lefthand conductor being coupled to magnet casing 110 through insulating material 113. The magnet casings can, for example, be bolted together, using a lower bolt (not shown) below conductor 125, and an upper bolt, such as an insulated bolt (not shown), above capacitor(s) 135, to form a sturdy and rugged structure.
FIG. 5 illustrates the field patterns of two z-independent [z being the longitudinal (or vertical) direction] dipolar fields, represented in solid and dashed line, respectively, that are orthogonal to each other at all points. These patterns are approximately representative of the static and RF fields, respectively, in the embodiment of FIGS. 2-4. For example, with the permanent magnet magnetization direction in FIG. 5 being represented by the arrows, the solid line field pattern approximately represents the static field pattern, and the dashed line field pattern approximately represents the RF field. In the illustrated embodiment, the RF field exits the sonde at one side of the ferrite 155 that is not blocked by the magnet cases, circulates around the sonde, and enters the sonde at the opposite side of the ferrite 155. This is illustrated in FIG. 6, which shows the magnets and magnet cases 110, 120, the ferrite block 155, and representative RF field lines (with arrows). The region of the sonde adjacent the gap between the magnet cases can be covered with a non-metallic material, 48, that will not inhibit the RF field, for example, nylon. FIG. 7 shows a configuration which employs a cylindrical nylon shell 48 that covers the region of the RF loop.
As above indicated, the magnets are substantially longer than the longitudinal extent of the RF loop, and extend substantially above and below the RF loop (defined by capacitors 135 and RF short 125, in this embodiment). Preferably, the length of each extension, or "guard section", is at least equal to the radial depth of investigation of the logging device. The upper and lower "guard sections" of the magnets are useful in providing a longer effective source of static field in the z-direction, which results in a relatively z-invariant static field in the device's investigation region around the RF loop. An important advantage of the guard sections is in reducing or eliminating any spurious NMR signal contribution from the borehole fluid beyond the longitudinal ends of the magnets. The resonant region in the borehole must be sufficiently far away from the RF loop so that no significant NMR signal is received from the borehole fluid which generally has a higher concentration of hydrogen nuclei compared to the formation. The guard sections of the magnets push the resonant region of the borehole away from the RF loop.
Referring to FIG. 8, there is shown a block diagram of the circuitry which, in the present embodiment, is located in region 42 of the logging device, but could be separately located in whole or in part. A transmitter section includes an oscillator, represented at 810. An output of the oscillator is coupled to a pulse former 815, the output of which is coupled to a power amplifier 818. The output of power amplifier 818 is coupled to a duplexer 820 which, in turn, is coupled to the input/output leads 111 of the RF coil. The duplexer 820 is also coupled to a receiving section that includes an amplifier 832, a phase sensitive detector 835, which also receives the oscillator output, and an analog-to-digital converter 840. The output of analog-to-digital converter 840 is coupled to a downhole processor 850, which may typically be a digital processor with associated memory, timing, and input/output circuitry. Timing circuitry is also separately represented at 852, and is coupled with pulse former 815, duplexer 820, and analog-to-digital converter 840. A Q-switch 860 is provided, and also receives timing information from timing circuit 852. Telemetry circuity 870 is conventionally provided for communicating with the earth' s surface.
As known in the art, the nuclear magnetic resonance circuitry can operate in three modes: transmitting, damping, and receiving. Reference can be made, for example, to U.S. Pat. Nos. 4,933,638, 5,055,787, and 5,055,788. As described in the referenced patents, during the transmitting mode, the transmitter section generates relatively large RF power of the order of 1 kilowatt at a frequency of the order of 1 MHz for a short precisely timed period, shut off this current very quickly, within about 10 microseconds, and then isolate any signals or noise of the power circuits from coupling with detection circuitry. The system operates with a high Q, which can result in undesirable ringing. The Q-switch 860 is provided to reduce this problem. The Q switch closes a circuit at the appropriate time, which changes the impedance seen by conductors 111 so that the system is critically damped, and ringing energy is quickly dissipated. The duplexer 820 protects the receiver section from high power pulses during the transmitting and damping modes. During the receiving mode the duplexer couples the RF loop antenna to the receiver amplifier 832. The amplified signal is coupled to phase sensitive detector 835, which also receives a reference signal from oscillator 810 that controls the frequency of sensitivity of the detector 835. The detected signals is converted to digital form by circuit 840, and coupled to processor 850. Ultimate transmission to the earth's surface for further known processing is implemented by circuitry 870. Reference can be made to the above noted U.S. Pat. Nos. 4,933,638, 5,055,787, and 5,055,788 for further details of circuitry and operation.
In an embodiment hereof, the magnet casings are layered structures that are advantageous in providing highly conductive current paths and in also reducing induced ultrasonic vibrations that can cause spurious electronic signals in the RF output. FIG. 9 shows a horizontal cross section through one of the magnet assemblies, 120. In the illustrated embodiment, the magnet material 911 comprises a rare-earth magnet material such as Sm-Co, contained within a structural casing 915 formed of a non-magnetic material, such as the metal titanium or monel. A rubber layer 916 covers the structural casing 915, and a conductive metal foil 920, such as a copper foil, covers the rubber layer.
The copper foil can carry the RF current. Because of the skin effect, RF current flows on the outer surfaces of conductors. For example, at 1 Mhz the skin depth in a copper conductor is 0.065 mm. Therefore, a copper foil can sufficiently carry the RF current. The layer of rubber between the copper foil and the structural magnet casing is useful in preventing the RF-indicated forces on the copper foil from setting up ultrasonic reverberations in the magnet or in the magnet cases 915. The copper foil itself is too thin to support ultrasonic resonances. In this regard, reference can be made to U.S. Pat. No. 5,153,514.
The invention has been described with reference to a particular preferred embodiment, but variations within the spirit and scope of the invention will occur to those skilled in the art. For example, it will be understood that other suitable materials or circuit arrangements could alternatively be employed.
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The disclosure invention is directed to a nuclear magnetic resonance measurement apparatus that can be utilized in a logging device which operates generally centrally in a borehole, and has a generally circumferential region of investigation, but which permits usage of relatively powerful permanent magnets, such as rare-earth magnets, that are not permeable to the RF magnetic field. This is achieved by employing side-by-side spaced apart elongated magnets, and an RF current loop in the region between the magnets. In a disclosed embodiment, the magnets are each in the shape of a segment of a cylinder, and the respective axes of elongation of the magnets are parallel. The magnets have respective casings with electrically conductive surfaces, and the RF current loop includes at least a portion of the conductive surfaces of the magnet casings.
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BACKGROUND
Thyristor random access memory (TRAM) provides a memory structure that does not need an exclusive storage capacitor, separate from a select transistor, to store a memory state. However device configurations to date use a considerable amount of surface area. Improvements in device configuration are needed to further improve memory density. Further, it is desirable to form devices using manufacturing methods that are reliable and efficient.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example memory cell according to an embodiment of the invention.
FIG. 2 shows trigger voltage of an example memory cell at various gate voltages according to an embodiment of the invention.
FIG. 3 shows an example method of forming a memory cell according to an embodiment of the invention.
FIG. 4 shows an information handling system that includes an example memory cell according to an embodiment of the invention.
DETAILED DESCRIPTION
In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof and in which are shown, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and chemical, structural, logical, electrical changes, etc. may be made.
The terms wafer and substrate used in the following description include any structure having an exposed surface with which to form a device or integrated circuit (IC) structure. The term substrate is understood to include semiconductor wafers. The term substrate is also used to refer to semiconductor structures during processing, and may include other layers, such as silicon-on-insulator (SOI), etc. that have been fabricated thereupon. Both wafer and substrate include doped and undoped semiconductors, epitaxial semiconductor layers supported by a base semiconductor or insulator, as well as other semiconductor structures well known to one skilled in the art. The term conductor is understood to include semiconductors, and the term insulator or dielectric is defined to include any material that is less electrically conductive than the materials referred to as conductors.
The term “horizontal” as used in this application is defined as a plane parallel to the conventional plane or surface of a wafer or substrate, regardless of the orientation of the wafer or substrate. The term “vertical” refers to a direction perpendicular to the horizontal as defined above. Prepositions, such as “on”, “side” (as in “sidewall”), “higher”, “lower”, “over” and “under” are defined with respect to the conventional plane or surface being on the top surface of the wafer or substrate, regardless of the orientation of the wafer or substrate. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
FIG. 1 shows a memory cell 100 according to an embodiment of the invention. The memory cell 100 includes a first type doped semiconductor base 110 . The first type doped semiconductor base 110 is shown with two upward facing ends 106 and 108 . As noted above, the term “upward” in the present specification is defined with respect to a semiconductor wafer during manufacture. A fabricated memory chip may have any of a number of possible orientations when in use. A space is included between the two upward facing ends 106 and 108 . In one embodiment, the space defines a part of a conduction path 140 , discussed in more detail below.
FIG. 1 further shows a second type doped semiconductor structure 112 coupled to a first of the upward facing ends 106 , and another second type doped semiconductor structure 114 coupled to a second of the upward facing ends 108 . In one embodiment, the first type doped semiconductor is p-type, and the second type doped semiconductor is n-type although the invention is not so limited. In other embodiments, the first type doped semiconductor is n-type, and the second type doped semiconductor is p-type.
Also shown is a first type doped semiconductor top structure 116 located over the second type doped semiconductor structure 112 . The configuration shown in FIG. 1 forms a first p-n junction 122 , a second p-n junction 124 , and a third p-n junction 126 . The p-n junctions ( 122 , 124 , 126 ) are coupled in series along a conduction path 140 to form a thyristor device.
In the configuration shown, the first type doped semiconductor base 110 , along with the upward facing ends 106 and 108 define a folded structure. A folded structure is more compact in areal footprint than horizontal structures. In one embodiment, the areal footprint includes a width 130 and a length 132 that is approximately four lithographic feature squares (4F 2 ). Lithographic feature squares define how many devices or elements of devices can fit into a given area on a substrate when manufactured by optical lithography. The actual device dimensions may depend on several factors, including lithography and etch conditions. However, the relative figure of merit “F” is independent of wavelength, and is often used in the semiconductor industry to compare device architectures to one another for spatial efficiency.
The folded structure shown in FIG. 1 results in electrical contact points 151 and 152 being at a top surface of the memory cell 100 . This allows subsequent wiring for a memory array to be formed on top of the memory cell instead of beneath the memory cell, or otherwise below a top surface 150 of the memory cell. Conductor traces or other wiring structures that are formed below a top surface 150 of a device can be more difficult to manufacture. For example, deep ion implant procedures, or deposition deep in an etched trench may be needed to form buried conductor wiring structures. In contrast, the memory cell 100 , with the contact points 151 and 152 on the top surface, allow more reliable deposition processes for conductor wiring without deep trenches or ion implants.
FIG. 1 further illustrates an embodiment where the first type doped semiconductor base 110 is located on an insulator region 102 . In one example, the insulator region 102 includes an oxide as the insulator material. In embodiments with an insulator region 102 , a floating body region 160 is created at the base of the memory device 100 . Embodiments with a floating body region 160 may show less charge leakage over embodiments formed directly on semiconductor material, without an insulator region.
In one example the insulator region 102 is an insulator region in a silicon-on-insulator (SOI) wafer. When using an SOI wafer, the first type doped semiconductor base 110 may be formed from a top semiconductor region in the wafer. In one example the top semiconductor region is provided as a p-doped region in the wafer form. In one example the top semiconductor region is doped during fabrication of the memory device 100 .
In another example, the insulator region 102 is formed under individual memory devices 100 using a shallow trench isolation (STI) undercut operation. In one example of an STI undercut operation, trenches are etched adjacent to the memory device 100 , and anisotropic etching is used to form an undercut region, that is subsequently filled, e.g. by deposition, with an insulator material, such as an oxide of silicon.
FIG. 1 further illustrates a gate 120 formed adjacent to at least one side of the first type doped semiconductor base 110 . The example shown in FIG. 1 illustrates the gate 120 formed adjacent to four sides of the first type doped semiconductor base 110 to substantially surround the first type doped semiconductor base 110 . In one embodiment, a gate insulator is formed at an interface 121 between the gate 120 and the first type doped semiconductor base 110 .
In operation, application of a gate voltage to the gate 120 above a threshold value causes the first type doped semiconductor base 110 to invert and causes the second type doped semiconductor structure 114 to overcome the barrier of the first type doped semiconductor base 110 and connect to the second type doped semiconductor structure 112 . Because of gate inversion, an anode to cathode voltage need not be high enough to cause avalanche generation, and therefore a snap back voltage resembles a diode turn-on. In one embodiment, a gate coupled base, e.g. gate 120 , as illustrated, is used to modulate “write” voltage conditions of the memory device 100 .
FIG. 2 illustrates a spectrum of gate voltages (VGs) and the effect on current versus applied voltage at the second type doped semiconductor structure 114 . As can be seen in the example of FIG. 2 , a higher anode to cathode voltage is needed to perform a “write” operation without the assistance of a gate trigger.
FIG. 3 shows an example method of making a memory cell according to an embodiment of the invention. In operation 310 , a p-type base region is formed on a semiconductor substrate. Operation 310 further describes forming a pair of upward facing ends in the p-type base region, with a folded conduction path between the pair of upward facing ends.
Operation 320 recites forming a pair of n-type structures over the upward facing ends of the p-type base structure to form first and second p-n junctions along the conduction path. As discussed above, although p-type base structure and n-type structures attached to the base structure are described, alternative doping arrangements are possible.
Operation 330 recites forming a p-type structure on one of the n-type structures to form a third p-n junction along the conduction path, and operation 340 recites forming a gate substantially surrounding the p-type base structure.
Operation 350 recites electrically isolating the p-type base region from the rest of the semiconductor substrate. In one example, electrical isolation is provided by forming the memory device 100 on an SOI substrate. In this example, the insulator region of the SOI substrate provides the electrical isolation, and at least the base region is formed from the surface semiconductor region of the SOI substrate. This example may use a small number of process steps, because the insulator region is part of the wafer, and does not need to be created during the manufacturing process. However, SOI wafers can cost more than silicon wafers. In another example, a silicon wafer is used, and an STI undercut operation is used to electrically isolate the memory device from the semiconductor substrate. This process may use more steps in manufacture, but the wafer can be less expensive.
An embodiment of an information handling system such as a computer is included in FIG. 4 to show an embodiment of a high-level device application for the present invention. FIG. 4 is a block diagram of an information handling system 400 incorporating at least one chip or chip assembly 404 that includes memory cells according to embodiments of the invention as described above. Information handling system 400 is merely one embodiment of an electronic system in which the present invention can be used. Other examples include, but are not limited to, netbooks, cameras, personal data assistants (PDAs), cellular telephones, MP3 players, aircraft, satellites, military vehicles, etc.
In this example, information handling system 400 comprises a data processing system that includes a system bus 402 to couple the various components of the system. System bus 402 provides communications links among the various components of the information handling system 400 and may be implemented as a single bus, as a combination of busses, or in any other suitable manner.
Chip assembly 404 is coupled to the system bus 402 . Chip assembly 404 may include any circuit or operably compatible combination of circuits. In one embodiment, chip assembly 404 includes a processor 406 that can be of any type. As used herein, “processor” means any type of computational circuit such as, but not limited to, a microprocessor, a microcontroller, a graphics processor, a digital signal processor (DSP), or any other type of processor or processing circuit.
In one embodiment, a memory chip 407 is included in the chip assembly 404 . In one embodiment, the memory chip 407 includes a thyristor memory device as described in embodiments above.
In one embodiment, additional logic chips 408 other than processor chips are included in the chip assembly 404 . An example of a logic chip 408 other than a processor includes an analog to digital converter. Other circuits on logic chips 408 such as custom circuits, an application-specific integrated circuit (ASIC), etc. are also included in one embodiment of the invention.
Information handling system 400 may also include an external memory 411 , which in turn can include one or more memory elements suitable to the particular application, such as one or more hard drives 412 , and/or one or more drives that handle removable media 413 such as floppy diskettes, compact disks (CDs), flash drives, digital video disks (DVDs), and the like. A memory constructed as described in examples above is included in the information handling system 400 .
Information handling system 400 may also include a display device 409 such as a monitor, additional peripheral components 410 , such as speakers, etc. and a keyboard and/or controller 414 , which can include a mouse, trackball, game controller, voice-recognition device, or any other device that permits a system user to input information into and receive information from the information handling system 400 .
While a number of embodiments of the invention are described, the above lists are not intended to be exhaustive. Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. It is to be understood that the above description is intended to be illustrative and not restrictive. Combinations of the above embodiments, and other embodiments, will be apparent to those of skill in the art upon studying the above description.
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Memory devices and methods of making memory devices are shown. Methods and configurations as shown provide folded and vertical memory devices for increased memory density. Methods provided allow trace wiring in a memory array to be formed on or near a surface of a memory device.
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BACKGROUND OF THE INVENTION
The subject of this invention is removing salt from sea water. This has been an important subject for man ever since he started sailing on the ocean sea. Evaporation, by heat and condensing the vapor was the first practicable method used to obtain fresh water from salt water, and to this day it is the system most often used. The evaporation-condensing system has been greatly improved over the years, but attempts to reduce the cost of fresh water extracted from salt water, other systems have been developed. For instance, the reverse osmosis system and the electrodialysis system have been developed and put into use in many locations. Both these latter systems work well with brackish water, but become over loaded and inefficient with ocean salt water - also both systems have to process much salt water to get fresh water the ratio may be 4 to 1 in instances.
My process was invented while considering the problem of removing dissolved salt and organic material from stillbottoms of Ethanol plants. After study it appears to be much cheaper to operate on a straight one for one basis than any of the other methods. When it was found that 9 gallons of salt water was pumped to produce 8 gallons of fresh water and one gallon of strong brine, it was realized that a major improvement in the art of cleaning water had been made. Also there are no membranes to replace - so the process can stand to remove chemicals that destroy membranes. Thirdly the system removes all organic material, even dissolved protein. Fourthly, the system will be made of material that can withstand the corrosion and erosion associated with both salty, and fresh water. Screen and filters are used in some instances, but in general anything that can get through the pump will be cleaned from the water.
In the following specification the teaching is directed to removing dissolved salt from sea water, this is for simplicity in explaining the system. Actually the invented process will separate and allow removal of all dissolved solids and gases and some liquids from solution. Also an often contaminate of surface water and of industrial process water is organic material both in solution and in mixture. The process will remove those by destructive distillation. The products of destructive distillation will be either acid or basic, either will be neutralized by injecting the opposite to make a salt. The just made salt will be taken out by the hydroclone. Other minerals and metals that may be dissolved in trace quantities will also be removed in the hydroclone due to the wide spacing of the water molecules as provided for in this invention. Colloids are a finely divided material suspended in a fluid which are in fact a mixture, but have many physical qualities of a solution and are treated by some as a solution, either way this process will separate and remove the solids from water. The product water from this process is as pure water as can be obtained. It is sterilized and demineralized and demetalized.
SUMMARY OF THE INVENTION
This invention employs pumps, heat exchangers, centrifuges, a hydraulic motor, a heat source and a hydraulic piping network to process sea water or industrial salt water into fresh water, meaning the water is de-salted, demineralized, sterilized, and is freed of organic matter.
Water to be cleaned is pumped into the system at approximately 3260 psia and is heated to critical temperature (705.4° F.) and is maintained at that temperature or above, until the salt and other minerals become undissolved and removed from the mixture by centrifuges.
During the heating period, organic material i.e. germs, virus, protein, fat etc. undergo destructive distillation, the residue from these occasionally form acids in water. If the acid is objectionable, a base material can be injected to neutralize the acid to form more salt in the mixture which will be separate along with the original salt. Once minerals have been removed the high pressure and temperature water will be put back into the main heat exchanger in heat exchange relationship with the cooler incoming contaminated salt water. The incoming water will receive most of its heat through the exchanger. The high pressure water will be let down to atmospheric pressure, through a hydraulic motor. The power developed in the hydraulic motor will be delivered to the pump. Thus very little new energy is required, to keep the process running, only replacement heat and power has to be added to make up the less than 100% efficient motive power and heat exchange. The energy input can be electric, internal or external combustion engine, fossil fuels, waste heat, geothermal heat or whatever is available. All of the above are included in this teaching.
Further - the process is carried out in hardware of a type commonly used in industry but modified to withstand the temperature and the pressure, if necessary.
While writing the specifications for the preferred embodiment of this invention it was impossible to give exact state points for the fluids entering the system while in the system and at system exit.
The feed water may be northern sea water or tropical sea water, the temperature may vary from 31° F. up to 90° F., on the other hand the feed may be an industrial waste water wherein both pressure and temperature may vary over a wide range also pressure does drop in a flowing system and the amount of the drop depends on the exact flow system. The exit temperature and pressure or certain station points can be maintained by pump and insulation adjustment. But there is a wide band of temperature and pressure at the feed to the process. The objective is to have the fluid heated and pressurized to the critical point upon entry to the hydroclone. Due to the nature of flow systems and particularly to components like hydroclone the pressure will drop during the passage through the component. Some hydroclones claim a pressure drop of 10 psi others are known to have a drop of 75 psi. Whatever the size of the drop the molecular spacing will get larger with the decrease in pressure provided the temperature stays up near critical. Because the heat in the fresh water is being used, through heat exchange to heat the incoming salt water to the critical temperature more heat and more pressure must be added to the fresh water before it enters the heat exchanger. The pressure should be high enough to keep the fluid or superheated steam dense enough to have a good heat exchange. The temperature should be enough above the critical temperature to bring the incoming fluid to critical temperature. The exact elevation depends on the type of heat exchanger equipment. Some exchangers work as close as one to two degrees separation. I have used approximately 5° separation on my calculations. So the result is the single state point is critical point entering the hydroclone. In fact if the critical point is achieved before the hydroclone or just inside the hydroclone the process will perform consequently we have tried to use middle band state points in the detailed description. In water a lower density is indicative of larger spacing between water molecules.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the process--with the components in symbolic form, connected by flow pipes represented as single solid lines--arrows on the flow lines show direction of flow.
FIG. 2 represents the utility structure used to support the process. In this figure the process of FIG. 1 is represented as a rectangle or box 15. The utilities that feed the process with water to be cleaned, and those that remove the clean water and the byproduct are shown again in schematic form.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 water to be de-mineralized is directed through line 18 to the large high pressure pump 19. The pump is driven by the electric motor 20 and the hydraulic motor 50, through connecting shafts 60 and 61. Most positive displacement pump impart a pulsating pressure variation to the pumped fluid, to reduce the pulsation air chamber 21 with a diaphrgm is connected to the main line 18 near the pump discharge.
The small high pressure pump 22 is driven by motor 23, and is supplied with fresh degassed water through line 56. Both pumps are protected by check valves 52.
An apparatus for magnetically treating fluids 25 is a patented device that splits the water flow into two or four or six streams, then applies a strong magnetic field to the streams, one half of the water receives a positive charge and the other half receives a negative charge. When the streams are brought together, the positive and negative particles are attracted to each other rather than to the container wall, thus keeping calcium, salt and other precipitates from sticking to the pipe and container walls as scale.
From the magnetizer 25 the high pressure (3256 psi) water is piped to the cold water inlet of the counter flow heat exchanger 26. The salt water passing through the heat exchanger is in heat exchange relationship to hot desalted and sterilized water flowing in counter-flow direction. The cold water entering the exchanger may be near freezing or up to 200° F. and above depending on whether it is degassed and its source. The suspended scale can be removed before the heat exchanger just to reduce the solids load - or the calcium can be left in the system and removed with the salt further along. The salty water will exit the heat exchanger to line 30 at a pressure of 3206.2 psia and a temperature of 705.4° F. This state point is the critical point in the thermal state of water. The critical point condition is a single phase fluid, in which the water has expanded and steam compressed such that both have the same density and are non-distinguishable. The volume of the liquids expands from 0.016 cu. ft./lb. at 100° F. to 0.0503 cu. ft./lb. at critical point which is a ratio of 3.125. The rate of volume increase or density decrease and larger molecular spacing is not uniform, most of the expansion takes place between 700° F. and 705.4° F. at saturated conditions.
At the expanded condition that exist at or near the critical point the critical fluid can not retain any salt or other minerals nor ions of salt in solution. The reason is the salt is dissolved into solution in two ways. The first is, a small percentage of salt disassociates into positive and negative ions which cling to and are surrounded by water molecules of the opposite sign in the highly polarized water. The second way is the remaining salt that is dissolved is divided by the water into small clusters of salt molecules that find a nesting place within the close molecular structures of liquid water. The salt molecules clusters are salt in every chemical and physical way, they are just too small to be seen by the best optical microscope. Even so the water molecule is smaller than the salt molecules because the dissolved salt can be filtered out of water with a reverse osmosis membrane, which uses size of molecule to make a separation. When the water expands due to the high temperature at the critical point (705.4° F.) the space between the molecules increases such that the salt particles just fall out of the water molecular nest, and become suspended solids. Suspended solids even colloid material too small to settle can be centrifuged out of the critical fluid.
The critical fluid, with the now suspended solid salt and other solids enter the first Hydroclone 27 which for all intents and purposes is shaped like a cyclone separator which is widely known in industry for removing dust from air. The hydroclone for removing solids from liquids are also used in industry. The water enters the hydroclone tangentally and begins to spin around inside the conical section rapidly enough to impart up to 2000 gravities on the solid particles. Under such force the salt and all solids move to the outside and then slides down the conical walls and exit the cone at its bottom through oriface 53 to line 29. The solids can be made to retain enough water to move it in the pipe line 29. The thick brine may be further diluted with sea water in pipe 29 by pumping the sea water into 29. The high temperature heat in the brine is desirable and may be recovered through heat exchanger 36 in FIG. 2. The heat is transferred to source water or to sea water taken from the tank 10 and is sent to the degasser 11. FIG. 2. Depending on the efficiencies of the hydroclones a plurality may be used both in parallel and in series, 27 and 28 are shown in series. The demineralized and sterilized water exiting from the top of the last hydroclone will have lost some pressure and temperature due to the energy required to spin the fluid. To reestablish the lost energy the pressure and temperature have to be increased before the fluid re-enters the heat exchanger on the hot side. Pump 32, driven by motor 33 is used to boost the pressure in line 31 up to 3300 psia and heater 34 supplied by energy by line 35 is used to bring the temperature to 710° F. This state point is high enough to give a sufficient temperature differences to drive the heat transfer to the cold side of heat exchanger 26. A plate type heat exchanger can have the two streams 1° F. to 2° F. apart. The heat transfer that takes place in exchanger 26 actually recycles the heat from the hot side to the cold side. Pump 32 is used to replace the lost pressure in the flow systems, and heater 34 brings the temperature up to aid in the heat transfer. The heater 34 and the pump 33 could be installed before the hydroclone in line 30 and this application covers that configuration. But my preferred arrangement is to introduce the heat into desalted water in line 31.
The cooled fresh water, demineralized and sterilized water exists exchanger 26 to line 39 at a temperature about 1 to 2° F above the cold water entrance temperature to exchanger 26 and a pressure of approximately 3270 psia. There is still heat in the fresh water that can be used in the front part of the process ie the degasser. Heat exchanger 40 supplied by line 42 and pump 43 uses sea water circulated from tank 10 FIG. 2 to get the heat transferred to the inlet of the process. Pump 43 driven by motor 44 circulated the salt water from tank 10, FIG. 2 to gather up the otherwise waste heat from exchangers 36 in FIG. 2 and 40 in FIG. 1 which adds to thermal efficiency but does not change the salt water to fresh water, production ratio.
The product water from exchanger 40 is approximately 80° F. and the pressure is approximately 3270 psia. The exact pressure depends on the line loss through the systems after pump 32. But the water has energy that needs to be recycled. Shown in FIG. 1 is a hydraulic motor 50 driven by the water pressure which is let down from 3270 psia to atmospheric pressure. This is enough energy to supply most of the pump work in 19. Shaft 61 transfers the energy from the hydraulic motor 50 to pump 19. The electric motor 20 connected to 19 by drive shaft 60 supplies the power not supplied by the hydraulic motor 20. A pelton type water wheel could be used at 50. If so the speed range can be made to match the pump, but the Pelton wheel likes lower pressure than the 3270 psia exit. The high pressure can be used to educt more fresh water into line 39 at a lower pressure. Eductor 45 is fed fresh water from storage tank 16 of FIG. 2. Finished product water exits the motor and is sent to storage tank 16, FIG. 2. A high pressure piston hydraulic motor could be used for motor 50 in which case the eductor 45 would not be necessary.
Referring to FIG. 2 salt water from whatever source is sent by line 1 and pump 2 driven by motor 3 to the settling tank 4. The purpose is to remove the heavy solids and debris that will settle to the tank bottom. From the settling tank pump 5 driven by motor 6 sends the water through a plurality of screens and and filters 7, 8, and 9 to remove suspended solids, and on to the ready storage tank 10. The filtered salt water in tank 10 is warmed by heat from heat exchanger 40. It is warmed even more by heat from exchanger 36 as it enters the degasser 11. It is not necessary to remove the intrained and dissolved gases from the filtered water. But the capacity to desalt water of a given system size would be greater if degassed water is used. The type or design of the degasser is not specified, they are common in industry and those that use heat are more efficient in this application because the total temperature has to be raised from the ambient temperature up to the critical temperature area, and all heat added before the exchanger 26 FIG. 1 is useful. From the degasser salt water is drawn and is sent to the magnetizer 14 FIG. 2 and on to the low pressure hydroclone 57, from 57 water enters the process through pipe 18 FIG. 1 and FIG. 2.
The process shown on FIG. 1 is contained in the box 15 of FIG. 2. Depending on the size of the system, a pump 12 driven by motor 13 may be needed to give the flow volume needed for item 14 and 57, because the pressure drop through these latter pieces of equipment can be high. Since the degasser if used will be heated to 212° F. by plate exchangers which are easy to clean, and in view of the high magnetic charge on the scale particles no scale will form on the degasser components. Calcium precipitates out of water beginning at 165-180° F. The magnetizer 14 will make the positive and negative particles cling to each other. A portion of these calcium particles can be separated in item 57 by centrifugal force. The calcium goes to waste through line 58.
Depending on the water characteristics items 11, 13, 14 and 57 may not be needed. Also depending on the characteristics of the water the ready storage tank 10, the filter 5 and screens 7, 8, 9 settling tank 4 and associated pump may not be needed. In which case line 1 would become line 18 feeding the source water directly to the main line pressure pump 19. Though the waste heat from heat exchanger 40, FIG. 1 and 36 FIG. 2 would be added directly to line 18 by heat exchanger.
The most important state point of temperature and pressure in the process is that in which the molecular spacing is large enough so that the salt molecules can be separated or fall out of solution. Below the critical point at 500° F. is a transistion point in the specific density curve. Above this temperature and for each degree of higher temperature, a sharp decrease in density occurs. The curve steepens, from 700° F. to 705.4° F. the greatest change occurs, the curve becoming asymtotic up to the critical point. Also the temperature and pressure of saturated water have a known relationship such that for each temperature there is a minimum pressure, but a higher pressure can be superimposed. Super pressure is used in this process up to the critical point which is 3206.2 PISA and 705.4° F. (as given by Keenan and Keyes, 1936 edition, Thermodynamics Properties of Steam.) Above the critical point into the superheat region the temperature and pressure can be varied independently of the other. In this process it is desirable to keep the pressure above the critical pressure until the fluid enters the hydroclone. In the hydroclone the temperature stays the same, but the pressure drop from critical (3206.2). The pressure continues to drop, but exits the hydroclone at about 3169 psia. The critical conditions entering the hydroclone are sufficient to drop dissolved material from the critical fluid, however by having the pressure drop below the critical the density of the fluid, which changes to superheated steam, is further reduced and the molecular spacing increases even more. The more open the spacing the quicker the separation phase can be completed. Some salt will come out of the solution prior to 705.4° F., all will come out at 705.4° F., but to make the mechanical separation of the salt in the hydroclone more efficient and timely a temperature above the critical into the superheated steam area would not be objectionable, but a drop in pressure accomplishes the same objective. For instance at critical of 3206.1 psia and 705.4° F. the specific volume of the liquid and its vapor 0.0503 cu. ft./lb. and heat content is 902.7 btu./lb. To hold the pressure and raise the temperature to 702° F. the specific volume has increased to 0.1020 cu. ft./lb. The fluid is now steam and is not the critical fluid. The reduced density is moving in the correct direction but the increase in heat to reach the temperature is costly. It is preferred to keep the temperature and pressure as low as possible to effect solid salt separations. After separation to prepare the desalted water to be the heating medium on the return journey through heat exchanger 26, the pressure is elevated to 3300 psi and the temperature to 710° F. The increase in pressure by pump 32 is to increase the fluid density for better heat exchange and the increase in the temperature is to have a wider temperature difference in exchanger 26. The temperature in line 31 after heater 34 can be adjusted to be no more than necessary to get good heat exchange. Referring to FIG. 2, line 55 pipes fresh product water out of the FIG. 1 process to a storage tank 16, line 55 also supplies fresh water to its intended use. Line 56 carries fresh (Desalted, sterilized) water back into the process in FIG. 1. Fresh water is used to fill the system to effect a start up or a restart by pump 22 and to reduce the pressure in inductor 45. The by-product or waste salt is brought out of the process on pipe 29. Heat is taken from the waste salt by heat exchanger 36, FIG. 2. Shown on FIG. 2 line 24 is a salt dilution line which brings salt water from the source to dilute the thick brine in the tank, so that it can be pumped out to a disposal means. If a dry salt product is desired, then a sonic oriface could be installed in the cone bottom 53 and 54 which would let the exhaust salt and a little water exhaust into a vented hopper, which is not shown. The critical fluid would evaporate, leaving only a little water in the salt.
The organic material, including but not limited to protein, fat, oils, germs, virus, bacteria, mites, coliform and fungi will undergo destructive distillation in the heating sector of the process. Some of the components will form acids. If the acids are not useful to the intended use of the product water, the acids are removed, by injecting caustic (base) into the hot salty acid water at 46 FIG. 1. The caustic will neutralize the acid to salt. The newly formed salt in the mixture will be taken out by the centrifuge 27 and 28. The caustic will be injected through injector 51 by the metering pump. Item 52 is a reverse flow check valve.
Referring to FIG. 1 line 62 is a bypass from the cold outlet of heat exchange to help in starting the process and to keep some of the units warm while checks or minor repair or adjustments are made. The line is controlled by shut off valves 63, 64, 65, and 66.
The heater item 34 is represented to be a gas burner, heating a pipe coil. It is pointed out that the heater can be an internal or external electrical resistance heater, a micro wave heater, a steam or metal vapor heater, the type of heater does not affect or change the process. Also the location of the heater can be in line 30 between 26 and 27. In some cases one or more heaters will be used in both preferable locations.
The system will be monitored and controlled by pressure and temperature readings taken throughout the system. The flow rate can be monitored by the pump revolution rate. The instruments are not shown, but can be placed by those familiar with hydraulic flow system art. The specification describes the system running in a steady state. To start the system the following steps are recommended.
(1.) shut off flow to the hydraulic motor open the gas vent valve 67
(2.) start the low volume, high pressure pump 22
(3.) fill system with fresh water, pump through until air is purged
(4.) raise the pressure to operating pressure
(5.) turn on the heater to bring the system up to temperature under low flow conditions
(6.) start the hydraulic motor and the main pump 19 and pump 32, stop pump 22
(7.) after temperature and pressure have stabilized, let the salt water into the system.
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This invention teaches a method of removing dissolved minerals and organic material from water. The water is heated under controlled pressure to reduce the density and thus opening the molecular spacing of the water, such that mineral particles and organics cannot stay within the water molecule cluster, so fall out of solution. To speed separation of the mixture a hydroclone type centrifuge is used. The hot, high pressure clean water gives its energy back to the process through heat exchange and a hydraulic motor. The net energy used to effect dissolution is thus very low, being equivalent to pump loss and heat loss, from the equipment.
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FIELD OF THE INVENTION
The present invention concerns stitchbonded comfort fabrics that are formed by using one or more layers of a fibrous, nonwoven web and stitching the layers with yarns in such a manner that a bulky and absorbent fabric is produced. In particular, the invention relates to a dual-layered stitchbonded comfort fabric having an absorbent, evaporation-reservoir layer and a nonabsorbent, transport layer. The invention provides for particularly lightweight, durable, quick-absorbing and quick-drying fabrics that have a dry-feeling, comfortable surface compared to presently available dual-layered fabric constructions such as double-knits, laminates, or other stitched nonwovens.
BACKGROUND OF THE INVENTION
Dual-faced knits, wovens and laminates are known in the textile art. Since these fabrics are constructed exclusively with yarns that have rather high density, and since they have to be relatively densely woven or knit to be durable, the resulting fabrics exhibit low drying speeds and have relatively low bulk and absorbency per unit weight. Such traditional fabric structures are only capable of absorbing a few times their weight in water, and have relatively long drying times. In apparel applications where perspiration occurs (e.g., sportswear and underwear), lightweight fabrics that feel dry (i.e., have a "water transport" face against the skin that does not absorb water itself) and absorb and evaporate perspiration quickly are very desirable. Experience in the art has indicated to the applicants that an absorbent fabric capable of holding at least 200 gms of water per square meter, that has a uniform nonabsorbent face of textile fibers (no gaps wider than 3 mm) weighing at least 10 gms/sq m, and that can dry quickly in open air, would act as an effective comfort fabric. However, the lightest constructions of present day dry-feeling knit or woven dual-faced fabrics of this type of construction (e.g., double knits) weigh at least 150-300 gms per sq. m, tend to be uncomfortable because of their sheer weight, and tend to be costly. A durable, absorbent fabric equipped with a "transport" layer that could perform this function at a much lower weight (e.g., a fabric basis weight of 20 to 120 gms per sq. m), and that could hold water at least 5 times its weight, with a bulk of at least 10 cc/gm (for quick-drying), would be very desirable.
Low-density absorbent and nonabsorbent stitchbonded nonwovens are also known. For instance, U.S. Pat. No. 4,773,238 (Zafiroglu) and copending U.S. patent application Ser. No. 07/584,161 filed Sep. 18, 1990, both describe fabrics stitched with elastic or bulkable yarns. These fabrics improve in bulk and absorbency after stitchbonding when the product is allowed to contract, "gather" and "bulk-up". Even higher bulk and absorbency values are achieved in the fabrics disclosed by U.S. Pat. 4,876,128 (Zafiroglu), wherein the degree of bulking is controlled by regulating post-stitching shrinkage. Absorbencies that go as high as 15 times the weight of the fabric are reported. However, in all of the above-identified stitchbonded fabric references, the fabric is constructed with only one layer of a nonwoven substrate, and no attempt is made to construct a dual-layered fabric. In this regard, Examples 3-1 and 3-2 of copending U.S. Ser. No. 07/584,161 are believed to come the closest. These examples disclose a pre-needled substrate containing 55 wt. % woodpulp. This construction results in a fabric that is heavy, relatively dense and slow-drying (bulk 3.3-5.8 cc/gm and absorbency 2.3-3.9 times the weight of the fabric).
Additionally, in the above-identified references, no effort is made to construct a nonabsorbent "transport" layer wherein yarn segments are placed over the absorbent nonwoven substrate. In order to build a 10 gm/sq. m nonabsorbent "transport" layer formed with yarn segments within the limits of U.S. Pat. No. 4,773,238, U.S. Pat. No. 4,876,128 or copending U.S. Ser. No. 07/584,161, with the surface yarn segments leaving stitching gaps no wider than 3 mm, and with at least one bulkable yarn stitched in, the total yarn consumption as stitched would have to be at least 15 gm/sq. m. The weight of yarn per unit area will then grow substantially higher as the fabric is relaxed and gathered.
In U.S. Pat. No. 4,773,238, the yarn content does not exceed 20% of the weight of the fabric. In addition, the fabric is gathered to less than 40% of its original stitched dimensions. With 15 gms/sq. m of yarn, the total fabric weight would be at least 15×5×2.5=187 gm/sq. m which would come close to exceeding the preferred weight limits of the reference, even at the maximum yarn level of 20 wt. %.
U.S. Pat. No. 4,876,128 does disclose bulkable yarns having up to a 20 wt. % yarn content and requires lower levels of shrinkage (a minimum of 10%). The same calculation performed above for U.S. Pat. No. 4,773,238, repeated for the extremes of U.S. Pat. No. 4,876,128, would require a minimum weight of 15×1.1×5=83 gm/sq. m. Although this is a suitable basis weight for purposes of the applicants' present invention, all examples in U.S. Pat. No. 4,876,128 which contain a relatively large amount of yarn (such as samples D, E, and F--10.7 to 11.7 wt. % yarn) have bulks lower than their prescribed limits (e.g., 13.0-14.1 cc/gm vs. 16 cc/gm minimum). Thus, the very high fabric bulks required by U.S. Pat. No. 4,876,128 cannot be obtained with high surface density yarn segments unless relatively heavy starting webs, highly-bulked to counteract yarn weight, are used. The webs disclosed in U.S. Pat. No. 4,876,128 start at a fabric weight of 103 gm/sq. m. With a minimum yarn weight of 15 gm/sq. m added, and the fabric shrunk at least 10%, the total minimum weight of the fabric would exceed 129 gms/sq. m (i.e., (103+15) 1.1=130 gms/sq. m).
Copending U.S. Ser. No. 07/584,161 recommends yarn percentages under 20 wt. %, but does disclose the use of higher yarn weight percentages. However, in the applicants' experience, in order to construct a comfort fabric, a low-density absorbent substrate (such as a lightly spunlaced staple web containing rayon or cotton or less than 25% woodpulp) must first be selected. The substrate selected must be chosen to be absorbent, have high bulk, low weight, and the stitch pattern would have to be arranged to provide a minimum weight of nonabsorbent yarn of 10 gm/sq. m exposed on one face. The stitch spacings or gaps would have to be no wider than 3 mm, the shrinkage of the fabric would have to be controlled to maximize bulk and avoid fabric densification due to excessive area gathering, and the yarn substrate materials would have to be chosen to allow rapid drying. In this regard, U.S. Ser. No. 07/584,161 does not contain any teaching or examples that approach these conditions. All examples provided in U.S. Ser. No. 07/584,161 are deficient in at least three of the areas the applicants have found necessary to make a comfort fabric. In general these areas of deficiency include:
(1) There is no provision for an absorbent substrate having low-density and quick-drying properties;
(2) When a satisfactory "transport" layer is inadvertently formed with yarn segments, the resulting fabric is overshrunk, overdensified and overweight; and
(3) If the fabric is not overshrunk, the "transport" layer is not properly formed because the yarn gaps or spacings are too large (i.e, more than 3 mm).
Moreover, copending U.S. Ser. No. 07/584,161 and U.S. Pat. No. 4,876,128 utilize textured nylon as the wrapping yarn over "Lycra®", or as the main yarn. Nylon, and especially textured nylon, tends to absorb over 10 wt. % water and to hold onto water for extended periods of time. (10 wt. %+regain). This causes the fabric to feel relatively wet when it comes in contact with a wearer's skin.
In summary, none of the above-identified references disclose a dual-layered comfort fabric having a separate, nonabsorbent "transport" layer; and if a transport" layer is inadvertently formed, it is not formed by yarn segments unless conditions are chosen at the extremes. Under these extreme conditions, the fabrics formed do not serve their intended prior art purposes. Moreover, as set forth in the Examples which follow (particularly Examples C and D), the fabrics formed serve the purposes of a comfort fabric very poorly.
Clearly, what is needed is a comfort fabric that does not have the deficiencies inherent in the prior art. It is therefore an object of the invention to provide for a lightweight, bulky comfort fabric which has a separate, nonabsorbent "transport" layer formed by stitched yarn segments or by a nonwoven web. Other objects and advantages of the present invention will become apparent to those skilled in the art upon reference to the attached drawings and to the detailed description of the invention which hereinafter follows.
SUMMARY OF THE INVENTION
In accordance with the invention, a dual-layered comfort fabric is provided which is absorbent, durable, lightweight, quick-drying and very bulky. The fabric comprises an outer, absorbent, evaporation-reservoir layer and an inner, nonabsorbent, transport layer. The absorbent, evaporation-reservoir layer is formed from an absorbent, nonwoven web. The transport layer comprises a fibrous, nonabsorbent surface that can be formed in two ways.
One way to form the nonabsorbent surface is to deploy nonabsorbent stitching yarns in such a manner that the yarn segments appearing on the surface of the transport layer of the fabric form a network that weighs at least 10 gm/sq. m and leaves stitching gaps no wider than 3 mm. The network of yarn segments forming the nonabsorbent, transport layer is made by stitching the yarn segments through the absorbent web in a particular stitching pattern. Stitching is performed such that at least one bulkable stitching yarn is used to form spaced-apart rows of stitches extending along the entire length of the absorbent web. The resulting fabric has a basis weight of from 20 to 120 grams per square meter, preferably 20 to 80 grams per square meter, a bulk of at least 10 cubic centimeters per gram and the capability of absorbing at least 5 times its weight in water.
The other way to form a nonabsorbent surface is to deploy a separate, nonabsorbent, nonwoven web, having a patterned or nonpatterned construction, against the surface of the absorbent, nonwoven web that makes up the evaporation-reservoir layer of the fabric. The nonabsorbent web and the absorbent web are then joined together by at least one bulkable stitching yarn that forms spaced-apart rows of stitches extending along the entire length of the absorbent web. The resulting comfort fabric has a bulk of at least 10 cubic centimeters per gram and the capability of absorbing at least 5 times its weight in water. Preferably, the fabric has a basis weight of between 20 to 120 grams per square meter.
When a garment is made from the comfort fabric and the inner, nonabsorbent, transport layer is placed against the wearer's skin, the fabric feels relatively dry even when the fabric is wet. This occurs because the transport layer transmits moisture away from the wearer's body and towards the absorbent, evaporation-reservoir layer. In particular, the fabric is useful in intimate apparel, underwear, swimwear, sports shirting, headbands and comfort linings.
As used herein, the "outer" fabric layer refers to the layer which is exposed and positioned away from the skin of the wearer when worn as a garment and the "inner" fabric layer refers to the layer which is hidden and positioned against the wearer's skin when worn as a garment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood with reference to the following figures:
FIG. 1 illustrates a pillar or chain stitched fabric inaccordance with the invention.
FIG. 2 illustrates a short tricot stitched fabric (A) and a jersey stitched fabric (B), both in accordance with the invention.
FIG. 3 illustrates a long-float stitched fabric (A) and a satin stitched fabric (B), both in accordance with the invention.
FIG. 4 illustrates two atlas stitched fabrics (A and B), in accordance with the invention.
FIG. 5 illustrates a (0,0/2,2) laid-in stitch (A) and a (0,0/3,3) laid-in stitch (B), in accordance with the invention.
FIG. 6 illustrates a (0,0/4,4) laid-in stitch (A) and a (0,0/5,5) laid-in stitch (B), in accordance with the invention.
FIG. 7 illustrates a fabric in accordance with the invention combining laid-in and stitched-in yarns.
FIG. 8 illustrates a fabric in accordance with the invention wherein an absorbent web is used with a nonabsorbent, transport layer made up of a combination of jersey and pillar stitches.
FIG. 9 illustrates the fabric of FIG. 8 with nylon yarns on the front face and back face to provide abrasive protection.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The stitching yarns utilized to form the "transport layer" of the invention are preferably constructed with fibers that do not significantly absorb water, and dry easily. For purposes of the invention, it will be understood that the terms "nonabsorbent" and "do not significantly absorb water" mean that the absorbency of the fibers of the transport layer is substantially lower than the absorbency of the fibers contained in the absorbent layer. Excellent non-limiting examples of the fibers of the transport layer include textured polyesters, textured polypropylene or polyethylene, spandex and other polymeric yarns which absorb less than 1 percent of their weight in water. Less preferable fibers include polyaramids, and even less preferable fibers include polyamids (over 10% absorbency resulting in slower drying). It is also preferred that the fibers used to form the "transport layer" be of yarn segments having fine deniers (30-150 denier, less than 10 dpf) to result in better comfort feel.
Alternatively, if the "transport layer" is comprised of a fibrous, nonabsorbent, nonwoven web, the fibers should be of low textile denier, under 10 dpf. Webs suitable as a "transport layer" include low-weight polyester, polypropylene and polyethylene. The webs can be air-laid, carded, spunlaced or spunbonded continuous filaments. It is preferred that the "transport layer" webs not be overly bonded so that they are porous and have good surface aesthetics.
The absorbent, nonwoven webs used to form the "reservoir-evaporation" layer, are preferably high-bulk nonwovens, or bulkable nonwovens such as lightly bonded filament or staple webs. These webs are preferably lightly consolidated. The webs can comprise 100 wt. % absorbent fibers (e.g., rayon, cotton) or other such fibers (e.g., chemically modified polyesters), or blends of cotton/polyester, cotton/polypropylene, rayon/polyester or even woodpulp/polyester. Blended rayon/polyester webs that are preconsolidated (i.e., not highly bonded or hydraulically entangled) make excellent absorbent webs, since they tend to dry quickly and increase in bulk after stitchbonding. The absorbent webs can also consist wholly or partially of continuous fibers (e.g., spunbonded polyester with staple rayon lightly entangled into the spunbonded filaments). However, the fabric should preferably not contain more than 25 wt. % woodpulp since woodpulp forms dense layers that do not dry quickly. It is preferred that if woodpulp is used, that the woodpulp be thoroughly blended with such fibers as polyester, acrylic or polypropylene.
Table I which follows illustrates the usual amount of yarn deployed on each face of a stitched fabric depending upon the stitch pattern used. The data presented shows yarn consumption factors per stitch in units of fabric length if the horizontal and vertical stitch spacings are roughly equal. In other words, this is the length of yarn per length of fabric per stitch. For denser stitches (i.e., larger numbers of stitches per unit length), yarn consumptions can be higher for the front "technical face" (hereinafter the "TECH FACE") of the fabric and substantially higher for the "technical back" (hereinafter the "TECH BACK") of the fabric. The stitches deployed to make a durable, comfort fabric according to the invention include at least one bulkable "stitched-in" yarn. If the transport layer includes "laid-in" yarns, the yarns must be attached to the web with a second, bulkable stitch which provides an anchor point at least every 1.5 mm (17 gauge) to avoid snagging and unraveling. Table I demonstrates that if a "transport layer" weighing at least 10 gm/sq. m is to be formed using only yarn segments, the amount of total yarn deployed must be at least 15 gm/sq. m for the greige, stitched fabric, even if the most favorable conditions are selected to minimize total yarn basis weight. Furthermore, if the fabric is allowed to gather, as provided by the prior art, the total utilized yarn weight increases in proportion to the percentage of gather. Non-limiting inventive examples of yarn stitching patterns that can be used to form a suitable "transport layer" with yarn segments are set forth in Table I, and illustrated in FIGS. 1 through 7. These stitching patterns are well known to those skilled in the textile art.
In brief, FIG. 1 illustrates chain or pillar stitches used to form a yarn segment "transport layer" with stitching gaps smaller than 3 mm. For chain or pillar stitches, the "wale" (the distance between columns of loops lying lengthwise in the fabric) must be smaller than 3 mm, and the "gauge" (the number of wales per inch in a fabric) must be at least 8.5 to satisfy the requirement that the stitching gaps be no wider than 3 mm. (Depending on the fabric stitching pattern chosen, the specified "critical length" will be different in order that the requirement of no gaps being wider than 3 mm will be satisfied.) The minimum length of yarn segments appearing on the front "technical face" ("TECH FACE") per stitch is approximately twice the length of the fabric. For the "technical back" face ("TECH BACK"), the minimum total length is equal to one length of fabric.
For tricot-type stitches (FIGS. 2 and 3), the "course length" (the length of a row of stitches running across a fabric) or the CPI (courses per inch) determines the "critical length" for the "technical back" of the fabric, while the requirements for the front "technical face" remain the same as with a chain or pillar stitch (i.e., a minimum gauge of 8.5). Yarn consumption increases with the number of spaces the yarn is displaced across for every stitch.
For an extended "atlas" stitch (FIG. 4), the spacing requirements and yarn consumptions are identical to that of a simple tricot stitch.
For "laid-in" stitches (FIGS. 5 and 6), the front "technical face" receives no yarn. The "technical back" has the same CPI requirements and yarn consumptions as for "stitched-in" tricot stitches. Laid-in stitches must be affixed with a second stitched-in stitch using bulkable yarn, usually a chain stitch to anchor the laid-in yarns and prevent the yarns from pulling out of the fabric (see FIG. 7). Since the laid-in segments are laid loosely and can continuously pull-out of the structure when snagged, it is necessary to use a tighter gauge (at least 17 gauge and a minimum wale or spacing of 1.5 mm) to catch the laid-in segments at narrow spacings. To provide durability, the yarns used should be no lighter than 30 denier. With this denier, the front-side yarn segment weight at 17 gauge would be at least 5.5 gms. Added to a very carefully constructed minimum 10 gm "technical back" layer, the total minimum yarn weight would be 15.5 gms. Table I illustrates that the absolute minimum construction for an acceptable "transport layer" using nonabsorbent yarn segments will approximately add at least 15 gm/sq. m of yarn weight to the fabric, no matter what stitch pattern is used.
TABLE I__________________________________________________________________________(GAUGE APPROXIMATELY EQUAL TO CPI) MINIMUM MINIMUM LENGTH OF YARN/STITCH TOTAL YARN PER LENGTH OF FABRIC WITH 10 GM/SQ M TECH TECH "TRANSPORT" LAYERSTITCH TYPE FIG NOTATION FACE BACK TOTAL GM/SQ M__________________________________________________________________________A. STITCHEDIN"Chain" or 1 1,0/0,1 2 1 3 15"Pillar""Short 2A 1,0/1,2 2 1.5 3.5 17.5Tricot""Jersey" 2B 1,0/2,3 2 2.5 4.5 18.0"Long 3A 1,0/3,4 2 3.2 5.2 16.3Float""Satin" 3B 1,0/4,5 2 4.1 6.1 14.9"Atlas" 4 2,3/2,1/ 2 1.5 3.5 17.5 1,0/1,2B. LAID-IN 5A 0,0/2,2 0 1.5 1.5 15.5* 5B 0,0/3,3 0 2.5 2.5 15.5* 6A 0,0/4,4 0 3.2 3.2 15.5* 6B 0,0/5,5 0 4.1 4.1 15.5*__________________________________________________________________________ *Assuming that a chain stitch with a minimum 30 denier yarn at 17 gauge i used to anchor the laidin stitches (see FIG. 7).
Referring now more precisely to the drawings, wherein like reference numeral sindicate like elements, FIG. 1 is a simple depiction of a pillar or chain stitch designated (1,0/0,1). Yarn segments 21 appear on the technical face or front and are shown as solid lines. With tight yarns, the yarn length is about equal to 2 times the length of fabric per stitch. The needle penetration or yarn insertion points are represented by "X"s 22. Space 23 represents one course. Space 24 represents one wale which, as noted before, is the "critical length" for the front technical face or the technical back face of the fabric. To maintain a 3 mm spacing either on the front technical face or the technical back face, the gauge must be maintained at at least 8.5. Yarn segments 25 are those appearing on the technical back and are shown as dotted lines. For the tight yarn shown, the yarn length is about 1 times the length of fabric per stitch.
FIG. 2A depicts short tricot stitches designated (1,0/1,2). Front segments 31 have a minimum tight length of about 2 times the length of fabric per stitch. Back segments 32 have a minimum tight length of about 1.5 times the length of fabric per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 33 is a maximum of 3 mm. Each course must then be less than 1.5 mm and there must be a minimum CPI of 16. Referring now to FIG. 2B, jersey stitches designated (1,0/2,3) are depicted. Front segments 34 have a minimum yarn length of about 2 times the length of fabric per stitch. Back segments 35 have a minimum yarn length of 2.5 times the length of fabric. Assuming the technical back of the fabric is going to be the transport layer, critical length 36 can be a maximum of 3 mm or have a minimum CPI of 8.5.
Referring now to FIG. 3, FIG. 3A depicts a long-float stitch (1,0/3,4) wherein the front yarn segments 41 have a minimum yarn length of about 2 times the fabric length per stitch. The back yarn segments 42 have a minimum yarn length of about 3.2 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 44 equals 2/3 of a course which is a maximum of 3 mm or the CPI is a minimum of 5.6. FIG. 3B depicts a satin stitch wherein the front yarn segments 45 have a minimum yarn length of about 2 times the fabric length per stitch and back yarn segments 46 have a minimum yarn length of about 4.1 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 47 is 1/2 of a course which is a maximum of 3 mm or the CPI is a minimum of 4.2.
FIGS. 4A and B are depictions of atlas stitches. FIG. 4A shows a single bar atlas stitch designated (2,3/2,1/1,0/1,2) wherein front yarns 51 have a minimum yarn length of about 2 times the fabric length per stitch and back yarns 52 have a minimum yarn length of about 1.5 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 53 is a maximum of 3 mm or the CPI is a minimum of 16. FIG. 4B shows a two-bar atlas stitch designated (2,3/2,1/1,0/1,2) back bar stitch and (1,0/1,2/2,3/1,0) front bar stitch. Front yarn 54 length is about (2+2=4) times the fabric length per stitch combined minimum and the back yarns 55 length is about (1.5+1.5=3) times the fabric length per stitch combined minimum. Assuming the technical back of the fabric is going to be the transport layer, critical length 56 is a maximum of 3 mm or the CPI is a minimum of 8.
FIGS. 5A and B depict "laid-in" stitches. The laid-in stitches are shown alone for purposes of illustration, and it will be understood that the laid-in stitches will be anchored into the fabric by employing stitched-in stitches. In this regard, FIG. 7 shows the laid-in stitches after they have been anchored by stitched-in stitches. FIG. 5A depicts a (0,0/2,2) stitch pattern wherein 61 is the back yarn (i.e., all yarn on the back) with a minimum yarn length of about 1.5 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 62 is a maximum of 3 mm or the CPI is a minimum of 17. FIG. 5B depicts a (0,0/3,3) stitch pattern wherein 64 is the back yarn (all yarn on back) with a minimum yarn length of about 2.5 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 65 is a maximum of 3 mm or the CPI is a minimum of 8.5.
FIGS. 6A and B also depict "laid-in" stitched fabrics. FIG. 6A is a (0,0/4,4) stitch pattern wherein the minimum back fabric yarn 71 length is about 3.2 times the fabric length per stitch (all yarn on back). Assuming the technical back of the fabric is going to be the transport layer, critical length 72 is a maximum of 3 mm or the CPI is a minimum of 5.6. FIG. 6B is a (0.0/5.5) stitch pattern wherein the minimum back yarn 73 length is about 4.2 times the fabric length per stitch. Assuming the technical back of the fabric is going to be the transport layer, critical length 74 is a maximum of 3 mm or the CPI is a minimum of 4.2.
FIG. 7 depicts a combination of "laid-in" and "stitched-in" stitches. FIG. 7 represents the way FIG. 6A would look after the laid-in stitches had been anchored with a second stitched-in stitch set at (1,0/0,1). Yarn segments 81 in front and in back originate from chain stitches. Yarn segments 82 originate from tricot stitches. The critical length for the front of the fabric is 83 and for the back of the fabric the critical length is 84.
In order to join two web layers (absorbent/nonabsorbent) with stitches, bulkable yarns over 30 denier are also desirable. Depending upon the mechanical properties of the webs, a range of stitches can be used for this purpose. If the fabric contains at least one stable layer (e.g., a spunbonded polyester filament web as the nonabsorbent, "transport layer", combined with a spunlaced rayon-polyester absorbent, evaporation-reservoir layer) a simple chain-stitch should suffice. However, if the fabric needs added cross-stability, tricot, jersey or other stitches may be necessary.
A relatively dense nonabsorbent yarn layer on the outer, front technical face opposite from the inner, "transport layer" face will not affect the drying performance of the fabric. Actually, such an outer yarn layer could be desirable as a protective layer to resist abrasive wear. For instance, in Example 4 below, the "transport layer" is formed with a thin polypropylene web, the absorbent layer is formed of a rayon/polyester web, and the LycraR/nylon stitching yarn sections exposed on the protective, outer front technical face of the fabric act as an abrasion-resistant surface. The Lycra®/nylon stitching yarn sections also tie the structure together and provide elasticity. It is to be noted that in this case, nylon is used as a protective yarn exposed to the outer surface, rather than as a moisture-transport yarn on the inner surface.
In the Examples which follow, measurements were made accordingly:
Fabric thickness is measured with the same apparatus as disclosed in U.S. Pat. No. 4,876,128, the contents of which are incorporated herein, using 10 gms of pressure on an area measuring 0.5 inch in diameter. Density and bulk values are calculated from the fabric thickness.
Absorbency is measured by gently placing a small piece of fabric 5 cm×5 cm flat on the open surface of 25° C. water contained in a laboratory tray (nonabsorbent layer facing against the water). All samples given below absorbed water and descended under the surface within 10-15 seconds. All except the sample of Example 4 also sank to the bottom of the tray. The wet sample was then carefully removed, allowed to drip for 1 minute, and placed on a horizontal non-absorbing surface (aluminum foil). Water pick-up was determined by weighing, and reported in gms of water absorbed per sq. m of fabric and in gms of water absorbed per gm of fabric.
The wet samples were allowed to dry at 40% relative humidity and 25° C. Water evaporation after 15 min and 1 hour was recorded. The retained water was measured every hour thereafter. The time required to come within 10 gm/sq. m of absorbed water is provided in Tables II and III below as the "drying time".
A final test, to determine the "dry feel" or "rewet" of the "transport layer" face vs. the "evaporation-reservoir" layer face, was performed in the following manner. The wet samples were placed between two identical dry paper towels and a 454 gm weight (bottom dimensions 3"×4") was placed on top for 15 seconds. The weight was removed and the water pick-up by the two towels was measured. Tables II and III show that the examples of this invention showed nearly zero "rewet" on the "transport layer" face. Conversely, the comparasion samples without a "transport layer", and those having nylon yarns on the "transport layer" face, had higher rewet values.
EXAMPLES
The invention will be further described by reference to the following non-limiting examples. All percentages are by weight unless indicated otherwise. In these examples, two fabrics of the invention, equipped with a moisture "transport layer" formed by yarn segments (Examples 1 and 2), are compared to (1) two commercially available knit fabrics used in comfort applications (Examples A and B); and (2) two stitched samples made according to the believed closest references (Examples C and D). Two more examples of the invention, where the transport layer is formed through the use of a nonabsorbent, nonwoven web stitchbonded to an absorbent, nonwoven web, are designated as Examples 3 and 4.
Tables II and III summarize fabric constructions and fabric evaluations. All basis weights are in gms per square meter. The "stitching" gauge or stitches per inch (GA) and courses per inch (CPI) are listed in English units. Stitch descriptions are given with the same notations as in Table I. The yarn and stitch utilized on each bar are listed separately. The stitching machine used was a 2-bar 150" wide Liba unit. Tables II and III assume that for "stitched-in" stitches an amount of yarn equal to two lengths of fabric per stitch was deployed on the front "technical face" of the fabric. The remainder of the yarn consumed (recorded on the machine) was assigned to the "technical back" of the fabric. Machine-recorded yarn consumptions were in close agreement to those predicted by Table I, which covers fabrics where the gauge and CPI were nearly equal (Examples C, D, 3 and 4). For examples where the CPI was much higher than the gauge (Examples 1 and 2), yarn consumption was, as predicted, substantially higher for the technical back of the fabric because of the high underlap density. In Tables II and III, total yarn weight per face, (marked "TOT") and total yarn-segment weight on the "transport" face (marked "TRANSP") are listed separately.
EXAMPLE 1
Table II, FIG. 8
FIG. 8 depicts the stitch pattern used in Example 1. 1st yarn 91 is set at (0,1/1,0) to provide 3.6 g/sq m in front and 1.8 g/sq m in back. 2nd yarn 92 is set at (1,0/2,3) to provide 9.0 g/sq m on the back and 3.6 gm/sq m on the front, thus providing a total yarn weight of 12.6 g/sq m. Critical length 93 is 1.27 mm. Course 94 is 1/20 inch (1.27 mm) and wale 95 is 1/12 inch (2.1 mm). Spunlaced "SONTARA®" Style 8411 (commercially available from E.I. du Pont de Nemours and Company, Wilmington, Delaware) was used as the absorbent, nonwoven web (70% rayon-30% polyester). Both yarns were 50 denier, 47 end (1.05 dpf) textured polyester yarn. The yarn weight forming the "transport layer" on the technical back face added up to 10.8 gm/sq. m, while total yarn in the greige fabric was 18.0 gm/sq. m. The fabric was finished on a pin-tenter with the machine and cross-direction dimensions held (zero overfeed, zero stretch) at 350° F. (177° C.), 3 ypm, and 1 minute dwell time. The fabric shrunk upon release of tension and increased in weight per unit area by approximately 10%. The fabric had high bulk and absorbency, very low rewet, and high and quick evaporation compared to the commercially available fabrics of Examples A, B, C and D set forth below. (Table III).
EXAMPLE A
Table III
In this example, a cotton knit fabric used in the gusset area of panties as an absorbent comfort insert was chosen as Example A. Table III shows that "A" is more than twice as heavy as Example 1 (which is intended for the same end-use), while it absorbs no more water than Example 1. Example 1 evaporates water much faster and dries 2-3 times faster. Also, Example 1 has a dramatic rewet advantage over cotton knit.
EXAMPLE B
Table III
In this example, a two-faced knit used in the gusset area of pantyhose was chosen as Example B. The less absorbent face is nylon and the highly absorbent face is cotton. In present day use, the nylon face is used outside as a protective layer. The fabric is much denser and heavier, with its basis weight out of the range of the present invention. This fabric absorbs less, and evaporates water much more slowly than Example 1. It also has substantial rewet values on both faces.
EXAMPLE C
Table III
In this example, a stitchbonded, absorbent sleeve fabric was made using textured nylon (70 denier, 34 filament) as the stitching yarn, and a lightly bonded, wetlaid sheet of 80 wt. % woodpulp and 20 wt. % 12 mm/1.5 dpf polyester as the absorbent component. This type of fabric is typically used as an absorbent sleeve for waste-fluid absorbing socks. The fabric forms a dense layer of nylon yarn segments on the technical back face amounting to a total of 21.6 gms/sq. m. The critical gap length in this case is 2/3×1/12×25.4 mm or slightly over 2 mm (see FIG. 9). The fabric absorbs less and dries more slowly than Example 1 because of the presence of nylon and the excessive content of woodpulp. It also has a rewet value closer to the double-knit of Example B, much higher than the rewet value of Example 1.
EXAMPLE D
Table III
This fabric is a representation of Example 3-2 of the applicants' copending U.S. patent application Ser. No. 07/584,161, filed Sep. 18, 1990. The fabric employs a woodpulp/polyester spunlaced substrate (Style 8801 "SONTARA®" commercially available from E. I. du Pont de Nemours and Company, Wilmington, Delaware) containing 60 wt. % woodpulp and 40 wt. % polyester. The stitching yarns were LycraR wrapped with nylon. An adequate "transport layer" density is formed on the technical back face (critical gap length in the greige fabric slightly over 1 mm), with a total nylon/Lycra® weight of 17.3 gm/sq. m. This fabric increased to 163 gm/sq. m (out of claimed range of the invention) after being allowed to shrink due to the retractive power of the highly tensioned "inextensible" nylon-covered Lycra® yarns. The fabric had low absorbency, high rewet, slow evaporation and very long drying times.
EXAMPLE 2
Table II, FIG. 9
FIG. 9 depicts the stitch pattern used in Example 2. 1st yarn 101 is applied using a (0,1/1,0) bar to provide 7.0+3.5=10.5 g/sq m yarns. 2nd yarn 102 is applied using a (1,0/2,3) bar to provide 5.8+10.9=16.7 g/sq m yarns. In this example, the same Style 8411 "SONTARA®" absorbent web as employed in Example 1 was used. The "transport layer" was also formed on the "technical back" face of the fabric with the same polyester yarn segments as in Example 1. Additionally, the fabric utilized nylon yarns (with 2/3 of the nylon on the technical front face and only 1/3 on the technical back face), to provide abrasive protection to the front technical face and elastic shrinkage power for the fabric. The total nylon and polyester yarn weight on the technical back face was 10.9+3.5=14.4 gm/sq m. The fabric had very good absorbency and high evaporation rates, although it was slightly inferior to Example 1 in drying time and rewet value.
EXAMPLES 3 and 4
Table II
In these examples, a dual-layered web was used to the best advantage. Two samples (Examples 3 and 4) were made from lightweight, randomly-layed, consolidated (unbonded), continuous filament (1.5 denier) webs and used as the "transport layer". Example 3 was made of polyester (PET) and Example 4 was made of polypropylene. These transport layers also provide overall dimensional stability and eliminate the need for highly-densified cross-stitching. Nylon or Lycra® wrapped with nylon were used for stitchbonding. The yarns used in these fabrics do not interfere with the rewet-barrier function (minimum yarn gap over 2 mm for Example 3 and over 4 mm for Example 4). Both fabrics had excellent absorbency, high drying speed and high rewet resistance. Both could be stretched to very low basis weights (28-30 gm/sq. m) without breaking, and could elastically recover back to basis weights as high as 56 gm/sq. m for Example 3, and 112 gm/sq. m for Example 4. These inventive fabrics represent excellent candidates for elastic or semi-elastic, ultra-low-weight, durable, comfort-wear or shirting uses.
TABLE II__________________________________________________________________________ 1 2 3 4INVENTIVE PANTY PANTYHOSE LOW-COST ELASTICEXAMPLE GUSSET GUSSET COMFORT GARMENT COMFORT GARMENT__________________________________________________________________________WEB #1 SONTARA 8411 SONTARA 8411 PET POLYPROPYLENEWT, GM/SQ M 38 38 16 23WEB #2 -- -- RAYON/PET CARDED SONTARA 8411WT, GM/SQ M -- -- 15 381st BARGAUGE/CPI 12/20 14/10 12/12 12/12YARN/DEN PET TEXT/50 NYL TEXT/70 NYL TEXT/40 LYCRA/NYL 70-40COUNT/DPF 47/1.04 34/2 13/3.1 13/1.7STITCH 0.1/1.0 0.1/1.0 1.0/2.3 1.0/1.2FRONT WT 3.6/0 7.0/0 3.2/3.2 5.3/5.3(TOT/TRANS)BACK WT 1.8/1.8 3.5/3.5 2.2/0 4.4/0(TOT/TRANS)TOTAL YN 5.4/1.8 10.5/3.5 5.4/3.2 9.7/5.3(TOT/TRANS)2nd BARGAUGE, CPI 12/20 14/20 -- --YARN/DEN PET TEXT/50 PET TEXT/50 -- --COUNT/DPF 47/1.04 47/1.05 -- --STITCH 1.0/2.3 1.0/2.3 -- --FRONT WT 3.6/0 5.8/0 -- --(TOT/TRANS)BACK WT 9.0/9.0 10.9/10.9 -- --(TOT/TRANS)TOTAL YARN 12.6/9.0 16.7/10.9 -- --(TOT/TRANS)FABRICTRANSPORT FACE BACK BACK FRONT FRONTWT (GREIGE/ 58/68 66/91 46/56(28) 79/112(30)FINISHED)ABSORBENCY,GM/SQ. M, 482 601 576 672TIMES WT 7.1 6.6 10.3 6.0BULK CC/GM 11.9 10.9 16.7 10.1EVAPORATION,GM/SQ. M15 MIN 64 68 78 831 HR 187 210 378 280DRYING TIMES 4 5 2 4HOURSREWET, GMS 121/5 81/8 71/2 79/2(TR/AB)__________________________________________________________________________
TABLE III__________________________________________________________________________ D A B COPENDINGCOMPARATIVE COTTON PANTYHOSE C USSN 07/584,161EXAMPLE GUSSET GUSSET SLEEVE FABRIC EX 3-2__________________________________________________________________________WEB #1 -- -- 80/20 PAPER SONTARA 8801WT, GM/SQ M -- -- 43 75WEB #2 -- -- -- --WT, GM/SQ M -- -- -- --1st BARGAUGE/CPI -- -- 12/12 14/11.5YARN/DEN -- -- NYL/TEXT 70 NYL/TEXT 40COUNT/DPF -- -- 34.2 34/2.7STITCH -- -- 0.1/1.0 0.1/1.0FRONT WT -- -- 7.0/0 4.0/0(TOT/TRANS)BACK WT -- -- 3.5/3.5 2.5/2.5(TOT/TRANS)TOTAL YN -- -- 10.5/3.5 6.5/2.5(TOT/TRANS)2nd BARGAUGE, CPI -- -- 12/12 14/11.5YARN/DEN -- -- NYL TEXT/70 LYCRA/NYLCOUNT/DPF -- -- 34/2 --STITCH -- -- 1.0/3.4 1.0/4.5FRONT WT -- -- 7.0/0 5.0/0(TOT/TRANS)BACK WT -- -- 18.8/18.1 14.8/14.8(TOT/TRANS)TOTAL YARN -- -- 25.1/18.1 19.8/14.8(TOT/TRANS)FABRICTRANSPORT FACE -- NYLON BACK BACKWT (GREIGE/ 153 144 78/121 81/163FINISHED)ABSORBENCY,GM/SQ. M, 513 446 375 635TIMES WT 3.8 3.1 3.1 3.9BULK CC/GM 2.9 2.2 4.8 5.0EVAPORATION,GM/SQ. M15 MIN 29 31 13 161 HR 48 112 42 48DRYING TIMES 9 12 16 29HOURSREWET, GMS 32/26 76/38 90/42 70/16(TR/AB)__________________________________________________________________________
Although particular embodiments of the present invention have been described in the foregoing description, it will be understood by those skilled in the art that the invention is capable of numerous modifications, substitutions and rearrangements without departing from the spirit or essential attributes of the invention. Reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.
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A stitchbonded comfort fabric is disclosed that is absorbent, durable and quick-drying. The fabric is made up of an absorbent, evaporation-reservoir layer and a nonabsorbent, transport layer. The evaporation-reservoir layer comprises a nonwoven web that is stitched with at least one bulkable stitching yarn. The transport layer weighs at least 10 gms/sq m and can be formed from a network of fibrous stitching yarns that do not significantly absorb water and do not exhibit stitching gaps wider than 3 mm. The resulting fabric has a basis weight of between 20 and 120 gm/sq. m, a bulk of at least 10 cc/gm and the capability of absorbing at least 5 times its weight in water. The fabric is useful in intimate apparel, underwear, swimwear, sports shirting, headbands and comfort linings.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to limiting degradation of orthopedic components composed of polymers. More particularly, the present invention relates to a method for reducing the number of free radicals present in ultrahigh molecular weight polyethylene orthopedic components.
2. Description of the Related Art
The development of polymers over the last several years has enabled the extensive use of polymer-based materials as orthopedic devices. The great variety of biocompatible polymers also allows the manufacture of a remarkable array of implantable components from such polymers, including artificial organs, vascular tubing, and housings for mechanisms such as pacemakers.
While opening a new world of possibilities for medical treatment, the increased use of polymers in the biomedical arts has been attended by a unique set of problems not exhibited by metal. Specifically, most polymers are susceptible to some form of chemical degradation when exposed to any of several environmental elements.
Much of this degradation is the result of oxidation of the polymer which is initiated during the sterilization process by ionizing radiation. It is the step of irradiating the polymerized biocompatible component which forms free radicals which then serve as active sites to react with available ambient or in vivo oxygen.
Free radicals (or simply "radicals") are defined as compounds having one unpaired electron. One might be surprised to find that, in spite of the odd number of electrons, free radicals may, in fact, be relatively stable. The stability is provided by structure, for example in the case of the planar shape of trivalent carbon free radicals having seven valence electrons. Nitric oxide is an example of a stable free radical. Free radicals may also be unstable and chemically reactive in the case of, for example, the methyl radical.
Free radicals are involved in several types of reactions, such as addition reactions and in chain reactions where they often serve as intermediates. In chain reactions such as polymerization and combustion, free radicals are involved in the initiation and propagation components.
While having value in the polymerization process, free radicals become potentially problematic after polymerization is completed, and this is particularly true in biomedical applications. Specifically, free radicals serve as active sites to react with available oxygen. (Interestingly, free radicals may also crosslink with local polymer chains or may recombine with other radicals if oxygen or other reactive species are not present. Crosslinking in polymers is characterized by an increase in the insoluble fraction of the material, an increase in the creep resistance, and an improvement in the abrasion resistance of the material. To this end, it may be argued that crosslinking actually improves the characteristics of the polymer for use as an orthopedic bearing.)
The greater the number of free radicals, the greater the number of possible oxidation sites. Oxidation of several polymers (including the UHMWPE preferred for prosthetic bearings) results in a lowering of the molecular weight of the polymer as a result of polymer chain scission reactions. This lowering of the average molecular weight can also result in an increased level of crystallinity, density, and stiffness of the polymer. Oxidation reduces the mechanical strength and durability of several polymers, including UHMWPE.
The presence of a high density of free radicals is most troublesome because, in this radical-rich environment, an autoxidation reaction may begin. (Autoxidation is a self-catalyzed and spontaneous oxidation process which is often initiated by a free-radical generator.) Once initiated, this process is continuously fueled by oxygen from the surrounding atmosphere (ambient air or in vivo) as it diffuses into the material.
Free radicals may be generated by one of several ways. These include electric and microwave discharge and photochemical and thermal decomposition. As regards implantable medical components, however, it is another way of generating free radicals--irradiation --which is of primary concern.
Gamma rays and X-rays are forms of high-energy radiation that disrupt molecules and result in the generation of free radicals. This fact is unwelcome in the case of prosthetic bearings formed from polymers because high-energy radiation, particularly gamma rays, are frequently used in sterilization. Once exposed to such radiation, the free radicals form and, when combined with oxygen (available in both ambient air and in vivo), degradation may start. The quantity of free radicals produced is dependent upon the total irradiation dose the implantable component receives (which may be as high as 10.0 MRad), as the higher the absorbed dosage the more active sites are created. If oxidation begins while there is a high density of free radicals, the above-discussed autoxidation process is initiated that is continually fueled by oxygen from the surrounding atmosphere as it diffuses into the material.
Several packaging and processing modifications have been tried in an effort to reduce the potential oxidation of the various implantable medical components. These methods include forming the component under a vacuum or an inert gas environment, controlling maximum process temperatures, and implementing alternative sterilization processes such as ethylene oxide and plasma vapor. Efforts to reduce the potential oxidation of the various implantable medical components have also included exposure of the component to hydrogen gas at various pressures after irradiation. However, these methods have not proved satisfactory and, accordingly, an improved method of reducing potential oxidation of implantable medical components remains wanting.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method for reducing the number of free radicals in an implantable medical component such as a prosthetic bearing that overcomes the problems and deficiencies of known methods by providing a method that is safe and effective.
It is a further object of the present invention to provide such a method which provides for the packaging of the component in a container which serves as an oxygen barrier so as to prevent exposure of oxygen to ambient air prior to the implanting of the component on the patient.
It is an additional object of the present invention to provide such a method which incorporates sterilization through gamma radiation.
It is a further object of the present invention to provide such a method that combines free radicals with hydrogen gas to thereby extinguish the radicals.
The implantable medical component referred to herein may be virtually any article formed from a polymerized material for which sterilization is required, although the method of the present invention has a particular application in reducing the number of free radicals in a prosthetic component such as a bearing. (Bearing surfaces are naturally susceptible to wear in use. Accordingly, any degradation of the bearing surface through oxidation is particularly undesirable in such an application.)
The method of the present invention includes several steps.
The implantable component or, more particularly, the bearing, is initially formed by machining from an isostatically molded bar stock of a polymerized material, such as a polypropylene or a polyethylene. Alternatively, the component may be formed by any of several processes, including sheet molding, ram extrusion, or direct compression molding. The preferred polyethylene is ultrahigh molecular weight polyethylene, or UHMWPE. Once formed, the component is positioned in a bag that is impermeable to oxygen but is permeable to hydrogen. The bag is flooded with an inert gas such as argon or nitrogen which is then removed leaving a vacuum. The bag is then sealed.
The packaged component is sterilized through radiation. A preferred (but not exclusive) method of irradiating the component is through exposure to gamma rays. The packaged and irradiated component is then positioned in a pressure vessel. A pressurized gas, such as hydrogen, is then introduced into the vessel at a pressure above one atmosphere. Gas pressure and exposure time are controlled so as to allow adequate diffusion of the gas into the component, forcing the hydrogen and free radicals to combine, thus reducing the number of free radicals. The component is removed from the pressure vessel following the selected amount of time, the amount of time and the pressure of the vessel being dependent upon the density of free radicals in the component following irradiation.
Immersion in pressurized hydrogen gas extinguishes the free radicals by diffusing into the material during the immersion phase, thus causing the gas to become combined with the free radicals. The level of peroxy and alkyl radicals remaining in the polymer after exposure to the hydrogen gas is greatly reduced if not entirely eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout the views, and in which:
FIG. 1 is a diagrammatic view of an prosthetic bearing construction positioned within an oxygen barrier package;
FIG. 2 is a diagrammatic view of the packaged prosthetic bearing in position before an irradiating unit; and
FIG. 3 is a diagrammatic view of the packaged and irradiated prosthetic bearing positioned within a pressure vessel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings disclose the preferred embodiments of the present invention. While the configurations according to the illustrated embodiments are preferred, it is envisioned that alternate configurations of the present invention may be adopted without deviating from the invention as portrayed. The preferred embodiments are discussed hereafter.
Briefly, the method of the present invention for reducing the number of free radicals in a medical implantable component includes the steps of packaging the component in an oxygen-resistant/hydrogen gas permeable container, sterilizing the package component, and exposing the packaged and sterilized component to hydrogen gas or to a gas mixture containing hydrogen. According, the apparatus of the present invention includes a packaging component, a sterilizing component, and a pressuring component.
Referring to FIG. 1, a diagrammatic view of a packaging component, generally illustrated as 10, is shown. The packaging component 10 includes an oxygen-resistant package 12, an adapter 14, a vacuum pump 16, a vacuum line 18, a gas line 20, and an inert-gas source 22.
Positioned within the package 12 is an implantable medical component 24. While the illustrated component 24 is a generic prosthetic bearing, it is to be understood that the component 24 may be any component composed of a polymerized material that is intended for implantation within the body as a part of a medical procedure and requires irradiating sterilization prior to implantation. Accordingly, the component 24 may be an artificial organ, vascular tubing, and housings for mechanical units such as pacemakers. However, the method according to the presenting invention finds particular application in situations where movement between two or more contacting surfaces is required, such as between bearing surfaces of a prosthetic implant.
The component 24 may be formed from one of several suitable polymers accepted for biological applications, although the polymer of a particularly concern is one that is commonly used for prosthetics, namely ultrahigh molecular weight polyethylene. (The polymers having high molecular weights demonstrate a particular susceptibility to degradation due to oxidation.) Where the component 24 is a prosthetic implant such as a bearing or related part, it is generally machined from isostatically molded bar stock.
The package 12 is selected for its ability to be substantially impermeable to oxygen while being substantially permeable to hydrogen. Accordingly, the package 12 may be an oxygen barrier bag or a glass-lined oxygen barrier bag. (A package demonstrating selective permeability such that it is suitable for application in the present method is manufactured by Stephen Gould, Inc. Indiana!, and is identified as 1P1C double-layer, 48 gauge, PET SiO 2 -coated adhesive, 2-mil LLDPE.)
The component 24 is generally positioned within the package 12 through an open end 26 which is fitted to the adapter 14. A removable sealing member 28 (or other attachment) is provided for temporarily fastening the open end 26 of the package 12 to a nozzle 30 of the adapter 14.
Fitted to the adapter 14 is the gas line 20 which fluidly connects the inert gas source 22 with the adapter 14. Also fitted to the adapter 14 is the vacuum line 18 which fluidly connects the inert gas source 22 to the adapter 14. The adapter 14 includes a valve 32 which is operable to be moved between a closed position, an inlet position between the nozzle 30 and the gas line 20, and an outlet position between the nozzle 30 and the vacuum line 18.
The packaging component 10 is operated as follows. The implantable medical component 24 is positioned within the package 12, after which the open end 26 of the package is positioned on the nozzle 30. The sealing member 28 is thereafter positioned so as to form a fluid-tight seal between the open end 26 of the package 12 and the nozzle 30. The valve 32, which is normally maintained at its closed position, is turned to the inlet position such that inert gas flows under pressure from the source 22, through the line 20, and into the package 12. The inert gas may be argon, nitrogen or a similar gas.
Once the inside of the package 12 is flooded with the inert gas, the valve 32 is moved to its outlet position and the vacuum pump 16 is operated to create a vacuum within the package 12. After the inert gas is evacuated from the package 12, a vacuum-sealed, packaged component 34 (shown in FIG. 2) results. The valve 32 is returned to its closed position and the vacuum pump 16 is shut off. The packaged component 34 may be placed in an additional package such as a double-blister pack-box combination (not shown). This additional packaging is useful and generally necessary for transit and storage.
Referring to FIG. 2, a sterilizing component 40 is shown and generally includes an irradiating unit 42. The irradiating unit 42 includes a radiation source portion 44, a beam focusing portion 46, and a beam outlet 48. The irradiating unit 42 produces high-energy radiation such as gamma radiation. (Electron beam radiation may also be used, although experiments have shown that it is difficult to identify a dosage that is effective on both metal and plastic, two materials commonly found in a single component.) The intensity of the radiation beam may be varied according to the size and shape of the component. The time of exposure is also variable, and depends on a variety of factors, including the age of the gamma source. (Age of the source may lead to a 10 percent variation of the exposure window.) In any event, radiation exposure time is generally between 2.2 to 2.9 hours. The object is a total absorbed dose of between 2.5 MRad and 3.8 MRad, with a limit of about 4.0 MRad.
Following the sterilization process by the sterilizing component 40, the packaged (and now irradiated) component 34 is gassed with hydrogen using the pressuring component 50. More particularly, the sealing cover 52 of a pressure vessel 54 is removed from a base portion 56. The component 34 is positioned within the base portion 56 of the vessel 54, and the cover 52 is returned and locked into place by locking fasteners 58. The pressure vessel 54 is connected to a hydrogen gas source 60 by a feed line 62. A valve 64 is fitted between the gas source 60 and the feed line 62. Normally in its closed position, the valve 64 is moved to its open position to allow hydrogen gas under pressure to enter the pressure vessel 54.
The total radiation dose (as determined by exposure time and beam intensity received by the material determines the quantity of free radicals produced in the material. The pressure of the hydrogen gas and the duration of exposure to the gas are accordingly functions of the density of free radicals present in the component 34. However, the pressure of the hydrogen gas within the pressure vessel 54 is preferably elevated to approximately 3 atm of pressure or above. The component 34 is exposed to this amount of pressure for several hours, with 6 hour exposure being suitable. Again, pressure and exposure ar variable and are adjusted according to the requirements of the particular irradiated component.
The presence of remaining free radicals in the package, sterilized, and gassed component 34 may be evaluated according to techniques such as electron spin resonance (ESR) testing. In addition to ESR testing, tensile evaluation with various strain rates may also be conducted on the prepared component.
The packaged, sterilized, and gassed component may be held for storage or may be distributed for use. The method according to the present invention reduces the risk of oxidative damage resulting upon exposure to in vivo and ambient environments.
It should be understood that while the packaging component 10, the sterilizing component 40, and the pressurizing component 50 have been illustrated in the various figures and discussed above as being separate components, it is conceivable that a single unit could well be formed which incorporates all three components. Accordingly, the apparatus as presented above is set forth for illustrative purposes and is not intended as being limiting.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.
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A method for reducing the number of free radicals in an implantable medical component requiring sterilization includes the steps of packaging the component in an oxygen-resistant container, sterilizing the packaged component, and exposing the packaged and sterilized component to a gas capable of combining with free radicals. The step of packaging includes vacuum sealing the component in an oxygen barrier bag. The step of sterilizing includes exposing the packaged component to radiation such as gamma radiation. The step of exposing the packaged and sterilized component to a gas capable of combining with free radicals includes placing the packaged and sterilized component in a pressure vessel and introducing pressurized hydrogen gas into the vessel for a period of time.
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FIELD OF THE INVENTION
This invention relates to computer processing systems and more particularly to systems and methods for expediting certain jobs in a computer processing system.
DESCRIPTION OF RELATED ART
In certain computer processing systems there are workloads (jobs) that have long processing time and certain jobs that process quickly. Since the short running jobs are those upon which humans are typically waiting, it enhances productivity if the quick processing jobs are handled in a queue separate from the long jobs.
For example, in a circuit or chip design simulation environment there are some simulations having a long processing time and thus a user will typically either run these jobs over night or at least will not expect the job to complete for a long period of time. Thus, these long running jobs are not sensitive to latency, that is, if they finish in 10.1 hours instead of 10 hours, nobody is inconvenienced.
Other jobs, however, are quick compiles of designs or simulations, for example, of a small section that an engineer is working on. The results of that short job are usually key to the next design step that the designer needs to perform. Quicker turnaround of this job then results in greater efficiency of the designer. Clearly, short jobs should be given preference over long jobs, but without sophisticated code or elaborate queuing systems, it is not always clear at job launch time which jobs will run quickly and which jobs are long running jobs.
One prior solution to this problem is for the user to establish separate queues (one for a short running job and one for a long running job). This works if jobs are correctly entered, but leaves significant room for abuse or simple mistakes. Also, this system limits the pool of running jobs to a set ratio of short to long, which may need to change over time. Another system is to only run long jobs at night. This reserves the computer-system for short jobs during the day, but leaves computer-resources unused if the short jobs do not use up all of the CPU (or other resource) capacity.
BRIEF SUMMARY OF THE INVENTION
In one embodiment, jobs requiring short processing time are given preference over jobs requiring long processing time by processing to completion all jobs for the first N time period (usually seconds) of the job. Jobs requiring longer than N time period to complete are given a lower priority than a newly arriving job and can continue being processed, but are subject to reduction in resources as newer jobs as such newer jobs arrive.
In one embodiment, long jobs are stopped when new jobs arrive and resume with short jobs finish. Medium and long jobs are done in FIFO order if no new short jobs arrive. This would be very beneficial to short jobs, but would be very detrimental to the long jobs' overall performance as stopping a job entirely may have many undesirable side effects.
In another embodiment, the system controls processing levels to control priority of the individual jobs.
In still another embodiment, jobs are moved to workload management (WLM) groups, which represent a pool of CPU resources shared by jobs in the group. Resizing the pool (as jobs are added or finished) has immediate effects on the job's resource use and runtime, but not the negative side effects of stopping the job or offers more control than adjusting levels individual priority levels.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates one embodiment of a system for expediting certain jobs in a computer system; and
FIG. 2 illustrates one embodiment of a method for processing certain jobs to completion ahead of earlier started jobs.
DETAILED DESCRIPTION
FIG. 1 illustrates one embodiment 10 of a system for expediting certain jobs in a computer system. Embodiment 10 is a batch processing system in which a group of jobs are started at the same time. However, the concepts discussed herein will work for systems in which jobs are presented sequentially.
In embodiment 10 , workload manager (WLM) 105 maintains separate resource pools for processing work jobs. As shown, there are three such pools, with pool 102 being a high priority group pool, i.e., pool 102 contains jobs that have not consumed more than N seconds of CPU time. In one embodiment, processing jobs in this manner (i.e., high priority jobs) are sized by WLM (between 10 and 80% of CPU allocation) based on actual CPU consumption. If the jobs want more processing they get more subject to, for example, a 10% minimum and 80% maximum of CPU allocation across all CPUs in the machine.
Pool 103 , in the embodiment, is a medium priority group pool such that any job in the pool has consumed more than N CPU time, but less than, say, 10N CPU time. The medium pool, for example, is sized (between 10 and 80% of CPU allocation) based on actual consumption subject to what the short pool has already taken. If the jobs want more processing, and more is available, they get more subject to only the, for example, 10% minimum and 80% maximum of CPU allocation. Thus, if the short pool is using 50% of the processing capability then only 40% is available to the medium group (and 10% for the long jobs' minimum as will be discussed).
An optimization would be to reduce the medium and long group from 10% minimums to 1%, or to only enforce the minimum allocation if there are jobs in any group requiring processing. For the minimum equals 10% case the following chart would apply.
Group
Min
Effective Max
Short
10
80
Medium
10
80 − (short_allocation − 10)
Long
10
80 − ((short_allocation − 10) +
(medium_allocation − 10))
Pool 104 is a low priority group pool such that any job in the pool has consumed more than 10N of CPU time. In this case, for example, the short and medium groups get the processing they need first, then the long group gets what is left. Thus, the 80% only happens when the short group and medium group are relatively idle.
Data collector scripts are called by the WLM daemon process to watch CPU seconds of individual job processes. The data collector program moves the jobs onto the next group if it accumulates enough CPU time to cross the job (or group) threshold.
All jobs are started in short group 102 where they run for the first N CPU seconds. After N CPU seconds, if a job has not completed it is moved to a lower priority group. If the lower priority job accumulates a second threshold of CPU time, such as 10N seconds, it is placed in the lowest priority group (pool 104 ). This method allocates CPU resources first to running short length jobs, then to medium length jobs, then to long jobs. Medium and long jobs have a minimum resource allocation, such as 10%, so these jobs continue to be processed even if there are many short jobs running.
Note that the N value for the initial threshold times (and the value 10N) can be set (and changed from time to time) by the user or if desired by WLM 103 monitoring the system and making adjustments according to a plan. A reasonable default would be, for example, 10 min. Also note that priority levels can take into account resources other than just CPU and could include, for example, memory, disk IO, coprocessors, etc.
Note that the jobs do not need to be instrumented, and the users do not have to worry about special short or long queue submission commands. In fact, the users do not even have to know how long their job will take since if it is a short job it is automatically expedited.
In operation, as shown in FIG. 1 , job B is a short job (i.e., it has processed in less than, say, 10 minutes and has completed prior to the end of N seconds. Jobs A and C did not complete within N seconds and thus have been moved to medium priority group 103 . Job C completes within this period (between time N and, say, time 10N). Job A has not completed within time 10N and thus is moved to the lowest priority in group 104 where job A joins other long running jobs D, E, F, G, H.
Note that the time N and the time 10N are arbitrary, as is the number of priority levels.
FIG. 2 illustrates one embodiment of a method for processing certain jobs to completion ahead of earlier started jobs.
As shown in embodiment 20 , process 201 begins a job, or a batch, and process 202 assigns the job the highest priority. This means that an established maximum amount of resources are assigned to the job. For single resource systems, the single resource, usually a CPU, is assigned to that job and the CPU would not be processing another job in the system. Alternatively, the CPU can process the new job for say 80% of its time while devoting the other 20% to jobs having lower priorities.
Process 203 determines if the new job has been processed to completion within N seconds. As discussed, N is an arbitrary time period and can be, if desired, adjusted from time to time. If it has the job is, by definition, competed and nothing further need be done. If the job has not completed, process 204 assigns it to a lower priority and it is processed either after all new jobs (jobs holding higher priority) are complete or during the, say 20% of CPU time set aside for lower priority jobs.
If there are one or more intermediate priority levels then processes 205 , 206 , 207 , 208 , 209 , 210 and 211 continue to move the job to lower and lower priority status if the job has not completed within each defined time. Note that the system should be designed such that even at the lowest priority a job will make reasonable progress towards completion regardless of how many other new or higher priority jobs arrive in the system. This is accomplished by being sure that all priority levels receive some minimum amount of resource time.
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In one embodiment, jobs requiring short processing time are given preference over jobs requiring long processing time by processing to completion all jobs for the first N seconds of the job. Jobs requiring longer than N seconds to complete are given a lower priority than a newly arriving job can and continue being processed, but are subject to reduction in resources by new jobs as each new job arrives.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to swimming pool covers and more particularly pertains to a pool cover which can be easily stored on and removed from a portable roller assembly.
2. Description of the Prior Art
The use of swimming pool covers is well known in the prior art. This is evidenced by the granting of a number of patents relating to various functional and structural aspects of such swimming pool covers, and these covers take all forms and shapes.
One of the biggest problems experienced when utilizing pool covers is how and where to store such covers during periods of non-use. Another problem involves the floatability of such covers. More specifically, pool covers are primarily designed to capture debris which would otherwise float on the pool surface and frequently sink to the bottom of the pool, and to also retain heat in the pool water. Some versions of pool covers include solar collection arrangements wherein the pool cover actually operates to both heat the pool water, while retain the heat that is already present.
None of these prior art pool covers are particularly adapted for supporting the weight of a human being thereon due to the fact that a much more bulky cover would be required so as to increase the floatability to an extent that is could support the weight of an adult who might accidentally fall into the pool. The increased bulkiness would again contribute significantly to the first mentioned problem of how to store a cover during periods of non-use.
With respect to addressing the problem of cover storage, a number of U.S. patents are relevant to the concept of the present invention. For example, U.S. Pat. No. 5,068,928, which issued to Powell on Dec. 3, 1991, discloses an apparatus for storing a rolled pool cover along the exterior sidewall of an above-ground swimming pool. The apparatus includes a plurality of perimetrically spaced-apart, upwardly opening hooks which are canitleverly supported on the pool sidewall, and a rolled pool cover can be supported exteriorly of the pool within the confines of the hooks when not being utilized.
U.S. Pat. No. 5,107,552, which issued to Lavalliere et al. on Apr. 28, 1992, discloses a swimming pool cover and roll-up device. The combination includes a flexible shaft which is positionable across the cover wherein such shaft is permanently attached to the cover, and it may be rolled so as to cause the cover to be rolled thereon from two directions. The entire shaft can then be lifted out of the pool and flexibly deformed to be hung on a plurality of hooks perimetrically aligned around a circular above-ground swimming pool.
Another novel swimming pool cover assembly is shown in U.S. Pat. No. 4,471,500 which issued to Long et at. on Sep. 18, 1984. The cover shown in this patent is of a self-rolling construction which is designed to extend over the water surface of a pool when connected to a pressure source, and it returns to a rolled position when disconnected therefrom. A fluid pressure source, such as water or air, is utilized to extend a rolled conduit, wherein the conduit is retained within the cover and is caused to go into a rolled condition by a permanently installed coil spring arrangement.
U.S. Pat. No. 4,324,370, which issued to Guard et al. on Apr. 13, 1982, is of interest as disclosing another pool cover roller assembly. A roller apparatus for winding and unwinding a pool cover includes a flexible cover which is permanently attached to a roller that can be manually operated to store the cover thereabout, and the entire assembly is mounted on wheels so that it can be removed easily to a desired storage area during periods of non-use. This cover, as well as all of the other covers as above-discussed, is designed to protectively cover the water surface of the pool so as to prevent the accumulation of debris therein, as well as to retain heat within the pool's water. The cover is not bulky or strong enough to serve the function of protecting against child or adult injury in those incidences where they might accidentally fall into the pool inasmuch as the disclosed roll-up structures most likely cannot easily support the increased size of such a cover.
While each of these prior arts patents disclose devices which fulfill their respective particular objectives and requirements, and are most likely quite functional for their intended purposes, none of them have apparently addressed the problem of how to construct a cover of sufficient strength to support the weight of an adult or child who might accidently fall into a pool and as such, there apparently still exists the need for swimming pool cover which would perform this desired function. In this respect, the present invention substantially fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of swimming pool covers now present in the prior art, the present invention provides a new swimming pool cover wherein the same can be utilized to clean and collect debris from a pool, capture or retain heat within the pool's water, and protect against accidental drownings of adults and children. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a swimming pool cover and method which has many of the advantages of the swimming pool covers mentioned heretofore and many additional novel features that result in a swimming pool cover which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art swimming pool covers, either alone or in any combination thereof.
To attain this, the present invention generally comprises a roll-up cover for a swimming pool comprises a continuous sheet of flexible reinforced plastic firmly attached to an aluminum roller with a number of reinforced loops at the free end of the plastic. The roller can be turned by a crank or wheel to roll the cover up, and a pull with a hooked end is used to unroll the cover by inserting it into one of the reinforced loops and pulling the cover off of the roller. The loop straps on the free end of the cover can be hooked at the end of the pull to keep the cover tight. The entire cover assembly is mounted on wheels so that it is of a portable construction, and it includes a debris removal and collection apparatus. The cover can be made of a plurality of interleaved pivotally connected members which is movable along the edges of a swimming pool by a plurality of rollers, and the cover is strong enough to support an adult or child in the event that they accidentally fall into the pool.
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 additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, 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 swimming pool cover and method which has many of the advantages of the swimming pool covers mentioned heretofore and many novel features that result in a swimming pool cover which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art swimming pool covers, either alone or in any combination thereof.
It is another object of the present invention to provide a new swimming pool cover which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new swimming pool cover which is of a durable and reliable construction.
An even further object of the present invention is to provide a new swimming pool cover 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 swimming pool cover economically available to the buying public.
Still yet another object of the present invention is to provide a new swimming pool cover 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.
Still another object of the present invention is to provide a new and improved swimming pool cover which facilitates the use of a cover which performs a cleaning function, a heat retention function, and a protection function against accidental drowning.
Yet another object of the present invention is to provide a new and improved swimming pool cover which provided with sufficient strength to guard against the accidental drowning of children who might accidentally fall into the associated swimming pool.
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 a perspective view of the swimming pool cover assembly comprising the present invention.
FIG. 2 is a partial exploded perspective view of the invention illustrating the method of assembly thereof.
FIG. 3 is a partial top plan view of the cover forming a part of the invention.
FIG. 4 is a partial exploded side elevation view of the cover.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference now to the drawings, and in particular to FIGS. 1-4 thereof, a new swimming pool cover embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the swimming pool cover assembly 10 essentially comprises a flexible cover 12 attached to an elongated roller 14 which in turn is rotatably mounted to a portable support structure 16 with a handle structure 18 being operable to effect a desired rotation of the roller.
The flexible cover 12 would be specially designed for each swimming pool, and could be made in a variety of sizes and shapes to fit most pools with standard shapes, including circles, squares, rectangles, ovals, and combinations of all of these. As shown, in the preferred embodiment 10, the flexible pool cover 12 is constructed of a plurality of interleaved slats 20 which are pivotally connected together to form the composite cover. As best illustrated in FIGS. 3 and 4, each slat 20 is provided with a series of integral conduits 22 on opposed sides thereof. These conduits 22 are spaced apart at equal lengths, and each space 24 is equal in length to a conduit 22. As shown in FIG. 3, the conduits 22 are integrally formed in a staggered array, whereby at an end 26 of a slat 22, one side of the slat begins with a conduit 22 and the opposed side begins with a space 24. This facilitates the inner engagement of conduits 22 between slats 20 so that an elongated hinge rod 28 can be inserted through the aligned openings of the interengaged conduits thereby to effectively hingedly attach the slats 20 together in a now apparent manner. The hinge rod 28 would be of a lightweight metal construction so as to impart strength to the slats 20 and wheels 30, 32 would be threadably attached to opposed ends of the hinge rod 28 so as to provide a mobility to the cover 12 as it is pulled along the edges of a swimming pool. In the preferred embodiment 10, the slats 20 could be formed of a flexible reinforced plastic, again to hold the accumulative weight down, and the hinge rods 28 then provide a strengthening reinforcement so that the cover could support the weight of an adult who might accidentally fall onto the cover while it is positioned over the surface of a swimming pool. The wheels 30, 32 would travel along the supporting edge of the pool and, in the case of a specially designed pool, the wheels could be operably retained within a receiving groove along the edge of the pool to further add support to the cover in the event of a child or adult falling thereon.
A free end 34 of the flexible pool cover 12 is provided with a plurality of reinforced loop straps 36. These loops may be engaged by a hook 38 attached to an elongated pole 40, and a user may employ the pole to pull the cover 12 off of the elongated roller 14 so as to effectively cover the surface of the swimming pool. Once the cover 12 reaches the end of the pool so as to substantially cover the entire surface thereof, the loop straps 36 may be attached to connectors which are permanently affixed to an end of the pool, thereby to retain the cover 12 in a secured position over the pool inasmuch as the other end of the cover is fixedly secured to the elongated roller 14.
As shown in FIG. 2, an elongated bar 42 is provided at an opposed end 44 of the pool cover 12, and the bar is provided with a plurality of spaced-apart conduits 46 which are interengagable with the conduits 22 formed on the slat 20 which lies against the bar. A final hinge rod 28 can be utilized to connect the bar 42 to the slat 20 at the end 44. The elongated roller 14 is of a substantially cylindrical design and would preferably be formed of a lightweight metal such as aluminum or the like. The roller 14 is provided with opposed flat surfaces 48, 50 which are countersunk into the roller, as illustrated in FIG. 2, and a plurality of apertures 52 extend through the roller and are centrally disposed in each of the flat surfaces 48, 50, whereby threaded connectors 54 can be directed therethrough. The bar 42 is provided with a plurality of through-extending apertures 56 which are alignable with apertures 52, whereby the threaded connectors 54 operably attach the bar 42 to the elongated roller 14 after internally threaded lock nuts 58 are connected to the connectors 54.
The portable support structure 16 comprises a pair of upstanding frame members 60, 62 which are disposed at opposite ends of the elongated roller 14 and which are therefor positionable on opposed sides of a swimming pool. The structures 60, 62 are substantially identical in construction and accordingly, only the structure 60 will be described in detail with it being understood that such description applies equally to the frame member 62.
The frame structure 60 includes a base member 64 having a pair of upstanding angularly directed supports 66, 68 affixed thereto, and the supports 66, 68 are further fixedly secured to a circular roller support 70 having a centrally positioned through-extending aperture 72. The frame structure 60, as well as the frame structure 62, is designed for portable movement by having the base 64 supported off of a ground surface by a plurality of wheels, all of which are generally designated by the reference numeral 74. Each wheel 74 is rotatably mounted over an externally threaded axle 76, and an internally threaded thumb nut 78 is threadably engagable with the axle 76 so as to maintain each wheel 74 in rolling engagement therewith. Once the frame structure 60 has been positioned where desired, an additional tightening of the thumb nut 78 will effect a locking of the wheel 74 whereby the portable support structure 16 is effectively lock against further movement. In those instances where it is not desired to occasionally move the portable support structure 16 to a storage location, the frame members 60, 62 can be permanently attached to a surface proximate the edge of a swimming pool, and such attachment is made possible by a plurality of through-extending apertures 80 in the base member 64. Conventional threaded bolts 82 can be directed through the apertures 80 so as to permanently secure each frame member 60, 62 into engagement with a surface proximate the edge of the pool.
The handle structure 18 can be used on one or both sides of the elongated roller 14 and essentially comprises a crank handle 84 which is threadably attachable to an elongate rod 86 which is of a conventional cylindrical design. A remaining free end 88 of the rod 86 is machined to a rectangular configuration and may be directed through the aperture 72 so as to be engagable with a rectangularly shaped aperture 90 formed in an end of the elongate roller 14. The rectangularly shaped end 88 of the rod 86 is further provided with a through-extending aperture 92 that is alignable with one of the apertures 52 and the elongate roller 14 so that a threaded connector 54 can be used to permanently attach the handle structure 18 to the roller. The outer curvilineral surface of the cylindrical portion of the rod 86 is slidably rotatably movable within the apertures 72 and a bearing surface exists therebetween so that a rotatable movement of the handle 84 effects a concurrent rotatable movement of the elongate roller 14 without any appreciable torque applied to the frame structure 60. The handle 84 is shown with a cushioned grip 94 and if desired, a bicycle handle-type grip could be employed wherein individual finger slots would provide greater comfort and ease of use.
Another novel feature of the present invention 10 involves the use of a debris removal and collection assembly which is generally designated by the reference numeral 96. The debris removal and collection assembly includes an elongate pan member 98 which is positionable beneath the roller 14 as best illustrated in FIG. 1. The pan extends over the entire length of the roller and is normally positionable beneath a debris deflector 100 as shown in FIG. 2. The debris collector 100 can take many shapes and forms but in the preferred embodiment 10, it essentially comprises an elongated brush having flexible yet rigid bristles 102 which are projected upwardly from a bar 104 supported at its opposed ends by upstanding vertical supports 106. The pair of upstanding vertical supports 106, only one of which is shown in FIG. 2, are fixedly secured to the bases 64 associated with the frame structures 60, 62. The debris deflector 100 is positioned whereby the bristles 102 will continually brush against an exposed surface of the flexible cover 12 as it is rolled about the roller 14. Debris which accumulates on the cover 12 will be deflected therefrom by the brash bristles 102 and will drop downwardly into the removal pan 98. The debris collects in the pan 98 and periodically, the pan can be removed for cleaning whereby the debris can be properly disposed of.
The embodiment 10 of the invention as shown in FIGS. 1, 2 and 3 relate strictly to a roller-up version thereof. It is also with the intent and purview of the present invention to utilize fold-out covers which could be constructed of two sections joined together with hinges. When not in use, the sections could fold together for storage proximate the pool. To utilize them, they can be dragged over part of the pool and unfolded to cover the rest of the pool. This second version of the invention, along with the first embodiment 10, provides a second line of defense against injury to child, i.e., it would be provided with sufficient floatability and strength to support the weight of a child or adult who might accidentally fall in the pool, thereby the substantially eliminate the danger of accidental drowning. Recognizing that most pool covers are designed to prevent debris collection in a pool as well as to retain and collect heat therein, a solar version of the present invention is also within the intent and purview hereof and is intended to be encompassed by the claims appended hereto. In the solar version, the individual slats 20 could be formed of a transparent material whereby sunlight would be allowed to pass therethrough into the pool water with the slats then operating to prevent heat from escaping therefrom. The slats could include hollow enclosed interiors similar to the bubble-type solar collecting pool covers, and these captures air chambers provide an even greater insulation effect.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will 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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A roll-up cover for a swimming pool comprises a continuous sheet of flexible reinforced plastic firmly attached to an aluminum roller with a number of reinforced loops at the free end of the plastic. The roller can be turned by a crank or wheel to roll the cover up, and a pull with a hooked end is used to unroll the cover by inserting it into one of the reinforced loops and pulling the cover off of the roller. The loop straps on the free end of the cover can be hooked at the end of the pull to keep the cover tight. The entire cover assembly is mounted on wheels so that it is of a portable construction, and it includes a debris removal and collection apparatus. The cover can be made of a plurality of interleaved pivotally connected members which is movable along the edges of a swimming pool by a plurality of rollers, and the cover is strong enough to support an adult or child in the event that they accidentally fall into the pool.
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RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent application Ser. No. 13/399,616 filed Feb. 17, 2012, now U.S. Pat. No. 9,439,574, issued Sep. 13, 2016, which claims the benefit of priority to U.S. Provisional Application No. 61/444,285, filed Feb. 18, 2011, each of which is hereby incorporated by reference, including the drawings.
BACKGROUND OF THE INVENTION
[0002] The following discussion of the background of the invention is merely provided to aid the reader in understanding the invention and is not admitted to describe or constitute prior art to the present invention.
[0003] Blood pressure is a vital sign often considered to be a good indicator of a patient's health. In critical care environments like the ICU and OR, blood pressure can be continuously monitored with an arterial catheter inserted in the patient's radial or femoral artery. Alternatively, blood pressure can be measured intermittently with a cuff using oscillometry, or manually by a medical professional using auscultation. Many patient monitors perform both the catheter and cuff-based measurements of blood pressure.
[0004] Blood pressure can also be monitored continuously with a technique called pulse transit time (PTT), defined as the transit time for a pressure pulse launched by a heartbeat in a patient's arterial system. Typical PTT measurements determine the time separating a maximum point on the QRS complex (indicating the peak of ventricular depolarization) and a foot of the PPG waveform (indicating the arriving pressure pulse). PTT depends primarily on arterial compliance, the propagation distance of the pressure pulse (which is closely approximated by the patient's arm length), and blood pressure.
[0005] PTT has been shown in a number of studies to correlate to systolic (SYS), diastolic (DIA), and mean (MAP) blood pressures. PTT can be measured with a patient monitor that includes separate modules to determine both an electrocardiogram (ECG) and SpO2. During a PTT measurement, multiple electrodes typically attach to a patient's chest to determine a time-dependent ECG component characterized by a sharp spike called the ‘QRS complex’. The QRS complex indicates an initial depolarization of ventricles within the heart and, informally, marks the beginning of the heartbeat and a pressure pulse that follows. International Patent Application No. PCT/US2010/048866, which is hereby incorporated by reference in its entirety, describes a body-worn monitor that continuously measures a plurality of vital signs from a patient. The body-worn monitor features a series of sensors that attach to the patient to measure time-dependent PPG, ECG, accelerometer-based motion (ACC), oscillometric (OSC), respiratory rate (RR), and impedance pneumography (IP) waveforms. A wrist-worn microprocessor (CPU) continuously processes these waveforms to determine the patient's vital signs, degree of motion, posture and activity level. Sensors that measure these signals typically send digitized information to a wrist-worn transceiver through a serial interface, or bus, operating on a controlled area network (CAN) protocol. The CAN bus is typically used in the automotive industry, which allows different electronic systems to effectively and robustly communicate with each other with a small number of dropped packets, even in the presence of electrically noisy environments. This is particularly advantageous for ambulatory patients that may generate signals with large amounts of motion-induced noise.
[0006] It is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0007] As such, 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.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide a body-worn data processing system for determining/monitoring physiological properties of the wearer. The system comprises a housing which contains the processor module, and a separate plastic casing which receives the housing. The processor module is sealed in a water-proof plastic fashion within the housing, which provides openings to access electrical interconnects operably connected to the processor module. During operation, the housing snaps into a separate plastic base (or “cradle”). Upon mating of the housing and the base, interface cavities, or “ports,” are formed for receiving the terminal ends of data cables leading to and/or from one or more sensors which collect data related to the physiological properties of interest. The ports may also provide connection to one or more peripheral devices such as blood pressure cuffs, wireless communication hardware, etc. Insertion of a terminal end into such a port establishes electrical communication between the port's corresponding electrical interconnects and the cable, thereby permitting electrical communication between the processor module and the corresponding sensor or peripheral device. In certain embodiments, the communications between the processor, sensors, and any peripherals connected through the ports are configured as a peer-to-peer network such that each device on the network is an equally privileged, equipotent participant node which can simultaneously function as both “clients” and “servers” to the other nodes on the network.
[0009] The design described herein facilitates activities such as cleaning and disinfection of the processor module, as housing contains no openings for fluids common in the hospital, such as water and blood, to flow inside. During a cleaning process the housing may simply be detached from the cradle and then cleaned. In addition, wear components, such as the tabs described above, can be provided on the cradle such that the majority of wear components are located on an inexpensive disposable unit while the relatively more expensive electronic components provide for multiple uses. Finally, the peer-to-peer architecture permits each node to communicate with, and so synchronize as necessary, with the other nodes available on the system.
[0010] In a first aspect, the invention provides a body-worn physiological data processing system, comprising:
[0000] a housing supporting electronic circuitry, the housing providing a waterproof enclosure for the electronic circuitry, the electronic circuitry comprising:
one or more processors configured to receive data from, and export data to, one or more peripheral devices external to the housing, and to use data received from one or more peripheral devices provide signals in deriving a measurement of at least one physiological property of the wearer, a display operably connected to the processor to display data received by the processor from one or more of the peripheral device(s), or a processed form thereof, a power supply operably connected to the processor and display, and one or more electrical contacts proximate to one or more openings in the housing and operably connected to the processor to provide one or more connections through which the processor receives data from, and exports data to, the one or more peripheral devices; and
(b) a base, or “cradle,” configured to releasably receive the housing, wherein when the housing is inserted into the base, one or more interface cavities are formed between the base and the housing.
wherein each interface cavity is adapted to establish an operable connection between one of the peripheral device(s) and the processor through a data cable connected to the peripheral device by insertion of a connector on the data cable into the interface cavity such that electrical contacts on the connector interconnect with a corresponding electrical contact on the housing,
[0015] The base and housing can be mated with a positive latch, or may be mated by a simple friction fit, or by a combination of these. In the case of a friction fit, the friction fit is preferably strong enough to prevent separation of the base and housing under the force of gravity. In certain embodiments, at least one interface cavity formed by mating of the housing and the base comprises a latch mechanism which acts to prevent separation of the base from the housing when a connector is inserted fully into the cavity. In preferred embodiments, this latch mechanism comprises at least one first recess in a wall of the interface cavity provided by the base, and at least one second recess in a wall of the interface cavity provided by the housing. The first and second recesses are configured to receive a portion of the connector when it is inserted which acts similarly to a latch bolt on a conventional lock to physically restrain separation of the base and housing until the connector is removed.
[0016] In certain embodiments, the base comprises a reclosable tape or retaining strap for reversibly fixing the data processing system to the wearer. In these embodiments, openings may be provided in the base through which such a strap can thread. Other alternatives for affixing the strap include bonding materials such as adhesives, ultrasonic welds, etc. The strap may comprise mated hook-and-loop patches or similar fastening elements such as tapes, snaps, buckles, etc., to secure the system to the wearer's body during use.
[0017] Preferably, the base is designed as a disposable component which receives an electronics housing preferably designed for multiple uses. As used herein, the term “disposable” with regard to the base refers to the characteristic that the base may be disengaged from housing in the course of normal use by the user of the system such that the electronics may be easily separated from, and need not be discarded with, the base. This can serve to place the device components of the system most susceptible to wear and cleanability issues on a disposable unit, while retaining the more expensive electronic components on an easily cleanable and reusable unit.
[0018] As noted above, the housing provides a waterproof enclosure for the electronic circuitry contained within the housing. The IP Code system defined in international standard IEC 60529 classifies the degrees of protection provided against the intrusion of solid objects (including body parts like hands and fingers), dust, accidental contact, and water in electrical enclosures. Preferably, the housing meets IEC 60529-2004 IPX7 standards, which provides that ingress of water in harmful quantity shall not be possible when the enclosure is immersed in water under up to 1 m of submersion for up to 30 minutes.
[0019] The connector may be held in the port by a friction fit, or may utilize a locking mechanism such as that of a standard RJ-45 modular connector which comprises a resilient tab which snap-fits into a recess on the housing. Removal of the connector is accomplished by simply pulling on the connector with sufficient force, or by disengaging the resilient tab from the recess prior to pulling. In preferred embodiments, a port can comprise a tab which exhibits a spring force and which flexes during insertion of a terminal end, and springs back when the terminal end is fully inserted for receiving and holding the cable in its proper orientation to establish data communication.
[0020] In certain embodiments, the processor is configured to derive a measurement of at least one physiological property of the wearer selected from the group consisting of heart rate, electrical activity of the heart, temperature, SpO2, blood pressure, cardiac stroke volume, cardiac output, motion, activity, posture, pulse rate, and respiration rate. Peripheral devices such as sensors to be connected to the system are selected appropriately for the physiological properties of interest. The peripheral devices which may be pluaggbly connected to the physiological data processing system may be selected from the group consisting of a body-worn optical probe adapted to measure at least one optical signal detected after interaction with the wearer's tissue, an accelerometer, a pump module configured to inflate a blood pressure cuff, an ECG sensor, an ICG sensor, and a temperature sensor. As noted, each peripheral device is adapted to establish an operable connection with the processor through a data cable connected to the peripheral device by insertion of a connector on the data cable into the interface cavity. This data cable can carry I/O signals to and from the peripheral, and preferably also provides power to one or more peripherals from a power supply contained within the housing. By powering a peripheral from the body worn housing, the peripheral may be made lighter, less expensive, and more readily disposable. It is not necessary that each peripheral be so powered; for example a first peripheral may be controlled and powered by the physiological data processing system, while a second peripheral may be controlled by the physiological data processing system but powered by its own on-board battery.
[0021] As noted above, the communications between the processor, sensors, and any other peripherals connected through the ports are configured as a peer-to-peer network such that each device on the network is an equally privileged, equipotent participant node which can simultaneously function as both “clients” and “servers” to the other nodes on the network. In preferred embodiments, the nodes communicate through a serial interface, or bus, operating on a controlled area network (CAN) protocol. The CAN bus, which is typically used in the automotive industry, allows different electronic systems to effectively and robustly communicate with each other with a small number of dropped packets, even in the presence of electrically noisy environments. This is particularly advantageous for ambulatory patients that may generate signals with large amounts of motion-induced noise.
[0022] In certain embodiments, the physiological data processing system comprises a transceiver for wirelessly communicating with a data acquisition system external to the body-worn physiological data processing system. In these embodiments, the necessary communications hardware may be provided within the housing, or may be external, e.g., provided as a “dongle” which pluggably inserts into one of the interface cavities formed by the housing and the base, or may be provided partially within the housing and partially externally. Provision of the communications hardware as an external pluggable component can provide additional flexibility in configuration for the end user.
[0023] The system may utilize one or more electronic connectors adapted to insert into an interface cavity and which act as “keys” to unlock menus within the processing system which are not otherwise available to the user. Examples of such key connectors include “mode connectors” which enable certain special modes including, but not limited to a sleep mode (disabling the system, for example during shipping), a manufacturer mode (permitting a manufacturer to interact with the system for calibration, servicing, etc.), a demo mode (permitting the unit to display a pre-programmed demonstration), and a biomedical mode (permitting a hospital or other care site access to settings generally not available to a patient).
[0024] Advantageously, the system may also utilize one or more non-electronic “dummy” connectors adapted to insert into an interface cavity which is not in operable use. These plugs can serve to protect the structures within an interface cavity and, in the case of a system utilizing connectors to provide a latch between the base and the housing, can serve as a latch when no electrically active connector is being employed by the user.
[0025] A number of additional features may be incorporated into the electronics contained within the housing. By way of non-limiting example, the display may provide a touch-screen interface for data entry to the processor; a microphone and speaker configured for two-way voice communication may be provided; a voice over Internet protocol (VOIP) communication protocol may be provided; etc.
[0026] Mis-connection of medical devices by medical workers due to the use of common connectors across different device types is increasingly understood as both a source of patient injury and damage to equipment. Thus, in certain embodiments, the interface cavity comprises a “key” structure, and the corresponding connector is adapted to match the key structure to reduce the risk of insertion of an incompatible connector into an interface cavity. For example, the base may comprise a raised element in the wall of the interface cavity which is matched by a recess in the appropriate connector. Incompatible connectors lacking the appropriate recess and interface dimension would be physically prevented from insertion. This description is by way of example only and is non-limiting on the types of lock-and-key structures which may be used.
[0027] In related aspects, the present invention provides a base configured to releasably receive a housing supporting a processor, wherein when the housing is inserted into the base, one or more interface cavities are formed between the base and the housing, each interface cavity comprising one or more electrical contacts on the housing operably connected to the processor, and each interface cavity adapted to receive an electrical connector which makes sliding contact with the electrical contacts within the interface cavity to establish an operable connection between a peripheral device and the processor, the base comprising:
a latch mechanism at a first end of the base, the latch mechanism comprising at least one recess in a portion of the base which forms part of a first interface cavity, said first recesses configured to receive a portion of the electrical connector when inserted; a tab on a portion of the base which forms part of the first interface cavity, the tab configured to insert into a recess on the electrical connector when inserted and thereby position the connector into a recess on a portion of the housing which forms part of the first interface cavity; a tab at a second end of the base which is configured to insert into a corresponding opening in the housing when mated thereto; wherein insertion of the electrical connector into the first interface cavity so that the connector is positioned into the recess on the housing prevents separation of the base from the housing until the connector is removed.
[0032] Still other embodiments are found in the following detailed description of the invention, and in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 shows a three-dimensional mechanical drawing of an exemplary processor module housing and base module of the present invention, depicting a mode of mating the processor module housing to the base module.
[0034] FIG. 2 shows an alternative view of a three-dimensional mechanical drawing of an exemplary processor module housing and base module of the present invention.
[0035] FIG. 3 shows a detailed view of a base module of the present invention.
[0036] FIG. 4 shows a series of sectional views of the base module shown in FIG. 3 .
[0037] FIG. 5 shows a three-dimensional mechanical drawing depicting the top and bottom halves of an exemplary connector shell for use in the present invention.
[0038] FIG. 6 shows a three-dimensional mechanical drawing of a completed connector for use in the present invention.
[0039] FIG. 7 shows a three-dimensional mechanical drawing depicting the bottom half of an exemplary processor module housing of the present invention.
[0040] FIG. 8 shows a three-dimensional mechanical drawing depicting one view of a completed processor module housing of the present invention.
[0041] FIG. 9 shows a pair of three-dimensional mechanical drawings depicting the mode of insertion of a connector as shown in FIG. 5 into the mated processor module housing and base module as shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIGS. 1 and 2 depict a top and bottom view of a base 100 , and housing 101 which releasably attaches thereto, for use in the body-worn data processing system of the present invention. The housing provides a water-proof plastic casing housing a processor (the “system processor”) and associated electronics (collectively the housing and the associated electronics being referred to herein as a “processing module”), and features openings on the underside that provide access to electrical interconnects that interface to connectors at the terminal ends of cables leading to the system's various sensors and other peripherals. In addition to being waterproof, this design facilitates activities such as cleaning and disinfection, as the housing contains no openings for fluids common in the hospital, such as water and blood, to flow inside.
[0043] The base is preferably designed as a disposable component which receives an electronics housing preferably designed for multiple uses. As used herein, the term “disposable” with regard to the base refers to the characteristic that the base may be disengaged from the housing in the course of normal use by the user of the body-worn data processing system such that the housing may be easily separated from, and need not be discarded with, the base. This can serve to place the system components most susceptible to wear and cleanability issues on a disposable unit, while retaining the more expensive electronic components in an easily cleanable and reusable unit.
[0044] During use, the housing reversibly snaps into the plastic base. Upon mating of the housing and the base, interface cavities, or “ports,” are formed for receiving the terminal connectors of data cables leading to and/or from one or more peripheral devices such as sensors which collect data related to the physiological properties of interest. Insertion of a terminal connectors into such a port establishes electrical communication between the port's corresponding electrical interconnects and the cable, thereby permitting electrical communication between the system processor and the corresponding sensor or peripheral device. When mated, the housing and base are releasably attached; likewise, when a connector is inserted into a port, the connector and the port are releasably attached. As used herein, the terms “releasably attached” and “releasably receive” refers to two separate modules which may be engaged with and disengaged from one another in the course of normal use.
[0045] FIGS. 3 and 4 depict base 100 in more detail. Openings 302 a, b and c positioned at a first end of the base, and a larger opening 303 positioned at a second end of the base, are configured to receive appropriately constructed terminal connectors, which are described in more detail below. The base provides a bottom wall and side walls for each interface cavity which receives a connector, while the waterproof electronics housing, when mated to the base, provides a top wall which includes electrical interconnects which are in sliding contact with the conductors of the terminal connector.
[0046] A tab 312 (also shown in cross section in FIG. 4, 402 ) fits into a groove in the housing to secure the first end of the base in the housing. Raised areas 313 and 314 at the second end of the base provide a friction fit for the housing; the tightness of this friction fit may be controlled by the thickness and flexibility of these raised areas. Preferably, the friction fit is sufficiently tight that the base can be inverted with the housing in place without the housing disengaging from the base.
[0047] Opening 303 (which in this example accommodates a terminal connector having 8 electrical interconnects) is capable of receiving a larger terminal connector than are openings 302 a, b and c (which each accommodate a terminal connector having 4 electrical interconnects). Opening 303 includes in its lateral walls recesses 304 and 305 (also shown in cross section in FIGS. 4, 404 and 405 ). These recesses are configured to receive extensions ( FIGS. 6, 603 and 605 ) at the edge of the terminal connector when it is inserted into the interface cavity. A tab 311 that exhibits a spring force due to its material composition (thickness and stiffness of the material forming the tab) flexes during insertion of the terminal connector, and springs back when the terminal connector is fully inserted into the interface cavity.
[0048] A raised portion of this tab (shown in cross-section in FIG. 4, 401 ) inserts into a depression in the bottom surface of the terminal connector ( FIG. 6, 602 ), thereby forming a detent to provide positive location of the terminal connector when in its proper position. In this position, the electrical conductors of the terminal connector are in sliding contact with the corresponding electrical interconnects on the housing, and the distal end of the terminal connector ( FIG. 6, 606 ) is inserted into a recess in the housing ( FIG. 8, 801 ). So inserted, the housing is secured at one end by tab 312 , while at the other end the terminal connector 600 forms a “deadbolt” lock due to insertion of its distal end 606 into recess 801 and insertion of extensions 603 and 605 into lateral walls recesses 304 and 305 . This “latch” prevents removal of the housing from the base until the terminal connector 600 is removed. Once the terminal connector is removed, the base and housing may be separated by simply lifting the housing from the base.
[0049] Like opening 303 , each of openings 302 a, b , and c also contain a tab that flexes during insertion of the terminal connector, and springs back when the terminal connector is fully inserted into the interface cavity. A raised portion of this tab (shown in cross-section in FIG. 4, 401 ) inserts into a depression in the bottom surface of the terminal connector ( FIG. 5, 504 ) to form a detent to provide positive location of the terminal connector when in its proper position. In this position, the electrical conductors of the terminal connector are in sliding contact with the corresponding electrical interconnects on the housing. These connectors, however, do not participate in the “latch” mechanism.
[0050] Raised posts 306 , 307 , 308 , and 309 in each interface cavity provide a keying mechanism to prevent inadvertent insertion of an incompatible terminal connector. Each terminal connector has a corresponding slot ( FIG. 5, 503 ; FIG. 6, 604 ) which is adapted to receive the raised post. A similarly sized connector lacking this slot would be prevented from insertion. It is preferred that this keying mechanism be unique as compared to other electrical cable connectors used in the particular care setting to limit chances for inadvertent insertion of an incorrect cable connector.
[0051] To affix the base to a wearer, slots ( FIG. 3, 310 ; FIG. 4, 403 ) are provided through which a strap may be threaded. This strap may be sized according to the body location to which the base is to be affixed. A preferred site is the wrist of the wearer.
[0052] FIGS. 5A and B show the top and bottom halves of a data cable connector 500 configured to insert into one of openings 302 a, b , and c without the associated cable hardware. An opening 501 allows the cable leads to pass into the connector, and spring-tension “sliding” or “wiping” electrical contacts (similar to those of a standard modular RJ-45 cable) are positioned in opening 502 . The connector is conveniently made as a 2-piece component for ease of cable attachment. As noted above, slot 503 and detent recess 504 serve to position the connector in its proper orientation and in a compatible interface recess.
[0053] FIG. 6 shows the bottom surface of a completed data cable connector 600 configured to fit larger opening 303 . Cable 601 extending from a peripheral (not shown) enters the connector at its proximal end, relative to distal end 606 which forms part of the latch mechanism described above. Spring-tension “sliding” or “wiping” electrical contacts are positioned on the top surface of the connector (not shown). In some cases, it may be desirable to latch the housing and base together without the use of a data cable. In this case, a “dummy” connector lacking cable 601 and the associated wiring and electrical contacts may be provided. This dummy connector will comprise slot 604 , detent recess 602 , distal end 606 , and extensions 605 and 603 to support insertion into opening 303 . As in the case of connector 600 , the dummy connector will provide a latch preventing removal of the housing from the base until the dummy connector is removed.
[0054] FIGS. 7 and 8 show the underside of bottom portion of the housing. When mated to the base, contact pads 701 a and b and 702 overlay openings 302 a, b , and c in the base, thus forming the electrical interconnects that interface to the terminal connector at the end of cables. As noted above, openings 302 a, b , and c are sized to accommodate a connector having four electrical contacts, and contact pads 701 a and b contain a corresponding number of electrical interconnects. In contrast, contact pad 702 contains 8 electrical interconnects. The central four interconnects interface to the terminal end of a cable inserted into opening 302 b , and when the housing is mated to the base, the other four electrical connectors are unavailable. However, when the housing is separated from the base, these additional four contacts can provide for additional electrical access to the electronics within the housing. These additional four contacts can be used, for example, for battery charging, and a separate battery charging station which is adapted to receive the housing can be provided for this purpose.
[0055] Similarly, contact pad 802 overlays opening 303 in the base, thus forming the electrical interconnects that interface to the terminal connector of the larger cable. As discussed, opening 303 is sized to accommodate a connector having eight electrical contacts, and contact pad 802 contains a corresponding number of electrical interconnects. FIG. 9 depicts the releasable insertion of connector 902 into the interface cavity formed between opening 303 and contact pad 802 when the housing is mated to the base. Connector 902 is inserted until the detent depression 904 snaps into the ridge on tab 903 . At this point, the distal end of the connector is inserted into recess 801 , forming the latch which retains the housing in the base until the connector is removed.
[0056] Suitable electronics to be provided within the housing is described in detail in International Patent Application No. PCT/US2010/048866, International publication WO2010/135518, U.S. publication US20090018453A1, and U.S. publication US20100168589A1, each of which is hereby incorporated by reference in its entirety. The electronics preferably support serial communication through the CAN protocol. This allows the system processor to easily interpret signals that arrive from the various sensors, and means that the interface cavities need not be associated with a specific cable; any cable can be plugged into any compatible port. Furthermore, because the CAN protocol supports peer-to-peer connection of the peripherals, these peripherals may communicate directly with one another, for example for purposes of synchronization. Digital information generated by the attached peripherals can include a header that indicates the identity or origin of the signals so that the system processor can process them accordingly.
[0057] A variety of peripheral devices may communicate with the processing module. For example, a cable may transport I/O signals to/from an ECG circuit and electrodes; accelerometers; a cuff-based system for determining blood pressure values; a glucometer; an infusion pump, a body-worn insulin pump; a ventilator; an end-tidal CO2 monitoring system; a pulse oximeter or other optical physiological probe; and a thermometer. This list is not meant to be limiting. Using one or more of these inputs, the processing system can determine one or more physiological properties associated with the wearer, such as heart rate, electrical activity of the heart, temperature, SpO2, blood pressure, cardiac stroke volume, cardiac output, medication dosage, patient weight, blood glucose levels, end tidal CO 2 , motion, activity, posture, pulse rate, and respiration rate.
[0058] The processing module can include a speaker and/or microphone that allows a medical professional to communicate with the patient, using an appropriate protocol such as a voice over Internet protocol (VOIP). For example, the medical professional can query the patient from a central nursing station; the electronics carried within the housing may function much like a conventional cellular telephone or ‘walkie talkie’: the processing module can be used for voice communications with a medical professional and can additionally relay information describing the patient's vital signs and motion. The processing module can be configured via software to support speech-to-text annotations. By this is meant that speech generated externally can be converted into text for display on the processing module, and/or speech generated at the processing module can be converted into text at an external computer.
[0059] The system processor is preferably operably connected to a data input device such as a keypad or touchscreen located at the top of the housing to permit the wearer or medical personnel to interact with the system. Openings may be provided in the top of the housing for the speaker and/or microphone, as depicted in FIGS. 9, 905 and 906 ; in order to maintain water resistance (e.g., at an IPX-7 standard), these openings may be sealed from underneath with a waterproof but breathable material such as a GORE-TEX® membrane (W. L. Gore & Associates, Inc.).
[0060] The electronics within the housing preferably include a battery or other power supply. Numerous battery technologies are known in the art, including common alkaline batteries, oxyride batteries, lithium batteries, etc. There are three preferred battery technologies that could be employed: Nickel Cadmium (NiCad), Nickel Metal Hydride (NIMH) and Lithium Ion (Li-ion), and most preferred are Li-ion batteries.
[0061] The battery can be provided in a “hot swap” configuration so that the electronics' data, wireless connections, etc., are preserved after the battery change. For example, prior to the hot swap a battery-powered dongle operating a firmware program may be plugged into one of the interface cavities. After being plugged in, the dongle sends a packet formatted according to the CAN protocol to the system processor indicating that its battery is about to be replaced with one having a full charge. The system processor receives the packet, and in response stores in non-volatile memory information that is normally not present when a device is initially powered on. Alternatively this information can be temporarily transferred for storage to a data buffer on an external network, or on non-volatile memory associated with the dongle. Once this is complete, the system processor can signal that the battery may be replaced. The depleted battery, located on the bottom side of the housing, can now be replaced with a charged battery. After this operation is complete the system processor can be returned to its configuration before the battery swap.
[0062] The “hot swap” configuration may not be suitable for IPX-7 standard waterproofing of the housing. Thus, in an alternative, the processor module itself may be swapped, rather than the battery within the module. In this scenario, a first processor module currently in use should transfer its store of data about the wearer to a second replacement processor module. Advantageously, a “bumping” action can be used to transfer this data. To initiate a transfer, a person accesses a special “data transfer” mode on the first and second processor modules. Then the first and second processor modules are brought into contact with one another using a sideways “bumping” action. Sensors (accelerometers) within each processor module sense the bump, and a matching algorithm pairs processor modules that detected the same bump (in terms of time and force). If and only if the bump is confirmed on the two processor modules will the data be exchanged. Following data exchange, the second processor module replaces the first processor module on the wrist-worn base of the wearer, and the first processor module is cleaned and recharged for later use. The matching algorithm may run locally on the processing modules themselves, or may run externally on a separate network. In the latter case, the processor modules would communicate the bump characteristics to the external network for processing.
[0063] Preferably, the electronics of the system support wireless transfer of data from the system to an external monitor or network. For relatively short distance RF communications, Bluetooth, Bluetooth LE, ANT+, HomeRF, IEEE 802.11x (e.g., IEEE 802.11a/b/g/n), and IEEE 802.15.4 are well known exemplary standard communications protocols that may be used. For somewhat longer range data transfers, cellular telephone protocols such as CDMA, TDMA, GSM, WAP, 3G (e.g., 3GPP, W-CDMA, TD-SCDMA, HSPA+, EVDO rev B, and CDMA2000), and 4G (e.g., LTE advanced, IEEE 802.16m) may be employed. These lists are not meant to be limiting. The electronics supporting wireless communication can be contained within the housing, or may be connected in a pluggable fashion through one of the interface cavities. Moreover, peripherals may also communicate with the system processor wirelessly rather than through a data cable connected to an interface cavity.
[0064] One skilled in the art readily appreciates that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The examples provided herein are representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention.
[0065] It will be readily apparent to a person skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
[0066] All patents and publications mentioned in the specification are indicative of the levels of those of ordinary skill in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
[0067] The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
[0068] Other embodiments are set forth within the following claims.
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The invention provides a physiological probe that comfortably attaches to the base of the patient's thumb, thereby freeing up their fingers for conventional activities in a hospital, such as reading and eating. The probe, which comprises a separate cradle module and sensor module, secures to the thumb and measures time-dependent signals corresponding to LEDs operating near 660 and 905 nm. The cradle module, which contains elements subject to wear, is preferably provided as a disposable unit.
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THE FIELD OF THE INVENTION
The present invention relates to closed-loop emission control apparatus for internal combustion engines which is operable in a clamped mode in the absence of the fluctuation of a sensed concentration of an exhaust emission, and in particular to such apparatus wherein the clamp mode is disabled during the start of the engine or deceleration.
BACKGROUND OF THE INVENTION
In a closed-loop emisson control system for internal combustion engines, the concenration fo of exhaust composition is detected to represent the mixture ratio of air-to-fuel combusted in the cylinder in a given cycle in order to control the mixture ratio in a subsequent cylinder cycle in such manner that the difference between the sensed ratio and a desired value is compensated. Conventionally, residual oxygen is sensed by a zirconium type oxygen sensor which provides an output having a sharp characteristic change in the vicinity of the stoichiometric air-fuel ratio. However, the conventional oxygen sensor is limited in performance by the temperature of the exhaust emissions. Therefore, it is sometimes the case that the output of the sensor remains at a low voltage level during the start of the engine or when fuel supply is cut off upon sudden deceleration of the engine. A similar situation occurs when the sensor should fail. With the sensor output being at the low or zero voltage level, the control signal would be such that an extremely rich mixture is supplied to the engine irrespective of the engine operating conditions.
A prior art emissiion control system utilizes the fluctuation of the sensed oxygen concentration due to the inherent transport delay time of the engine as a signal for determining the performance of the exhaust sensor. If the fluctuation ceases, a detector senses the absence of the fluctuation to clamp the air-fuel ratio to a constant value to prevent the mixture from becoming too rich or too lean. Although such clamping action is advantageous when the sensor should fail, it is disadvantageous during sudden deceleration and particularly when the engine is restarted after warm-up operation. Upon restart of the engine after warm-up operation, the mixture is leaned and the output of the exhaust gas sensor remains low so that the detecting circuit permits the clamping circuit to operate to cause the engine to run under an open loop control mode. Therefore, as long as the lean mixture condition exists the closed control operation is disabled generating noxious exhaust components to the atmosphere even though the gas sensor is working properly.
SUMMARY OF THE INVENTION
An object of the present invention is to provide emission control apparatus which is free from the above-mentioned disadvantage while assuring the clamping action when the exhaust composition sensor should fail.
Another object of the invention is to provide emission control apparatus which reduces the amount of noxious emissions when the engine operating condition is such that the sensor is adversely affected in performance.
A further object of the invention is to provide emission control apparatus which comprises a disabling circuit for disabling the clamping action while there exists such engine operating condition which would otherwise caused the exhaust sensor to produce low voltage signals over a prolonged length of time.
A still further object of the invention is to provide emission control apparatus in which means are provided to interrupt clamping action at intervals and the interruption is counted to determine whether the exhaust sensor has actually failed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the invention will be understood from the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a circuit diagram of an embodiment of the invention;
FIG. 2 is a circuit diagram of a modification of the embodiment of FIG. 1;
FIGS. 3 and 4 are circuit diagrams of a modification of the circuit of FIG. 2; and
FIG. 5 is a waveform diagram useful for describing the operation of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Emission control apparatus embodying the invention is shown in FIG. 1 comprising an exhaust composition sensor 10 disposed in the exhaust passage of an internal combustion engine 11 to detect the concentration of an exhaust composition, oxygen for example, in the emissions to generate an output having a sharp characteristic change in amplitude in the vicinity of the stoichiometric value of the air-fuel mixture. Such output characteristic is provided by a conventional zirconium type oxygen sensor wherein the output is high in amplitude at air-fuel ratios smaller than stoichiometric (rich mixture) and low in amplitude at ratios greater than stoichiometry (lean mixture).
The output of the exhaust composition sensor 10 is connected to the noninverting input of an operational amplifier (differential amplifier) 12 for comparison with a reference voltage on the inverting input thereof supplied from a voltage divider formed by resistors R1 and R2. The output from the amplifier 12 is a result of the comparison in the form of a positive polarity output when the sensor output is greater than the reference voltage and a negative polarity output when the situation is reversed.
The output from the operational amplifier 12 is connected to the inverting input of an integral controller formed by an operational amplifier 13 through resistor R3. Integration is provided by an integrating capacitor C1 coupled between the inverting input and output terminals of the operational amplifier 13 and the rate of integration is determined by the time constant value R3C1. The noninverting input of amplifier 13 is connected to a voltage divider.
The output of the integral controller 13 is connected through relay contact unit SW1 to air-fuel mixing and proportioning device 14 which may be a valve-operated carburetor or fuel injection type device. In response to the integrated output, the proportioning device 14 provides mixing and proportioning of air and fuel and supplies the mixture to the internal combustion engine 11. When the sensed oxygen concentration represents a mixture value leaner than stoichiometry, the integrator delivers an error correction signal that enriches the mixture. Conversely, when the sensed mixture is richer than stoichiometry, the direction of control is reversed so that the mixture is controlled at the stoichiometric value. A three-way catalytic converter 15 is disposed in the exhaust passage at the downstream side of the sensor 10 to provide simultaneous reduction of the noxious components, with its conversion efficiency being at a maximum when the mixture is controlled in the neighborhood of stoichiometry.
Since the oxygen sensor 10 is exposed to a high temperature environment, its characteristic is temperature dependent and its performance is liable to degradation with time. Particularly, when the engine is started or idled, the temperature of exhaust passage is relatively low and as a consequence the voltage output from the oxygen sensor does not faithfully represents the air-fuel mixture ratio.
Furthermore, it is to be noted that due to the transport delay time of the engine there is an inherent time lag in the control system in responding to the input control signal, and therefore control oscillation is normally present when the air-fuel mixture is controlled in a closed loop mode.
The output from the differential amplifier 12 is connected to a differentiator circuit 16 formed by capacitor C2 and resistor R4 coupled to ground. The junction point between capacitor C2 and resistor R4 is connected to the anode terminal of a diode D1, the cathode terminal of which is connected to the base electrode of a transistor T1, the collector and emitter of which are connected to a voltage supply Vcc through load resistor R5 and to ground, respectively. A storage capacitor C3 is connected to the cathode terminal of the diode D1 to be charged by the positive-poled differentiated signal to develop a voltage as an input to the base of transistor T1.
The transistor T1 is switched on when the storage capacitor C3 is discharged through resistor R11 and the voltage thereacross falls below a predetermined level to provide a low-level output to the base of a transistor T2 to turn it off. The turn-off of transistor T2 provides a high-voltage output on its collector connected through load resistor R6 to the voltage supply Vcc. Under this circumstance, transistor T3 will be switched on to draw current through a relay coil RL1 from voltage supply Vcc. The relay RL1 has its contact SW1 connected between the output of integral controller 13 and the input to the air-fuel mixing device 14. The relay contact SW1 is a transfer type contact which is arranged to permit the engine to operate in the closed loop mode when relay RL1 is not energized and permit the engine to operate in the open loop control mode by supplying a control voltage of suitable value from voltage supply +B to the air-fuel mixing device when relay RL1 is energized. In the open loop mode the system is clamped to a constant value irrespective of the sensed air-fuel ratio.
The collector of transistor T2 is also connected to the anode terminal of a diode D2, with its cathode terminal being connected to the base of transistor T4 through resistor R8. The diode D2 is in shunt with a resistor R7. Between the cathode terminal of diode D2 and resistor R8 is disposed a storage capacitor C4 coupled to ground which is charged when the diode D2 is forwardly biased by the high-level output at the collector of transistor T2 while the system is being clamped. Transistor T4 is switched on when the voltage across capacitor C4 reaches the threshold level of the pn junction of transistor T4. A transistor T5 is provided with its base connected to the collector of transistor T4 through resistor R9. To the base of transistor T5 is also connected a DC potential from voltage supply Vcc through normally open contact unit MS1. The contact unit MS1 is a manual switch to be operated by the vehicle driver. The contact Msl is operated to apply the biasing potential to the base of transistor T5 through resistor R13 to render the same to conduct irrespective of the conducting state of transistor T4.
The collector of transistor T5 is connected to the base of transistor T6, with its collector being connected through a relay coil RL2 to the voltage supply Vcc.
Between the storage capacitor C3 and the voltage supply Vcc is provided a clamp release circuit formed by a diode D3, a resistor R10 and a normally open switch contact SW2 which is operated to complete the clamp release circuit in response to the energization of the relay RL2 as indicated by broken lines 17. Diode D3 is connected in a sense to apply recharging potential to the storage capacitor C3 upon completion of the circuit.
In the operation of the circuit of FIG. 1, it is assumed in the first place that the oxygen sensor 10 is working properly so that the output from the operational amplifier 12 fluctuates above and below the reference value as the system oscillates as previously described. As long as the system oscillates, output is delivered from the differentiator 16 to charge the capacitor C3 to build up voltage thereacross which, upon reaching the predetermined voltage level, causes transistor T1 to turn off. Therefore, under normal operating conditions, transistor T1 is switched off and transistor T3 remains nonconductive and the output from the integral controller 13 is coupled to the air-fuel mixing and proportioning device 14.
During start-up or idling conditions, the output level of the oxygen R15. 10 remains at low voltage level and the capacitor C3 develops no voltage. This turns on transistor T1, turns off transistor T2 and then turns on transistor T3. Thus, relay RL1 is energized to operate it contact SW1 as shown in FIG. 5a and the system is clamped. The high potential at the collector of transistor T2 charges capacitor C4 through diode D2 (FIG. 5b) and biases transistor T4 into conduction. Transistor T5 is switched off, which in turn switches on transistor T6 to energize relay RL2. Switch contact SW2 is closed and capacitor C3 is charged through diode D3 (FIGS. 5c and 5d) so that transistor T1 is turned off resulting in the de-energization of relay RL1 to disable the clamped or open loop control mode. In response to the turn-off transistor T1, transistor T2 is turned on to provide a discharge path to the capacitor C4 so that transistor R4 is turned off and as a result relay RL2 is de-energized to open relay contact SW2. Capacitor C3 discharges its stored energy until transistor T1 is turned on whereupon transistor T2 is turned off to charge capacitor C4. This process will be repeated as long as the exhaust composition sensor 10 output remains and as a result the engine is operated in closed and open loop control modes in succession.
After the engine has warmed up, the exhaust sensor 10 becomes operational and generates a fluctuating voltage and transistor T1 is turned off to operate the system in a closed loop mode. If the sensor 10 has failed, pulses will be continuously generated from the collector of transistor T2.
To determine whether the oxygen sensor 10 has actually failed or simply becomes inoperative due to the low exhaust temperature during start-up or due to fuel cut-off under deceleration, a pulse counter 18 is connected to the connector of transistor T2 to respond to transitions of the engine operating condition between closed and open loop modes to generate an output when a predetermined number of such transitions are counted as an indication that the sensor 10 has failed. The output signal from the counter 18 activates an indicator 19 to alert the vehicle occupant, who is response to the indication would actuate the switch MSl. Transistor T5 is turned on to turn off transistor T6 so that recharging action for capacitor C3 is discontinued and relay RL1 is operated to clamp the control system.
If the predetermined count has not been reached in the counter, no indication will be provided and the system will assume its normal oscillatory control action as described before, and the capacitor C3 will be charged up to turn off transistor T1 and relay RL1 will thus remain de-energized (FIG. 5d).
When the system is allowed to operate in the closed loop mode in response to the charging of capacitor C3 in the absence of a valid control signal from the gas sensor 10, the integrator 13 will provide a correction signal so that the mixture is automatically enriched, which results in the mixture osciollating about the desired value and capacitor C3 is charged up to cause the system to remain in the closed loop control mode. Therefore, upon restart of engine after warmup operation, the engine is automatically operated under the closed loop mode even though the air-fuel mixture is leaned.
By intermittent disabling of the clamping action, the disadvantage as encountered with the prior art apparatus during the restarting of the engine after warm-up operation, is successfully eliminated.
In a modification of the circuit of FIG. 1 shown in FIG. 2, the comparator 12 of FIG. 1 is replaced with a circuit 20 which includes operational amplifiers 21 and 23. Amplifier 21 has its noninverting input connected to the output of oxygen sensor 10 and its inverting input connected to a reference voltage. The output of the amplifier 21 is connected to an RC filter 22 including a resistor R14 and a capacitor C5. Through resistor R14 the amplifier 21 output is connected to the inverting input of the operational amplifier 23 whose non-inverting input is connected to the output of amplifier 21 through connection 24. The operational amplifier 21 acts as a differential amplifier to compare the sensed oxygen concentration with a reference value. The output from amplifier 21 is smoothed out by the filter 22 so that the voltage developed across capacitor C5 represents a mean value of the fluctuating output of the amplifier 21. If the operating performance of the oxygen sensor 10 should change or deteriorate with time, the fluctuating range of the amplifier 21 is affected and the mean value of the amplifier 21 output will settle at a new value. The mean value serves as a reference level for the operational amplifier 23 which compares it with the fluctuating output from amplifier 21. therefore, the circuit 20 has a self-compensating function to compensate for the aging of the exhaust composition sensor 10.
To the junction point between resistor R14 and capacitor C5 of filter 22 is connected the base of a transistor T7 which senses the voltage developed across the capacitor C5 and switches on when the capacitor voltage falls below a predetermined value. The emitter of transistor T7 is connected to the base of transistor T8 to turn if off when transistor T7 is conducting. The collector of transistor T8 is connected on the one hand to the base of transistor T9 and also to the base of transistor T10. When transistor T8 is conducting, transistors T9 and T10 are turned off. Thus, transistor T9 is made conducting when the capacitor C5 has discharged. A relay coil RL3 is connected to the collector of transistor T9. The relay RL3 has its contact SW3 disposed in the output of integrator 25 and acts in a manner identical to the relay RL1 of the previous embodiment so that upon energization contact unit SW3 is operated to clamp the control loop.
The collector of transistor T10 is connected to the base of transistor T11 whose collector is connected to a monostable multivibrator 26. A manual switch MS2 is connected between the base of transistor T11 and the voltage supply Vcc to forwardly bias the transistor T11 into conduction when manually operated. The monostable multivibrator 26 is activated to produce a pulse of a predetermined duration in response to the switching off of transistor T11 when the control loop is clamped. The monostable multivibrator 26 activates a transistor T12 for the period of the pulse duration to energize a relay coil RL4 coupled to the collector thereof. The relay RL4 has its contact unit SW4 disposed in a recharging circuit connected to the capacitor C5 and the voltage supply Vcc. The recharging circuit includes a diode D4, resistor R15 and the relay contact SW4 connected in series, the operation of the recharging circuit being identical to the recharging circuit of FIG. 1.
In operation, the low voltage condition of exhaust composition sensor 10 discharges capacitor C5 to turn on transistor T7 to clamp the control loop. Simultaneously, monostable multivibrator 26 is activated to energize relay RL4 for the period of the monostable to complete the recharging circuit. Capacitor C5 is recharged so that transistor T7 is turned off so that relay RL3 is released. As long as the low voltage condition exists, the control system is clamped at intervals in a manner identical to the previous embodiment, the collector of transistor T8 delivers a train of pulses to the counter 18.
FIG. 3 illustrates another embodiment of the invention in which identical numerals are used to indicate identical parts to those used in FIG. 2. In this embodiment, a manually operated start switch MS3 is provided to turn on transistor T13 in a clamp release circuit 30. To the collector of transistor T13 is connected a monostable multivibrator 31, which is activated in response to a high voltage output at the collector of transistor T13 when the switch MS3 is released. The pulse output from monostable 31 is used to activate transistor T14, to the collector of which is connected a relay RL5 having its contact unit SW5 disposed in the recharging circuit comprised by diode D4 and resistor r15. The recharging circuit will thus be completed to charge capacitor C5 in response to the release of the switch MS3. When switch MS3 is operated as the engine is started, the capacitor C5 will be charged and transistor T7 turns off to prevent relay RL3 from being energized so that the control loop is prevented from being clamped during the period of the monostable 31.
Alternatively, the clamp release circuit 30 may be replaced with a circuit 40 shown in FIG. 4, in which identical parts are designated by the same numerals as used in the FIG. 3 circuit. A capacitor C6 is connected between the emitter of transistor T15 and ground. When switch MS4 is operated to turn on transistor T15, capacitor C6 is charged to develop a biasing voltage for transistor T16 with its collector connected to the base of transistor T17 which in turn has its collector connected to the base of transistor T14. The turn-on of transistor T15 results in turn on of transistor T14 to energize relay RL5. When switch MS4 is released transistor T15 is turned off to allow capacitor C6 to discharge through resistor R16. Upon the biasing potential of transistor T16 falling below its conducting threshold, transistor T17 is turned on to turn off transistor T14. Thus capacitor C6 and resistor R16 constitute a delay element and relay RL5 remains operated for a duration commencing with the operation of switch MS4 to the time the capacitor C6 has discharged.
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Emission control apparatus for internal combustion engine includes an exhaust composition sensor to sense the mixture ratio, a circuit for clamping the mixture ratio to a predetermined constant value to prevent the mixture from becoming too rich or too lean when a failure should occur in the control loop, for example, in the exhaust composition sensor fail and a circuit for interrupting the clamping circuit when the engine operating condition is such that the sensor is caused to produce low voltage signals although the sensor is functioning properly.
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PRIORITY CLAIM
The present application is a Continuation application of U.S. patent application Ser. No. 11/240,124 filed on Sep. 30, 2005 entitled “System and Method for Automated Titration of Continuous Positive Airway Pressure Using an Obstruction Index” which (a) claims priority to U.S. Provisional Patent Application Ser. No. 60/618,969 filed on Oct. 15, 2004 entitled “ System and Method for Automated Titration of Continuous Positive Airway Pressure Using an Obstruction Index ” and (b) is a Continuation-in-part of U.S. patent application Ser. No. 10/862,067 filed on Jun. 4, 2004, the entire disclosures of these applications are expressly incorporated herein by reference.
BACKGROUND
Obstructive sleep apnea/hypopnea syndrome (OSAHS) is a well recognized disorder which may affect as much as 1-5% of the adult population. OSAHS is one of the most common causes of excessive daytime somnolence. OSAHS is most frequent in obese males, and it is the single most frequent reason for referral to sleep disorder clinics.
OSAHS is associated with conditions in which there is anatomic or functional narrowing of the patient's upper airway, and is characterized by an intermittent obstruction of the upper airway during sleep. The obstruction results in a spectrum of respiratory disturbances ranging from the total absence of airflow despite continued respiratory effort (apnea), to significant obstruction with or without reduced airflow (hypopnea, episodes of elevated upper airway resistance, and snoring). Morbidity associated with the syndrome arises from hypoxemia, hypercapnia, bradycardia and sleep disruption associated with the respiratory obstructions and arousals from sleep.
The pathophysiology of OSAHS is not fully worked out. However, it is now well recognized that obstruction of the upper airway during sleep is in part due to the collapsible behavior of the supraglottic segment of the respiratory airway during the negative intraluminal pressure generated by inspiratory effort. The human upper airway during sleep behaves substantially similar to a Starling resistor which by definition limits the flow to a fixed value irrespective of the driving (inspiratory) pressure. Partial or complete airway collapse can occur associated with the loss of airway tone, which is characteristic of the onset of sleep and may be exaggerated with OSAHS.
Since 1981, positive airway pressure (“PAP”) applied by a tightly fitted nasal mask worn during sleep has evolved to become the most effective treatment for this disorder, and is now the standard of care. The availability of this non-invasive form of therapy has resulted in extensive publicity for sleep apnea/hypopnea and increased appearance of large numbers of patients who previously may otherwise avoid medical treatment because of the fear of tracheotomy. Increasing the comfort of the system (e.g., by minimizing the applied nasal pressure) has been a major goal of research aimed at improving patient compliance with therapy.
PAP therapy has become the mainstay of treatment in Obstructive Sleep Disordered Breathing (“OSDB”), which includes Obstructive Sleep Apnea/Hypopnea, Upper Airway Resistance Syndrome, Snoring, exaggerated rises of sleep-induced collapsibility of the upper airway and all conditions in which inappropriate collapsing of a segment of the upper airway causes significant non-physiologic obstruction to airflow. Collapse of a portion of the airway generally occurs whenever pressure in the collapsible portion of the airway becomes sub-atmospheric. Stated another way, collapse occurs when pressure in the airway falls below a “tissue pressure” in the surrounding wall. PAP therapy is directed to maintaining pressure in the collapsible portion of the airway at or above the critical “tissue pressure” at all times. This goal is achieved by raising the airway pressure in the entire respiratory system to a level higher than this critical pressure.
Despite its success, conventional PAP systems have certain limitations. For example, the determination of the appropriate pressure for therapy, referred to as PAP titration, is normally performed in a sleep laboratory where a specific treatment pressure is determined. However, during the first week of treatment the necessary pressure to treat the OSDB may decrease, which results in a prescribed pressure that is too high and may compromise patient compliance. In addition, the patient may assume body positions or sleep stages, other than those occurring in the sleep laboratory that may change the therapeutic pressure. Finally, patients may require periodic retitration following changes in condition, such as weight gain or loss. Retitration of the PAP in the laboratory is usually expensive and is not part of the usual standard of care. Thus, there is a need for a system and method that would provide initial PAP titration and retitration to patients as required during subsequent treatments.
SUMMARY OF THE INVENTION
The present invention relates to a system including an air pressure supply arrangement, a sensor and a titration device. The air pressure supply arrangement provides air pressure to a patient's airways. The sensor detects input data corresponding to a patient's breathing patterns of a plurality of breaths. The titration device receives and analyzes the input data to determine existence of breathing disorder and corresponding characteristics. The titration device generates output data for adjusting the air pressure supplied to the patient as a function of an index of abnormal respiratory events included in the input data.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a waveform of airflow from a sleeping patient in a 30 second epoch when subjected to a substantially constant PAP pressure of 10 cm H 2 O;
FIG. 2 shows a waveform of airflow from a sleeping patient in a 30 second epoch when subjected to a substantially constant PAP pressure of 8 cm H 2 O;
FIG. 3 shows a waveform of airflow from a sleeping patient in a 30 second epoch when subjected to a substantially constant PAP pressure of 6 cm H 2 O;
FIG. 4 shows a waveform of airflow from a sleeping patient in a 30 second epoch when subjected to a substantially constant PAP pressure of 4 cm H 2 O;
FIG. 5 shows a waveform of airflow from a sleeping patient in a 30 second epoch when subjected to a substantially constant PAP pressure of 2 cm H 2 O;
FIG. 6 shows an exemplary embodiment of a system according to the present invention;
FIG. 7 shows an exemplary embodiment of a method according to the present invention;
FIG. 8 shows graphically indices of obstruction sleep disordered breathing as a function of pressure deviation from a therapeutic pressure;
FIG. 9A shows graphically an apnea/hypopnea index at different CPAP levels;
FIG. 9B shows graphically an obstruction index according to the present invention at different continuous positive airway pressure levels;
FIG. 10 shows graphically a correlation between a subjective sleepiness measure and an obstruction index according to the present invention and a correlation between an apnea/hypopnea index and an obstruction index according to the present invention; and
FIG. 11 shows graphically a correlation between psychomotor vigilance task lapses and an obstruction index according to the present invention and a correlation between a fatigability and an obstruction index according to the present invention.
DETAILED DESCRIPTION
FIGS. 1-5 illustrate waveforms of flow from a PAP generator, obtained during the testing of a patient in sleep studies. In these tests, the patient was wearing a PAP mask connected to an air source, for example, in the manner illustrated in U.S. Pat. No. 5,065,765, the entire disclosure of which is hereby incorporated by reference. Each of these tests illustrates an epoch of 30 seconds, with the vertical lines depicting seconds during the tests. FIGS. 1-5 depict separate sweeps taken from 1 to 2 minutes apart, and with different pressures from the source of air.
FIG. 1 illustrates a “normal” waveform, in this instance with a Continuous Positive Airway Pressure (“CPAP”) of 10 cm H 2 O. Although this description uses a CPAP system to illustrate the system and method according to the present invention, those skilled in the art will understand that this invention is equally useful in conjunction with any variety of PAP systems supplying constant or varying pressure to patients. However, any other pressure identified as corresponding to apnea free respiration may also be used. It is noted that this waveform, at least in the inspiration periods, is substantially sinusoidal. The waveforms of FIGS. 2-5 illustrate that, as the controlled positive pressure is lowered, a predictable index of increasing collapsibility of the airway occurs, prior to the occurrence of frank apnea, periodic breathing or arousal.
When CPAP pressure is decreased to 8 cm H 2 O, as illustrated in FIG. 2 , a partial flattening of the inspiratory flow waveform, at region 2 a , begins. This flattening becomes more definite when the controlled positive pressure is decreased to 6 cm H 2 O, as seen in the region 3 a of FIG. 3 . The flattening becomes even more pronounced, as seen in the region 4 a of FIG. 4 , when the controlled positive pressure is reduced to 4 cm H 2 O. These reductions in the CPAP pressure from the pressure of apnea free respiration, result in, for example, snoring or other signs of patient airway obstruction. When the CPAP pressure is further reduced to 2 cm H 2 O, as illustrated in FIG. 5 , inspiratory flow may decrease to a virtually zero level during inspiratory effort, as seen in the region 5 a . Shortly after the recording of the waveform of FIG. 5 , the patient in the example developed frank apnea and awoke.
FIG. 6 shows an exemplary embodiment of a system 1 according to the present invention. The system 1 may include a mask 20 that is connected via a tube 21 to receive airflow at a particular pressure from a flow generator 22 or any other suitable airway pressure supply system. The amount of pressure provided to a particular patient varies depending on that patient's particular condition.
The mask 20 may cover the patient's nose and/or mouth. However in other exemplary embodiments according to the present invention, the mask 20 is a nasal cannula. Conventional flow and/or pressure sensors 23 are coupled to the tube 21 to detect the volume of the airflow to and from the patient and the pressure supplied to the patient by the generator 22 . The sensors 23 may be internal or external to the generator 22 . Signals corresponding to the airflow and the pressure from the sensors 23 are provided to a processing arrangement 24 . The processing arrangement 24 generates pressure control outputs signals to a conventional flow control device 25 that controls the pressure applied to the flow tube 21 by the flow generator 22 . Those skilled in the art will understand that, for certain types of flow generators which may be employed as the flow generator 22 , the processing arrangement 24 may directly control the flow generator 22 , instead of controlling airflow therefrom by manipulating a separate flow control device 25 .
The system 1 may also include a venting arrangement 28 which allows for gases exhaled by the patient to be diverted from the incoming air to prevent re-breathing of the exhaled gases. In an alternative exemplary embodiment of the present invention, the system 1 may include a further sensor 29 situated at or near the mask 20 . The further sensor 29 is connected to the processing arrangement 24 and provides data regarding the airflow and the pressure in the mask 20 to the processing arrangement 24 .
Those skilled in the art will understand that the system 1 may be utilized for the purpose of detecting abnormal respirations and flow limitations in the patient's airway. Alternatively, the system 1 may be utilized for detection of sleeping disorders (e.g., flow limitations), autotitration and treatment of such sleeping disorders.
The system 1 also includes an automatic titration device 26 which provides an initial titration (i.e., determination of an appropriate pressure or an appropriate varying pressure function for a particular patient) as well as subsequent retitrations. The titration device 26 may be a portable device which is attachable (e.g., using convention wired or wireless techniques) to the processing arrangement 24 when it is necessary to obtain appropriate pressure for the PAP therapy or to update previously calculated pressures. Those skilled in the art will understand that the titration device 26 may be attached to any conventional PAP therapy system. Alternatively, the titration device 26 may be built into the system 1 (e.g., the titration device 26 may be combined with the processing arrangement 24 ).
FIG. 7 shows an exemplary method according to the invention for automatic titration to determine an appropriate pressure or varying pressure function for the PAP therapy. In step 700 , the titration device 26 is activated, e.g., (a) by powering the titration device 26 if it is a part of the processing arrangement 24 or (b) by connecting the titration device 26 , if it is a stand-alone unit, to the processing arrangement 24 . Since it may not be necessary to perform titration on a daily basis, the titration device 26 may be activated by the patient or medical personnel initially to obtain appropriate data for calculation of the pressure or pressure function for the PAP therapy. The titration device 26 can be again activated at such times as may be determined are desired to retitrate to ensure the PAP therapy is properly tailored to the patient's current condition. The activation process may be performed immediately prior to initiation of the PAP therapy or may be preset to automatically activate at predetermined points, such as days and/or times.
Once activated, the titration device 26 may remain active for a predetermined period of time. For example, the titration device 26 may remain active for a specific period of time (e.g., a single sleeping cycle of 6-8 hours) or until it is manually deactivated. While active, the titration device 26 may work in the background processing and analyzing data collected by the processing arrangement 24 (step 702 ) without interfering with the PAP therapy. In particular, the processing arrangement 24 transmits data to the titration device 26 data which includes, among other information, the patient's airflow and the pressure applied to the airways of the patient. Such data may be provided continuously or periodically (e.g., every hour). Alternatively, the titration device 26 may be programmed to update immediately the PAP treatment under predetermined conditions.
The data collected by the titration device 26 may be stored in a database with, for example, data related to each particular patient collected during various titration procedures. Or, collected data may be stored together so that the data from several titration procedures may be accessed and analyzed by the titration device 26 to determine appropriate pressure controls for that patient. For example, the data may be stored on a removable memory arrangement which may be kept by the patient and provided to the titration device 26 each time the titration procedure for this patient is initiated. Alternatively, data for multiple patients may be stored in corresponding files of a single memory arrangement. Those skilled in the art would understand that the single memory arrangement may be a part of the system 1 ; alternatively, the single memory arrangement may be situated at a remote location that can be accessed via a communications network (e.g., the Internet, VPN, etc.).
In step 704 , the titration device 26 analyzes the collected data. In particular, data relating to patient airflow is utilized to accurately map patient's breathing patterns. The titration device 26 analyzes these breathing patterns to detect abnormal respiratory events and to identify the conditions under which they arise. Abnormal respiratory events that may be identified include apnea, hypopnea and events of elevated upper airway resistance. Apnea is identified by a cessation of respiratory airflow in the patient, where the cessation can last, for example, approximately ten seconds. Hypopnea is identified by a decrease in amplitude of the airflow signal relative to a baseline value, where the decrease can last, for example, approximately ten seconds. Elevations in the resistance of the upper airway may be identified by changes in the shape of the inspiratory airflow contour. The airflow signal from the entire collection period may be analyzed for the presence of sleep disordered breathing events.
In step 706 , based on the analysis of respiratory events, the titration device 26 determines, using a predefined algorithm, an appropriate pressure or a varying pressure function to be supplied to the patient. The counts and other indexes of respiratory events (e.g., a total time of abnormal respiration, a percentage of abnormal breath, total number of events in general and by type, etc.) that occurred during the previous collection period indicate the efficacy of the pressure administered. When the count or index increases to beyond a preset absolute value or relative value (e.g., compared to previous values for that patient) the pressure may be increased for the next CPAP period. If the number of events is below a preset value then the pressure may be decreased for the next predefined time period. In addition, the response to previous pressure decreases may also be incorporated into the pressure determination algorithm. For example, the titration device 26 may determine that a constant pressure supplied to the patient needs to be increased if a number of abnormal events identified reaches a threshold within a specified time period (e.g., when number of apneas, hypopneas or elevated resistance events exceeds the preset limit or increases by a specified amount above the previous values for the patient).
Alternatively, the supplied pressure may need to be decreased or remain unchanged if no abnormal respiratory events are detected or if the number detected is less than the threshold level. If the titration device 26 is used to adjust a variable pressure supplied to a patient, those skilled in the art will understand that, based on the number of abnormal events identified and the circumstances under which they occurred, any number of modifications of the pressure supply function may be initiated. For example, if a pressure supplied to the patient varies substantially sinusoidally, an average value or an amplitude of the pressure may be adjusted.
In a preferred embodiment of the present invention, the titration device 26 determines the appropriate pressure or a varying pressure function to be supplied to the patient using a unique obstruction index (“OI”). Embodiments of the OI according to the present invention combine several indices of elevated resistance, such as snoring and flow limitation (“FL”), into one number. One embodiment of the OI includes the sum of the apnea/hypopnea index (“AHI”), the number of discrete (e.g., 10-120 seconds) FL events per hour, and an amount of time in sustained (e.g., greater than 2 minutes) FL.
The validity the OI was evaluated in a study of 4 patients previously diagnosed with OSAHS. The patients were monitored in their homes for multiple nights (mean 19 nights, range 10-32 nights) at different levels of CPAP, while pressure and airflow were continuously monitored. Changes in collapsibility were produced in patients with OSAHS by varying an applied nasal CPAP. CPAP was varied 1-3 cm H 2 O above and below the patient's prescription pressure as previously obtained from an in-lab titration. Several indices of obstructive SDB were calculated including: a traditional AHI, the OI (as described above), and a respiratory disturbance index (“RDI”).
The AHI was calculated as the sum of apneas and hypopneas per hour and was based on airflow amplitude changes >50%. The OI was calculated as the sum of all obstructive events <2 mins+⅓ of the time spent with breaths showing abnormal morphology of flow (e.g., time spent in sustained FL). The abnormality (flow limitation) was associated with a high upper airway collapsibility (resistance). The justification for the factor of ⅓ was that when this formula for calculating OI is applied to a normal subject with minimal AHI and with sustained flow limitation only, the OI value had to be below 15. As one of ordinary skill in the art will understand however, the factor may be adjusted up or down to reflect additional received data.
FIG. 8 shows graphically each calculated index as a function of pressure deviation from the therapeutic pressure. As shown, all indices were low above the prescription pressure. However, up to 3 cm below this pressure, AHI remained flat. RDI rose above 5 but did not vary with CPAP. In contrast, both sustained FL and OI increased sharply below therapeutic pressure and are inversely related to CPAP. The present analysis assumes a difference between therapeutic and subtherapeutic CPAP exists. The study showed that the OI according to the present invention can detect changes in the pattern of SDB that are produced by increased levels of the collapsibility and upper airway resistance (by lowering CPAP) that are masked when the AHI alone is used. AHI and RDI are not as sensitive to these differences as the OI and sustained FL. Although the sustained FL % works well in this range of pressures, it can fall markedly whenever the AHI is elevated (as in the diagnostic night) and thus the OI has a conceptual advantage.
FIGS. 9A and 9B show variability in the AHI and OI, respectively, at different CPAP levels. The difference between the actual pressure delivered and the prescribed CPAP pressure is plotted on the x-axis (delta CPAP) against the AHI or the OI on the y-axes wherein each symbol represents one subject. The mean value of each index over multiple nights of recording at that pressure along with the range at that pressure is plotted. Note that the AHI was <5 per hour at all pressures on all nights, which would have been considered therapeutic. The OI shows significant variability at pressures below the patients prescribed therapeutic pressure and captures the changes in sleep disordered breathing at sub-therapeutic pressures.
Current clinical definitions for adequacy of CPAP or other therapeutic modalities generally use an AHI values less than 5/hour as optimal. The disclosed data suggests that use of this cutoff could result is significant residual obstruction as seen in the OI, and could potentially contribute to residual sleepiness in subjects who are thought to be on therapeutic levels of CPAP based on their AHI.
In the disclosed study, pilot data was obtained in subjects with OSAHS (n=9) who underwent psychomotor vigilance task (“PVT”) testing following a night of nocturnal polysomnography (“NPSG”) in a lab. NPSG data was also obtained in 5 normal volunteers/snorers, without PVT. Subjective sleepiness measures (e.g., an Epworth Sleepiness Scale or “ESS”) were obtained in all subjects and an OI was calculated as described above.
FIG. 10 shows that a good relationship between the ESS and the OI was obtained in all subjects (r 2 =0.75). The relationship of ESS to AHI was also good in this small group (r 2 =0.64), however there is no variability in AHI values closer to zero. The PVT data obtained in the patients shows a good correlation between the obstructive SDB index and the PVT lapses (transformed) and fatigability. Thus, the OI correlates to outcomes of subjective sleepiness (ESS) and objective daytime function measured by the PVT.
As described in reference to the disclosed study, the titration device 26 of the system 1 may analyze data collected during, e.g, a predetermined time period. For example, the predetermined time period may be a single sleeping cycle such as one night of observation. Alternatively, or in addition, the predetermined time period may be a portion of the single sleeping cycle such as one or two hours of observation. The pressure may be adjusted for the subsequent time period. For example, the pressure may be adjusted once per hour in response to events occurring during the previous hour.
The titration process may then be repeated during the subsequent time period using the adjusted pressure to evaluate the efficacy of the adjusted pressure. Thus, over a several time periods, the titration process may be repeated to enhance the accuracy with which the appropriate pressure is determined. In an alternative embodiment, the titration device 26 may be adapted to continually collect data for the entire duration of the treatment so that the titration process is continuously updated.
As described above, the titration device 26 according to the present invention may be manufactured as a portable stand-alone unit. Such a unit may be easily attached to most conventional therapy systems by positioning the device in the flow path, parallel to the patient and the flow generator 22 . If the generator 22 were externally controllable (e.g., by a serial interface), then the titration device 26 may be connected to an external control. Alternatively, a variable pressure valve could be incorporated into the stand-alone unit to control the pressure directly. The valve can mitigate the cost of a therapy system since the patient may rent the titration device 26 only when titration is necessary.
The system 1 may determine appropriate pressures by adjusting pressure only at the beginning of a sleeping cycle and by operating over the course of several sleeping cycles to arrive at a more accurate image of the patient's breathing patterns. For example, some patients may have “good” or “bad” nights which may not be representative of an “average” night for the patient. In contrast, conventional automatic titrating systems may generate immediate feedback responses to the abnormal respiratory events from which they attempt to determine a single therapeutic pressure. Conventional titration systems generally obtain data only during a single sleeping cycle, since multiple visits to sleep clinics, where these systems are located, are unlikely. Furthermore, the more accurate the pressure supplied to a particular patient, the more likely the patient will regularly make use of this PAP therapy.
Another advantage of the present invention is that it may also be used in ongoing treatment of OSDB patients with varying pressure needs. In these cases, the titration device 26 is connected to the PAP therapy system continually so that the pressure supplied may be constantly adjusted by retitration.
In the preceding description, the present invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broadest spirit and scope of the present invention.
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Described is a system including an air pressure supply arrangement, a sensor and a titration device. The air pressure supply arrangement provides air pressure to a patient's airways. The sensor detects input data corresponding to a patient's breathing patterns of a plurality of breaths. The titration device receives and analyzes the input data to determine existence of breathing disorder and corresponding characteristics. The titration device generates output data for adjusting the air pressure supplied to the patient as a function of an index of abnormal respiratory events included in the input data.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to expert systems and knowledge management and, more particularly, to systems and methods for assisting an operator where real-time support and automatic decision-making may be required.
[0003] 2. Background and Related Art
[0004] It is known in the art that an expert system is a computer program intended to embody the knowledge and the ability of a human expert in a certain domain.
[0005] The objective of an expert system is to resolve a problem or give advice to resolve it. It can be, for instance, a system to answer a question from a non-expert user, or to react to an event. Generally, an expert system requires knowledge and data. Knowledge contains a set of rules that act upon data to accomplish the objectives of the system. Data represents facts and information concerning the specific domain for which the expert system runs. When reacting to an event, an expert system must respond reliably and quickly to treat the ongoing situation. This is particularly true when situations are continually changing. The expert system detects the event and determines the applicable actions in accordance to the class of the event and/or the circumstance in which the event appears. Then, the expert system evaluates the effects of its selected action and quickly initiates the event response mechanisms accordingly. Actual expert systems provide a solution to respond to a specific circumstance if the scenario exists. The computer normally applies heuristics and rules in a knowledge-specific domain to render advice or make recommendations, much like a human expert would. Expert systems have managed to achieve fairly a high level of performance in task areas that require a good deal of specialized knowledge and training. Often they perform tasks that are complex, tedious, or expensive to have a non-expert human perform.
[0006] Event Management Systems used to monitor and manage data centers work like “event expert systems”, specialized in the management of data center events. They receive events that they must analyze and to which they must react according to rules. To work effectively, they have their own representation of the environments they must monitor, through a data model like the one provided by the standard Common Information Model (CIM), describing the detailed information needed to monitor systems, networks and applications.
[0007] The Common Information Model (CIM) is an open standard that defines how managed elements in an Information Technology (IT) environment are represented as a common set of objects and relationships between them.
[0008] However, present event expert systems only manage events for which proven solutions exist and do not permit convenient management of an unexpected or unknown event (i.e. one that occurs for a first time) and/or recurrent events reappearing after event screening. The detection of such unresolved events triggers alerts to the operator console. In that sense, an alert is an event that could not be resolved by the event expert system.
[0009] Managing alerts differ from managing an event. Data models, such as the one provided by CIM for IT environments, are useless to IT operators in managing alerts. IT operators have, indeed, their own representation of the environment being monitored, made of other concepts. For instance, IT operators usually don't handle detailed technical information like IP addresses, but use rather the name of the application and the customer to identify the resolution action to be taken. IT operators, therefore, need a certain degree of common sense to interpret the information carried by the alert, to identify it unambiguously and finally, to make the correct decision. Failure to monitor addressing alerts can jeopardize system performance and management of the environment, particularly when monitoring data centers. The purpose of a data center is to host and run applications that handle the business (be it a core or a secondary business) and data of the organization, like operational data and/or decisional data and/or transient and/or audit data and so on.
[0010] Generally, a data center contains a set of servers, storage, firewalls, routers and switches that transport traffic between the servers and to/from the outside world. Some of the applications are composed of multiple components (like file servers, application servers, database servers and the like) running on multiple hosts. Some applications also make use of several infrastructure servers (e,g., LDAP, mail relays, load balancers). A complex modem data center hosts infrastructures made of shared, clustered and/or virtualized systems running multiple applications (such as ERP packages) and subsystems (such as database instances or transactions managers) for multiple customers, geographically dispersed, supported by multiple teams of systems engineers. In such an environment, subsystems do not always run on the same dedicated host, and every subsystem could serve several applications for several customers. Operators have to deal with this challenging complexity when analyzing and handling alerts issued from data centers.
[0011] Normally, when a recognized event occurs, the event expert system (e.g., an Event Management System monitoring the data center) manages it at the system level only, without interaction with the rest of the environment.
[0012] Unlike events, alerts need a human intervention. When the event expert system triggers an alert to the operator console, the alert is interpreted out of the system level by the operator, and is handled by some appropriate recovery actions.
[0013] The recovery actions consist in editing any of the alert messages before implementing a solution and cancelling them all, if necessary. To achieve this, the operator uses console procedures.
[0014] The operator starts certain tasks to recover the alert error by applying some recovery concepts provided from an operator step-by-step guide or the operator involves the assistance of a predefined set of decisions described in the guide emphasizing the actions to be run. Those skilled in the art will perceive numerous action support for assisting the operator all along the recovery process task.
[0015] Depending on the complexity of the data center, various different alert errors can potentially appear simultaneously, some of them can be unknown to the operator and/or not clearly indexed when searching an adequate solution in the operating manual. In addition, the alert message and the solution provided by the operating manual may be subject to interpretation that represents a risk about the solution assessment. Moreover, the adopted solutions may be subject to uncertainty about the underlying alert error that the operator tries to examine, since some of them may be obsolete because of new technology systems. Thus, it may be impossible to respond rapidly to the alert error and the action attempted may no longer be relevant.
[0016] To summarize, the aforementioned methods present several drawbacks. For example:
[0017] The information carried by alerts issued from an Event Management System does not match the concepts used by operator's reasoning.
[0018] Existing alert recovery makes difficult the process of finding out what the problem is and what to do about it.
[0019] Existing operating manuals present a risk about the identification of an alert and the solution assessment when used in a complex data center.
[0020] The solution presented by the operating manual may be obsolete when an unknown alert error is generated. The operating manual contains documentation to help identify an alert (such as, for example, the DB instance ‘xx’ on the IP address ‘zz’ runs for the customer ‘cc’). When a system arrangement moves from one configuration to another one, the operating manual may become quickly obsolete and thus does not reflect the organization changes. Thus, a well known alert may be transformed into an unknown alert that needs to be handled.
[0021] The action attempted is often no longer relevant in a case of paramount necessity and emergency.
[0022] There is no adequate assistance given to the operator when multiple alert errors appear simultaneously that slow down the process of identifying the alert, finding the solution procedure, and applying the solution.
[0023] These drawbacks are made worse in a virtualized environment, where the resources are shared among several applications and customers, thereby making the data center more complex to manage and monitor.
[0024] The present invention offers solutions to solve the aforementioned problems. Such solutions will be more apparent in the following description.
SUMMARY OF THE PRESENT INVENTION
[0025] Accordingly, a first object of the present invention is to provide a system and a method for assisting an operator, particularly where challenging real-time automatic decision-making is required.
[0026] It is a second object of the present invention to provide step-by-step methods and techniques for the automatic handling of addressing alerts issued from a system in order to manage the resources belonging to a complex data center.
[0027] It is a further object of the present invention to identify, unambiguously, alerts and take the appropriate actions using a generic data model representing the information and concepts needed by various kind of operators. It targets operators like system watchers and/or help desks and/or inexperienced system administrators and/or in general, any non-expert users not knowledgeable in the systems being monitored. The invention described herein is intended for operators as defined above.
[0028] Another object of the present invention to automate decision-making and actions of an operator by using a conceptual generic data model representing all information that an operator (or any replacing tool) must have.
[0029] It is also an object of the present invention to assist the operator in editing alert messages without ambiguity using a conceptual generic data model
[0030] Likewise, it is an object of the present invention to provide the operator with some knowledge management features, when alert handling cannot be automated.
[0031] Yet another object of the present invention is to offer the ability to implement a specialized version of the generic data model that fits with a specific data center implementation.
[0032] A further object of the present invention is to provide a system having the ability to automatically derive the specialized version of the generic data model adapted to a specific data center.
[0033] According one embodiment of the invention, there is provided a method for controlling the decision-making of an operator, the method comprising the steps of:
implementing a generic conceptual data model into an expert system; automatically adding constrains on the generic data model to make it a specialized model adapted to a specific data center environment; enriching information carried by alerts; and automating the actions of the operator.
[0038] Therefore, it is an object of the present invention to analyze automatically the environment that needs to be monitored, and to define a framework for intelligent alert management that is autonomous, self-adaptive and portable across data centers.
[0039] Finally, it is an object of the invention to offer a system and method adaptable to any existing and running Event Expert System (those expert systems that do system management and monitoring in data centers) without having to redefine or rewrite the system configuration.
[0040] According to the invention, there is provided a method, system and program storage device as further described in the appended independent claims. Particularly, a method for automating alert decision-making in a computer network is disclosed. The method comprises the steps of:
receiving an alert request; associating the received alert request to a generic conceptual data model of alert request and alert resolution and using a set of inference rules to construct a personalized model related to the computer network being monitored; using another set of inference rules to generate information identifying the received alert as an instance of said personalized model; and using a further set of inference rules to enrich the identified alert with at least contextual information relevant to an operator, including at least identification of the components in said computer network that are impacted by the alert.
[0045] The method further comprises the step of using a set of inference rules to enrich the identified alert with at least a target service level for said components and at least a list of resolution actions.
[0046] The method comprises the further steps of using historical statistics data to identify the past behavior of said components and combining the enriched alert and identified past behavior of said components to generate at least one alert resolution action.
[0047] Further embodiments are described in the appended dependent claims.
[0048] Further aspects of the invention will now be described, by way of preferred implementation and examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The above and other items, features and advantages of the invention will be better understood by reading the following more particular description of the invention in conjunction with the accompanying drawings wherein:
[0050] FIG. 1 shows a block diagram of a preferred implementation of the present invention.
[0051] FIG. 2 illustrates the Alert Decision-Maker architecture for handling a stream of alerts within a system framework.
[0052] FIG. 3 is a flow chart of the Alert Decision-Maker process to initiate automatically an identification of an addressing alert in real time.
[0053] FIG. 4 is a flow chart of the Alert Decision-Maker process which acts to initiate adequate decision-making operator assistance and alert resolution corresponding to an identified addressing alert.
DETAILED DESCRIPTION OF THE INVENTION
[0054] Embodiments of the invention as described hereinafter by way of examples with reference to the accompanying figures.
[0055] More specifically, according to a first aspect, the present invention consists in a decision-making system, named Alert Decision-Maker, and a method for assisting an operator when confronting an addressing alert in real-time.
[0056] FIG. 1 illustrates by schematic block diagram the preferred implementation ( 100 ) for practicing the invention. The preferred implementation ( 100 ) combines an Event Decision-Maker ( 102 ) with associated Event Knowledge Database ( 104 ), an Alert Decision Requester ( 112 ), an Operator Console ( 114 ), an Alert Decision-Maker ( 116 ) and associated Alert Knowledge Database ( 118 ). The Alert Decision-Maker ( 116 ) allows the operator to manage the addressing alert in real time by using a structured model, methodically implemented. Further details about the arrangement of the Alert Decision-Maker ( 116 ) will be provided in FIG. 2 .
[0057] Returning to FIG. 1 , the Event Decision-Maker expert ( 102 ) manages, respectively, a DataCenter_ 1 ( 106 ) and a DataCenter_ 2 ( 108 ).
[0058] For the sake of simplicity, the system arrangement of the chosen example is reduced to a representation of two data centers with a minimum configuration. Those skilled in the art will readily understand that the arrangement of the present invention may operate identically whatever the size of the system configuration.
[0059] DataCenter_ 1 represents a system containing a cluster of Servers ( 110 ) linked together in a network. DataCenter_ 2 ( 108 ) communicates with an external network (external network) that represents, for example, a link for off sites backup, an internet access, a Business Partner access or equivalent networks. In the present invention, the DataCenter_ 1 ( 106 ) arrangement differs from the DataCenter_ 2 ( 108 ) arrangement to demonstrate the diversity of the application available in such a system environment. It is to be noted that a local Event Decision-Maker ( 102 ) and its associated Event Knowledge Database ( 104 ) can be also installed locally in each data center.
[0060] The Event Decision-Maker ( 102 ) receives an event signal from a data center ( 106 / 108 ) and makes a decision using the Event Knowledge Database ( 104 ). Then, the Event Decision-Maker launches actions by providing all the required system adjustments that any of the data centers needs to operate effectively. Similarly, the role of the Alert Decision-Maker ( 116 ) is to access the information concerning an alert, and use the Alert Knowledge Database ( 118 ) to interpret the information, make a decision, and launch an action. The Event Decision-Maker ( 102 ) can access the event information in systems or application logs, or can receive it in a specific data structure, such as, a Simple Network Management Protocol (SNMP).
[0061] Although the manner and protocols used to access that information may vary, they do not have an impact on the general approach. If the Event Decision-Maker ( 102 ) cannot automatically handle the event, it raises an alert. As explained in the background, the managing of an alert, unlike managing events, requires common sense for making the correct decision. Various elements make alert analysis difficult to carry out. Some of these elements are:
the intrinsic nature of the data center (e.g. the nature of the services it provides and the application it runs); the geographic locations of the data center, that can indeed be dispersed; the existence of virtual or shared systems serving multiple customers as well as business applications made of several distributed components; and the need to take into account service level objectives or agreements that can vary over time.
[0066] Since the Event Decision-Maker ( 102 ) does not provide standard ways to manage addressing alerts, it initiates the Alert Decision Requester ( 112 ) that requests an operator intervention by displaying a message on the Operator Console ( 114 ). A skilled expert operator, well trained in the monitored data center, can recognize the addressing alert and directly recover it, via the operator console ( 114 ). This is done by applying the appropriate procedure, obtained from the Alert Operating Manual ( 120 ), to the Event Decision-Maker ( 102 ).
[0067] However, an operator that has limited experience in the world of data center management may activate the Alert Decision-Maker ( 116 ), using the operator console ( 114 ), without regard to Alert Operating Manual ( 120 ). Once activated, the Alert Decision-Maker ( 116 ) overrides the actions. The Alert Decision-Maker ( 116 ) discerns the patterns of the addressing alert and uses its own Alert Knowledge Database ( 118 ) to interpret the alert, by inferring operator-relevant information (like the required service level, the particular customer, the business application), and then automatically derives the actions needed to be applied.
[0068] It is to be noted that actions, such as, sending a message, a SMS, making a phone call, can be taken by the Alert Decision-Maker ( 116 ) itself. Alternately, such actions may be proposed to the operator via the operator console ( 114 ). The actions for the monitored environment can be a second level event to be interpreted by the Event Decision-Maker ( 102 ) or can be proposed directly to the Event Decision-Maker ( 102 ).
[0069] It is worth noting that the term “operator” is to be understood in a general sense: it can be for instance a system watcher, a help desk operator or a system administrator.
[0070] It is also worth noting that in an alternate embodiment, an alert raised in the Event Management System (Event Decision-Maker 102 and Event Knowledge Database 104 of FIG. 1 ) can be directed to the Alert Decision-Maker ( 116 ) directly and be displayed on the operator console for information.
[0071] In regard to Alert Decision-Maker ( 116 ), there is shown in FIG. 2 a system framework for handling alerts, identified as Alert Decision-Maker System ( 200 ). The system comprises an Inference Module ( 202 ) interfacing with an operator Console ( 204 ), a Conceptual Data Model ( 206 ) of the monitored environment made of 3 sub-models ( 208 , 210 , 212 ), an Alert Knowledge Database ( 214 ), a database containing Historical Statistics Database ( 216 ) about the behavior of the monitored environment, an Automation Module ( 218 ) encapsulating modules that automate different levels of actions (illustrated by blocks 220 , 222 , 224 ).
[0072] The Inference Module ( 202 ) is a knowledge-based system that analyzes a stream of alerts, abstracts system-level alert messages and then transforms them into a set of actions that are submitted to the automation Module ( 218 ).
[0073] When processing an alert, the Inference Module ( 202 ) consults the Systems and Alerts View Generic Sub-Model ( 208 ) and the Actions and Service Levels View Generic Sub-Model ( 210 ) of the Conceptual Data Model ( 206 ) to determine what is considered an alert and a resolution action from the operator's perspective. It queries the Specific Constraints Specific Sub-Model ( 212 ) of the Conceptual Data Model ( 206 ) to construct a specialized knowledge of the environment being monitored. Then, in other steps, it generates information identifying the alert as an instance of said personalized model. It also generates contextual information relevant to the operator. Contextual information may include any of a variety of relevant information, such as, the computer network impacted by the alert, customer name, application name, time when alert occurred, etc. In a further step, the Inference Module ( 202 ) identifies the resolution actions to be triggered. These steps result in the creation of a data structure made of several fields representing the contextual information needed to identify the alert and its associated actions. This structure is an enriched representation of the alert, as perceived by the operator; its fields are filled by the Inference Module ( 202 ), using the Alert Knowledge Database ( 214 ), the Historical Statistics Database ( 216 ) or the input of the operator, as explained below.
[0074] Knowing what fields must be used to identify the alert and the resolution actions to be taken, the Inference Module ( 202 ) uses the rules stored in the Alert Knowledge Database ( 214 ) to infer the information that identify the alert; it uses both the Alert Knowledge Database ( 214 ) and the Historical Statistics Database ( 216 ) to infer the list of actions that must be taken. During this inference process, the Inference Module ( 202 ) interacts with the operator on the Operator Console ( 204 ) to request help when it cannot fully derive the information that identifies the arising alert or the associated actions. The interaction with the operator is implemented through a dynamic dialog initiated by the Inference Module ( 202 ), using the concepts described in the Conceptual Data Model ( 206 ). This dialog leads to the acquisition of new knowledge by the Inference Module ( 202 ), be it new inference rules or new specific constraints. This new knowledge is stored by the Inference Module ( 202 ), into the Specific Constraints Specific Sub-Model ( 212 ) for later reuse.
[0075] In the last step of its alert analysis, the Inference Module ( 202 ) submits to the Automation Module ( 218 ) the alert enriched with the inferred contextual and identifying information, and the list of identified actions.
[0076] The Operator Console ( 204 ) receives a stream of alerts from the Alert Decision Requester (not shown in FIG. 2 ). It also receives operator command orders for directly monitoring, controlling, and interacting with the Inference Module ( 202 ).
[0077] The Systems and Alerts View Generic Sub-Model ( 208 ) of the Conceptual Data Model ( 206 ) describes what is an alert in a Data Center, what are its attributes and what are the identifying key attributes. It also describes how the alert attributes are associated with the elements being monitored, i.e., the several component types (operating systems, database or transaction management systems, networks, and so on) managed in the Data Center and the concepts handled by the operator (application, customer, platforms, and so on). It provides a generic description of the information that must be found out by the Inference Module ( 202 ) to identify the alert from the operator's perspective.
[0078] The Actions and Service Levels View Generic Sub-Model ( 210 ) of the Conceptual Data Model ( 206 ) describes what are criteria that uniquely identify the actions which must be taken in answer to a well identified alert. It describes the actions that must be initiated to respond to the alerts, and how these actions can depend on the expected behavior of the monitored elements (operating systems, applications, etc.). Usually, the expected behavior is described in terms of service levels to be obtained for a system, an application, a customer (or any other concept relevant to the service management). Typically, service levels are defined for the percentage of availability of an application with different degrees, like critical or not critical, or bronze, silver, gold or platinum. The average response time of a critical transaction is another example of a service level, but one can define a plurality of other service types that those skilled in the art may readily recognize.
[0079] The service levels and the actions to be taken usually vary over time. Indeed, the expected level of service given (and consequently the operator's action) might not be the same during critical hours as that given outside critical hours. Critical hours can be either business hours or any specific critical period decided by the customer or by systems engineers. Such critical period could be, for instance, a year-end closure during which critical accountancy programs must run or a short period after the transfer of a new application release in production. The Actions and Service Levels View Generic Sub-Model ( 210 ) will therefore make the service levels dependent from a calendar of critical periods associated with the monitored resources.
[0080] The Actions and Service Levels View Generic Sub-Model ( 210 ) provides a generic description of the information that must be found out by the Inference Module ( 202 ) to identify the resolution actions from the operator's perspective.
[0081] Both the Systems and Alerts View Generic Sub-Model ( 208 ) and the Actions and Service Levels View Generic Sub-Model ( 210 ) are generic elements of the Conceptual Data Model. They provide a general description of the components of data centers, how arising alerts can be related to these components, how systems and applications behavior can be described in terms of expected service levels, how resolution actions can be dependent on the alerts, the components, and the systems or applications behavior. Having such generic models allows the implementation of an alert management system framework that is portable across different data centers. The generic data models are indeed usable in all data center environments. However, they might need some adaptations to take into account the possible specificities of the monitored environment; these specificities are to be described in the Specific Constraints Specific Sub-Model ( 212 ) part of the model. Such specific constraints can be for instance the fact that a concept or a relationship described in the generic models does not exist in the monitored environment. For instance, while the notion of geographic location is needed when managing multiple data centers, it is useless when managing a single data center located in a single site. While it is important to identify to which application (or customer) belongs every resource of a shared system, this is useless when the system is entirely dedicated to a given application (or customer). This kind of constraint can be translated by the assignment of a ‘null’ value to the attributes that describe a non-existent concept or relationship. Another kind of constraint could be the redefinition of the identification key of a concept. In such case, the constraint is translated into the redefinition of the key attributes of a concept and into the inference rule to provide values to these attributes. These two kinds of constraints are given for illustration purposes only; those skilled in the art of data modeling can easily see the kind of constraints that can be added to an existing data model.
[0082] The specific constraints can be inserted directly in the model when customizing the framework to the specific monitored environment, or more interestingly, they can be discovered by the Inference Module 202 during its alert analysis. When the Inference Module does not find an inference rule to infer one of the fields prescribed by the generic models, it asks the operator to describe how the information must be found or to provide directly the missing value. This results in the creation of a new inference rule or specific constraints refining its knowledge of the environment. The Inference Module ( 202 ) stores this new specialized knowledge in the Specific Constraints Specific Sub-Model ( 212 ). It must be noted that specific constraints can also disappear, and be automatically removed from the Specific Constraints Specific Sub-Model ( 212 ) by the Inference Module ( 202 ). Such would be the case, for instance, when a single-site data center becomes a dual-site center, making obsolete the constraint that the geographic location is not needed.
[0083] Moreover, the framework can run in learning mode. In this case, before any action, the Inference Module ( 202 ) systematically presents the operator with a step-by-step development of the reasoning (from the generic sub-models ( 208 , 210 ), the Specific Constraints Specific Sub-Model ( 212 ) and the used inference rules (from 214 ) it has applied to complete the enriched information. The operator is asked for a validation of the proposed reasoning and, if needed, the reasoning is rectified and new knowledge is inserted into the Specific Constraints Specific Sub-Model ( 212 ).
[0084] The Inference Module ( 202 ) together with its ability to interact with the operator, and to interpret the generic sub-models ( 208 , 210 ) and the Specific Constraints Specific Sub-Model ( 212 ), make the framework autonomous, self-adaptive, and portable across data centers. It is worth noting here that the framework uses operator concepts and is therefore also independent from (and portable on) any Event Management System that generates the alerts.
[0085] While the Conceptual Data Model describes “what” must be known by the framework to identify an alert and the corresponding actions, the Alert Knowledge Database ( 214 ) and the Historical Statistics Database ( 216 ) describes “how” the framework can infer this knowledge.
[0086] The Alert Knowledge Database ( 214 ) provides the Inference Module ( 202 ) with the rules explaining how to extract or derive from the original alert information, the elements that identify the alert; it also provides the target of agreed values of the service levels of any given monitored resource. Finally, it provides the rules to infer the action that must be taken, according to the criteria defined in the Actions and Service Levels View Generic Sub-Model ( 210 ).
[0087] The Historical Statistics Database ( 216 ) provides the Inference Module ( 202 ) with statistical facts about the behavior of the monitored elements (operating systems, applications, etc.). These statistics are related to the levels of service to be provided; they measure for instance the percentage of availability of a system over one month, the average response time of a specific transaction over one week, or the number of occurrences of a given alert type on a given application of a given customer during a given time period, and so on. These statistics can be updated offline by a batch job analyzing systems log, or online by the inference module when identifying the actions to be taken. The statistics are aggregated over the key attributes that identify the alerts. They are used by the Inference Module ( 202 ) to check whether the addressing alert is jeopardizing the service. When the Inference Module ( 202 ) has identified in the Alert Knowledge Database ( 214 ), the target values of the service levels defined on the resources impacted by the addressing alert, it checks in the Historical Statistics Database ( 216 ) whether the alert endangers that service level. If this is the case, it finds in the Alert Knowledge Database ( 214 ) what are the relevant actions to be taken.
[0088] The Historical Statistics Database ( 216 ) provides the possibility of controlling and adopting, preventively, the behavior of the systems or applications. It can be used, for instance, to implement a Statistical Process Control mechanism, tracking any deviation in the comportment of critical resources.
[0089] The Automation Module ( 218 ) might receive from the Inference Module ( 202 ) many actions or orders for one single alert. The module dispatches the orders to the appropriate modules; i.e., the Operator Automation Module ( 220 ) that will directly automate all actions towards the outside world, the Knowledge Management Module ( 222 ) that will evaluate the possible actions and provide advice to the operator and the Behavior Adaptation Module ( 224 ) that will automate actions towards the environment being monitored. These automation modules ( 220 , 222 and 224 ) use enriched alert information (i.e. the data structure representing the alert and the contextual information, created and filled-in by the Inference Module) as input parameters, so that they can be modified, extended and reused across various applications.
[0090] The Operator Automation Module ( 220 ) receives from the Automation Module ( 212 ) the enriched alert information with the inferred contextual information that fully identifies the alert, and the execution orders for the outside world, like sending mail to a group of persons, or a SMS, or giving a call, or creating a problem ticket or any type of warning that one skilled in the art might consider appropriate.
[0091] The Knowledge Management Module ( 222 ) receives from the Automation Module ( 218 ) the alert, enriched with the inferred contextual information that fully identifies the alert. It classifies the alert according to this information and assigns to it a set of documented applicable resolution procedures classified according to the same criteria. These procedures are sorted by priority order and are presented as recommendations to the operator. This is one example of providing advice to the operator. Other possibilities exist for providing relevant advice, as those skilled in the art of Knowledge Management can easily imagine.
[0092] The Behavior Adaptation Module ( 224 ) receives from the Automation Module ( 218 ) the alert, enriched with the inferred contextual information that fully identifies the alert, and the execution orders to take preventive action that will avoid possible non-compliances with the expected service levels. The simplest action would be to inform an expert that the resources are not functioning correctly and to request an in-depth analysis. Another example of actions that could be taken would be to interact with the Event Management System, identified above in FIG. 1 , and require it to correct the behavior of the systems or applications, e.g. by providing more memory or CPU resources to some specific components. The Event Management System has no access to the Inference Module of the Alert Decision-Maker and could not do the conceptual analysis that leads for instance to identification of a deviation in the behavior of a given application of a given customer.
[0093] Going now to FIG. 3 , a flow chart process ( 300 ) is shown representing the operation of the Alert Decision-Maker System ( 200 ) of the FIG. 2 when identifying an alert.
[0094] The Alert Decision-Maker System ( 200 ) of FIG. 2 receives alerts from the Alert Decision Requester ( 112 ), shown in FIG. 1 . These alerts automatically initiate operator assistance in real time at Operator Console ( 204 ) in Alert Decision-Maker System ( 200 ).
[0095] The Operator Console ( 204 ) detects an addressing alert issued by the Alert Decision Requester in FIG. 1 . to thereby initiate action by the Operator and/or Inference Module ( 202 ). The information contained in the addressing alert is adapted from the current format (imposed by the Event Management System) into a format compatible (Formatted Addressing Alert) for processing by the Inference Module ( 202 ), and is transmitted to the Inference Module ( 202 ) for identification and action. Then, the process of FIG. 3 goes from alert observation step 302 to step 304 .
[0096] In step 304 (Alert Pre-processing) the Inference Module ( 202 ) of FIG. 2 queries the Conceptual Data Model (Generic Conceptual Data Model—all views) to find out which operator concepts are used to recognize an alert and the resolution actions, how these concepts are linked, and which attributes describe and identify them. The Inference Module ( 202 ) creates a data structure (Enriched Alert) which fields map the operator real-time representation of the alerts and the context in which they occur. Then, the process goes to step 306 in FIG. 3 .
[0097] In step 306 (Alert Identification) of FIG. 3 , the Inference Module ( 202 ) of FIG. 2 uses the inference rules stored in the Alert Knowledge Database ( 214 ) to derive the contextual information, or to extract it from the original message. Inference Module ( 202 ) uses this enriched information to fill-in the enriched alert structure (Enriched Alert). Then the process goes to step 308 in FIG. 3 .
[0098] In step 308 (Alert Unambiguously Fully Identified), a status check is made to check that all fields of the enriched contextual information (Enriched Alert) required for identifying an alert are filled. If this is the case, the process goes to step 312 (branch Yes of the comparator ( 308 ). Otherwise, the process goes to step 310 (branch No of the comparator 308 ).
[0099] In step 310 (Alert identification Adjustment) of FIG. 3 , the Inference Module ( 202 ) of FIG. 2 interacts with the operator at Operator Console ( 204 ) to ask how to derive the missing contextual information, or to request directly a value for this missing information. The Inference Module interprets the answer of the operator to complete the enriched alert (Enriched Alert) and to complete its knowledge of the monitored environment via Specific Constraints ( 212 ) of FIG. 2 . Then, the process loops back to step 306 to check again the completeness of the enriched contextual information (Enriched Alert). To avoid an infinite loop, the Inference Module operates to take a default action (e.g. calling specialized support) when the operator cannot help in the information collection.
[0100] In step 312 (Alert Management System in Learning Mode) of FIG. 3 , a status check is made to check the system mode. If the system is running in learning mode for acquiring specific knowledge about the data center being monitored, the process goes to step 314 (branch Yes of the comparator 312 ). Otherwise, the system stores the reasoning of the Inference Module into a log file for offline analysis and the process goes to step 316 (branch No of the comparator 312 ).
[0101] In step 314 (Reasoning Validation and Adjustment) of FIG. 3 , the system is in learning mode. The Inference Module ( 202 ) of FIG. 2 interacts with the operator to display the contextual enriched information, explains how it was derived (detailing the concepts, constraints and inference rules used to infer the information), and asks for a validation or corrections to the applied rules or constraints. The Inference Module ( 202 ) stores the possible corrections introduced by the operator as new specific knowledge in the database of specific constraints of Specific Constraints ( 212 ) in FIG. 2 . If corrections are introduced, Inference Module ( 202 ) updates the enriched information (Enriched Alert). Then the process goes to step 316 of FIG. 3 .
[0102] In step 316 (Resolution identification), Inference Module ( 202 ) uses the addressing alert's identification to select, from the Alert Knowledge Database ( 214 ) of FIG. 2 , a set of actions (List of Actions) that must be taken to handle the alert. It infers the direct actions (e.g. sending a mail to a specific expert, providing ranked recommendations to the operator), and the preventive actions to be taken in case of warning or alarm on the level of services. Inference Module ( 202 ) also checks in the Historical Statistics Database ( 216 ) as to whether the service is really in jeopardy before deciding to effectively select the preventive actions. Then the process goes to FIG. 4 , step 402 .
[0103] Going now to FIG. 4 , a flow chart process ( 400 ) represents the Alert Decision-Maker ( 200 ) of the FIG. 2 when initiating decision-making operator assistance and an alert resolution corresponding to an identified addressing alert, as previously processed in FIG. 3 .
[0104] The process of FIG. 4 starts from step 316 of FIG. 3 , and goes to step 402 in FIG. 4 . In step 402 (Resolution Action Fully Identified), a status check is made to check the integrity of the information provided by the Inference Module ( 202 ). If the information is not complete (for instance, contextual information missing or statistics data incomplete), the process goes to step 404 (branch No of the comparator 402 ). Otherwise, the process goes to step 406 (branch Yes of the comparator 402 ).
[0105] In step 404 (Resolution Identification Adjustment) of FIG. 4 , Inference Module ( 202 ) interacts with the operator by asking for directives to derive the missing contextual information, to request directly a value for this missing information, or to directly describe which action must be taken. Then, Inference Module ( 202 ) receives operator feedback and upgrades both the enriched alert (Enriched Alert) and the knowledge of the monitored environment in Specific Constraints ( 212 ) in FIG. 2 . The resolution actions must be redefined to take into account the newly upgraded contextual information and the process goes back to step 316 . To avoid any undesirable infinite loop (via 402 , 404 , 316 , 402 ), Inference Module ( 202 ) can decide to initiate a default action (e.g. calling specialized support) when the operator cannot help in the information collection (not shown here).
[0106] In step 406 (Alert Management System in Learning Mode) of FIG. 4 , Inference Module ( 202 ) provides a complete list of actions (List of Actions). A status check is made to check the system mode. If the system is running in learning mode for acquiring specific knowledge about the data center being monitored, the process goes to step 408 (branch Yes of the comparator 406 ); otherwise the reasoning of Inference Module ( 202 ) is stored in a log file (not shown here) for offline analysis and the process goes to step 410 (branch No of the comparator 406 ).
[0107] In step 408 (Reasoning and Validation Adjustment), the system is in learning mode. In learning mode, Inference Module ( 202 ) of FIG. 2 interacts with the operator (Operator). It displays the contextual enriched information, explains how it was derived (detailing the concepts, constraints, inference rules and statistics used to infer the information), and requests an operator's validation or corrections accordingly. Then, the Inference Module stores the possible corrections brought by the operator as new specific knowledge into the database of specific constraints in Specific Constraints ( 212 ) in FIG. 2 . In addition, it updates the list of actions (List of Actions) according to the corrections. After reasoning validation and adjustment, the process goes to step 410 in FIG. 4 .
[0108] In step 410 (Actions Dispatching), the Automation Module ( 218 ) in FIG. 2 receives from Inference Module ( 202 ) the data structure containing the enriched contextual information (Enriched Alert) and a list of selected actions (List of Actions) that must be taken to handle the alert. The Automation Module ( 218 ) selects one or more of the modules ( 220 , 222 and 224 ) of FIG. 2 to initiate the actions and transmits them the enriched information (Enriched Alert). Firstly, if Automation Module ( 218 ) selects the Operator Automation Module ( 220 ), then the process goes to step 412 . Secondly, if Automation Module ( 218 ) selects the Knowledge Management Module ( 222 ), then the process goes to step 414 . Finally, if Automation Module ( 218 ) selects the Behavior Adaptation Module ( 224 ), then the process goes to step 416 .
[0109] In step 412 (Operator Automation) of FIG. 4 , Operator Automation Module ( 220 ) of FIG. 2 receives the enriched contextual information (Enriched Alert 0 and the execution orders (Execution Orders) from Automation Module ( 218 ). It executes the given orders, interfacing with any relevant tool (for instance to send a SMS, create a problem ticket and so on). Then the process goes to step 418 .
[0110] In step 414 (Resolution Advices), Knowledge Management Module ( 222 ) receives the enriched contextual information (Enriched Alert) and the execution orders (Execution Orders) from the Automation Module ( 218 ). It executes the given orders, providing the operator with relevant, ranked, documented resolution recommendations to handle the alert. Then the process goes to step 418 .
[0111] In step 416 (Behavior Adaptation), Behavior Adaptation Module ( 224 ) receives the enriched contextual information (Enriched Alert) and the execution orders (Execution Orders) from the Automation Module ( 218 ). It executes the given orders, interfacing with any relevant tool (for instance to ask an in-depth analysis to an expert), possibly with the event Management System (for instance to request an action at the system level, or to simulate an event that will engender this action). Then the process goes to step 418 in FIG. 4 .
[0112] In step 418 (Alert Completion Complete) of FIG. 4 , a status check is made to check the completion of the alert resolution corresponding to the addressing alert. If the alert resolution is complete, the process goes to step 420 (branch Yes of the comparator 418 ). Otherwise, the process loops back to step 316 in FIG. 3 allowing the operator automation baselines of conceptual models to be updated in real time (branch No of the comparator 418 ).
[0113] In step 420 (Alert Knowledge Database Updating) of FIG. 4 , once the Alert resolution is complete, the system commits the updates made during the process on:
the specific constraints sub-model (i.e. the elements of the data model that describe the specificities of the environment being monitored); the content of the automation modules ( 220 , 222 and 224 of FIG. 2 ); various parameters and attributes belonging to the current refined alert enriched framework sequence in the Alert Knowledge Database ( 214 in FIG. 2 ) and in the Historical Statistics Database ( 216 in FIG. 2 ) for future reuse.
[0117] It will be understood from the foregoing description that various modifications and changes may be made in the preferred embodiment of the present invention without departing from its true spirit. It is intended that this description is for purposes of illustration only and should not be construed in a limiting sense. The scope of this invention should be limited only by the language of the following claims.
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A system and related method for automating alert decision-making in a computer network are disclosed. The system and method act to receive an alert request from an event management system, and then carries out operations using several sets of inference rules, associating the alert request to a generic conceptual data model of alert request and alert resolution. The generic model is specialized to represent the specific environment being monitored. The alert request is enriched with contextual and network information in order to generate one or several alert resolution actions.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a heat-treating apparatus used in the manufacture of a semiconductor device, such as an IC, and adapted for the low-pressure CVD, impurity diffusion and so on.
2. Description of the Prior Art
Many conventional heat-treating apparatuses, e.g., low-pressure CVD apparatuses, are of a horizontal-furnace type in which a furnace body for heat treatment is set horizontally. Recently, however, heat-treating apparatuses of a vertical-furnace type have started to be used, providing the following advantages.
A first advantage of the vertical-furnace type is that the installation area for the apparatus can be reduced.
Naturally, a horizontal-furnace heat-treating apparatus requires an installation area proportional to the length of the furnace. In contrast with this, the installation area for a vertical-furnace apparatus depends only on the diameter of the furnace. In general, the furnace diameter is shorter than the furnace length, so that the installation area for the vertical-furnace type is smaller. Since semiconductor wafers are aligned successively in the furnace during heat treatment, moreover, the furnace length is extended in proportion to the processing capacity, while the furnace diameter has no relation to the capacity. Thus, the higher the processing capability, the greater the advantage of the vertical-furnace type, with respect to the installation area.
A second advantage of the vertical-furnace type is that a vertical convection of gas can be utilized for the supply of working gas to the furnace.
One of the most important requisites of a heat-treating apparatus, whether horizontal or vertical, is the uniformity of temperature distribution along the length of the inside of the furnace. If the temperature distribution is uneven, semiconductor wafers treated in the same lot will be subject to variation in quality. In this regard, the vertical-furnace heat-treating apparatus is inferior to the horizontal-furnace apparatus. This is because heat, in the vertical-furnace type, is transferred upward by the convection, so that the temperature of the top portion of the furnace increases cumulatively. Such accumulation of heat entails thermal fatigue of the heater means.
For avoiding the variation in quality of the wafers treated in the same lot, the heat-treating apparatus is designed so that uniform temperature distribution is attained in a predetermined limited region inside the furnace, and the semiconductor wafers are heat-treated only within this region. This is because a low-temperature region is inevitably created at each end of the furnace, due to an effect of heat radiation to the periphery, so that the internal temperature cannot be made uniform throughout the length of the furnace. In order to improve the production capability of the heat-treating apparatus, it is essential to increase the percentage of a uniform-temperature region. Also in this regard, the vertical-furnace type is handicapped due to the heat convection described above.
One such conventional heat-treating apparatus has means for attaining uniform temperature distribution in a wider region inside the furnace in a steady state. As shown in FIG. 1, this means includes divided heater 2 which surrounds process tube 1. Heater 2, which is formed of an integrated resistance wire, is divided into three portions 3a, 3b and 3c by means of terminals Tl to T4, for example. Currents flowing through resistors 3a, 3b and 3c can be independently controlled by separately setting supply voltages applied between terminals Tl and T2, between T2 and T3, and between T3 and T4. In this prior art apparatus, heating temperatures at both end portions are increased by making the currents flowing through end resistors 3a and 3c greater than the current flowing through central resistor 3b. Thus, the effect of heat radiation at both ends of the process tube is compensated, so that a uniform-temperature region in the central portion is made wider than in the case where all resistors 3a, 3b and 3c have the same heating temperature.
Even with use of the divided heater as described above, however, the efficiency of temperature control at both ends of the process tube is not very high. It is difficult, therefore, to increase the percentage of the uniform-temperature region by shortening resistors 3a and 3c. If resistors 3a and 3c are enhanced in heating temperature and reduced in length, for example, uneven, irregular temperature distribution is observed at the boundary regions between these end resistors and central resistor 3b.The inventors hereof found that this phenomenon is attributable to heat transfer between resistors 3a, 3b and 3c.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a heat-treating apparatus capable of attaining uniform temperature distribution in a wider region inside a process tube.
The above object can be achieved by a heat-treating apparatus comprising a process tube accommodating an object to be heat-treated therein, and a plurality of independent heaters including at least three heaters arranged at both end portions and the central portion of a side wall of the process tube, so as to surround the process tube, the heating temperatures of the individual heaters being freely adjustable.
In the heat-treating apparatus of the present invention, as compared with the prior art apparatus of FIG. 1, resistors 3a, 3b and 3c as shown in FIG. 1 are not connected to each other, so that there is no direct heat transfer between them. Accordingly, the heating temperatures of end resistors 3a and 3c can be set to be higher than in the case of the conventional apparatus, without entailing such an irregular temperature distribution as the conventional apparatus suffers. In consequence, uniform temperature distribution can be attained in a region covering the same range for the conventional apparatus even though resistors 3a and 3c are reduced in length. This indicates that uniform temperature distribution can be attained in a wider region than in the conventional case if uneven-temperature regions such as those in the prior art apparatus are permitted at both ends.
Another object of the present invention is to provide a vertical-type heat-treating apparatus capable of reducing thermal fatigue of heater means and electric power loss. This second object is achieved in the manner which will be apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram schematically showing divided heater means used in a prior art heat-treating apparatus;
FIG. 2 is a diagram showing a furnace of a heat-treating apparatus according to an embodiment of the present invention;
FIG. 3 is an equivalent circuit diagram of heater means of the furnace of FIG. 2;
FIG. 4 is a sectional view more specifically showing the heat-treating apparatus using the furnace of FIG. 2;
FIGS. 5A and 5B are sectional views showing the heater arrangement of the heat-treating apparatus of FIG. 4 in further detail;
FIG. 6A is a diagram showing a modification of the heater means of the furnace of FIG. 2;
FIG. 6B is an equivalent circuit diagram of the heater means of FIG. 6A;
FIG. 7A is a diagram showing another modification of the heater means of the furnace of FIG. 2;
FIG. 7B is an equivalent circuit diagram of the heater means of FIG. 7A;
FIG. 8 is a diagram showing a furnace of a heat-treating apparatus according to another embodiment of the present invention; and
FIG. 9 is an enlarged sectional view showing part of the heat-treating apparatus using the furnace of FIG. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following is a description of preferred embodiments of the present invention applied to a heat-treating apparatus of a vertical-furnace type, although the invention is not limited to apparatuses of this type.
FIG. 2 shows an embodiment of a furnace which constitutes a heat-treating apparatus according to the present invention. In FIG. 2, numeral 1 designates a vertical process tube which is formed of quartz or silicon carbide and has a double-tube structure composed of outer and inner tubes 4a and 4b. Working gas G fed from supply tube 23 to inner tube 4b is discharged through the gap between inner and outer tubes 4b and 4a. Three independent heaters 6, 8 and 10 are arranged around process tube 1 corresponding to the central, top, and bottom portions, respectively. Each formed of a heat-generative resistor coil or coils, heaters 6, 8 and 10 are connected to independent power sources 18, 20 and 22, respectively. Heater 6 is formed of a single coil, while heaters 8 and 10 have a double-coil structure. More specifically, heater 8 is formed of two coils 8A and 8B, and heater 10 is also formed of two coils 10A and 10B. FIG. 3 shows equivalent circuits of heaters 6, 8 and 10. Heater 6 is provided with terminals 12a and 12b, which are connected to power source 18. Coil 8A of heater 8 has terminals 14a and 14b, and coil 8B has terminals 14c and 14d. There is a short circuit between terminals 14a and 14c, while terminals 14b and 14d are connected to power source 20. Also in heater 10, there is a short circuit between terminals 16a and 16c, among terminals 16a, 16b, 16c and 16d attached to coils 10A and 10B, while terminals 16b and 16d are connected to power source 22. Heaters 6, 8 and 10 are heated by current supplied from independent power sources 18, 20 and 22, respectively, thus serving to heat process tube 1.
Corresponding to cylindrical process tube 1, all heaters 6, 8 and 10 are cylindrical in shape. These heaters are disposed on the outer peripheral surface of tube 1 so that their central axes are in alignment with the axis of the tube. That area of process tube 1 heated by central heater 6 is an area in which semiconductor wafers are to be heat-treated. The apparatus is designed so that uniform temperature distribution is attained in this area. Top and bottom heaters 8 and 10 serve to compensate for the effect of heat radiation at both ends of the process tube, thereby permitting uniform temperature distribution in the whole central area of the tube. As mentioned before, a general purpose of the present invention is to minimize the axial lengths of heaters 8 and 10.
In the arrangement shown in FIG. 2, the amount of heat per unit area generated by top and bottom heaters 8 and 10 is adjusted to twice that for central heater 6, or more. It is to this end that end heaters 8 and 10 are designed for the double-coil structure, as compared with the single-coil structure of central heater 6. Even if the amount of heat from heaters 8 and 10 is increased, the central area of the process tube will not be subject to any uneven, irregular temperature distribution. This is because end heaters 8 and 10 are entirely isolated from central heater 6 to prevent direct heat transfer. Further, the arrangement of FIG. 2 is effected in consideration of convective accumulation of heat in the top area. The heating area of top heater 8 is shorter than that of bottom heater 10. The coil density of the heat-generative resistor, which constitutes central heater 6, becomes lower in proportion to distance from the lower end of heater 6. Thus, the heat accumulation at the top area can be compensated to provide uniform temperature distribution. Moreover, temperature distribution with a desired gradient may be obtained as required.
FIG. 4 is a sectional view more specifically showing the heat-treating apparatus using the furnace of FIG. 2. In FIG. 4, numeral 21 designates an outer wall of the apparatus. The furnace of FIG. 2 is set vertically inside wall 21. Outside the furnace, retaining frames 24, 26, 28 and 30 are arranged at intervals corresponding individually to the lengths of heaters 8, 6 and 10. The three heaters are located between these retaining frames. Frames 24, 26, 28 and 30 are formed of an adiabatic material, so that heat transfer between heaters 6, 8 and 10 is prevented. Frame 30 serves to prevent overheating at the open end portion of the heat-treating apparatus. Adiabatic material 32 is packed between the heaters and outer wall 21, whereby wall 21 is prevented from being over-heated.
FIG. 5A illustrates pitches of the coil constituting heater 6, and FIG. 5B illustrates pitches of coils constituting heaters 8 and 10. As seen from FIG. 5A, there are relations P1>P2>P3 . . . Pn where P1, P2, P3 . . . Pn are the coil pitches of heater 6 as named from top to bottom. In order to make the temperature distribution inside process tube 1 uniform, as mentioned before, the pitch size is gradually reduced in distance from the top end of the coil.
As seen from FIG. 4B, inner coils 8A and 10A and outer coils 8B and 10B of heaters 8 and 10 have the same pitch P. Also, there is a locational offset of P/2 between inner coils 8A and 10A and their corresponding outer coils 8B and 10B.
Length L of each coil is properly set corresponding to the length of process tube 1. As shown in FIG. 2, upper heater 8 is made shorter in length than lower heater 10. This is done in order to compensate for the convective heat accumulation in the top portion, as described before. The coil diameter of heaters 8 and 10 (d2) is greater than that of heater 6 (d1). Thus, the amount of heat per unit area from both end heaters 8 and 10 can be increased, and the thermal durability of top heater 8, which is subjected to accumulated heat, can be improved.
In heat-treating semiconductor wafers by means of the apparatus of this embodiment, as shown in FIG. 4, a number of semiconductor wafers 38 held in quartz boat 36 are stored in inner tube 4b of the process tube. Boat 36 is supported by means of heat insulating cylinder 40. Cylinder 40 serves to maintain the temperature of the area around the inlet/outlet aperture of the apparatus, as well as to support the boat. Rotating mechanism 42 is disposed at the lower end portion of cylinder 40, whereby semiconductor wafers are rotated as they are heat-treated. In order to seal the process tube during the heat treatment, moreover, plug 44 is used to close the aperture.
Working gas G for the heat treatment is introduced into inner tube 4b of the process tube through supply tube 23, as mentioned before. The introduced gas is brought into contact with semiconductor wafers 38 to effect a predetermined heat treatment. In doing this, wafers 38 are rotated for uniform contact with the gas. Thereafter, the working gas is delivered to an exhaust portion (not shown) through opening 46 at the top portion of the inner tube 4b and gap 34 between inner and outer tubes 4b and 4a.
The arrangement of the heaters according to the aforementioned embodiment may be changed or modified by one skilled in the art without departing from the scope or spirit of the present invention. FIGS. 6A and 6B and FIGS. 7A and 7B show modifications of the heater arrangement.
FIG. 6A shows a modification of the heater means, and FIG. 6B is an equivalent circuit diagram of the modified heater means. In this example, coils 8A and 8B of top heater 8 are connected to independent power sources 20A and 20B, respectively, without a short circuit between coils 8A and 8B. Likewise, coils 10A and 10B of bottom heater 10 are connected to independent power sources 22A and 22B, respectively. Thus, five independent drive circuits in all are formed including the central heater. In this modification, the amount of heat generated by top and bottom heaters 8 and 10 can be controlled over a wider range.
FIG. 7A shows another modification of the heater means, and FIG. 7B is an equivalent circuit diagram of the modified heater means. Although top and bottom heaters 8 and 10 of this modification are arranged in the same manner as the ones shown in FIGS. 2 and 3, the central heater means is arranged differently. More specifically, the central heater means is composed of three heaters 6A, 6B and 6C which are connected to independent power sources 18A, 18B and 18C, respectively. Power source 18A is connected to terminals 12c and 12d of heater 6A, power source 18B is connected to terminals 12e and 12f of heater 6B, and power source 18C is connected to terminals 12g and 12h of heater 6C. This modification can be effectively used when the process tube of the heat-treating apparatus is relatively long.
Although a process tube with a double-tube structure is used in the embodiment described above, the present invention may be also applied to a process tube with a single-tube structure.
In top and bottom heaters 8 and 10 at the opposite end portions of the process tube, moreover, the coils may be arranged in three layers for a greater amount of heat generation. In contrast with this, the end heaters may be formed of single-layer coils.
Furthermore, all heaters 6, 8 and 10 may be made of a wire having equal diameter, or top and bottom heaters 8 and 10 may be made equal in length.
Referring now to FIGS. 8 and 9, another embodiment of the present invention will be described.
FIG. 8 shows a heat-treating apparatus according to the second embodiment of the invention, and FIG. 9 illustrates the lower end portion of the apparatus in detail. In this embodiment, process tube 1 is of a single-tube structure. Working gas G is introduced through the top portion of tube 1, and is discharged through exhaust port 50 in the lower end portion. Three independent heaters 6, 8', and 10', having the same construction as those of the foregoing embodiment, are provided on the side wall of process tube 1. End heaters 8' and 10' are formed of a single-layer coil each. This embodiment is characterized in that independent heater 51 is attached to a plug used to close an inlet/outlet aperture at the lower end portion of the process tube. The plug is composed of outer cylinder 52, which is filled with adiabatic material 53, and inner cylinder 55 having protective cylinder 56 therein. FIG. 9 shows the construction of the plug in detail.
In FIG. 9, outer cylinder 52 is provided with flange 54, and adiabatic material 53 serves to prevent heat from spreading toward an opening of process tube 1. Inner cylinder 55 is located inside of outer cylinder 52, so as to be removable. Thus, it serves as a support member for supporting quartz boat 36 which contains semiconductor wafers 38 therein. Heater 51, along with thermocouple thermometer 58, is disposed inside protective cylinder 56 which is located inside inner cylinder 55. Cylinder 56 serves to intercept working gas G in process tube 1, thereby preventing heater 51 from deteriorating due to contact with the gas. Further, heater 51 is provided with terminal electrodes 51a and 51b, which are connected to a power source (not shown). Numeral 60 designates a support base which is fixed to arm portion 63 of lift 62. Bellows 61 is disposed between support base 60 and flange 54 of outer cylinder 52. Cooling water passage 64 is formed inside the lower end portion of outer wall 21. The apparatus can be cooled by circulating cooling water through passage 64.
In the embodiment shown in FIGS. 8 and 9, the inlet/outlet aperture at the bottom portion of process tube 1 is also heated independently by means of additional heater 51. The aperture region is most influenced by radiation of heat. Therefore, the temperature distribution inside the process tube can be made further uniform by the use of heater 51.
The heater for heating the bottom opening portion of the process tube, used in the embodiment of FIGS. 8 and 9, may be applied independently, without being combined with the heater within the scope of the present invention. In the embodiment shown in FIGS. 8 and 9, for example, even if the conventional heater means as shown in FIG. 1 is used for the side wall of the process tube, the additional use of heater 51 can produce a predetermined effect.
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A heat-treating apparatus includes a process tube accommodating an object to be heat-treated therein, and a plurality of independent heaters including at least three heaters arranged at both end portions and the central portion of a side wall of the process tube, so as to surround the process tube and, the heating temperatures of the individual heaters being freely adjustable. In this heat-treating apparatus, no direct heat transfer is caused between the heaters, so that the heating temperature of the heater at each end portion of the process tube can be adjusted to a high value, without entailing such an uneven temperature distribution as is caused in the case of a conventional heat-treating apparatus. Thus, uniform temperature distribution can be attained in an area covering the same range for the conventional apparatus, even though the heaters at both end portions are reduced in length.
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BACKGROUND OF THE INVENTION
This invention relates to bearing guards The invention is especially adapted for guarding the bearing of a rotating mandrel of a compost turner, or aerator, from entanglement by polymeric bags used to haul leaves, grass clippings and the like.
A problem of immense proportion in the United States and throughout the world is the dwindling availability of landfill sites. Up to 40% of the volume of landfills, depending on the time of the year, is occupied by yard waste such as leaves, grass clippings and the like. One solution is to recycle such waste by converting it to topsoil through composting. Composting utilizes naturally occurring organisms to convert dead plant matter into a form that growing plants can use again. In order to be commercially feasible, it is necessary to process large volumes of yard waste in the least possible time. One method under consideration includes the arranging of yard waste in long piles known as windrows. The windrows must be occasionally churned to maintain the proper composition, temperature, moisture and oxygen levels. The internal temperature of the windrow must be maintained between 100 and 140° F. for rapid decomposition.
Compost turners, or aerators, have been developed for churning the windrows. One problem that has developed is that yard waste is often received by municipalities in polyethylene bags, commonly known as garbage bags. Such bags have a tendency to wrap around the shaft of the turning mandrel and foul its support bearing, significantly reducing the bearings' useful life.
SUMMARY OF THE INVENTION
In order to significantly enhance the useful life of mandrel bearings in compost turners, a unique bearing guard is proposed. The guard provides shredding means for shredding articles in the vicinity of the bearing. In this manner, articles such as polymeric bags are shredded into pieces of a size that do not have a tendency to wrap around the mandrel shaft where they may readily foul the bearing. Instead, the small pieces fall away from the bearing. These and other objects, advantages and features of this invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a compost turner, or aerator, in which the present invention is especially useful,
FIG. 2 is a side perspective view illustrating the compost turner in FIG. 1 as it is used;
FIG. 3 is an enlarged partial front view of the mandrel bearing portion of the compost turner in FIG. 1;
FIG. 4 is a sectional view taken along the lines IV--IV in FIG. 3;
FIG. 5 is a partial front view illustrating the support plate for the bearing to which the present invention is applied;
FIG. 6 is a side view of the bearing support plate in FIG. 5;
FIG. 7 is a perspective view illustrating the invention; and
FIG. 8 is a front perspective view illustrating the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, and the illustrative embodiments depicted therein, a compost turner, or aerator, 10 includes a frame 12 and a turning mandrel 14 rotatably supported with respect to frame 12 by an inboard bearing assembly (not shown) at an inboard support area 16 thereof by a bearing 38 at an outboard support area generally, shown at 18 (FIGS. 1 and 4). Mandrel 14 is rotated by an internal combustion engine 20 about a shaft 36 which extends through bearing 38. In FIG. 2, a compost turner 10 is shown in use with a tractor 30 which propels compost turner 10 along windrows. Tractor 30 includes hydraulically actuated lifting means 32 which may elevate compost turner 10 in order to churn the upper portions of tall windrows. Compost turner 10 may also be guided along the ground on a skid member 34. Compost turner 10 is commercially available and is marketed by Wildcat Manufacturing Company, Inc., of Freeman, S. Dak.
Outboard support area 18 is positioned inwardly of the outer end of mandrel 14 in order to reduce the length of mandrel 14 that is unsupported. This reduces the amount of shaft wobble. However, this divides mandrel 14 into first portion 22 located between inboard and outboard support areas 16, 18 and a second outboard portion 24 located outboard of outboard support area 18. Each portion 22, 24 includes a cylindrical surface 26a, 26b and a multiplicity of turning tines 28, extending generally perpendicularly from surface 26a, 26b. Tines 28 are arranged in spiraling rows around the perimeter of surface 26a, 26b. The tines 28 are oriented on surface 26a, 26b in a manner that will urge compost toward the longitudinal central plane of the mandrel, shown as A in FIG. 1. Thus, compost to the right of plane A, as viewed in FIG. 1, is urged toward the left and compost to the left of plane A is urged toward the right. The purpose of this arrangement is to urge the compost material toward the center of the windrow and thus to maintain the integrity of the windrow. However, this lateral urging of compost by tines 28 creates a tendency for material engaged by the tines on outer portion 24 to press against outboard support area 18. Bearing 38 is mounted to a support plate 40 extending vertically downwardly from frame 12 at outboard support area 18. Plate 40 includes a web portion 45 extending between a forward vertical edge 44 and a rearward vertical edge 46 thereof. A space, or passage, shown at 42a, 42b is defined between web portion 45 of plate 40 and surface 26a, 26b.
Many municipalities receive yard waste in large polymeric garbage bags. If the windrows are built in whole or in part with yard waste in such bags, the bags will be encountered by tines 28 during the compost churning process. Because tines 28 urge material towards the central plane A of mandrel 14, plastic bags encountered by tines 28 on outboard portion 24 are pressed against support area 18. Due to the rotational motion of mandrel 14, the bags have a tendency to wind around shaft 36, which supports mandrel 14, and enter bearing 38, thus fouling the races of the bearing.
In order to guard bearing 38 against the entry of polymeric bags, and the like, guard means generally shown at 48 are provided. Guard means 48 includes a first set of shearing members 52a, 52b positioned on surface 26a, 26b and second shearing members 54 mounted on support plate 40. First shearing members 52a, 52b move with the rotation of surface 26a, 26b and provide a shearing action with stationary shearing members 54. Shearing members 52a, 52b are spaced around the perimeter of surface 26a, 26b, except at areas occupied by the mounting of a tine 28, and extend laterally beyond surface 26a, 26b in the direction of support plate 40. Second shearing members 54 are positioned on forward and rearward vertical edges 44, 46 and extend in both directions toward surfaces 26a and 26b such that there is considerable overlap of shearing members 52a and 52b with respective portions of second shearing members 54.
As best seen by reference to FIG. 4, each shearing member 52a, 52b defines a pair of peripheral edges 56, 58 which are flush with surface 26a, 26b. Each shearing member 54 includes a pair of peripheral edges 60, 62 which are positioned to be aligned with surfaces 26a and 26b. In this manner, as mandrel 14 rotates, shearing members 52a, 52b will produce a shearing action with second shearing members 54 as each peripheral edge 56, 58 of each first shearing member registers with each peripheral edge 60, 62 of each shearing member 54. Thus, it is seen that a multiplicity of shearing edges register with one another at different times to produce shearing action as mandrel 14 rotates.
In the illustrated embodiment, first shearing members 52a, 52b are made from L-shaped metal members having first and second sides 64, 66 joined at a bight 68. The edges of surfaces 64, 66 opposite bight 68 define peripheral edges 56, 58 of each shearing member 52a, 52b. Each shearing member 52a, 52b is welded to surface 26a, 26b with bight 68 extending away from the surface. This aligns edges 56, 58 with surface 26a, 26b and provides a stable support engagement between shearing members 52a, 52b and the surface of the mandrel. The arrangement of sides 64 and 66 at right angles orients the surfaces of sides 64 and 66 that define edges 56, 58 at approximately 45° to surface 26a, 26b and positions edges 56 and 58 against surface 26a, 26b such that they are in proper orientation with edges 60, 62 of shearing members 54. Shearing members 54 are made from rectangular metal plate whose width W is preselected in order to position peripheral edges 60, 62 in alignment with surfaces 26a, 26b when members 54 are properly positioned on support plate 40. Surface portions 72, 74 of members 54 that define edges 60 and 62 are also oriented approximately 45° with respect to surface 26a, 26b. This produces a desirable shearing action between shearing members 52a, 52b and shearing member 54. In the illustrated embodiment, shearing members 52a, 52b are made from 0.25" thick angle steel. Shearing members 54 are made from 0.25" thick steel plate.
While second shearing members 54 are provided on opposite vertical edges 44, 46 of the support plate 40, it is additionally possible to provide one or more third shearing members 70a, 70b extending laterally from web portion 45 of support plate 40 toward one surface 26a, 26b in order to engage in a shearing motion with first shearing members 52a, 52b. The use of third shearing members 72a, 72b is optional and the selection and positioning of such would be well within the skill of the artisan. Third shearing members each include a pair of shearing edges 76, 78, both of which engage shearing members 52a, 52b.
The shearing action provided by the interface between first shearing members 52a, 52b with second shearing members 54 and third shearing members 70a, 70b, reduces polymeric bags to small portions that do not have a tendency to wrap multiple times around shaft 36. Thus, the tendency for the pieces of polymeric material to enter bearing 38 is reduced. Furthermore, the present invention makes use of the space 42a, 42b between support plate 40 and surfaces 26a, 26b to allow the shredded material to fall free of the mandrel.
While the invention has been illustrated and described in relationship to the bearing of a rotatable mandrel for a compost turner, its principles may find application in other environments. For example, a bearing guard according to the present invention may be applied to the beater bar of a vacuum cleaner in order to shred long threads into short thread portions and thereby reduce bearing damage as a result of the entwining of long threads around the beater bar bearing. Other changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law, including the doctrine of equivalents.
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A compost turner including a rotatable mandrel supported by a shaft and at least one bearing includes a guard for reducing the tendency of polymeric garbage bags to wrap around the mandrel shaft and foul the bearing. The guard includes stationary cutting members mounted to a bearing support and rotating cutting members mounted to the mandrel which interact with the stationary guard members to shred garbage bags into harmless pieces.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of Swiss Application No. 01 993/93-3, filed Jul. 2, 1993, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for texturizing continuous filament threads by means of heated flowing media, the device including a thread infeed part for taking in the threads, a treatment part connected with the infeed part and a treatment chamber for heating the threads, and a crimping part, the crimping part containing a slot nozzle, with the crimping part being connected to the treatment part, with the heated threads being stuffed into the crimping part for forming a crimping in the threads, the slot nozzle being provided with plates having slots, the plates having an essentially rectangular cross section and being radially arranged with their narrow sides facing the stuffed thread, with every plate taking the form of a flat steel part.
2. Discussion of the Background of the Invention and Material Information
Swiss Patent Publication No. 527,931 discloses a device as set forth above in the Field of the Invention wherein the plates have an essentially rectangular cross section, with the narrow side facing the stuffed thread, and are permanently arranged in a radial manner.
During the use of slot nozzles for texturizing continuous filament threads there exists the problem that the thread snarls, located in the stuffer box, penetrate more or less deeply into the space between the plates, depending on the degree of plastification of the threads, the previous treatment of the threads with any kind of treatment and dyeing agent, as well as depending upon the frictional conditions at the end faces of the plates facing the thread, and in this way change, to an undetermined degree, the frictional conditions for the transporting of the quantity of thread in the stuffer box.
A further shortcoming consists in that the frictional conditions are subject to continuous change on account of the wear of the end faces of the plates, this requiring continuous control of the texturizing product and simultaneously a corresponding adaptation of the operating conditions in relation to the media supply, respectively requiring frequent replacement of the slot nozzles. These frequent replacements of the slot nozzles as well as frequent checks of the finished yarn are furthermore very demanding in terms of labor and costs.
Therefore it was the object of another invention, published in the European Patent Application No. 0,163,039 B, to remedy these shortcomings and to produce a device for the crimping of threads in which the crimping characteristics of the finished texturized thread, with essentially unchanged conditions in relation to the media supply, are within a useable tolerance over a longer period of time. A further object consisted in avoiding the frequent replacement of the slot nozzle.
According to the noted invention, this object was solved by European Patent No. 0,163,039 B, in that each plate is a flat steel part which is rounded and polished at the thread guiding end face. Advantageous embodiments consist in that the plates are attached in the slot nozzle in a replaceable or pluggable manner.
An advantage of the noted invention consisted in that, by rounding the end faces and by polishing, there existed the possibility of forming this thread transporting surface such that the operating conditions, defined by the friction between the tread and this surface, are subjected to substantially fewer changes due to the wear of the end face.
Furthermore, the exchangeable attachment entailed the advantage that the plates can be replaced in a simple manner after a certain time interval so that the operating conditions stay within acceptable tolerances.
The shortcoming of this nearest state of the art is that the plates are both relatively expensive and still had to be replaced after a relatively short predefined time period.
SUMMARY OF THE INVENTION
The primary object or purpose of this invention is to increase the application or use of the plates, with the advantage of the invention consisting in doubling the service life of the plates.
One embodiment of this invention pertains to a device for texturizing continuous filament threads by means of heated flowing media, the device including a thread infeed part for taking in the threads, a treatment part connected with the infeed part and having a treatment chamber for heating the threads, and a crimping part, the crimping part containing a slot nozzle, with the crimping part being connected to the treatment part, with the heated threads being stuffed into the crimping part for forming a crimping in the threads, the slot nozzle being provided with plates being inserted in slots, the plates having an essentially rectangular cross having first and second end faces and being radially arranged with one of the end faces facing the stuffed thread, with every plate taking the form of a flat steel part, with the ends of each plate being provided with a prolongation, with these prolongations having a width smaller than the width of the plate, wherein one prolongation borders directly on one of the end faces of the plate and the other prolongation borders directly on another one of the end faces of the plate.
In a further embodiment of this invention, each prolongation has the same length and the same width.
In another embodiment of this invention, each plate end includes, in addition to the prolongation, a chamfer between the prolongation and a bordering one of the end faces of the plate and opposite to the prolongation, with the chamfer, together with the bordering one of the end faces, defining an angle within a given angle range.
In an additional embodiment of this invention, the angle lies within a range of 120° and 150°.
In yet a further embodiment of this invention, the end faces of the plates are rounded and polished.
In still another embodiment of this invention, the rounded end faces have a maximum roughness value of between 0.2μand 0.4μ.
In yet an additional embodiment of this invention, the rounded end faces have a radius which is essentially equal to one half the thickness of the plates.
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 throughout the various figures of the drawings, there have generally been used the same reference characters to denote the same or analogous components and wherein:
FIG. 1 shows the device of this invention as a semi-schematic longitudinal section taken along line I--I of FIG. 2;
FIG. 2 is a semi-schematic section of the device of FIG. 1 taken along line II--II of FIG. 1;
FIG. 3 is a greatly enlarged view of a part of the device of FIG. 1;
FIG. 4 is a cross section of the part of FIG. 3, taken along line III--III of FIG. 3;
FIG. 5 is an enlarged longitudinal section taken through a detail of the device of FIG. 1, taken along line IV--IV of FIG. 6;
FIG. 6 is a cross section through the detail of FIG. 5, taken along line V--V of FIG. 5;
FIG. 7 is an enlarged longitudinal section through a further detail of the device of FIG. 1, taken along line VI--VI of FIG. 8; and
FIG. 8 is a top plan view of the detail of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With respect to the drawings it is to be understood that only enough of the construction of the invention and the surrounding environment in which the invention is employed have been depicted therein, in order to simplify the illustrations, as needed for those skilled in the art to readily understand the underlying principles and concepts of the invention.
The device 1 for texturizing continuous filament threads (not shown) of this invention includes a thread infeed part 2 having a thread infeed channel 3, a treatment part 4 having an exterior pipe 5, and an interior pipe 6 located therein which contains a treatment chamber 7.
Furthermore, device 1 includes, downstream of treatment part 4, a crimping part 8 with a perforated jacket pipe 9 having steel plates 10 located therein, which plates delimit a stuffer box 11.
Thread infeed part 2 is connected to exterior pipe 5 via a thread 12, and exterior pipe 5 and perforated jacket pipe 9 are centered, via an inner connection element 13, and are mutually connectable therewith via screws 22, 23 respectively. Connection element 13 furthermore serves on the one hand for the tight reception of interior pipe 6 (shown in FIG. 5 with dash-dot lines) and on the other hand for the pluggable reception of the upper (seen in the viewing direction of FIG. 1) plate ends 24 (FIGS. 1 and 3).
For this purpose, connection element 13 is provided with a ring-shaped insert 26, having slots 25 (FIGS. 5 and 6), which is tightly received in a cylindrical cavity 27 of connection element 13. Insert 26 has a bore with a diameter D and a depth or height R.
For the reception of the upper plate ends 24 of plates 10, slots 25 have a depth which is composed of the depth or height portions T and R. Furthermore, for the radial centering of plate ends 24, in connection element 13, a coaxial connection pipe 14 is provided which covers slots 25 for a length m.
Therefore, upper plate ends 24 with prolongations or integral extensions 15a are, as indicated with dash-dot lines in FIG. 3 and shown in FIG. 5, radially supported at the inner rounded end face 39 along the length m and at the outer end face 40, which is also rounded, along the length n, in relation to the axis of device 1. The radius of each rounded end face 39, 40 essentially equals one half of the thickness of plates 10. Diameter D is chosen such that the surface limiting this diameter does not touch the plate prolongations 15a.
Furthermore, the tolerances at the guiding surfaces having the measures or extents m and n are chosen or selected in such a manner that upper plate end 24 is guided in a gliding or sliding manner in slot 25 with little play, e.g., 0.05 mm, such that plates 10 may expand in case they heat up more quickly than their surroundings without losing their flat shapes.
Connection pipe 14, in addition, has a connection bore 28 which connects treatment chamber 7 with stuffer area 11.
The lower ends of plates 10, formed again as prolongations or integral extensions 15, are tightly held or received in slots 29 of muzzle part 16. Here the length L of prolongations 15 is somewhat longer than the depth t of slots 29, so that an end surface 30 of plates 10 does not rest on the inner end face 31 of muzzle part 16.
In each slot 25, 29 respectively, a plate 10 is placed so that they are radially arranged, as shown in FIG. 2. For the formation of slots 29 muzzle part 16 consists of a ring body 32 that is provided with the slots 29, a sleeve 33 that embraces ring body 32 as well as an inner ring 34.
Muzzle part 16 also has a muzzle bore 17 from which the crimped thread (not shown) as well as a part of the treatment medium exit.
The other part or portion of the treatment medium, which escapes between plates 10, escapes through bores 18 of perforated jacket pipe 9.
A connection sleeve 19, connected to exterior pipe 5 via a thread 20, serves for the supply of the treatment medium into device 1.
More specifically, the treatment medium is transported via a supply channel 21 of connection sleeve 19 into a ring-shaped space 35 disposed between exterior pipe 5 and interior pipe 6, and enters into treatment chamber 7 from there. A screw 38, fitted into perforated jacket pipe 9, serves for the attachment of muzzle part 16.
Furthermore, as shown in FIGS. 1 and 3, prolongations 15 and 15a are centrically-symmetrically arranged (as e.g. like a propeller), this permitting, upon the excessive wear of the first end face, e.g. 39, of plates 10, to use the second end face, e.g., 40, by turning the plates, whereby the application duration or use of the plates is doubled as compared to that of the plates used in the current state of the art. Prolongations or extensions 15 and 15a have a width B that is smaller than the width B1 of plates 10, with prolongations 15 bordering directly on outer end face 40 of plates 10 and prolongations 15a bordering directly on plate inner end faces 39.
In addition, chamfers 41, with an included angle α of an angle range of 120° to 150°, can be provided, which have the advantage over a 90° corner (shown in dash-dot lines in FIG. 3) in that any possible fibril loops, which have reached the area below the area denominated by length R, due to the expansion of the texturizing medium following connection pipe 14, will not snag and hence do not rupture.
The illustrated centrically-symmetric types of plates according to the invention, having the advantage of the noted reversing possibility, can also be employed without rounded end faces 39 and 40. Advantageously, however, this rounding is combined therewith.
Finally, it should also be noted that rounded end faces 39, 40 are polished and have a maximum roughness value Ra of 0.4μ, and preferably of 0.2μ, with 0.2μ being finer than 0.4μ.
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 and the reasonably equivalent structures thereto. Further, the invention illustratively disclosed herein may be practiced in the absence of any element which is not specifically disclosed herein.
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A device for texturizing continuous filament threads including plates in a crimping part which have a prolongation at both ends thereof, with the prolongation being located centrically-symmetrically, however offset, relative to each other and have rounded end faces thus permitting reversing the plates upon wear of one end face thereof, thus increasing their service life.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This is continuation application claiming the benefit of the filing date of U.S. application Ser. No. 13/936,805, filed on Jul. 8, 2013, which is a continuation application claiming the benefit of the filing date of U.S. application Ser. No. 12/702,169, filed Feb. 8, 2010, both of which are incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a downhole tool for oil and/or gas production. More specifically, the invention is a well stimulation tool having an expandable seat for use with a tubing string disposed in a hydrocarbon well.
2. Description of the Related Art
In hydrocarbon wells, fracturing (or “fracing”) is a technique used by well operators to create and/or extend a fracture from the wellbore deeper into the surrounding formation, thus increasing the surface area for formation fluids to flow into the well. Fracing is typically accomplished by either injecting fluids into the formation at high pressure (hydraulic fracturing) or injecting fluids laced with round granular material (proppant fracturing) into the formation.
Fracing multiple-stage production wells requires selective actuation of downhole tools, such as fracing valves, to control fluid flow from the tubing string to the formation. For example, U.S. Published Application No. 2008/0302538, entitled Cemented Open Hole Selective Fracing System and which is incorporated by reference herein, describes one system for selectively actuating a fracing sleeve that incorporates a shifting tool. The tool is run into the tubing string and engages with a profile within the interior of the valve. An inner sleeve may then be moved to an open position to allow fracing or to a closed position to prevent fluid flow to or from the formation.
That same application describes a system using multiple ball-and-seat tools, each having a differently-sized ball seat and corresponding ball. Ball-and-seat systems are simpler actuating mechanisms than shifting tools and do not require running such tools thousands of feet into the tubing string. Most ball-and-seat systems allow a one-quarter inch difference between sleeves and the inner diameters of the seats of the valves within the string. For example, in a 4.5-inch liner, it would be common to drop balls from 1.25-inches in diameter to 3.5-inches in diameters in one-quarter inch or one-eighth inch increments, with the smallest ball seat positioned in the last valve in the tubing string. This, however, limits the number of valves that can be used in a given tubing string because each ball would only be able to actuate a single valve, the size of the liner only provides for a set number of valves with differently-sized ball seats. In other words, because a ball must be larger than the ball seat of the valve to be actuated and smaller than the ball seats of all upwell valve, each ball can only actuate one tool.
BRIEF SUMMARY OF THE INVENTION
The present invention allows a well operator to increase the number of flow ports to the formation in each stage of a formation and to supplement the number of flow ports in unlimited numbers and multiple orientations to increase the ability of fracing the formation.
The present invention is a downhole tool comprising a housing having at least one flow port providing a communication path between the interior and exterior of the tool. A sleeve assembly containing an inner sleeve and an expandable seat is moveable within the housing between a first position and a second position. In the first position, the sleeve assembly is radially positioned between the flow ports and the flowpath to substantially prevent fluid communication therebetween. Shearable port inserts are initially positioned within the flow ports, with each port insert having a shearable portion extending into the interior of the housing and engaging the sleeve assembly when the inner sleeve is in the first position.
According to one aspect of the present invention, the expandable seat is comprised of a plurality of seat segments connected to a plurality of elastomeric members. Upon application of sufficient pressure, the ball engages the expandable seat substantially preventing fluid from flowing through the expandable seat. When an adequate pressure differential is caused above and below the engaged ball, the differential forces the sleeve assembly to shear the port inserts and move to the second position. Continued pressure differential of at least that pressure thereafter causes radial expansion of the elastomeric members and separation of the seat segments relative to the expandable seats unstressed state, allowing the ball to proceed through the expandable seat. In this manner, a single ball may be used to actuate multiple downhole tools within the same tubing string.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a partial sectional elevation of the preferred embodiment of the present invention in a “closed” state wherein fluid communication through flow ports is substantially prevented.
FIG. 2 is an enlarged sectional elevation of the port insert shown in FIG. 1 .
FIG. 3 is a partial sectional elevation of the preferred embodiment of the present invention in an “opened” state wherein fluid communication through the flow ports is permitted.
FIG. 4 is an enlarged sectional view of the port insert shown in FIG. 3 .
FIG. 5 is a sectional elevation of the expandable seat of the preferred embodiment.
FIG. 6 is side elevation of the expandable seat of the preferred embodiment.
FIG. 7 is a sectional view of the expandable seat through section line 7 - 7 of FIG. 6 .
FIG. 8 is a section view of an alternative embodiment of an expandable seat.
DETAILED DESCRIPTION OF THE INVENTION
When used with reference to the figures, unless otherwise specified, the terms “upwell,” “above,” “top,” “upper,” “downwell,” “below,” “bottom,” “lower,” and like terms are used relative to the direction of normal production through the tool and wellbore. Thus, normal production of hydrocarbons results in migration through the wellbore and production string from the downwell to upwell direction without regard to whether the tubing string is disposed in a vertical wellbore, a horizontal wellbore, or some combination of both. Similarly, during the fracing process, fracing fluids moves from the surface in the downwell direction to the portion of the tubing string within the formation.
FIG. 1 depicts a partial sectional elevation of a preferred embodiment of a downhole tool 20 having the features of the present invention. The tool 20 comprises a housing 22 attached to a top connection 24 at an upper end 26 and a bottom connection 28 at a lower end 30 , respectively. Grub screws 36 secure the connection between the housing 22 and the top and bottom connections 24 , 28 . Annular upper and lower sealing elements 38 , 40 are positioned circumferentially around the top connection 24 and bottom connection 28 , respectively, and inside the housing 22 . The inner surface of the housing 22 includes a locking section 57 having a plurality of downwardly-directed annular ridges.
A plurality of flow ports 32 is circumferentially positioned around and through a first section of the housing 22 having a first inner diameter. The flow ports 32 provide a number of fluid communication paths between the interior and exterior of the tool 20 . A sleeve assembly 50 nested within the housing 22 comprises an expandable seat 52 and an inner sleeve 54 , and is moveable between a first position, as shown in FIG. 1 , and a second position as shown in FIG. 3 . The expandable seat 52 has an annular upper shoulder 53 adjacent the top connection 24 , and an annular lower shoulder 56 adjacent to inner sleeve 54 . Two annular sealing elements 51 are circumferentially disposed around the expandable seat 52 in corresponding circumferential grooves.
In the first position, the expandable ball seat 52 is positioned in the first section of the housing 22 , with the upper shoulder 53 contacting a lower annular shoulder 55 of the top connection 24 . The outer diameter of the expandable seat 52 in a normal state is only slightly smaller than the inner diameter of the first section of the housing 22 .
FIG. 2 shows a sectional view of a shearable port insert 42 in greater detail, with hatching removed for clarity. In the first position, the port insert 42 is positioned in the flow port 32 to close the communication path to the exterior of the housing 22 . The shearable port insert 42 comprises a cylindrical body portion 44 having approximately the same circumference as the corresponding flow port 32 , and a cylindrical shearable portion 46 extending into the interior of the housing 22 and having a smaller circumference than the body portion 44 . The junction of the shearable portion 46 and body portion 44 is a shear joint 47 created with a shear riser cut and shearable at a predetermined amount of shear force, which in the preferred embodiment can be adjusted between eight hundred psi and four thousand psi by altering the depth of the stress riser cut. A channel 48 extends through the body portion 44 and partially through the shearable portion 46 such that, once sheared, the channel 48 provides a fluid communication path through the port insert 42 between the interior and exterior of the housing 22 .
In the first position, the shearable portion 46 of each port insert 42 extends into a corresponding circumferential insert groove 49 in the outer surface of the expandable seat 52 . Two annular sealing elements 51 are disposed circumferentially around the expandable seat 52 in two circumferential grooves. Alternative embodiments contemplate a plurality of recesses formed in the outer surface of and spaced radially about the expandable seat 52 and aligned with the port inserts 42 .
The port insert 42 is retained in the flow port 32 with a snap ring 70 disposed in a groove 63 formed in the sidewall 65 of the flow port 32 . The snap ring 70 constricts around a cylindrical top portion 67 of the port insert 42 . An annular sealing element 72 is located between an annular shoulder portion 74 of the port insert 42 to prevent fluid communication into or out of the flow ports 32 around the exterior of the port insert 42 . An exemplary snap ring 70 is Smalley Snap Ring XFHE-0125-502.
In the preferred embodiment, the port inserts 42 are made of erodible (i.e., non-erosion resistant) material (e.g., 6061-T651 or 7075-T651 aluminum alloy) such that flow of fracing fluid through the channel 48 at typical fracing flow rates erodes the insert 42 to increase the diameter of the channel 48 . When sheared as a system, the port inserts 42 will erode to or past the internal sidewall of the housing 22 as a result of downwell flow, which thereafter allows the full open flow area of the tubing to be used for upwell or downwell flow. In alternative embodiments, however, the port inserts may be constructed of an erosion resistant material when the full flow area of the housing 22 is not desired.
An expandable ratchet ring 59 is positioned circumferentially around the outer surface of the expandable seat 52 , downwell from the cylindrical insert groove 49 , in a snap ring groove 61 , and has a plurality of upwardly-directed ridges engagable with the locking section 57 to prevent upwell movement. Operation of the ratchet ring 59 will be described more fully with reference to FIG. 3 and FIG. 5 infra.
FIG. 3 and FIG. 4 more fully show the downhole tool 20 in an “opened” state, wherein the sleeve assembly 50 is in the second position. The port inserts 42 are sheared at the shear joints 47 to provide a communication path from the interior to the exterior of the tool 20 through the channel 48 . The lower end 56 of the inner sleeve 54 contacts the lower annular shoulder 58 of the bottom connection 28 . The ratchet ring 59 is engaged with the locking section 57 of the housing 22 to prevent upwell movement of the sleeve assembly 50 due to flow pressure or friction load during remedial completion operations. A ball 60 is seated against the expandable seat 52 to prevent further downwell fluid flow. FIG. 3 does not show the expandable seat 52 in a radially expanded state and is the precursor stage prior to the ball 60 being forced through the expandable seat 52 , as will be discussed infra.
FIG. 5 more fully shows the expandable seat 52 in a radially expanded state nested within a second section of the housing 22 in the second position. The expandable seat 52 is comprised of a plurality of seat segments 62 interconnected with elastomeric members 64 in a generally tubular shape with outwardly flared upper and lowered ends, with each set segment 62 having an inner surface 71 partially defining the seat flowpath 43 . The elastomeric members 64 are bonded to the seat segments 62 with a suitable bonding agent. Although in the preferred embodiment the expandable seat 52 is attached to the inner sleeve 54 , in alternative embodiments the expandable seat 52 may be integrally formed with the inner sleeve 54 at an end thereof. The elastomeric members 64 are preferably formed of HNBR rubber.
FIG. 6 is an elevation of the expandable ball seat 52 and annular sealing elements 51 shown in FIG. 5 . FIG. 7 is a sectional perspective through section line 7 - 7 of FIG. 6 . The expandable seat 52 is formed with eight seat segments 62 interconnected with the elastomeric members 64 . The annular sealing elements 51 are circumferentially disposed in grooves formed in and around the seat segments 62 . A portion of each of the grooves is formed in the outer surface of each seat segment. Seven of the seat segments 62 are identically shaped, with the eight seat segment having a clutch profile 69 that engages with a profile of bottom connection to prevent rotation during milling out of the tool. The elastomeric members 64 are in the unstressed configuration shown in FIG. 1 and FIG. 3 . When in the first position and prior to shearing, the port inserts are engaged with the circumferential insert groove 49 . The ratchet ring groove 61 receives the expandable ratchet ring for engagement with a locking section of the housing.
FIG. 8 is a sectional elevation through a plane intersection the longitudinal axis 100 of an alternative embodiment of an expandable seat 152 comprising only six seat segments 162 interconnected with elastomeric members 164 . Grooves 151 are formed around the seat segments 162 to receive annular sealing elements. An insert groove 149 is circumferentially formed in the outer surface between the sealing element grooves 151 for engagement with the port inserts when in the first position. A ratchet ring groove 161 receives an expandable ratchet ring for engagement with a locking section 57 of the housing 22 . A series of tabs 166 are spaced around the lower end of, and extend longitudinally from, the expandable seat 152 to engage with the bottom shoulder of an alternative embodiment of a bottom connection (not shown), thus preventing rotation of the seat 152 during milling out.
Operation of the invention is initially described with reference to FIG. 1 and FIG. 2 . While in the first position, the associated ball 60 (not shown) flows down the tubing string and seats against the seat segments 62 and elastomeric members 64 that compose the expandable seat 52 . In this manner, the ball 60 engages with and seals against the expandable seat 52 to substantially prevent fluid flow through the expandable seat 52 and connected inner sleeve 54 , causing an increase in pressure applied to the ball 60 and sleeve assembly 50 relative to the pressure below the sleeve assembly 50 . When this pressure differential is sufficient to cause the sleeve assembly 50 to exert a shearing force on the port inserts 32 greater than the shear strength of the shear joints 47 , the force exerted by the expandable seat 52 separates the shearable portions 46 of the port inserts 42 and releases the sleeve assembly 50 . The pressure differential causes downward movement of the sleeve assembly 50 , with the ball 60 engaged to the expandable seat 52 , to the second position shown in FIG. 3 .
As shown in FIGS. 3 and 4 , the insert sleeve 54 is impeded from further downwell movement once in contact with the lower annular shoulder 58 . After moving to the second position, the ball 60 is impeded from further downwell movement and initially remains engaged with the expandable seat 52 , which is in an unstressed state. The ratchet ring 59 engages with the locking section 57 to prevent upwell movement of the sleeve assembly 50 .
As a result of the shearing, the channels 48 of the port inserts 42 provide fluid communication paths to the exterior of the housing 22 . In this “opened” state, fracing may commence through the channels 48 . Flow of fracing material at normal fracing velocities causes erosion of the port inserts 42 and increases the diameter of the channels 48 .
As shown in FIG. 5 , while the sleeve assembly 50 is in the second position, the ball 60 may be forced through the expandable seat 52 by increasing the pressure differential within the tubing string to overcome the radially-inwardly contracting forces exerted by the elastomeric members 64 on the seat segments 62 . As the ball 60 is forced into the expandable seat 52 , the elastomeric members 64 expand resulting in increased separation between the seat segments 62 and allowing the ball 60 to pass. Whereas in the first position the outer diameter of the expandable seat is only slightly larger than the first inner diameter of the housing, in the open state the second inner diameter of the housing 22 is sufficiently large to permit outward expansion of the elastomeric members 64 such that the seat segments 62 can separate to allow the ball 60 to pass.
After exiting the lower end of the expandable seat 52 , pressure within the housing 22 decreases and the expandable seat 52 returns to its unstressed state. The ball 60 continues to travel downwell to the next downhole tool in the tubing string, if any. The furthest downwell tool each stage of a multi-stage well is typically a standard (i.e., non-expandable) seat valve on which the ball 60 would seat to allow the tubing string pressure to be elevated to fracture the isolated stage.
The present invention is described above in terms of a preferred illustrative embodiment of a specifically described downhole tool. Those skilled in the art will recognize that alternative constructions of such an apparatus can be used in carrying out the present invention. 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 downhole tool for use in a hydrocarbon production well. The downhole tool has a housing defining a flowpath around a longitudinal axis and a seat radially expandable between an unstressed state and an expanded state. The seat has a frame comprising at least one annular sealing element and a plurality of unconnected seat segments. The seat segments are engaged with the frame. The annular sealing element are engaged with an outer surface of each of the plurality of seat segments. The seat forms a tubular structure in the unstressed state.
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FIELD OF THE INVENTION
The invention relates to building structures, and more particularly to trim members for protecting, covering and decorating the area from the base of the roof to the upper portion of the outer wall of a building structure, such as a home or office or other commercial building, where the trim members are manufactured by pultrusion.
BACKGROUND OF THE INVENTION
In the United States, most residential or light weight-building systems employ wood or metal rafters, which extend from six to twenty-four inches beyond the outer wall. The outer wall is typically constructed of masonry or wood construction. Typically, the rafters and the sub-fascia (a member that connects the rafter ends together) support roof decking which forms the base of the roof. Shingles or other roofing materials cover the roof decking. Typically, the entire area from the lower edge of the roof decking to the upper portion of the outer wall of the building structure is covered with a cornice assembly, usually made of wood or wood covered with aluminum or vinyl. Aluminum or vinyl is a preferred material because of the high maintenance of wood trim pieces, which require repainting every few years (but in fact, vinyl cannot be painted at all). A fascia, usually the upper trim member of the cornice assembly, typically covers the sub-fascia or the outer portion of the rafter ends. This fascia protects the sub-fascia or rafter ends from the elements, and provides a decorative cover. The soffit, another trim member of the cornice, typically extends horizontally between the bottom inside edge of the fascia to the upper portion of the outer wall. The third trim member of the cornice assembly, known as the frieze, is a decorative member that starts at the soffit and runs down the outside surface of the top of the outer wall. The frieze is usually made of the same material as the fascia and soffit.
One problem associated with decorative and protective cornice assemblies is the labor required to install the several component parts, such as the fascia, the soffit, the frieze, and decorative moldings associated therewith. A second problem occurs when wood is used, which may rot and which requires regular repainting. A third problem is denting of aluminum products, and a fourth problem is expanding and contracting of aluminum and vinyl. Numerous fastening means, such as nails, staples, and the like must be used to attach the component parts together and/or to the building. This practice adds significant time and expense to the construction of a conventional building structure.
In addition, a problem associated with aluminum or vinyl cornice assemblies is the shearing of the fasteners used to fasten the cornice assembly or the enlarging of the holes created for fastening the assembly to the building structure. This shearing/enlarging problem is due to the relatively large amount of expansion and contraction due to temperature or moisture variations, which also causes buckling of the aluminum or vinyl material. As a result, the cornice assembly may become detached from the building structure or may appear warped.
In the past, a cornice assembly has had to be fabricated in place. Each portion of the cornice assembly is attached to the building individually. When a wood backing is used in conjunction with vinyl or aluminum assembly, yet another aspect of the assembly must be attached individually. This process is time-consuming, labor-intensive, and difficult to attain professional looking results.
A known method of manufacturing articles which have a lineal profile and a constant cross-section is called pultrusion. Pultrusion is the opposite of extrusion. It is a continuous pulling process in which rovings or strands of fibers are impregnated with resin and are then pulled through a heated die which cures the resin while also providing the cross-sectional shape to the piece. The cured piece is cut to length as it comes off the line. See, for example, “Pultrusion for Engineers” (Trevor F. Starr ed., CRC Press, 2000), which is hereby incorporated by reference. Pultruded material can be colored during manufacture, but unlike vinyl, also has surface that can accept and permanently retain paint.
Therefore, pultrusion is desirable to provide an improved method for the manufacture of the cornice assembly (or other trim members used in home construction), to protect the interface between the roof decking and the upper portion of the outer wall of a building structure. Pultrusion would provide a cornice assembly that minimizes structural instability by eliminating expansion and contraction of the cornice assembly and minimizes the use of fasteners while providing a less labor-intensive fabrication process. In addition, a pultruded cornice assembly is desirable to reduce production and labor costs, including the elimination of the need to paint the trim after assembly—although painting remains an option if color change is desired.
SUMMARY OF THE INVENTION
The present invention includes improved methods for fabricating cornice assemblies and other trim members used in house construction. The cornice assemblies and trim members are fabricated through a process of pultrusion. Improved cornice assemblies are disclosed, which include at least a fascia, a soffit and a frieze with crown molding, all of which may be integrated into a unitary structure. The improved cornice assemblies may be constructed from one, two or more trim members. Also disclosed is a method of trimming a building structure using the cornice assemblies and trim members made by pultrusion. The dies utilized in the pultrusion of the cornice assemblies and trim members are also disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of a cornice assembly made of a unitary construction which includes a facia, a soffit, a crown, a frieze and a gutter.
FIG. 2 is a cross-section of a cornice assembly made of two trim members.
FIG. 3 is a pultrusion die with a channel for a unitary construction cornice assembly with a facia, a soffit, a crown, a frieze and a gutter.
FIG. 4 is a pultrusion die for a trim member including a soffit and a crown.
FIG. 5 is a pultrusion die for a trim member including a facia and a gutter.
FIG. 6 is a pultrusion die for a trim member including a frieze.
FIG. 7 is a cross-section of a cornice assembly made of three trim members.
FIG. 8 is a cross-section of a cornice assembly made of two trim members.
FIG. 9 is a cross-section of a trim member including a facia, a soffit and a gutter and a longitudinal section of the soffit including an area of vent holes.
FIG. 10 is a cross-section of a trim member including a facia and a soffit without gutter.
FIG. 11 is a cross-section of a trim member including a crown and a frieze where the frieze includes a slotted opening to receive wood, metal or vinyl siding.
FIG. 12 is a cross-section of a trim member including a crown and a frieze where the frieze includes a slotted opening to receive brick veneer.
FIG. 13A is a cross-section of a outside edge cap trim member.
FIG. 13B is a cross section of an inside edge cap.
FIG. 14 is a cross-section of a belt board trim member.
FIG. 15 is a cross-section of a rake trim member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a cornice assembly 10 according to the invention is shown. The cornice assembly 10 includes portions a facia 12 , a soffit 14 , a crown 16 , and a frieze 18 . Optionally, the cornice assembly may also include a gutter 20 in which case the facia 12 forms the back side of the gutter 20 .
A significant advantage may be gained through a unitary construction (formed as one piece) of the cornice assembly 10 in terms of the amount of labor needed to install the cornice assembly 10 . With a unitary construction, effort need only be spent on attaching the cornice assembly 10 to the building structure, while effort spent on fabricating the cornice assembly 10 is completely eliminated.
The cornice assembly 10 may be used in with walls made of any suitable outer sheathing building material known in the art, such as plywood, fiber board, celotex, OSB (oriented strand board) and the like.
In a second embodiment, as best seen in FIG. 2 , the cornice assembly 22 may be made of two or more trim members which are connected together to form the overall cornice assembly 22 . For example, one trim member may comprise the gutter 20 , the facia 12 and the soffit 14 , while another trim member includes the crown 16 and the frieze 18 . In this embodiment, the trim members are preferably constructed such that they may be press fit together. However, any suitable means of connecting the trim members to form the cornice assembly 22 may be used, including adhesives, bolts, nails or screws. By using press fit connections, the effort of fabricating the cornice assembly 22 on the job site is reduced as compared to traditional cornice assemblies. First, trim members capable of being press fit can be connected without the use of tools. Second, because press fitting connections are separate from the means for attaching the cornice assembly 22 to the building structure, the cornice assembly 22 can be fabricated at ground level as opposed to during attachment to the building structure. This saves both on the effort needed to fabricate the cornice assembly 22 and to attach the cornice assembly 22 to the building structure.
The cornice assemblies and trim members of the present invention are preferably manufactured through the process of pultrusion. Pultrusion is an economical technique which is especially suited for the manufacture of cornice assemblies and other trim members because they have uniform cross-sections and also benefit from the high strength to weight ratio provided by pultrusion.
Of importance to the pultrusion process is the die through which the resin impregnated reinforcements are pulled. Die include multiple metal blocks, which, when assembled, has a through-hole or channel in the shape of the desired cross-section of the trim member. FIG. 3 shows a die 24 with a channel 25 which would be used to manufacture an entire cornice assembly in a unitary construction. As can be seen, a total of ten different blocks 26 - 44 make up the die 24 for the unitary construction of the cornice assembly. The various blocks of the die 24 are held together with bolts, screws or other suitable fasteners 46 . FIG. 4 shows a die 48 which is used to manufacture a portion of a cornice assembly including a soffit 14 and a crown 16 . The soffit/crown trim member made with die 48 would be connected to a trim member including a gutter 20 and a facia 12 made with die 50 , shown in FIG. 5 , and to a trim member including a frieze 18 made with die 52 , shown in FIG. 6 . Together the trim members created by these die 48 , 50 and 52 would fit together to form a cornice assembly 54 , shown in FIG. 7 .
Selection of the particular resin and reinforcements that may be used in the pultrusion of cornice assemblies and trim members are well within the design capability of those skilled in the art. Exemplary reinforcements include continuous strands of fiberglass, aramid fibers, and graphite. In addition, chopped strand, continuous strand or swirl mats may also be used as reinforcements. A useful reinforcement is glass fiber because it is economically priced as compared to other fibers, such as carbon fibers, and has a high strength to weight ratio. Exemplary resin include polyurethane, polyesters, vinyl esters, epoxy resins, acrylic and phenolic resins.
One or more stiffening ribs may be attached to the building structure side of the cornice assemblies and trim members. In FIG. 8 , stiffening rib 55 included in a two piece cornice assembly made of a trim member with a gutter 20 , a facia 12 and a soffit 14 and a trim member with a crown 16 and a frieze 18 . These stiffening ribs maybe pultruded from the same die as the cornice assemblies or trim members. The stiffening ribs provide extra support for the cornice assemblies and trim members against forces applied there against. This bracing prevents damage which may result from the placement of ladders against the cornice assemblies and trim members, particularly placement of ladders at the frieze 18 . Furthermore, nailers 57 , 61 , which form a nailing surface for nailing the cornice assembly or trim member to the building structure.
The available cross-sections for trim members is unlimited. Exemplary crosssections, in addition to the ones previously shown with regard to the die 48 - 52 , include a trim member 56 which includes a gutter 20 , a facia 12 and a soffit 14 shown in FIG. 9 , a trim member 58 which includes a facia 12 and a soffit 14 shown in FIG. 10 , a trim member 60 which includes a crown 16 and a frieze 18 (adapted for use with exterior sheet siding) shown in FIG. 11 . shown in FIG. 12 . The friezes shown in FIGS. 8 and 11 show a relatively narrow channel 63 for accepting exterior sheet siding (such as aluminum, vinyl, wood, or the like). The frieze shown in FIG. 12 has a relatively wide channel 65 designed to accept brick or stone veneering. The trim members 56 - 62 may be mixed and matched to achieve the desired cornice assembly.
Other trim members which may be pultruded include caps for covering vertical edges, as shown in FIG. 13A , which are used to cover an outside edge cap where two pieces of siding come together. Belt boards as shown in FIG. 14 , which are used to transition from one siding material 71 to another FIG. 13B shows an inside edge cap. One trim member which may be pultruded is a rake, which is used along the gable side of the intersection between the siding material 71 and the roof deck 73 , as seen in FIG. 15 .
One or more vent holes may be made in the soffit allow circulation of air and escape of moisture. These vent holes may be made shortly after the time of fabrication of the pultruded member or at the job site, as dictated by the needs of the installer. Vent holes 64 in the soffit 14 , are shown in a longitudinal view of the soffit portion 14 of trim member 56 in FIG. 9 .
Preferably, the method of attaching the trim members to each other are press fit connections 59 , as best seen in FIG. 11 , because such fasteners are easily constructed during the pultrusion process. However, because of the thermal stability of pultruded members, any fastening means may be used without concern about the expansion and contraction due to variations in temperature or moisture. Cornice assemblies and trim member manufactured via pultrusion expand and contract less than 1/26 th of that of steel over a given temperature range. Thus, fasteners will not be sheared by pultruded cornice assemblies and trim members.
Various fastening slots are needed in aluminum and vinyl siding trim members to facilitate expansion and contraction that occurs after installation around the fastening nail after installation. However, such fastening slots are not necessary with pultruded members because, as discussed above, the pultruded cornice assemblies and trim members of the present invention do not expand or contract due to changes in temperature or moisture. Thus, when fastening pultruded cornice assemblies to building structures, the step of having to form slots can be eliminated. Also, trim members made from aluminum or vinyl and more difficult to install than pultruded members because they cannot be firmly nailed to the sheathing but must be loosely nailed so that they literally “hang” from the mounting nails by way of the slots. Pultruded members can be nailed firm just like wood can be nailed to other wood.
Because the pultruded cornice assemblies and trim members of the present invention have superior rigidity and strength to weight ratios, a significantly fewer fasteners are needed to attach the cornice assemblies and trim members to building structures.
In combination with the pultruded cornice assemblies of the present invention and other trim members, a variety of butt joint caps, corner caps, and end caps may be used to complete the trimming of a building structure. Butt joint caps are used to bridge the area where two linear sections of a cornice assembly or trim member come together.
Corner caps are used to bridge the area where two linear section of a cornice assembly or trim members come together at a corner. Both inside and outside corners are needed. While not suitable for manufacturing by pultrusion, butt joint, end, and corner caps may cost effectively be manufactured by other conventional methods such as foam injection, plastic injection, urethane casting, and the like. Caps are preferably attached with two-sided tape.
End caps are used to close off the ends of cornice assemblies and trim members to prevent dirt and water from penetrating behind the cornice assembly and potentially damaging the building structure.
While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation, and the scope of the appended claims should be construed as broadly as the prior art will permit.
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The present invention is an improved method of making cornice assemblies and other trim members utilizing the process of pultrusion. The cornice assemblies and the other trim members made by the method of the present invention exhibit superior strength to weight ratios, low expansion and contraction due to changes in temperature and humidity, as well being less labor intensive to install.
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BACKGROUND
The present invention relates to releasable interlock assemblies, particularly to those used in medical devices such as catheter introducer assemblies, catheter introducer-to-accessory assemblies, and catheters which generally comprise two or more portions, each of which must releasably engage with the other. The present invention relates particularly to elective engagements where the axial engagement between the portions must withstand forces urging the portions to separate from one another.
Catheter introducers provide a reusable conduit for the passage of guide wires, catheters, pacemaker leads, or other medical devices, e.g. biopsy instruments, through the skin, flesh, and vessel walls to gain access into blood vessels or other body passageways and cavities. Many types of accessories are used in conjunction with catheter introducers, such as hemostasis valves, Tuohy-Borst adapters, and aseptic catheter shields These accessories must by necessity couple to the catheter introducer or each other, or both, in some combination. This invention is directed to providing a simple and secure means of releasably coupling any combination of these and other devices to one another.
In typical use, say for introducing a catheter into a blood vessel, a physician inserts a needle through the body flesh and into a blood vessel, and then inserts a guide wire in to the blood vessel through the center passage of the needle. The needle is then removed leaving the guide wire in place. The introducer assembly is then inserted over the guide ire such that the tapered distal portion of the dilator acts to gradually expand the puncture opening to ease the pas sage of the introducer sheath into the blood vessel. After the introducer sheath has been inserted to a desired depth within the blood vessel, the dilator portion is removed from within the introducer portion. In this disclosure, “proximal” refers to the portions of an introducer nearest to the physician or health care worker performing the insertion procedure, and “distal” refers to the portions of the introducer nearest to, or inside of, the human or animal patient receiving the catheter.
During the initial insertion of the introducer assembly, the body's resistance to the expansion of the puncture opening exerts forces on the distal portion of the dilator tending to push the dilator distal end rearwardly in the proximal direction into the introducer sheath. In order to ensure that the tapered distal portion of the dilator remains extended beyond the blunt distal end of the introducer sheath during the initial insertion the introducer assembly, the dilator hub should be connected to the introducer hub to prevent relative axial movement of the two portions. It is important that the dilator hub and the introducer hub not disengage during the insertion procedure, but be capable of being disengaged when desired.
Catheter introducers of various forms exist in the prior art. Such devices generally consist of: (1) a dilator comprised of an elongated flexible tube with a hub permanently affixed to the proximal end. The distal end of the tube is fashioned into a generally conical tapered tip. (2) an introducer comprised of an elongated flexible tube or sheath with a hub permanently affixed to the proximal end and a distal tip which is fashioned in such a way as to minimize the resistance to insertion and trauma to the body tissue. The introducer interior diameter is sized to slidably accommodate the exterior of the dilator tube, since the two are inserted into the body as a set.
As a set, the dilator resides within the introducer, and while assembled, the distal tip of the introducer resides axially proximal to the proximal end of the tapered end of the dilator. As the name would suggest, the purpose of the dilator is to dilate or enlarge a hole in the body tissues so as to allow entry of the tubular portion of the introducer. This dilation is accomplished by means of the conical tip of the dilator which, as it is progressively inserted into the body, stretches the tissue radially outward to allow entry of the distal portion of the introducer. Once the insertion is achieved, the dilator is removed and the introducer remains as a transcutaneous conduit whereby other instruments are afforded ready access into the passageway.
During the insertion process, the body tissues resist stretching, and the resistance force vector in the axial direction would cause the dilator to move axially relative to the introducer if there were no means present to prevent such relative movement. Accidental movement of the dilator relative to the introducer during the insertion process is undesirable, for if the distal tip of the introducer is allowed to extend beyond the proximal end of the dilator tip, significant trauma to the vessel and surrounding tissues would result.
Numerous means for releasably connecting the introducer to the dilator, or to connect accessories to the introducer, or to one another, are known in the prior art. Prior art means for releasably connecting the dilator hub and the introducer hub have utilized rotatably engaging studs and complimentary slots, tapered fits, exterior clips, and ring and collar mechanisms. Many of these devices either require a significant effort to engage the locking mechanism, or do not prevent the portions from accidentally disengaging, or leave exposed protrusions on one or more members which can snag and tear a surgical glove.
The present invention solves the problems associated with prior art devices by generally providing an axial coupling means with an improved rotatably engaging releasable interlock between the dilator and introducer portions of an introducer assembly. It reduces the risk of inadvertent disengagement while minimizing the effort required for proper deployment and eliminates externally protruding portions. Additionally, all protrusions, grooves, and parts of the locking mechanism are internal when the releasable interlock is engaged, thus eliminating the risk that such parts could snag and tear a surgical glove.
SUMMARY
The present invention describes an improvement of a rotatably engaging axial coupling connection between at least two constituents of a medical device, such as between a dilator hub and an introducer hub of a catheter introducer, although the scope of application of this invention is not limited to the example.
The releasable interlock assembly with axial and rotational engagement has a first portion having a generally cylindrical or conical male member at the engaging end with one or more radially disposed grooves which engage a second portion. The second portion has a generally cylindrical or conical female member at the engaging end dimensioned so as to receive the male member of the first portion. The female portion has one or more protrusions which extend from the interior wall of the tapered female member, or socket, radially inward towards the common longitudinal axis of the two portions and which engage and cooperate with the grooves of the first portion. Upon axial engagement of the two portions, male member into female member, one portion is rotated relative to the other portion causing the protrusions in the second portion to enter engagement with the grooves of the first portion. Upon continued rotation, the protrusions of the second portion encounter a dimensional interference with the grooves of the first portion. Upon continued rotation, and with a greater amount of applied torque required, one or both of the portions elastically deform into a stressed condition so as to overcome the dimensional interference thus allowing continued relative rotational motion between the two portions.
With continued applied torque, this relative rotational motion is sustained, with one or both portions in a stressed condition, until the inwardly radially directed protrusions of the second portion come to a blind end of the grooves of the first portion at which point the dimensional interference between the two portions is significantly reduced. This represents the releasably locked state of engagement between the two portions. The sudden reduction of dimensional interference and subsequent stress relaxation provides a tactile sensation thus signaling the user that the releasably locked state has been achieved. Only by reversing the amount and direction of applied torque and retracing the original path of the protrusions within the grooves can the interference fit be defeated and disengagement of the two members achieved.
The preferred embodiment of this invention achieves the engagement and disengagement within a ninety-degree range of rotation. The preferred embodiment of this invention would be comprised of portions with generally elastic, but resilient, materials which will elastically deform at the strain represented by the interference fit overcome, but would possess a relatively high stiffness and natural frequency of vibration so as to spring back into their unstressed state with a minimum of damping. Some of the suitable materials would be polypropylene or acrylonitril butadine styrene (ABS), or metals having these characteristics.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of the preferred embodiment of the improved catheter introducer which depicts the two major portions axially disengaged from their locked state.
FIG. 2 is an side view of dilator portion of the introducer assembly showing the portion of the locking mechanism associated with the dilator hub.
FIG. 3 is a sectional view of the dilator portion depicted in FIG. 2 .
FIG. 4 is an enlarged sectional view of the dilator and introducer portions of the preferred embodiment showing the two portions engaged.
FIG. 5 is sectional side view of the introducer portion of the preferred embodiment.
FIG. 6 is an end view of the introducer portion of the preferred embodiment.
FIG. 7 is a side view of the dilator hub of the preferred embodiment, showing the groove and pocket which cooperate with the protrusions of the introducer hub.
FIG. 8 is an end view of the dilator hub.
FIGS. 9, 10 , 11 , and 12 show, respectively, a hemostasis valve, a Tuohy-Borst adapter, an aseptic shield assembly, and an obturator, each connecting to the female portion of an introducer by means of the preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description will disclose an embodiment of the invention in the context of a catheter introducer. However, this is intended to be illustrative only. The invention is not limited to applications in catheter introducers, and is applicable to other medical devices, as the reader will see.
Referring to FIG. 1, the catheter introducer assembly comprises a dilator portion 100 and an introducer portion 110 . The dilator portion 100 comprises a dilator hub 120 and a dilator tube 160 with a conical tapered distal tip 170 . The introducer portion is comprises an introducer hub 180 and an introducer tube 150 with a tip 190 fashioned onto the distal end. The introducer portion and the dilator portion are shown partly disengaged and unlocked in FIG. 1 . FIG. 1 also shows the common longitudinal axis 330 of the dilator portion 100 and the introducer portion 110 .
FIG. 2 shows the dilator of the preferred embodiment, comprising a hub 120 and a tube 160 . The dilator hub 120 includes a conically tapered male member 210 disposed on the distal end of the hub. In the preferred embodiment, the male member 210 is an integral part of the dilator hub 120 , is symmetric about the longitudinal axis of the hub, and is dimensioned to establish a slip fit relationship when fully engaged with the female member 220 of the introducer hub 180 (See FIG. 5 ). In the preferred embodiment, two grooves 260 are disposed on the male member 210 , with each of the grooves 260 having an open end 270 and a blind end 280 . In the preferred embodiment, the two grooves 260 are identical in geometry and axial location and positioned 180 degrees apart in radial orientation. The grooves 260 are oriented to require a clockwise rotation of the dilator hub 120 within the introducer hub 180 when viewed from the proximal end, so as to cause a locking engagement between the introducer hub 180 and the dilator hub 120 . The open end 270 of each groove 260 is distally disposed and broadened at the open end to readily receive the complementary protrusions 240 on the introducer hub 180 (see FIGS. 4 and 5) upon insertion of the dilator hub 120 into the introducer hub 180 .
FIGS. 4 and 5 more clearly show the protrusions 240 on the interior wall of the introducer hub engaged with the pockets 250 in the dilator hub. The two portions are depicted in the mechanically interlocked state in FIG. 4 .
Tracing the groove 260 from its broad distal opening 275 proximally, the width of the groove 260 decreases until it enters the distal opening of the groove knee 290 where the groove transitions from being generally axially aligned to generally circumferentially aligned. That is, the groove 260 has a generally axially aligned portion 295 and a generally circumferentially aligned portion 300 . At the distal opening of the knee 290 , the width is slightly greater than the greatest width of the introducer hub protrusion 240 . Similarly, as the width of the groove 260 diminishes, the radial distance to the bottom of the grooves as measured from the longitudinal axis 330 of the dilator hub 120 increases until the radial distance from the bottom of one groove 260 to the bottom of the other groove 260 is slightly less than the minimum radial distance from one introducer hub protrusion 240 to the other. Continuing to trace the groove 260 along the knee 290 in a proximal and increasingly radial direction, the distance from the bottom of the groove 260 to the longitudinal axis 330 of the dilator hub 120 (which is also the axis of rotation of the dilator hub 120 ) increases until the distance from the bottom of one groove 260 to the bottom of the other groove 260 is greater than the minimum radial distance from one introducer hub protrusion 240 to the other.
It would be possible to implement the invention with only one groove 260 and one complementary protrusion 240 , although the best mode for practicing the invention requires the use of at least two, or more, complementary grooves 260 and protrusions 240 . In the case of one groove 260 , and one protrusion 240 , it may be explained that the distance from the bottom of the groove 260 from the longitudinal axis 330 of the introducer hub (which is also the axis of rotation of the introducer hub) is greater than the radial distance from the longitudinal axis 330 of the dilator hub to the protrusion, at a point before the pocket 250 . And, the radial distance of the bottom of the pocket 250 from the longitudinal axis 330 of the introducer hub 180 is equal to or less than the radial distance from the longitudinal axis 330 of the introducer hub 180 to the protrusion 240 , so that the introducer hub 180 and the dilator hub 120 are again inhibited from axial and rotational disengagement.
Continuing to trace the groove 260 around its now generally circumferential portion 300 about the male member 210 , the radial spacing between grooves 260 continues until the blind end 280 of the groove 260 is approached. A pocket 250 is disposed at the blind end 280 of the groove 260 . In the preferred embodiment, the radial distance between the bottom of each pocket 250 in each of the two grooves 260 is equal to or less than the minimum radial distance from one introducer hub protrusion 240 to the other. The pocket 250 is otherwise designed geometrically to receive the complementary protrusion 240 on the introducer hub 180 . The axial distance separating the pocket 250 from the proximal end of the male member 210 of the dilator hub 120 is sufficient to allow for a fall locking engagement of the dilator hub 120 into the introducer hub 180 without causing dimensional interference between the two hubs 120 and 180 in the axial direction. In the preferred embodiment, the dilator hub 120 includes fins 130 to facilitate a greater degree of fingertip control by the user when locking or unlocking the dilator hub 120 with the introducer hub 180 .
Referring to FIGS. 5 and 6, the introducer portion 110 of the preferred embodiment comprises a hub 180 and an introducer tube 150 . The introducer tube 150 is sized to allow for easy passage over the dilator tubing 160 . Proximally disposed in the introducer hub 180 is a conically tapered female member 220 dimensioned to establish a slip fit relationship when fully engaged with the conical male member 210 of the dilator hub 120 . Two protrusions 240 are disposed in the proximal end of the female member 220 . Each protrusion 240 is directed inwardly toward the long axis of the hub, and faces the other protrusion. The protrusions 240 may be an integral part of the introducer hub 180 or may be included as inserts 320 which are permanently attached to the introducer hub 180 , depending on the actual manufacturing method and materials chosen. In FIGS. 5 and 6, they are shown incorporated into inserts 320 , which are permanently affixed within the introducer hub 180 . Each protrusion 240 is positioned within the introducer hub 180 in the same location axially and at the same distance from the longitudinal axis 330 of the hub 180 thus forming a symmetrical relationship. The distance separating the protrusions 240 from the proximal end of the hub 180 is sufficient to allow for a full locking engagement of the dilator hub 120 into the introducer hub 180 without causing dimensional interference between the two hubs 120 and 180 in the axial direction.
The dilator hub 120 and the introducer hub 180 are mechanically interlocked by first introducing the distal end of the dilator tube 160 into the proximal end of the introducer hub 180 and engaging the two axially until the distal end of the male member 210 of the dilator hub enters the female member 220 of the introducer hub 180 . Next, the user orientates the open ends of the dilator hub grooves 260 radially until they align with the protrusions 240 in the introducer hub 180 , to make possible further axial engagement. Upon further axial engagement, the grooves 260 engage and slidably cooperate with the introducer protrusions 240 until the protrusions 240 approach the knee 290 of the grooves 260 , at which point a combination of axial and radial relative motion is necessary to continue engagement. At the radially disposed point of the knee 290 , the relative movement between the two hubs 120 and 180 is generally radial and the protrusions 240 ramp into a state of dimensional interference. Further rotation causes compression in the outward radial direction of the introducer hub 180 via the protrusions 240 , and to a lesser extent a deflection in the inward radial direction of the dilator hub 120 . This deflection allows the further passage of the protrusions 240 along and within the grooves 260 , although the hubs 120 and 180 are now in a state of compressive stress and require a greater amount of torque to defeat the increased friction between the sliding surfaces and allow continued rotation. Once the protrusions 240 reach the blind end 280 of the grooves 260 , the dimensional interference between the two hubs 120 and 180 is substantially and rapidly reduced, and the stressed condition between the hubs 120 and 180 is relieved as the protrusions 240 fall into the pockets 250 and thus engage in the locked position. This rapid decompression caused by the protrusions 240 falling into engagement with the pockets 240 creates a tactile sensation to the user and provides a signal to the user that the locked condition has been achieved. The hubs 120 and 180 will remain in the locked position until the user reverses the engagement process. In the preferred embodiment of the invention, as shown in FIG. 7, the circumferential portion 300 of the grooves 260 is disposed at an angle, α, 340 greater than 90 degrees with the generally axial portion of the grooves 260 , which tends to urge the tapered male member 210 of the dilator hub 160 firmly into the tapered female member 220 of the introducer hub 180 . In the preferred embodiment this angle 340 is 92 degrees, or 2 degrees from the centerline of the circumferential portion 300 of each groove 260 .
As shown in FIG. 6, the introducer hub 180 preferably has a handle 140 . Removal of the introducer tube 150 may be accomplished by conventional means, such as the splitting away of the introducer tube 150 , which may have been pre-scored to allow this action. In this case, the handle 140 is constructed so as to allow the operator to grasp its two arms and break it in two along intentionally weakened areas 200 , thus beginning splits which remove the introducer tube 150 from the catheter or other medical device inserted into the body. In the preferred embodiment the dilator hub 120 has a conventional connection to other medical equipment. A Luer thread 225 and Luer taper 227 are shown in FIGS. 4 and 7.
The reader should understand that the invention is not limited to the catheter introducer described above. As shown in FIGS. 9-12, the hub 120 previously shown connected to a dilator portion 100 can be connected to other medical devices. Examples are the hub 120 containing the tapered male member 210 having the grooves 260 and pockets 250 previously described connected to a hemostasis valve 400 , a Tuohy-Borst adapter 410 , an aseptic catheter shield 420 , and an obturator 430 . Once the introducer portion 110 is in place within the desired blood vessel or body cavity, one of these instruments may be interchangeably connected to it.
The need for a mechanically simple yet secure introducer assembly capable of being releasably locked and disengaged has been attained by the present invention, as described above. Since certain changes could be made in the embodiment of the invention described above without departing from the spirit and scope of the invention, I intend that all matter contained in the foregoing description and drawings shall be interpreted as illustrative and not in a limiting sense. The reader should understand that the following claims are intended to cover all of the generic and specific features of the invention described in this application, and all statements of the scope of the invention which might be interpreted to fall between these features.
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A releasable interlock assembly having axial and rotational engagement, and suitable for use in catheter introducers and other medical devices, has a tapered female member which receives a tapered male member. The female member has protrusions which engage corresponding grooves on the male member. The grooves have a generally axially aligned portion and a generally circumferentially aligned portion, terminating in a pocket to receive the corresponding protrusion on the female member. The depth of the each groove decreases from the open axially aligned end to a point just before the pocket, causing a dimensional interference which prevents the protrusion from disengaging the pocket axially, unless deliberately rotated by an operator.
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BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to a louver construction for the rear window of an automobile.
The present invention is related to my copending patent application Ser. No. 419,083, filed Sept. 16, 1982 for Louver Construction and that disclosure is incorporated herein by reference.
It is common in automobile designs to provide a substantially large rear window area. Such a rear window area permits heat build up in the vehicle which can be objectionable especially during the warm seasons. Louver structures have been used on rear windows to minimize such heat build up and in fact have been and are being used for the latter reason as well as other reasons including greater privacy, rear passenger comfort (again from the sun), etc.
The present invention is an improved rear window louver construction which can be readily adapted for diferent window shapes. The improved rear window louver also provides sufficient center and vertical clearance to permit the continued use of rear window windshield wipers.
The louver of the present invention is a simple construction which lends itself to easy assembly and also to compact "knock down" packaging and is of a `fool proof` design to minimize the chance of improper assembly.
The louver design of the present invention has significant flexibility and versatility and can, with slight modification, accommodate the different shapes, i.e. width, length, etc., of various rear windows. The design is particularly useful for accommodating changes in vertical sweep (i.e. top to bottom curvature) of various rear windows.
It is an object of the present invention to provide a louver design which can be readily adapted to rear windows of varying shapes and contours.
It is still another object of the present invention to provide a louver of a simple construction which lends itself to easy assembly and to compact "knock down" packaging while still permitting the use of generally common components on a number of different rear window shapes.
It is another object of the present invention to provide a louver construction which is of a construction which inhibits the possibility of improper assembly.
It is an object of the present invention to provide a louver construction for the rear window of an automobile which permits use of rear window windshield wipers.
It is another object of the present invention to provide a louver construction which is readily removable from the rear window.
It is a general object of the present invention to provide an improved louver construction for rear windows of automobiles.
Other objects, features and advantages of the present invention will become apparent from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a fragmentary pictorial view of the rear portion of an automobile including the rear window area and further including a louver assembly of the present invention;
FIG. 2 is a partially exploded pictorial view of end cap units and louver channels of the louver assembly of FIG. 1;
FIG. 3 is a pictorial view, to enlarged scale, depicting the preassembled relationship of a portion of an end cap unit and louver channel;
FIG. 4 is a fragmentary sectional view to enlarged scale of the louver assembly taken generally along the lines 4--4 in FIG. 1;
FIG. 5 is a fragmentary, pictorial view to enlarged scale of the upper portion of one of the end cap units of FIG. 2;
FIG. 6 is a sectional view to enlarged scale of a locking, detent construction between the louver channel and end cap unit and generally taken along the lines 6--6 in FIG. 3;
FIG. 7 is a fragmentary elevational view of the louver assembly of FIG. 1 during assembly and depicting the end cap units at one angle;
FIG. 8 is a fragmentary elevational view of louver assembly similar to that of FIG. 7 with the angle of the end cap units being greater than that shown in FIG. 7; and
FIG. 9 is a pictorial view of and end cap unit modified to accommodate a window assembly of different length than that shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Looking now to FIG. 1 the rear portion of a vehicle 10 (only partially shown) includes a rear window assembly 12. The rear window assembly 12 includes a peripheral molding 14 and window 16. The window 16 is shown shaded for purposes of clarity; assembly 12 includes the necessary seals and associated support structure the details of which have been omitted for simplicity.
A louver assembly 18, embodying features of the present invention, is shown mounted to the rear window assembly 12. An exploded view of the louver assembly 18 can be seen in FIG. 2 and includes a pair of longitudinal right and left hand end cap units 20 and 22, respectively. The right and left hand end cap units 20 and 22 are of identical but reverse constructions. The end cap unit 20 is comprised of a plurality of longitudinally spaced end caps 24a-24i integrally formed and connected together via a longitudinally extending support base 25; similarly, end cap unit 22 has end caps 26a-26i connected together via support base 27. The end cap units 20 and 22 are of one piece integral constructions and in one form of the invention are formed of a high impact thermoplastic material by injection molding. Pairs of opposite end caps 24a and 26a, 24b and 26b, etc., are connected via elongated louver channels 28.
The end caps 24a-24i and 26a-26i provide a means of interconnecting the louver channels 28a-28i and are contoured such as to orient the louver channels 28a-28i generally horizontally. The horizontal orientation of louver channels 28 is provided to permit good rear vision for the vehicle driver, i.e. through the spaces between adjacent ones of louver channels 28a-28i. Each of the end caps is of a generally similar construction and thus for purposes of simplicity only the construction of end cap 24f will be described in detail. Thus looking now to FIG. 3 end cap 24f is generally L-shaped having a pair of leg portions 38 and 40. Downwardly (or generally vertically) extending leg portion 38 is formed integrally with the base 25.
A radiused transition portion 46 smoothly connects leg portions 38 and 40 such that it compensates for the angle of the glass 16 to locate leg portion 40 in a generally horizontal plane when the louver assembly 18 is located upon the rear window assembly 12. Thus the result is that the leg portions 38 and 40 are not "square" or "rectangular" since opposite edges are of different widths. However, the `horizontal` or laterally extending leg portion 40 terminates in an elongated end section or tongue 48 which is generally tapered and which, as will be seen, functions to connect the end cap 24f with louver channel 28f. In FIG. 3 louver channel 28f is shown in a pre-assembled condition relative to end cap 24f. The tapered construction serves a purpose to be described. In general it can be seen that end section 48 is of a reduced width and is recessed on top to define a shoulder 50 (see FIG. 2).
The louver channel 28f can be roll formed from aluminum and includes a slightly bowed center portion 52 terminating in channel portions 53 and 55 located at opposite sides. Channel portions 53 and 55 are formed integrally with center portion 52, are relatively narrow and are adapted to receive the opposite sides of tongue 48. The channel portions 53 and 55 terminate in inwardly directed flanges 57 and 59, respectively, which are adapted to be received in locating grooves 61 and 63, respectively in tongue 48. With the flanges 57, 59 located in grooves 61, 63 the louver channel 28f will be laterally aligned and guided during assembly (in direction of the arrow in FIG. 3) to end cap 24f. While louver channel 28f has been described, the remaining louver channels are similarly constructed.
When the louver channel 28f is assembled to the end cap 24f its associated end surface 60 is adapted to engage the shoulder 50. The depth of shoulder 50 is approximately the same as the material thickness of the louver channel 28f so that a smooth surface is provided at the juncture. In order to avoid separation and gaps appearing, the louver channel 28f and end cap 24f are locked together with a detent type construction comprising molded projections 62 in tongue 48 and openings 64 in channel portions 53 and 55 adapted to lockingly receive projections 62 (see FIG. 6). Note that the projections 62 are inclined at their forward surfaces 65 in the direction of relative movement between the louver channel 28f and the tongue 48 to facilitate assembly. The flanges 53 and 55 are sufficiently flexibile to resiliently move over projection 62 permitting assembly. The opposite side of projections 62 define a generally transverse surface 67 which inhibits separation of louver channel 28f and tongue 48.
In order to provide for a uniformly contoured appearance when the louver channel 28f is assembled to the end cap 24f, the ends of the opposite sides of leg portion 40 of end cap 24f adjacent the tongue 48 are contoured for at least a portion thereof to have a stepped construction generally matching that at the opposite sides of louver channel 28f.
The assembly of end cap units 20, 22 and louver channels 28a-28i is quite simple and lends itself to ease of shipment and storage and for distribution in a `kit` form. All that is required for final assembly is to insert the tongues (such as tongue 48) of end caps 24a-24i and 26a-26i into the ends of louver channels 28a-28i until detenting occurs (such as between projections 62 and indentations 64) and the louver assembly 18 is assembled and ready for installation onto the rear window assembly 12.
Louver assembly 18 includes a pair of hinge assemblies 64 (see FIG. 1) located at the top thereof which permit the louver assembly 18 to be pivoted away from the window assembly 12 for cleaning and/or maintenance purposes. The details of the hinge assemblies do not constitute a part of the present invention and are shown in detail in my copending application (supra).
The louver assembly 18 is further (removably) held in place by means of a pair of tie down assemblies 96 (see FIG. 1) located at opposite sides of louver assembly 18. The details of the tie down assemblies 96 do not constitute a part of the present invention and are shown in detail in my copending application (supra). The tie down assemblies 96 can be manipulated to permit pivoting of the louver assembly 18 about hinge assemblies 64 and/or removal.
Note that the channel portions (such as 53 and 55) extend longitudinally for the length of louver channels 28a-28i and provide substantial stiffness to bending and twisting whereby the need for intermediate supports along the length of the louver channels 28a-28i is obviated.
At the same time note that the end caps 24a-24i and 26a-26i are structured to locate the inner ends of the louver channels 28a-28i spaced a preselected distance from the rear window glass 16. The absence of any center support structure permits the continued use of rear windshield wipers in the clearance between the louver channels 28a-28i and the rear window glass 16.
The louver assembly 18 is shown with a window assembly 12 which is generally `trapezoidal` in shape, i.e. wider at the bottom than at the top, and has a generally matching shape. This is accomplished simply by making the louver channels 28a-28i progressively longer. The components of louver assembly 18, however, are readily adaptable to accommodate window assemblies of different sizes and shapes.
For a window assembly of greater or lesser width, i.e. square, rectangular or trapezoidal, the louver channels 28a-28i can simply be cut to the desired length.
For a window assembly of greater or lesser length the end cap units 20 and 22 can be cut at their lower ends to the desired size. Thus end cap units 20 and 22 are molded to a uniform length and are then cut to size by removing one or more of the lower end caps, starting with end caps 24i and 26i; for in between lengths, the vertical leg portion (such as leg portion 38) can be cut to size, still leaving the horizontal leg portion and tongue (such as 40 and 48) whereby a louver channel 28 can still be received at that lowermost, remaining end cap (see FIG. 9).
It can be seen that by varying the angle of end cap units 20 and 22 (to accommodate different window assembly shapes) the tongues (such as 48) will not always extend along the same horizontal line as the associated louver channel 28. In this case the tongues (such as 48) will be angulated relative to the mating end of the associated louver channel 28 (see FIGS. 7 and 8). This can be seen in FIGS. 7 and 8 where FIG. 7 depicts the louver assembly 18 of FIGS. 1-3 (during assembly) and FIG. 8 depicts a louver assembly 18a for a different shaped window assembly. Thus in FIG. 8 components similar to like components in the embodiment of FIGS. 1-7 are given the same numeral designation with the addition of a prime. Thus in FIG. 7 the end cap unit 22 extends at an angle X with a line 65 which extends parallely to a vertical plane extending fore and aft through the center of the vehicle 10. At this angle X the horizontal leg portions (such as 40) and associated tongues (such as 48) extend generally at right angles to the line 65 and hence the tongues will extend generally along the same horizontal line as the louver channels (28). Thus the ends of each of the louver channels (28) are cut square relative to its length. In FIG. 8, the end cap unit 22' is oriented at a larger angle X' relative to fore and aft line 65'. Here the louver channels (such as 28c', 28d' etc.) are cut at the appropriate angle (as shown in phantom in FIG. 8) such that the end surfaces of the louver channels will be along the same line and will matingly engage end cap shoulders such as 50'. Of course the detent openings (such as 64) are formed after the louver channels are cut to the correct size and angle.
In general the angulation such as X and X' will vary from 0 degrees to 25 degrees for a wide range of vehicles. In order to minimize the mismatch in angles over this range, the end cap units 20 and 22 are formed such that the horizontal leg portions (such as 40) and associated tongues (such as 48) extend generally at right angles to the line 65 when the angle X is approximately 12.5 degrees or in the center of the expected range of angles for which the end cap units 20 and 22 are expected to be used.
It is desirable that the tongues (such as 48) be long to provide good, rigid end support to the louver channels (28). In this regard it is believed that the tongue length `1` (see FIG. 7) should be at least around 30% of its maximum width `w`. In a preferred form the tongue length is around 40% of its width `w`. The width `w` is also approximately 87.5% of the overall width of the associated louver channel (28). A rectangular shape for the tongues of adequate width would require a short tongue length to accommodate any significant range of angulation. In the present invention, however, the noted range of angulation, i.e. 0-25 degrees, can be accommodated with the desired percentage of support by tapering the tongues (48). In order to accommodate a mismatch in angles between the tongues (48) and louver channels (28) the guide grooves (such as 61 and 63 on tongue 48) are made of a sufficient width to permit entry of the guide flanges (such as 53 and 55 of louver 28f) at an angle. Note that the tapered structure also helps to accommodate variations in the horizontal sweep radius of the louver channels (28) from one window assembly to another.
With an assembly involving a mismatch in angles it is desirable to avoid the appearance of a sharp surface break at the forward juncture of the louver channel (28) and horizontal leg portion (40) of the end cap (24f). The sharp break, for example, would occur on opposite sides of the juncture line 67 in FIG. 8. This is avoided by maintaining the distance Y (see FIG. 3) of the horizontal leg portion 48 from the transition portion 46 (i.e. the end of the curved portion) to a minimum. In one form of the invention that distance Y was essentially zero.
Many window assemblies have a vertical sweep, i.e. radius of curvature such as radius Vr in FIG. 4. This radius can normally vary from flat (no radius) to around 75.125" (referred to as a No. 0 to No. 50 sweep). A No. 1 sweep would have a radius of curvature of 3600.06". In order for the louver assembly to be able to fit these various curvatures, the end cap units 20 and 22 are made flexible in a vertical plane.
Thus end cap unit 22 has its end caps 26a-26i generally separated from each other by deep V notches such as notch 69 in FIGS. 2 and 3 which extend to depth generally to the support base portion 25. Support base portion 25 has a relatively small vertical thickness such that it is flexible at the V notches. The depth of the V notch can be varied even to extend partially within base portion 25 in order to provide the desired flexibility. With this construction, the end cap unit 22 (and similarly, end cap unit 20) can be resiliently bent to accommodate the sweep of the associated rear window assembly. This can be seen by the radius Vr of the phantom representation of end cap unit 22 (as curved) in FIG. 2.
In order to prevent distortion in molding the end cap units 20 and 22, the base portions 25 and 27 are notched on the inside surface to form a plurality of notches 71. These notches 71 are located generally midway between adjacent V notches (69) and further enhance the flexibility of the end cap units 20 and 22 and their ability to conform to the curvature of the window assembly with which it is associated.
The vertical leg portions (such as 38) of end caps 26a-26i increase in height from ha to hi from top to bottom (see FIG. 4). This increase in height allows the back edge 73 of the uppermost louver channel 28a (associated with end caps 24a, 26a) to be located close to the surface of the window assembly 12. This results in a minimum clearance which minimizes wind noise, vibration etc., caused by air moving underneath the louver assembly 18 and also blocks out light. At the same time the increase in height at the bottom of the louver assembly 18 permits sufficient clearance to accommodate rear window windshield wipers. Note that while the vertical leg portions (such as 38) vary the height of successive louvers 28a-28i the distance D between adjacent louvers can be maintained the same.
The uppermost end of end caps 24a, 26a terminate in a generally flat portion 75 which is adapted to rest against the glass 16 of the rear window assembly 12. (See FIG. 4). The corner contour of different window assemblies, however, will be slightly varied. It is desirable to be able to reasonably accommodate that contour while still providing a generally finished surface and at the same time to provide an end surface which will block air flow to minimize wind noise. This is accomplished by providing flat portion 75 with a plurality of molded ribs 77a-77c (see FIGS. 4 and 5). The space between these ribs 77a-77c define cut lines at which the flat portion 75 can be trimmed while still leaving at least one of the ribs 77a-77c intact to provide a finished surface and a surface to block air flow and light.
In addition to the vertical sweep noted, it is common for rear window assemblies to have a horizontal sweep radius such as radius Hr in FIG. 2. This is accommodated by forming the louver channels 28a-28i to have the appropriate curvature (sweep). This means, however, that the louver channels 28a-28i must be assembled with the appropriate fore and aft orientation to the end caps 26a-26i, 24a-24i. These sweeps can be quite small and hence not readily detectable in assembly whereby a reverse assembly could be made. This potential for error in assembly is eliminated by providing the guide flanges (such as 57 and 59) of the louver channels (28f) to have different shapes. Looking now to FIG. 3 guide flange 59 is provided with a horizontal lip portion 79. This necessitates that guide groove 63 be wider in order to receive guide flange 59 and lip portion 79. The other guide flange 57, however, is narrower and hence its associated guide groove 61 is accordingly narrower. Thus guide groove 61 is wide enough to receive guide flange 57 but is not sufficiently wide to receive guide flange 59 and lip portion 79. In this way louver channels 28a-28i can only be assembled to the end caps 24a-24i, 26a-26i with the sweep radius oriented in the proper fore and aft direction.
It is desirable to minimize the possibility of rattling of the louver channels. This is accomplished by the use of a generally cone shaped plug 81 located in openings 83 in each of the tongues (such as 48), see FIGS. 2, 3 and 5. The plugs 81 are made of an elastomeric material and are readily, elastically deformable by the channel louvers upon installation on the associated tongues (48). The plugs 81, which are partially compressed upon assembly will elastically maintain the louver channels (28) in place and dampen the tendency for vibration. At the same time the plugs 81 will act as a spring to provide a bias on the channel louvers to further enhance the lock provided by the detent action of the detent projections (62) in detent openings (64).
While it will be apparent that the preferred embodiments of the invention disclosed are well calculated to fulfill the objects above stated, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope or fair meaning of the invention.
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A louver assembly adapted to be mounted to the rear window assembly of an automotive vehicle having a pair of integrally formed, one piece end cap unit and a plurality of elongated channel members, the end cap unit having a plurality of identical right hand end caps and a plurality of similar but reverse formed left hand end caps, a detent structure for locating and locking the channel members in alignment with the associated one of the end caps with resilient bias means for enhancing the lock and minimizing noise, the channel member being of a preselected length to connect right hand and left hand end caps in a predetermined spaced relationship whereby the louver assembly will be of the desired width to fit the rear window assembly, the end cap units being of a preselected length to provide a selected number of end caps whereby the louver assembly will be of the desired length to fit the rear window assembly, the end cap units being generally flexible between adjacent end caps whereby the end cap units can fit the vertical sweep the rear window, the channel members formed to provide a horizontal sweep, the end caps having tongue members adapted to be received within the associated ends of the channel members and being tapered to permit acceptance of the channel member ends over a wide range of angles while still providing support, guide means operative between the tongues of the end caps and the channel members to guide the same into engagement and including a blocking structure to preclude assembly of the channel members onto the tongues with the sweep in the wrong direction.
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BACKGROUND OF THE INVENTION
The present invention relates to recombinant DNA which encodes the SapI restriction endonuclease and modification methylase, as well as the production of SapI restriction endonuclease from the recombinant DNA.
Type II restriction endonucleases are a class of enzymes that occur naturally in bacteria. When they are purified away from other bacterial components, restriction endonucleases can be used in the laboratory to cleave DNA molecules into precise fragments for molecular cloning and gene characterization.
Restriction endonucleases act by recognizing and binding to particular sequences of nucleotides (the `recognition sequence`) along the DNA molecule. Once bound, they cleave the molecule within, or to one side of, the recognition sequence. Different restriction endonucleases have affinity for different recognition sequences. Over two hundred restriction endonucleases with unique specificities have been identified among the many hundreds of bacterial species that have been examined to date.
Bacteria tend to possess at most, only a small number of restriction endonucleases per species. The endonucleases typically are named according to the bacteria from which they are derived. Thus, the species Deinococcus radiophilus for example, synthesizes three different restriction endonucleases, named DraI, DraII and DraIII. These enzymes recognize and cleave the sequences 5'TTTAAA3', 5'PuGGNCCPy3' and 5'CACNNNGTG3' respectively. Escherichia coli RY13, on the other hand, synthesizes only one enzyme, EcoRI, which recognizes the sequence 5'GAATTC3'.
It is thought that in nature, restriction endonucleases play a protective role in the welfare of the bacterial cell. They enable bacteria to resist infection by foreign DNA molecules like viruses and plasmids that would otherwise destroy or parasitize them. They impart resistance by cleaving invading foreign DNA molecule each time that the recognition sequence occurs. The cleavage that takes place disables many of the infecting genes and renders the DNA susceptible to further degradation by non-specific nucleases.
A second component of bacterial protective systems are the modification methylases. These enzymes are complementary to restriction endonucleases and they provide the means by which bacteria are able to protect their own DNA and distinguish it from foreign, infecting DNA. Modification methylases recognize and bind to the same recognition sequence as the corresponding restriction endonuclease, but instead of cleaving the DNA, they chemically modify one or other of the nucleotides within the sequence by the addition of a methyl group. Following methylation, the recognition sequence is no longer cleaved by the restriction endonuclease. The DNA of a bacterial cell is always fully modified by virtue of the activity of its modification methylase. It is therefore completely insensitive to the presence of the endogenous restriction endonuclease. It is only unmodified, and therefore identifiably foreign DNA, that is sensitive to restriction endonuclease recognition and cleavage.
With the advent of genetic engineering technology, it is now possible to clone genes and to produce the proteins and enzymes that they encode in greater quantities than are obtainable by conventional purification techniques. The key to isolating clones of restriction endonuclease genes is to develop a simple and reliable method to identify such clones within complex `libraries`, i.e. populations of clones derived by `shotgun` procedures, when they occur at frequencies as low as 10 -3 to 10 -4 . Preferably, the method should be selective, such that the unwanted majority of clones are destroyed while the desirable rare clones survive.
Type II restriction-modification systems are being cloned with increasing frequency. The first cloned systems used bacteriophage infection as a means of identifying or selecting restriction endonuclease clones (EcoRII: Kosykh et al., Molec. Gen. Genet. 178:717-719, (1980); HhaII: Mann et al., Gene 3:97-112, (1978); PstI: Walder et al., Proc. Nat. Acad. Sci. 78:1503-1507, (1981)). Since the presence of restriction-modification systems in bacteria enable them to resist infection by bacteriophages, cells that carry cloned restriction-modification genes can, in principle, be selectively isolated as survivors from libraries that have been exposed to phage. This method has been found, however, to have only limited value. Specifically, it has been found that cloned restriction-modification genes do not always manifest sufficient phage resistance to confer selective survival.
Another cloning approach involves transferring systems initially characterized as plasmid-borne into E. coli cloning plasmids (EcoRV: Bougueleret et al., Nucl. Acid. Res. 12: 3659-3676, (1984); PaeR7: Gingeras and Brooks, Proc. Natl. Acad. Sci. USA 80:402-406, (1983); Theriault and Roy, Gene 19:355-359 (1982); PvuII: Blumenthal et al., J. Bacteriol. 164:501-509, (1985)).
A third approach, and one that is being used to clone a growing number of systems are now being cloned by selection for an active methylase gene (U.S. Pat. No. 5,200,333 issued Apr. 6, 1993 and BsuRI: Kiss et al., Nucl. Acid. Res. 13:6403-6421, (1985)). Since restriction and modification genes are often closely linked, both genes can often be cloned simultaneously. This selection does not always yield a complete restriction system however, but instead yields only the methylase gene (BspRI: Szomolanyi et al., Gene 10:219-225, (1980); Bcn I: Janulaitis et al., Gene 20:197-204 (1982); Bsu RI: Kiss and Baldauf, Gene 21:111-119, (1983); and Msp I: Walder et al., J. Bioi. Chem. 258:1235-1241, (1983)).
A more recent method (the "endo-blue method") has been described for direct cloning of restriction endonuclease genes in E. coli based on the indicator strain of E. coli containing the dinD::lacZ fusion (Fomenkov et al., Nucl. Acids Res. 22:2399-2403, 1994). This method utilizes the E. coli SOS response following DNA damages caused by restriction endonucleases or non-specific nucleases. A number of thermostable nuclease genes (Tth111I, BsoBI, Tf nuclease) have been cloned by this method (U.S. Pat. No. 5,498,535, issued on Mar. 12, 1996).
Another obstacle to cloning these systems in E. coli was discovered in the process of cloning diverse methylase genes. Many E. coli strains (including those normally used in cloning) have systems that resist the introduction of DNA containing cytostne methylation. (Raleigh and Wilson, Proc. Natl. Acad. Sci., USA 83:9070-9074, (1986)). Therefore, it is also necessary to carefully consider which E. coli strain(s) to use for cloning.
Because purified restriction endonucleases, and to a lesser extent, modification methylases, are useful tools for characterizing genes in the laboratory, there is a commercial incentive to obtain bacterial strains through recombinant DNA techniques that synthesize these enzymes in abundance. Such strains would be useful because they would simplify the task of purification as well as providing the means for production in commercially useful amounts.
In addition to the above noted problems associated with cloning restriction-modification genes, when such foreign restriction modification systems are cloned and introduced into E. coli, sometimes the methylase and endonuclease yield is very low compared to the native endonuclease-producing strain, probably due to inefficient transcription or translation of the genes in E. coli. This is particularly true for cloning of Actinomycetes genes into E. coli because of the different GC contents of the two microorganisms. It would therefore also be desirable to have a cloning system that allows Actinomycetes genes such as the SapI restriction endonuclease gene from Saccharopolyspora species to be sufficiently expressed in E. coli and selected for based on efficient gene expression.
SUMMARY OF THE INVENTION
The present invention relates to a method for cloning the SapI restriction-modification system methylase into E. coli by a modified methylase selection method. The preferred steps of which are depicted in FIG. 1. In the cloning of the Actinomycete SapI methylase gene, standard methylase gene selection method was used to clone the targeted methylases gene from Saccharopolyspora species, the SapI methylase gene using pUC19 vector. One SapI methylase gene (M1) was cloned. Because the recognition sequence of SapI is asymmetric (5'GCTCTTC3' on one strand and 5'GAAGAGC3' on the opposite strand), it was thought that SapI restriction-modification system might contain two methylases and one endonuclease. A genomic DNA map was obtained using the left half and right half of MI DNA as probes in Southern blots. EcoRI, KpnI, and SmaI genomic DNA libraries were constructed to clone the second methylase gene by the methylase selection method.
After the second SapI methylase gene (M2) was cloned and sequenced, efforts were made to clone and sequence DNA fragments upstream and downstream of the two SapI methylase genes. Usally methylase gene and endonuclease gene in a particular restriction-modification system are located in close proximity to each other. A total of 1731 bp of DNA upstream of M2 gene was sequenced and compared with all known genes in GenBank. It contains a putative gene that has homology to a gene involved in antibiotics synthesis. It was concluded that the SapI restriction endonuclease is not located upstream of M2, but instead may be located downstream of M1 gene. NlaIII partial genomic library was constructed to clone larger genomic inserts that carry M1 and downstream DNA. The downstream DNA was screened from the NlaIII library and sequenced. It only extended further out 657 bp, not large enough to encode the entire endonuclease gene. Inverse PCR was then used to amplify and clone the rest of what was believed to comprise the endonuclease gene.
After two separate inverse PCR amplifications, DNA fragments downstream of M1 were cloned and sequenced and one open reading frame was discovered. This ORF does not share any homology to the known genes in the GenBank and was presumed to be the SapI restriction endonuclease gene. The gene organization of SapI restriction-modification system is shown in FIG. 2. The M1 and M2 genes were cloned into pACYC184 or pSC101-derived vectors and transformed into E. coli to premodify chromosomal DNA.
The putative SapI endonuclease gene was amplified by PCR and cloned into pUC19 and transformed into the premodified E. coli host. Plasmids carrying inserts in pUC19 displayed low SapI endonuclease activity in cell extracts, but all isolates lost activity in large cultures, indicating the clones were not stable. To stabalize the expression clone, efficient ribosome binding site was incorporated in front of M2 and cloned into pACYC184. The M1 gene was also cloned into the same vector. The SapI endonuclease gene was cloned into a T7 expression vector (pET21 derivative) that carried transcription terminators upstream of the T7 promotor. The transcription terminators further reduced the basal level of gene expression under uninduced condition. The endonuclease gene was amplified by PCR and inserted into the T7 expression vector. The final construct was more stable than pUC19-SapIR.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a scheme for cloning and producing the SapI restriction endonuclease.
FIG. 2 is a diagram of gene organizations of SapI restriction-modification sytem.
FIG. 3 is the DNA sequence (SEQ ID NO:1) of sapIM1 gene and its encoded protein sequence.
FIG. 4 is the DNA sequence (SEQ ID NO:2) of sapIM2 gene and its encoded protein sequence.
FIG. 5 is the DNA sequence (SEQ ID NO:3) of sapIR gene and its encoded protein sequence.
FIG. 6 shows the construction of pR976. Vector pR976 is a pACYC184 derivative that carries a P tac promoter and multiple cloning sites downstream of the P tac promoter. It also carries lacI gene that encodes the Lac repressor to regulate gene expression from the P tac promoter (Amann, et al., Gene 25:167-178 (1983)).
DETAILED DESCRIPTION OF THE INVENTION
The method described herein by which the SapI methylase genes and endonuclease gene are cloned and expressed is illustrated in FIG. 1 and includes the following steps: 1. The genomic DNA of Saccharopolyspora species was purified.
2. The DNA is digested partially with a restriction endonuclease such as Sau3AI or NlaIII, or any of its isoschizomers, that generates a DNA fragment(s) containing the entire SapI methylase gene. The DNA fragments ranging between 2-20 kb were gel-purified.
3. The Sau3AI-digested genomic DNA of step 2 was ligated into BamHI-cleaved/CIP treated pUC19 cloning vector. The NlaIII-digested genomic DNA was ligated into SphI-cleaved/CIP treated pUC19 cloning vector. The resulting mixtures were used to transform an appropriate host, i.e. a HsdR - , McrBC - , Mrr - strain, such as E. coli strain RR1. The DNA/cell mixtures were plated on ampicillin selective media for transformed cells. After incubation, the transformed colonies were harvested together to form the primary cell library.
4. The recombinant plasmids were purified in toto from the primary cell library to make primary plasmid library. The purified plasmid library was then digested to completion in vitro with SapI endonuclease, or any SapI isoschizomer. SapI endonuclease digestion causes the selective destruction of unmodified, non-methylase-containing clones, resulting in an increase in the relative frequency of SapI methylase-carrying clones.
5. Identification of SapI methylase clone: The digested plasmid library DNA was transformed back into a host such as E. coli strain RR1 and transformed colonies were again obtained by plating on ampicillin plates. The colonies were picked and their plasmid DNAs were prepared and analyzed for the presence of the SapI methylase gene by incubating purified plasmid DNA in vitro with SapI endonuclease to determine whether it is resistant to SapI digestion.
6. Once it has been established that the methylase gene has been closed, the clone was analyzed by restriction mapping and deletion mapping. The entire insert was sequenced and one open reading frame corresponding the SapI M1 methylase gene was found. (See FIG. 3, SEQ ID NO:1).
7. To construct a genomic DNA map adjacent to the M1 gene, two DNA fragments from the M1 clone (ClaI-SmaI fragment and Clai-SphI fragment) were used as probes in Southern blots to detect genomic DNA that had been digested by AatII, EcoO109I, EcoRI, KpnI, PvuI, SmaI, SphI, SspI, XbaI, XmnI, AflII, AvrII, BsgI, BspEI, BstBi, Bsu36I, DraIII, EagI, Eco47III, EcoNI, MscI, SnaBI, SpeI, or StyI. The Southern blots indicated that EcoRI (11 kb), KpnI (5.8 kb), and SmaI (6.5 kb) fragments were good candidates for clonging of SapI M2 gene and/or SapI restriction endonuclease gene.
8. The genomic DNA was digested with EcoRI, KpnI, or SmaI. EcoRI fragments around 11 kb, KpnI fragments about 5.8 kb, and SmaI fragments about 6.5 kb were gel-purified and ligated into EcoRI, KpnI, or SmaI digested and CIP treated pUC19 vectors and the ligated DNAs were transformed into RR1 competent cells to construct EcoRI, KpnI, and SmaI genomic DNA libraries. The library DNAs were mixed together and digested with SapI restriction endonuclease and retransformed into RR1 competent cells to screen SapI resistant clones.
9. Three clones with 5.8 kb KpnI fragment insert were isolated that showed partial resistance to SapI digestion. They were analysed by restriction mapping and deletion mapping. Subclones were sequenced. An open reading frame was found to code for a second methylase (M2). (See FIG. 4, SEQ ID NO:2)
10. The 5.8 kb KpnI fragment insert contains the entire M2 gene and majority of M1 gene. The DNA upstream of M2 was sequenced in the hope of locating an open reading frame. A total of 1731 bp of DNA was sequenced upstream of M2 gene and this new sequence was compared with all known genes in GenBank. An open reading frame was found that has homology to the abaA gene involved in antibiotics synthesis. It was concluded that SapI restriction endonuclease gene is not located upstream of M2 gene.
11. Inverse PCR was used to amplify DNA sequences that are downstream of M1 gene. Saccharopolyspora sp. genomic DNA was digested with AflIII, AgeI, AseI, BglII, BsaHI, BsrFI, BstYI, ClaI, EcoRI, KasI, KpnI, MluI, NgoMI, PaeR7I, Ppu10I, or PstI restriction enzymes or any other restriction enzymes that will give rise to reasonable size template DNA (less than 10 kb) for inverse PCR reaction. The digested DNA were self-ligated at a low DNA concentration (less than 2 microgram per ml). The ligated circular DNA was used as templates for inverse PCR reaction using a set of primers (see Example I, Section 5) that annealed to the end of the SapI M1 gene.
12. Amplified products were found in AflIII, AgeI, AseI, BsaHI, BsrFI, BstYI, ClaI, KasI, MluI, PaeR7I, and Ppu10I digested and self-ligated DNA templates used in inverse PCR. The inverse PCR products from ClaI (1.4 kb) and NsiI (1.6 kb) reactions were treated with T4 polynucleotide kinase and T4 DNA polymerase and cloned into HincII-cleaved/CIP treated pUC19 vector. The entire inserts were sequenced. One open reading frame which encoded the SapI endonuclease gene (FIG. 5, SEQ ID NO:3) was found that runs in the opposite direction as compared to M1 gene.
13. The SapI M1 and M2 genes were cloned into pACYC184 to premodify E. coli host. The entire open reading frame (SapI endonuclease gene) was amplified by PCR with two primers. An efficient ribosome binding site and 7 bp spacing were engineered before the ATG start codon. The endonuclease gene was first cloned into high-copy-number expression vectors such as pUC19. But the clones were not stable. SapI endonuclease activity can be found from cell extract of 10 ml culture, but not from 500 ml culture. To stabilize the clone, the endonuclease gene was inserted into a modified T7 expression vector pET21t and transformed into SapI methylase modified cells. ER2504 [pACYC-SapIM1-M2, pET21t-SapIR] (NEB#998; New England Biolabs, Inc.; Beverly, Mass.) produced about 20,000 units of SapI endonuclease activity per gram of wet E. coli cells. A sample of NEB#998 has been deposited under the terms and conditions of the Budapest Treaty with the American Type Culture Collection on Jul. 11, 1996 and received ATCC Accession Number 98102.
The following Example is given to illustrate embodiments of the present invention as it is presently preferred to practice. It will be understood that this Example is illustrative, and that the invention is not to be considered as restricted thereto except as indicated in the appended claims.
The references cited above and below are herein incorporated by reference.
EXAMPLE I
CLONING OF SapI RESTRICTION-MODIFICATION SYSTEM
1. Cloning of SapI Methylase Gene (M1).
10 μg of Saccharopolyspora sp. genomic DNA was cleaved partially by 4, 2, 1, 0.5, 0.25 units of Sau3AI at 37° C. for 30 min. The partilly digested DNA was analysed by gel electrophoresis. It was found that 1 unit and 0.5 unit of Sau3AI digestion gave rise to limited partial digestion. The partial digestion was repeated for 200 μg DNA (10 μg DNA in one tube, 20 digestions were performed). Genomic DNA fragments in the range of 2-20 kb were gel purified by excision of DNA from the agarose gel, freeze-thawing, and centrifugation. The supernatants containing DNA was precipitated with 95% ethanol. The pellet was washed with 70% ethanol, dried, and resuspended in TE buffer. The Sau3AI partially digested Saccharopolyspora sp. genomic DNA was ligated into BamHI cleaved/CIP treated pUC19 DNA at 16° C. onvernight. Ligated DNA was transformed into RR1 competent cells and plated on ampicillin plates. A total of about 5×10 4 cells were derived from the transformation. These cells were pooled together and inoculated into 1 liter LB broth plus Ap and cultured overnight at 37° C. Plasmid DNAs were prepared from the primary cell library. 10, 5, 2, 1 μg of plasmid DNA were cleaved with SapI restriction endonuclease for four hours at 37° C. The SapI-digested DNAs were retransformed into RR1 competent cells. Plasmid DNAs were isolated again from the surviving transformants and digested with SapI restriction enzyme to see if the plasmid DNA is resistant to SapI digestion. 72 plasmids were checked for resistance to SapI digestion. One resistant clone (#32) was found that carries about 1.5 kb genomic DNA insert. The entire insert was sequenced using deletion clones and primer walking with custom primers. It was found that the insert contains the SapI methylase gene (M1). The predicted amino acid (aa) sequence contains conserved N 4 cytosine methylase motifs of VXDPXGGXGT (SEQ ID NO:4) and SPPF. The DNA coding sequence and predicted aa sequence are shown in FIG. 3.
2. Restriction Mapping of Genomic DNA Surrounding SapI M1 Gene.
One ClaI-SmaI DNA fragment encoding the C-terminus of M1 methylase from the M1 clone was used as a probe in the Southern blot to detect genomic DNA that had been digested by AatII, EcoO109I, EcoRI, KpnI, PvuI, SmaI, SphI, SspI, XbaI, XmnI. AflII, AvrII, BsgI, BspEI, BstBI, Bsu36I, DraIII, EagI, Eco47III, EcoNI, MscI, MunI, NcoI, NdeI, NruI, PflMI, PmlI, RsrII, SacII, SnaBI, SpeI, or StyI. The endonuclease digested genomic DNA was subjected to electrophoresis in a 0.8% agarose gel. The DNA was denatured and transferred to a nitrocellulose membrane by blotting. The DNA in the membrane was hybridized with biotinylated ClaI-SmaI fragment probe at 65° C. overnight. The hybridized DNA was detected by NEBlot® phototope detection system. (New England Biolabs, Inc. Beverly, Mass.) The same genomic DNA membrane was stripped and reprobed with a ClaI-SphI DNA probe coding for the N-terminus of SapI methylase MI. The Southern blots indicated that EcoRI (11 kb), KpnI (5.8 kb), and SmaI (6.5 kb) fragments were good candidates for cloning of surrounding DNA encoding SapI M2 gene and/or SapI retriction endonuclease gene.
3. Cloning of SapI Methylase Gene M2.
Saccharopolyspora sp. genomic DNA was cleaved with EcoRI, KpnI, or SmaI. The digested DNA was subjected to electrophoresis in a 0.8% agarose gel. EcoRI fragments about 11 kb, KpnI about 5.8 kb, and SmaI fragments about 6.5 kb were gel-purified and ligated into EcoRI, KpnI, and SmaI digested and CIP-treated pUC19 vector. The ligated DNA was transformed into RR1 competent cells. About 6,000 colonies were pooled together and inoculated into 500 ml LB broth plus Ap and cultured overnight. Plasmid DNAs were prepared from the mixed primary cell libraries. 10, 5, 2, 1 μg of plasmid DNA were cleaved with SapI restriction endonuclease for four hours at 37° C. The SapI-digested DNAs were retransformed into RR1 competent cells. The transformants were used for colony hybridization using M1 DNA probe. Plasmid DNAs were isolated from positive clones and digested with SapI restriction enzyme to see if the plasmid DNA is resistant to SapI digestion. Isolates #5, #18, and #32 were partially resistant to SapI digestion and contains the 5.8 kb KpnI genomic insert. Restriction mapping, deletion mapping, and DNA sequencing indicated that the insert carries a second methylase gene M2 and majority of M1. The coding sequence and predicted aa sequence of M2 is shown in FIG. 4. SapI M2 methylase also contains conserved N 4 cytosine methylase motifs: VXDPXGGXGT (SEQ ID NO:4) and SPPY. The extra DNA upstream of M2 is about 3.3 kb. The DNA adjacent to M2 was sequenced in the hope of finding open reading frames that might be SapI endonuclease gene. A total of 1731 bp of DNA was sequenced and this sequence was used to search homology to all known genes in GenBank. One open reading frame upstream of M2 was found to have similarity to a gene that is involved in antibiotics synthesis. It was concluded that this open reading frame upstream of M2 gene is not SapI restriction endonuclease gene.
4. Cloning of Part of SapI Restriction Endonuclease Gene by Construction Partial NlaIII Library.
Since the SapI endonuclease gene is most likely located downstream of M1 gene, we tried to clone larger DNA fragments carrying both M1 and SapI endonuclease gene. Saccharopolyspora sp. genomic DNA was partially digested with NlaIII restriction endonuclease. Genomic DNA fragments ranging from 3-20 kb were gel-purified and inserted into SphI-digested and CIP-treated pUC19. The ligated DNA was used to transform RR1 competent cells. Plasmid DNAs were prepared from the primary cell library. 10, 5, 2, 1 μg of plasmid DNA were cleaved with SapI restriction endonuclease for four hours at 37° C. The SapI-digested DNAs were retransformed into RR1 competent cells. Plasmid DNAs were isolated and digested with SapI restriction enzyme to see if the plasmid DNA is resistant to SapI digestion. After screening 153 plasmid isolates, pUC19-genomic inserts #9, #13, #14, #59, #83, #84, #88, #109, #118, #123, #126, #133, #148 were found to be resistant to SapI digestion. Restriction mapping indicated that #13, #14, and ##59 carry the same inserts and the DNA downstream of M1 methylase gene was sequenced. The insert of #13 contains extra DNA that extended the M1 insert further out 657 bp. But this 657 bp is not large enough to encode the entire SapI restriction endonculease gene. #13 did not displayed any detectable SapI restriction endonuclease activity in cell extract.
5. Cloning the Remainder of SapI Endonuclease Gene by Inverse PCR.
Inverse PCR was used to amplify DNA sequences that are downstream of M1 gene. Saccharopolyspora sp. genomic DNA was digested with AflIII, AgeI, AseI, BglII, BsaHI, BsrFI, BstYI, ClaI, EcoRI, KasI, KpnI, MluI, NgoMI, PaeR7I, Ppu10I, or PstI restriction enzymes. The digested DNAs were self-ligated at a low DNA concentration (ligation reaction: 20 μl of digested DNA, about 1 μg, 50 μl 10× ligation buffer, 5 μl of T4 DNA ligase, 425 μl of sterile distilled water, 16° C. overnight). The ligated circular DNA was purified by phenol-CHCl 3 extraction and ethanol precipitation and used as templates for inverse PCR reaction using a set of primers that annealed to the end of the SapI M1 gene. The primer sequences used in inverse PCR were:
forward primer: 5' TAAGCTATCTTGGTCAGTCAAAG 3' (SEQ ID NO:5)
reverse primer: 5' AACAGGAGATGATGTTTAGTTGTA 3' (SEQ ID NO: 6)
The inverse PCR reaction conditions were 95° C. for 1 min, 60° C. for 1 min, and 72° C. for 2 min, running 30 cycles. Inverse PCR products were found in AflIII, AgeI, AseI, BsaHI, BsrFI, BstYI, ClaI, KasI, MluI, PaeR7I, and Ppu10I digested and self-ligated DNA templates. The inverse PCR products from ClaI (1.4 kb) and NsiI (1.6 kb) reactions were treated with T4 polynucleotide kinase and T4 DNA polymerase and cloned into HincII-cleaved/CIP treated pUC19 vector. The entire inserts were sequenced using deletion clones and custom primers. One open reading frame was found that runs in the opposite direction as compared to M1 gene. The DNA coding sequence and the predicated aa sequence are shown FIG. 5.
6. Expression of SapI Endonuclease Gene in PUC19.
The SapI M1 gene was subloned into pR976 (Tc R , a pACYC184 derivative, FIG. 6) and the M2 gene was cloned into pLG339 (Kn R , a pSC101 derivative, Stoker et al., Gene 18:335-341). Both pR976-M1 and pLG339-M2 were transformed into E. coli to premodify host chromosome. The SapI endonuclease gene was amplified by PCR and ligated into pUC19. A low level of SapI expression was achieved in E. coli [pR976-M1, pLG339-M2, pUC19-SapIR], but the strain was not stable. SapI activity was detected only in 10 ml culture. SapI activity was lost in 500 ml culture.
7. Expression of SapI Endonuclease Gene in a Low Copy Number Plasmid pR976 Under P tac Promoter Control.
Since SapI expression in a high copy number plasmid such as pUC19 was not stable, it was thought that expression on a low copy number plasmid may stablize the expression. E. coli competent cell was transformed with pUC19-M1 and pLG339-M2 to modify the host DNA. SapI endonuclease gene was amplified by PCR and inserted into the PstI site of pR976. The strain E. coli [pUC19-M1, pLG339-M2, pR976-SapIR] produced about 1000 units of SapI per gram of wet E. coli cells, a 3-fold overproduction than the native strain. Again the strain was not stable because it reduced the activity in large cell culture. This instability was probably caused by the under-methylation and constitutive endonuclease expression from the P tac promotor.
8. Expression of M1 and M2 on DUC19 and pACYC184.
Because the SapI expression clone was not stable, it was thought that overexpression SapI methylase genes M1 and M2 may help to alleviate the problem. An efficient ribosome binding site GGAGGT and 6 bp spacing AAATAA were engineered in front of M2 gene by PCR and the gene was inserted into pUC19-SapIM1. The resulting plasmid was pUC19-SapIM1-M2 (there is one SapI site in the vector). When this plasmid was isolated and digested with SapI, only about 70% of DNA was resistant to SapI digestion, indicating poor SapI methylase expression/instability of SapI methylase proteins in vivo.
To compare the SapI methylase modification level in vivo, the M1 and M2 genes were also cloned into pACYC184. The resulting plasmid was pACYC184-SapIM1-M2. This plasmid and pUC19 was co-transformed into E. coli cells. Plasmid DNA mixture was isolated from the cells and subjected to SapI digestion (there is one SapI site in pUC19, no SapI site in pACYC184-SapIM1-M2). It was found that about 70% of pUC19 DNA was resistant to SapI digestion, indicating that the methylase expression from a high copy number plasmid and a low copy number plasmid resulted in the similar level of SapI site modification.
9. Expression of SapI Endonuclease Gene in a Modified T7 Expression Vector.
Two primers were made to amplify the SapI endonuclease gene. The primer sequences are:
forward primer:
5' CGCTCTAGA (XbaI site) GGAGGT (ribosome binding site) TAAATA (spacing) ATGCGGAGGCTTGCTACACAACGACGC 3' (SEQ ID NO:7)
reverse primer:
5' GAGGGATCC (BamHI site) TCAGTCCAGTGGTAGTGCTTCATC GAG 3' (SEQ ID NO:8).
The SapI endonuclease gene was amplified from Saccharopolyspora sp. genomic DNA with Taq DNA polymerase plus Vent® DNA polymerase (50:1 ratio) under the PCR condition 95° C., 1 min, 60° C., 1 min, 72° C., 1 min 30 sec for 20 cycles. The PCR DNA was purified by phenol-CHCl 3 extraction and ethanol precipitation and resuspended in TE buffer. The DNA was digested with BamHI and XbaI restriction endonucleases and ligated into a modified T7 expression vector pET21t. The expression vector pET21t contains transcription terminators upstream of the T7 promotor to further reduce the basal level of expression under non-induced condition (pET21t was constructed and provided by H. Kong, New England Biolabs, Inc., Beverly, Mass.). The ligated DNA was used to transform SapI methylase modified cell ER2504 [pACYC-SapIM1-M2]. ER2504 is a BL21(λDE3) derivative that is also TonA - and DNasI - . E. coli cells ER2504 [pACYC-SapIM1-M2, pET21t-SapIR] were grown in LB broth to late log phase (about 150 klett units) and IPTG was added to a final concentration of 0.5 mM to induce endonuclease production. IPTG-induction and cell culture continued for 3 hours. Cells were harvested by centrifugation and resuspended in sonication buffer (10 mM β-mercaptoethanol, 50 mM Tris-HCl pH 7.5). Cells were lysed by addition of lysozyme and sonication. Cell debris was removed by centrifugation and the supernatant was assayed for SapI activity on λDNA. The strain produced about 20,000 units of SapI restriction endonuclease per gram of wet E. coli cells. It still produces SapI endonuclease in cells cultured in a 100 liter fermentor.
10. Purification of Recombinant SapI Restriction Endonuclease.
The recombinant SapI restriction endonuclease was purified by chromatography through Heparin-Sepharose column, phosphocellulose column, and Q-Separose HPLC. The purified enzyme was assayed on λ DNA and pUC19 substrate.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 8(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1131 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: genomic DNA(ix) FEATURE:(A) NAME/KEY: Coding Sequence(B) LOCATION: 1...1128(D) OTHER INFORMATION:(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:GTGTTGGAAACTCTTGAGCTAGTCAACAAAATTGCGGAGTTTCAAAGG48MetLeuGluThrLeuGluLeuValAsnLysIleAlaGluPheGlnArg151015AAGCTACCTTACACGCAGGACGACTATAAGAGTCGCTCCTGGGGGCAC96LysLeuProTyrThrGlnAspAspTyrLysSerArgSerTrpGlyHis202530CCCTTGCACTCCCTTTGTTCGTACCAGGGAAAGTTGAAACCTTCGCTT144ProLeuHisSerLeuCysSerTyrGlnGlyLysLeuLysProSerLeu354045GCTCACTGGCTCGTTAAGACATTCTCGCCGGAAGGTGGCACGGTACTC192AlaHisTrpLeuValLysThrPheSerProGluGlyGlyThrValLeu505560GATCCGATGGGAGGCGTGGGAACAATAGCCTTTGAAGCGGCTCTAACG240AspProMetGlyGlyValGlyThrIleAlaPheGluAlaAlaLeuThr65707580GGTCGGGTCGGGATAACCAACGACAAAAGTCCATTGGCCGCTACTGTC288GlyArgValGlyIleThrAsnAspLysSerProLeuAlaAlaThrVal859095ACCGCCGGCAAGCTTGCCCCGTCGTCTATACTGGAAGCTGAAGAGGCC336ThrAlaGlyLysLeuAlaProSerSerIleLeuGluAlaGluGluAla100105110ATTGGTCGACTGGCGGAAGATATTGAATCGGTGGACCTCAGTGCTGCA384IleGlyArgLeuAlaGluAspIleGluSerValAspLeuSerAlaAla115120125GATTATGAAGCCGCCAATTTCGGCTTGAATGCACGCGTTTCTGACTAC432AspTyrGluAlaAlaAsnPheGlyLeuAsnAlaArgValSerAspTyr130135140TATCACCCGGATACTCTCAAAGAGATTTTGCGCGCGCGCCGTATTTTT480TyrHisProAspThrLeuLysGluIleLeuArgAlaArgArgIlePhe145150155160AGCGAGAGACGAGAAGCTTACCCAGCATTTGTCTGGGCATCTTTGTTG528SerGluArgArgGluAlaTyrProAlaPheValTrpAlaSerLeuLeu165170175CATGTACTGCATGGAAATCGGCCATATGCGTTGTCGCGGATTTCGCAC576HisValLeuHisGlyAsnArgProTyrAlaLeuSerArgIleSerHis180185190CCAATTACACCTTTCAACCCGTCAGGGGTAGCTGAGTACAGATCGGTA624ProIleThrProPheAsnProSerGlyValAlaGluTyrArgSerVal195200205GTCGAGAAGATTGCCCACCGCGCCCGGCTTGCTCTAAGGAATCCGTTG672ValGluLysIleAlaHisArgAlaArgLeuAlaLeuArgAsnProLeu210215220CCAGAGGCATTCACTTCTGGCGCCGCCATCGAGGGGGACTTCAGAGAT720ProGluAlaPheThrSerGlyAlaAlaIleGluGlyAspPheArgAsp225230235240CTCTCGGAACATATTAATGAACCGGTTGATGCGATAATTACGAGCCCT768LeuSerGluHisIleAsnGluProValAspAlaIleIleThrSerPro245250255CCATTCATGGGAATGCGTTTCGATCGGCCTAATTGGCTTCGCCTGTGG816ProPheMetGlyMetArgPheAspArgProAsnTrpLeuArgLeuTrp260265270TTCTGCGGATGGGACGCTGAGGACTTCTGGACGACAAGCCTGGGTTTT864PheCysGlyTrpAspAlaGluAspPheTrpThrThrSerLeuGlyPhe275280285TTGGAGCGCCACCAAGTGAAATCGCGGGATTCCTACATCGATTTTTTC912LeuGluArgHisGlnValLysSerArgAspSerTyrIleAspPhePhe290295300GAGATGTCCATCAAGACGTTGAAGCAAGACGGCTTGCTTGTCATGCAT960GluMetSerIleLysThrLeuLysGlnAspGlyLeuLeuValMetHis305310315320CTGGGGAGTGGCGGGAAAAAGAATCTTGTCAACGATCTCAAGTCCCT1008LeuGlySerGlyGlyLysLysAsnLeuValAsnAspLeuLysSerLeu325330335GCGGTACCGCTTTTTGAACTTGCAGGCGAGGTGATCGAAGACGTGGA1056AlaValProLeuPheGluLeuAlaGlyGluValIleGluAspValAsp340345350GACCATCAGACACATGGAATTCGAGACCGAGGCCTTACAACTAAACA1104AspHisGlnThrHisGlyIleArgAspArgGlyLeuThrThrLysHis355360365CATCTCCTGTTCTTCAAACCTGCATAG1131HisLeuLeuPhePheLysProAla370375(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1302 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: genomic DNA(ix) FEATURE:(A) NAME/KEY: Coding Sequence(B) LOCATION: 1...1299(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:ATGAGCGTCGATGCACCTTCGCCTGCTCGCCGCCGGGGTCAAGCTGCT48MetSerValAspAlaProSerProAlaArgArgArgGlyGlnAlaAla151015ACCTCCGGACGAGGAACAAATGAAAATAGATTGCCAATTGACCTCGGG96ThrSerGlyArgGlyThrAsnGluAsnArgLeuProIleAspLeuGly202530GTAACCTTCCGGGACAACAGAAACCGGCCTGTTCATTCATGGTATCCA144ValThrPheArgAspAsnArgAsnArgProValHisSerTrpTyrPro354045TATGTAGAGGGGTTCTCGGCCGCTTACGTGGAGGGCGTCTTGGCGCCC192TyrValGluGlyPheSerAlaAlaTyrValGluGlyValLeuAlaPro505560TATAATGGGCACAACGTAGCAGTTTATGACCCATTTGGCGGGTCTGGG240TyrAsnGlyHisAsnValAlaValTyrAspProPheGlyGlySerGly65707580ACACTGCAATCGACAGCGTCGTGGCTCGGTATCAATTCGTTCTATTCA288ThrLeuGlnSerThrAlaSerTrpLeuGlyIleAsnSerPheTyrSer859095GAAGTCAATCCTTTCATGCGCTTTGTGGCCGAAGCCAAGGTTAACGCA336GluValAsnProPheMetArgPheValAlaGluAlaLysValAsnAla100105110ACATTGAAGGCTGCGCAGAATAAGGACGTCTTTCGTTGTGCCGCCAAG384ThrLeuLysAlaAlaGlnAsnLysAspValPheArgCysAlaAlaLys115120125GAATTTCTAGACATGCTCAGCGAGAAGGAATTGGCACACCGAGGACGC432GluPheLeuAspMetLeuSerGluLysGluLeuAlaHisArgGlyArg130135140TCTGTCGATCTTTCGCAGTATTATAGCGCTTTCCCGGGGCGCGACTTC480SerValAspLeuSerGlnTyrTyrSerAlaPheProGlyArgAspPhe145150155160TTTGAAGAAGAACATATTCGCCAATTGTTGGCTGCTTGCGATGCCGCA528PheGluGluGluHisIleArgGlnLeuLeuAlaAlaCysAspAlaAla165170175CGACTTATCGGTTCTGATTATGCTTGGGTTCGGCAGCTCCTCTTGCTG576ArgLeuIleGlySerAspTyrAlaTrpValArgGlnLeuLeuLeuLeu180185190GCCTGCGCTGCAAATGCCGTACATAGTTCAAACATGACGCGTAGGGCA624AlaCysAlaAlaAsnAlaValHisSerSerAsnMetThrArgArgAla195200205GACCTCCGTAGGCGGCGCCAAAATGAATACATCAACCGGAAGGTTGAT672AspLeuArgArgArgArgGlnAsnGluTyrIleAsnArgLysValAsp210215220GTGGCGCGATTCATTTCTGATACGGTTCAAGCAATGCTCGACGATGTC720ValAlaArgPheIleSerAspThrValGlnAlaMetLeuAspAspVal225230235240GAGCAGGTCCCCTTTGGAGCGGTAGCATCACATTATGTTTCCGATGAC768GluGlnValProPheGlyAlaValAlaSerHisTyrValSerAspAsp245250255TGCCGAGACCTTCCTAGTCGATATATAGATTGTTTCGATATCGCTATC816CysArgAspLeuProSerArgTyrIleAspCysPheAspIleAlaIle260265270ACCTCCCCGCCATACCTCAACGGAACAAACTATTTCAGAAATACGAAG864ThrSerProProTyrLeuAsnGlyThrAsnTyrPheArgAsnThrLys275280285ATTGAGCTATGGTTGCTGGGGTTTTTGAGTCACGAGAGTGAGTTGCCA912IleGluLeuTrpLeuLeuGlyPheLeuSerHisGluSerGluLeuPro290295300AAATTTTGCCGAGAGGCTATCACTGCAGGCATTAATAATGTAAGCGGA960LysPheCysArgGluAlaIleThrAlaGlyIleAsnAsnValSerGly305310315320AATAAGGCGCTCGATCACCATTTCGACGTCGTGGAGGATGTGGCCAC1008AsnLysAlaLeuAspHisHisPheAspValValGluAspValAlaThr325330335AAGCTGGATGATGTGGCACCGGATCGGCGAATCCCAAAGCTTGTCCG1056LysLeuAspAspValAlaProAspArgArgIleProLysLeuValArg340345350CATTATTTTTCCGATATGTACGAAGTACTAACGTCAGTGAGAAGTTC1104HisTyrPheSerAspMetTyrGluValLeuThrSerValArgSerSer355360365CTTCGTTTGGGAGGAAGGTTCATTCTGGATATCGGCGATTCCAAGTT1152LeuArgLeuGlyGlyArgPheIleLeuAspIleGlyAspSerLysPhe370375380TATGGAGTCCATGTCCCCGTCGATCGTATTTTGGTGGAGTTGGGTAA1200TyrGlyValHisValProValAspArgIleLeuValGluLeuGlyLys385390395400CAAGTCGGGTTTCAACTTCATCAAGATGTAGTAATCGCTAGGCGACA1248GlnValGlyPheGlnLeuHisGlnAspValValIleAlaArgArgHis405410415TCTCGGGATAAAACTCCGCTTGTCCAGGTTGAGCTCGAGTTCAGGAA1296SerArgAspLysThrProLeuValGlnValGluLeuGluPheArgLys420425430GCCTAG1302Ala(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 1299 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: genomic DNA(ix) FEATURE:(A) NAME/KEY: Coding Sequence(B) LOCATION: 1...1296(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:ATGCGGAGGCTTGCTACACAACGACGCGAGGACGCGTACAAATCAAAT48MetArgArgLeuAlaThrGlnArgArgGluAspAlaTyrLysSerAsn151015AGGGATTATCAGACCGTGCACGAAGCTCAGAGCCTTCGAGTCAACTCG96ArgAspTyrGlnThrValHisGluAlaGlnSerLeuArgValAsnSer202530ACCGATGATGACAACCTGAGCCTCTTCCTCTTGAAAGATATTTCACCC144ThrAspAspAspAsnLeuSerLeuPheLeuLeuLysAspIleSerPro354045CGCGAAGATTCTAAAAATATTGTAGGATTTGGAGGCTTCGTCAAGCCC192ArgGluAspSerLysAsnIleValGlyPheGlyGlyPheValLysPro505560GAAATCGCCACCACCATGGCGCTTACCTTAACGACAGACATCGATAAA240GluIleAlaThrThrMetAlaLeuThrLeuThrThrAspIleAspLys65707580CAAATAAAATCAGTGCCGTTATCCTCGAATTGGAATCGGATCAGCATC288GlnIleLysSerValProLeuSerSerAsnTrpAsnArgIleSerIle859095GTTGCAAAGTTCGCGAGCAACCCGTCTGTTAGCATTACTCTGGGATTT336ValAlaLysPheAlaSerAsnProSerValSerIleThrLeuGlyPhe100105110GATCAAACCCCATGGGTCGATTTCTGGGGNATCAATTCGGACGATATC384AspGlnThrProTrpValAspPheTrpXaaIleAsnSerAspAspIle115120125GGCCTTTCATTTGTATCGGACGCAGTCCCTCTTGAAATGAGCATGATT432GlyLeuSerPheValSerAspAlaValProLeuGluMetSerMetIle130135140GATAGCATACATATTGCCCCCGAAACACTATACCTTGATCACTCAAGC480AspSerIleHisIleAlaProGluThrLeuTyrLeuAspHisSerSer145150155160GCATGTCTCCTTGACATTGATCCAGTGGAATCGACACGCTTCAAAACA528AlaCysLeuLeuAspIleAspProValGluSerThrArgPheLysThr165170175GGRCATGGTGACCCTTTAAGTCTGAAGAGATGGTCATACTGGGGGCGC576XaaHisGlyAspProLeuSerLeuLysArgTrpSerTyrTrpGlyArg180185190CTTCTTCCTATAGACCTCGAGCGTCCCGGCAAGCTGTCTTTTCACAAA624LeuLeuProIleAspLeuGluArgProGlyLysLeuSerPheHisLys195200205CATCGAGCCAAAATCACTAATCATCAGAACGAGTGTCGTTCATGTAAG672HisArgAlaLysIleThrAsnHisGlnAsnGluCysArgSerCysLys210215220AAGTGGCGAATAAACATCTCCTTCAATCCGATGCGCACGATTGACCAG720LysTrpArgIleAsnIleSerPheAsnProMetArgThrIleAspGln225230235240CTTAACGAGTCAGCACTTATCACACGTGAGCGAAAGATATTCCTGCAA768LeuAsnGluSerAlaLeuIleThrArgGluArgLysIlePheLeuGln245250255GAACCAGAAATTCTTCAGGAAATTAAGGATAGGACCGGCGCGGGACTT816GluProGluIleLeuGlnGluIleLysAspArgThrGlyAlaGlyLeu260265270AAAAGTCAAGTGTGGGAACGATTCCATCGCAAGTGCTTCAACTGTAGA864LysSerGlnValTrpGluArgPheHisArgLysCysPheAsnCysArg275280285AAAGATCTCAAACTAAGCGAGGTTCAACTGGACCACACTCGGCCGCTT912LysAspLeuLysLeuSerGluValGlnLeuAspHisThrArgProLeu290295300GCATACCTATGGCCGATTGATGAGCATGCGACTTGCTTGTGCGCACAA960AlaTyrLeuTrpProIleAspGluHisAlaThrCysLeuCysAlaGln305310315320TGCAACAATACCAAAAAAGACCGCTTTCCTGTAGATTTCTATAGCGA1008CysAsnAsnThrLysLysAspArgPheProValAspPheTyrSerGlu325330335CAGCAGATACGCGAACTGTCGGACATTTGCGGACTTCCGTATCAGGA1056GlnGlnIleArgGluLeuSerAspIleCysGlyLeuProTyrGlnAsp340345350CTATGTGCTCGCTCGTTGAATTTAGATCAACTCGATAGGATCGAGCG1104LeuCysAlaArgSerLeuAsnLeuAspGlnLeuAspArgIleGluArg355360365AATATCGCAGAGTTCTCCAAAGAATGGGATGTAAGAACTTTCGCATC1152AsnIleAlaGluPheSerLysGluTrpAspValArgThrPheAlaSer370375380ACCGCCCGGAGAATATCGGAAGTTTACCCCGCGCGAGACCTATTTGA1200ThrAlaArgArgIleSerGluValTyrProAlaArgAspLeuPheGlu385390395400ACTCTTAAGAAGGAAAGCGAGTCAGCGTACAATAAAATTATTGAGAA1248ThrLeuLysLysGluSerGluSerAlaTyrAsnLysIleIleGluLys405410415TTGAAGGAAAGACCAGACGCACTTCTCGATGAAGCACTACCACTGGA1298LeuLysGluArgProAspAlaLeuLeuAspGluAlaLeuProLeuAsp420425430A1299(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 10 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:ValXaaAspProXaaGlyGlyXaaGlyThr1510(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: single-stranded DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:TAAGCTATCTTGGTCAGTCAAAG23(2) INFORMATION FOR SEQ ID NO:6:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 24 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: single-stranded DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:6:AACAGGAGATGATGTTTAGTTGTA24(2) INFORMATION FOR SEQ ID NO:7:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 27 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: single-stranded DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:7:ATGCGGAGGCTTGCTACACAACGACGC27(2) INFORMATION FOR SEQ ID NO:8:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 27 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: unknown(D) TOPOLOGY: unknown(ii) MOLECULE TYPE: single-stranded DNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:8:TCAGTCCAGTGGTAGTGCTTCATCGAG27__________________________________________________________________________
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The present invention relates to recombinant DNA which encodes the SapI restriction endonuclease and modification methylase, and the production of SapI restriction endonuclease from the recombinant DNA as well as to methods for cloning Actinomycetes genes into suitable hosts such as E. coli.
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BACKGROUND OF THE INVENTION
[0001] 1. Area of the Art
[0002] The present application relates to systems for the handling and local transport of disc shaped flat sheets of stiff but flexible materials such as integrated circuit wafers, flat screen displays, glass reticules used in semiconductor chip manufacture and the like materials. Particularly, the present invention relates to an intelligent integrated circuit wafer location and handling system and a method for selectively positioning and processing both sides of a subject wafer.
[0003] 2. Description of the Prior Art
[0004] Semiconductor wafers are produced by complex multi-step processes. Sophisticated integrated circuit type electronic chips are derived from wafers during processes involving often greater than 100 steps. Many of steps require extremely accurate positioning of the chips because the submicron range technologies used in manufacturing the chips are both error and inspection intensive. Also, the wafers before processing are extremely expensive, and become even more valuable after processing. There is therefore a strong need for heightened control of processing and handling methods for the involved wafers.
[0005] It follows that the high production rates required for production of integrated circuits necessitate that the wafers upon which individual circuits are located be processed rapidly and in batches. Typical wafers being processed have diameters ranging from about 4 inches to about 12 inches. Such wafers are generally housed for processing in cassettes, or caddies in closely stacked vertical arrangements.
[0006] Processing generally entails separate removal of each subject wafer from its housing cassette and loading of the same into the processing equipment utilized, followed by return of the processed wafer to a cassette or carrier. The receiving cassette may be different than the first cassette, and the fragile nature of the wafers, generally silicon, provides further constraints. Removal, processing and repositioning of these varying sized wafers has created a longstanding need for more efficient apparatus and methods for processing them. Further, because the wafers are thin as well as formed from brittle materials, the pressure exerted on the wafers by the handling device can be critical and the gripping pressure must be carefully controlled to minimize bending, cracking or chipping of the costly wafers while still assuring a firm grip on the wafer to avoid dropping it during handling.
[0007] Patented Apr. 14, 1992, the WAFER INSPECTION SYSTEM of U.S. Pat. No. 5,105,147 (“Karasikov” et al.) is typical of the state of at least one aspect of the existing art. The disclosed system is for the semiautomatic inspection of printed circuits on silicon wafers. Included in the Karasikov patent are the combination of a floating table, and a robotic arm optical inspection device which includes a sophisticated optoscanner for the alignment and positioning of a wafer.
[0008] Karasikov removes involved wafers by applying a vacuum to a narrow zone at the circumference of a wafer. The mechanism of the Karasikov patent highlights problems, which result in many of the processing errors ameliorated by the teachings of the present invention. Likewise, U.S. Pat. No. 5,504,345 (“Bartunek” et al.) which issued Apr. 2, 1996, disclosed a dual beam sensor and edge detection system and method. Two light sources, or solid state lasers, are used to detect the edges of the involved wafers. The Bartunek patent essentially shows that lasers may be used for the detection of, for example, the reflective surface of a wafer or optical disc.
[0009] Other known systems for wafer handling similarly either address improvements in locating wafers or quasi-automated means for handling wafers. It would be highly advantageous to have the capability for concurrently improving the performance of both of these functions within a single system. Capitalizing upon the use of lasers without the drawbacks of vacuum-based technology would solve many longstanding needs.
[0010] By way of example, current technology often uses a vacuum chuck mounted on a robotic arm to remove or replace individual wafers in the cassettes. Since the position of each cassette and each wafer within the cassettes is unique, the location of each disk within the three ordinal planes (“X, Y, and Z”) relative to some reference has to be entered into the software driving system controlling the robotics that handle the wafers.
[0011] Existing methodology requires mechanical measurement of each location followed by the data being manually entered into the software being utilized. This is a time consuming process additionally constrained by the high likelihood of human error. Sufficient differences exist among known cassettes and cassette holders, that a calibration of every cassette to be employed is generally required.
[0012] Further, these constraints are complicated by the fact that, for example, in semi-portable processing systems, relocation of any part of the system requires new calibration.
[0013] Conventional vacuum chucks, or pickup devices, referred to as vacuum end effectors, further induce harmful artifacts of the processing steps and these artifacts can result in lower industrial efficacy. Any warpage in the employed vacuum pickups may cause malfunctioning because of air leaks. Since the vacuum pickups must be thin and contain air passages, they are difficult and expensive to build. Further, since the wafer is held by the surface, the wafer is prone to slip under the high acceleration rates necessary in high speed processing. Any misalignment of the disk with the end effector can cause the system to crash. Contamination of the surface by the vacuum pickup parts on the end effector itself occurs with alarming frequency.
[0014] Likewise, a clear need exists for a way to process both sides of a semiconductor wafer. Among the prior art, various attempts at solutions to related problems, and methods for handling wafers for processing are illustrative of the paucity of patents actually addressing the above enumerated constraints. The state of the art clearly shows a need for improvement, such as taught by the present invention.
[0015] Another method of lifting wafers is the use of mechanical grippers, U.S. Pat. No. 5,570,920 (“Crisman” et al.) issued Nov. 5, 1996, utilizes a DC motor to drive a robotic finger. Unlike the teachings of the present invention, strain gauges 171 , 173 , 175 on the inner surfaces of the fingers are used to sense gripping pressure and, once an over pressure is sensed, stop the motor.
[0016] By way of further example, U.S. Pat. No. 5,435,133, which issued Jun. 13, 1995 (“Yasuhara” et al.) utilizes servo motors which drive robotic fingers based on positioning signals. However, no sensors to indicate or control grasping force were found. Likewise, the complex attaching/detaching portion of the hand portion was the focus of Yasuhara's disclosure, differentiating this patent from the teachings of the present invention.
[0017] Additionally, U.S. Pat. No. 5,378,033 (“Guo” et al.), which issued Jan. 3, 1995, utilizes a single drive mechanism for all of the involved mechanical fingers so that they apply a uniform force on the object grasped. The Guo patent teaches a purely mechanical robotic or prosthetic hand. However, the method of controlling the drive mechanism was not apparent, differentiating the Guo patent from the teachings of the present invention.
[0018] U.S. Pat. No. 5,280,981 (“Schulz”) issued Jan. 25, 1994 uses a load responsive two-speed drive assembly and a slip clutch (Col 9, line 63-col 10, line 28).
[0019] Notably, the digit actuation mechanism of the Schulz patent contemplates neither using solenoids, voice coils nor other current generation means wherein a force directly proportional to current is used.
[0020] U.S. Pat. No. 5,188,501 (“Tomita” et al.) issued Feb. 23, 1992, was directed to a wafer transfer system which uses a set of claws which pivot under a wafer to serve as a lifting platform for the wafer. The Tomita patent is thus different from the teachings of the present invention because it works by creating a lifting force which cradles the wafer rather than applying a grasping force.
[0021] Issued Dec. 22, 1992, the “Jacobsen” U.S. Pat. No. 5,172,951 does not appear to disclose a tension sensing or controlling technique. This ROBOTIC GRASPING APPARATUS operates with three degree of freedom, yet does not disclose wafer-friendly usages such as those which are an object of the present invention.
[0022] U.S. Pat. No. 5,108,140 (“Bartholet”) issued Apr. 4, 1992, includes a palm plate and grippers having tactile or other sensors on its upper surface to detect the position of the payload or to provide input to the control mechanism (Col 5. lines 20-37). A parallel vise like grip is generated but no means of detecting or controlling the gripping force appears to be given.
[0023] Likewise, the “Ulrich” U.S. Pat. No. 5,501,49 (issued Mar. 26, 1996) and U.S. Pat. No. 4,957,320 (issued Sep. 18, 1990) each use tactile sensors 200 , 210 located on the palmar surfaces of the fingers and the palm.
[0024] U.S. Pat. No. 4,354,553 (“Rovetta” et al.) issued Sep. 28, 1982 shows a three finger grasping system where the force applied by the fingers is supplied by traction cables 42 , 43 , 44 along the inner surface of the fingers such that tension applied to the fingers causes the fingers to pivot inward, tightening the grasp on the held object. Sensors 84 , 85 , 86 , shown in FIG. 6 of the Rovetta patent, attached to the tension cables sense the traction force applied thereto, differentiating the Rovetta patent from the teachings of the present invention.
[0025] U.S. Pat. No. 4,654,793 (“Guinot”) also incorporates strain gauges 26 , 28 on the fingers.
[0026] U.S. Pat. No. 6,092,971 to Balg et al is direceted to a system for removing wafers from a carrier using a robotic arm. This system uses a combination of a holding rake, several gripping heads which swivel and a counter holder, all of which must be used to grasp and remove the wafers.
[0027] Accordingly, since nothing among the prior art has adequately addressed the longstanding needs ameliorated by the present invention, an intelligent integrated circuit wafer handling system is offered to meet these needs.
OBJECTS AND SUMMARY OF THE INVENTION
[0028] Accordingly, it is an objective of the present invention to provide a system which overcomes the drawbacks of the prior art for chip holding apparatus and techniques. It is a further objective to prove fail-safe means should power feed to the holding device be interrupted. It is a still further objective to provide fail safe means, which do not adversely effect the grasping sensitivity of the grasping fingers and posts during normal operation.
[0029] Briefly stated, there is provided a system for handling stiff but flexible discs, particularly semiconductor wafers, which is capable of allowing processing on both sides of a wafer. Optical beams can be employed to detect a wafer's edge and ascertain a wafer position. Grasping by a unique robotic wafer hand assembly 101 plugged into other robotic systems for positioning is taught. A stiff wafer hand assembly member has one or more actuating rods disposed either centrally or spaced apart along the length of the member. As the wafer hand assembly member is slipped under a wafer, or between parallel stacked, spaced wafers, one or more rotating fingers, which begin in a released position are rotated 90 degrees and spaced from the wafer edge. A translator solenoid, voice coil, or combination thereof acting through an arm, applies lateral movement to the finger or a separate post to grasp the wafer. A rotator solenoid or coil 109 turns the finger 90°. This combination presents a thin profile so the wafer hand assembly member can be inserted under a top wafer between stacked, spaced wafers in a tray as shown in FIG. 8, or rotated 180° to pick up the wafer residing in a processing device. Once positioned under, over or along side a wafer, the finger is rotated to the vertical position by the rotator solenoid. Depending on the embodiment, the finger is pulled or the post is pushed in by the translator solenoid, grasping the wafer with controlled traction force between the post(s) and the movable finger(s). Methods for use of the apparatus of the system of the present invention are also taught.
[0030] A further improvement is the addition of fail safe systems. The disks handled by the disk handling systems are fragile and if dropped can readily chip or crack. In prior available vacuum, pneumatic and electrical systems, a major drawback has been a loss or reduction of the gripping action if power to the gripper control is interrupted due to a power failure or fluctuations in the electrical control circuit. This deficiency has been eliminated in the presently described devices by adding a closing spring specifically selected to have a force, either in expansion or compression, to positively grip the disk held by the handling system if the electricity, or other force supplying means, inadvertently decreases below the force necessary to adequately hold the disc. At the same time, the spring is selected so that, should there be a total failure of the force holding the disks, the force now applied solely by the spring is such that the disks will not be damaged by the gripping means. Also included are sensing means to indicate the position of the finger and whether a disk is held in the gripper.
[0031] As shown schematically in FIG. 8, the wafers are usually carried in a tray. In various different embodiments of the tray 150 , the circular wafer may contact and rest on the tray sides and/or the tray bottom. More specifically, the lower most point of the wafer as it rests in the tray 150 may be in contact with a point in the center of the tray bottom (See FIG. 9). In an alternative tray design the wafer may only contact the sides of the tray thus spacing the bottom of the wafer from the tray bottom. As a further alternative, the tray bottom may have an opening along the length thereof. If the wafer is sufficiently spaced from the bottom of the tray 150 , or there is an open space in the tray bottom the wafer handling system of FIGS. 1 - 8 , having a centrally located rotatable finger, can be used. However, if the wafer contacts the bottom of the tray 150 along the tray center line then the rotatable fingers must be spaced from the center of the front edge 124 of the handling system as shown in the embodiment of FIGS. 9 - 11 and more particularly in FIG. 9.
[0032] According to a feature of the present invention, there is provided a system for handling wafers and the like substrate means, which comprises, in combination, a hand assembly, a means for grasping, transporting and returning said substrate means to be handled, and at least a control means for programming and implementing a desired sequence of operations. This system may also include a separate or integral optical means for detecting a local position and orientation of a substrate means to be handled.
[0033] The system may further include optical detection means in combination with computer based identification calibration and control means for determining the size or identity of the wafers and subsequent control of the movement and positioning of the moving finger and the tension placed on the wafer grasped by the system.
[0034] According to another feature of the present invention there is provided a method for handling wafers, and related compact planar devices without damaging their surface integrity, the method comprising the steps of:
[0035] a) providing a robotic wafer hand assembly equipped with at least one or more posts, which may be fixed or moveable, a rotating finger and optical sensing means, which robotic wafer hand assembly is attached to other robotic systems for positioning;
[0036] b) reading a plurality of data regarding the relative position and orientation of a plurality of wafers;
[0037] c) grasping a wafer by use of an actuating rod disposed in a central portion of said robotic wafer;
[0038] d) locking the wafer between the post(s) and the figure(s);
[0039] e) transporting the wafer to a desired location, processing the wafer;
[0040] f) releasing said wafer into a desired location, and
[0041] g) repeating each of said steps for a subsequent wafer.
[0042] According to a feature of the present invention, there is provided a system for handling wafers and the like substrate means, which comprises, in combination, a hand assembly, an optical means for detecting a local position and orientation of a substrate means to be handled, a means for grasping, transporting and returning said substrate means to be handled, and at least a control means for programming and implementing a desired sequence of operations.
[0043] The system may further include optical detection means in combination with computer based identification calibration and control means for determining the size or identity of the wafers and subsequent control of the movement and positioning of the moving finger and the tension placed on the wafer grasped by the system.
[0044] According to another feature of the present invention there is provided a method for handling wafers, and related compact planar devices without damaging their surface integrity, the method comprising the steps of; providing a robotic wafer hand assembly equipped with at least two fixed posts, a rotating finger and optical sensing means, which robotic wafer hand assembly is attached to other robotic systems for positioning, reading a plurality of data regarding the relative position and orientation of a plurality of wafers, grasping a wafer by use of an actuating rod disposed in a central portion of said robotic wafer, locking the wafer between the fixed posts and the finger, transporting the wafer to a desired location, processing the wafer; releasing said wafer into a desired location, and repeating each of said steps for a subsequent wafer.
BRIEF DESCRIPTION OF THE FIGURES
[0045] The above-mentioned and other features of this invention and the manner of obtaining them will become more apparent, and will be best understood by reference to the following description, taken in conjunction with the accompanying drawings. These drawings depict only a typical embodiment of the invention and do not therefore limit its scope. They serve to add specificity and detail, in which:
[0046] [0046]FIG. 1 is a perspective top plan view of a first version of a robotics wafer hand assembly according to an embodiment of the present invention;
[0047] [0047]FIG. 2 a, b, and c are detailed views of enlarged portions of FIG. 1, showing the rotating finger in three different positions;
[0048] [0048]FIG. 3 is an enlarged detailed view of FIG. 1 showing one of the fixed pressure posts;
[0049] [0049]FIG. 4 is an additional perspective bottom plan view of a robotics wafer hand assembly according to an embodiment of the present invention as depicted in FIG. 1, showing a finger actuating rod, a finger translator solenoid and a finger rotating solenoid;
[0050] [0050]FIG. 5 is a side view of a modified version of the robotics wafer hand assembly according to an embodiment of the present invention with certain of the components relocated to the top of the assembly;
[0051] [0051]FIG. 6 is a top plan view of the embodiment of FIG. 5 showing a robotics wafer hand assembly according to an embodiment of the present invention with a wafer disposed thereupon the structure underlying the wafer also being shown;
[0052] [0052]FIG. 7 is a schematic perspective top plan view of a robotics wafer hand assembly according to an embodiment of the present invention showing the cooperative interplay of each of the described and claimed elements above and below the paddle as if the paddle were transparent;
[0053] [0053]FIG. 8 is a schematic perspective top plan view of a series of wafers in a carrier.
[0054] [0054]FIG. 9 is a top view of a further embodiment with two rotating fingers and a single moveable post.
[0055] [0055]FIG. 10 is a side view of the embodiment of FIG. 9.
[0056] [0056]FIG. 11 is a top view of a modification of the embodiment of FIG. 9 with flexible, rotational actuating rods.
[0057] [0057]FIG. 12 is a top schematic cutaway view of a coil assembly with a fail safe spring mechanism.
[0058] [0058]FIG. 13 is an end schematic cutaway view of the coil assembly with the fail safe spring mechanism of FIG. 12.
[0059] [0059]FIG. 14 is a top schematic cutaway view of a solenoid assembly with a fail safe spring mechanism.
[0060] [0060]FIG. 15 is an end schematic cutaway view of the solenoid assembly with the fail safe spring mechanism of FIG. 14.
[0061] [0061]FIG. 16 is a top schematic cutaway view of the coil assembly with a fail safe spring mechanism of FIG. 12 installed in the wafer hand of FIGS. 1 - 7 , which includes a single rotating finger.
[0062] The invention is defined in its fullest scope in the appended claims and is described below in its preferred embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0063] Disclosed is a system to handle flat stiff but flexible discs, such as semiconductor wafers, that is capable of allowing processing on both sides of any respective wafer. The system may employ optical beams or other sensor techniques to detect the wafer edge and consequently the wafer position. The system also incorporates unique grasping pressure control means. A unique robotics hand then grasps the wafer in such a manner as to allow rotation through 360 degrees around the long axis of the hand or angular movement up or down much the same as flexing the natural wrist, or rotating the hand or arm. The hand design is such that it plugs into or otherwise attaches to positioning robotics. This permits quick interchange of configurations (size for example) and minimum downtime for maintenance.
[0064] The system likewise employs state-of-the-art robotics to control all positioning functions. This includes computer technology as well as specialized electronics. Software driving the system is necessarily unique to the required application, but is structured as compatible with existing commercially available software. Data output may include any or all of the common technologies now in use, or those within the technical knowledge of an artisan.
[0065] As discussed in detail below, at least six major subsystems are found within or used in conjunction with preferred embodiments of the present invention:
[0066] 1) a robotics ‘hand’ to grasp the wafers and allow them to be rotated through 360 degrees for processing on both sides; 2) an optical reading or other sensor system that accurately locates the position of each wafer, enabling the ‘hand’ to access the wafer without breakage; 3) a data processing and control system to control the hand and associated mechanics and to act on the data supplied by the optical subsystem; 4) control means to select the appropriate pressure or tension applied to the wafer; 5) both software and firmware to drive the system, and 6) a mechanical fail safe system to prevent water loss during a power failure.
[0067] In addition to being used for wafer processing, the system of the present invention can be used in other applications. This would include, but not be limited to, magnetic disk processing, CD ROM processing, processing of flat screen displays, handling of reticules in semiconductor chip processing, gene chip handling, and in general any process that could utilize a robotics hand with these characteristics. The ability to uniquely locate a part makes the proposed system an exceptional and unique candidate for inventory, parts tracking, and all other manufacturing processes where it is required, or beneficial, to keep track of the number and location of assemblies.
[0068] A particular example of uses of a preferred embodiment of the present invention is for placing wafers into specific cassettes or caddies for different processing steps. This exemplary embodiment is offered hereafter as demonstrative of examples of the working models of the present invention and is not meant to be limiting of the claimed subject matter of the present invention. Accordingly, while the embodiment is representative of the subject matter set forth in the claims appended hereto, it is in no way meant to limit the same.
[0069] Referring now to FIG. 1, a robotics wafer hand assembly 101 includes a paddle 100 , which is made up of 2 thin stiff members secured together, for ease of manufacturing, to form a single thin stiff member, made from a material appropriate for the application, with two fixed pressure posts 103 located thereon, and a rotating finger 105 at the end thereof located in opposition to the posts 103 . Mounted to the wafer hand assembly 101 are the actuating mechanisms to rotate the finger 105 and locating/positioning optics mount 107 . The stiff members may be secured by typical assembly means such as screws, adhesives, rivets or other comparable means.
[0070] Design of the wafer hand assembly 101 is such that it can plug into or be otherwise attached to a robotics arm (not shown) at a first end proximate to optics mount 107 using hand mount 115 , or other suitable mounting or connecting means common in the industry. Also included would be electrical and data coupling means to attach the hand to control systems. This permits quick removal for repair. Also, various configurations of the wafer hand assembly 101 ; e.g. different sizes, can be interchanged in minimal time. Such combination with known systems and interchanging would be known to those working with such systems; therefore, further detail regarding the same has been omitted.
[0071] Once the desired optical readings are taken and the programmed sequence of operations to be performed ascertained, lifting hand 101 grabs a wafer at three points of the disk. Two of the points 103 are in fixed locations spaced apart on a circumferential line with the radius equal to approximately that of the wafer. At each point is a small post 103 with small groove 126 to hold the edge of the wafer. The third lifting point is the moveable finger 105 that supplies the clinching action for the lift.
[0072] Wafer hand assembly 101 moves to the wafer with the finger 105 retracted. In the retracted position, the finger 105 rotates 90 degrees, so it now has the same orientation as the other posts, and is drawn back toward the other two holding points 103 . This action holds the wafer between the posts 103 and the finger 105 .
[0073] Rotation of the finger can be accomplished electromechanically or merely mechanically by a cam. Cam operation simplifies the electronics, but is subject to wear, lubrication, and contamination factors. In addition, more machining may be required. It is also contemplated that the finger 105 in its retracted position may point along the axis, and in the plane of the hand 101 , rather than perpendicular to the axis as shown on FIG. 2 a.
[0074] Referring now to FIGS. 2 a, b, and c and FIG. 3, detailed views of a rotating finger 105 and of one of two fixed pressure posts 103 according to the embodiment of the present invention are shown. Wafer hand assembly 101 member has an actuating rod 111 disposed in a central portion thereof (see FIG. 7). When the assembly 101 is formed of two sheets of material, the actuating rod may be disposed in a channel between the two sheets of material so that it is not externally exposed. The wafer hand assembly 101 as shown in FIG. 2 a , is slipped under a wafer 122 , or between two wafers in a stack (FIG. 8) and rotating finger 105 , is rotated 90 to the position shown in FIG. 2 b . At this point, the finger 105 is spaced from the wafer hand assembly 101 front edge 124 . It is then moved toward the wafer hand assembly edge 124 as shown in FIG. 2 c to grasp the wafer 122 between finger 105 and posts 103 as shown in FIG. 6.
[0075] Referring to FIGS. 1 and 4- 7 , a translator solenoid or voice coil 117 , through an arm 119 , positions the finger 105 outwardly while a rotator device 109 , such as a solenoid, motor or similar translational and/or rotational device turns the finger 105 90 °, presenting a lower profile whereby the wafer hand assembly 101 member can be inserted between wafers or rotated 180 degrees to pick up the wafer from the top. Once positioned under, over or between wafers 122 , the finger 105 is rotated to the vertical position by the rotator solenoid 109 (see FIG. 2 b ) and then is pulled in by the translator solenoid 117 (see FIG. 2 c ).
[0076] Finger translator solenoid 117 or similar electrically powered translational device, finger rotator device 109 , and finger actuating rod 111 , as discussed in detail below, cooperatively act for effective grasping and releasing of a wafer (or the like substrate member item to be held), and holding the same in a fixed position for transfer from one processing location to another, without breaking or dropping the wafer or bending it beyond acceptable limits. Likewise, a substrate member may be released and picked up at a position 180 degrees from its released position.
[0077] Finger actuating rod 111 is driven by the magnetic coil energized and controlled by finger translator solenoid 117 and finger rotator solenoid 109 , as discussed in further detail below.
[0078] The wafer hand assembly 101 member has an actuating rod 111 disposed in a central portion thereof.
[0079] Translator solenoid 117 , through an arm 119 attached thereto, pushes the finger 105 in or out while rotator solenoid 109 turns finger 105 90°, presenting a lower profile whereby the wafer hand assembly 101 member can be inserted between wafer 122 or manipulated 180° to pick up the wafer 122 from the top or bottom. Once positioned under, over or alongside a wafer 122 , the finger 105 is rotated to the vertical position (FIG. 2 b ) by the rotator solenoid 109 and then is pulled in (FIG. 2 c ) by the translator solenoid 117 , locking the wafer 122 between the fixed posts 103 and the finger 105 , as shown in FIG. 6.
[0080] Grasping action is accomplished by using finger 105 to pressure a wafer against fixed posts 103 . This is very much like the natural grasping action of the human hand with the opposable thumb applying pressure on an object held against the fingers. Likewise, as mentioned above and treated in detail below, the analogy between wafer hand assembly 101 and the human arm includes the 180 degree rotation which would be characterized by, or controlled, like the action of a human wrist in changing the position of a human arm from one with a top side facing up to a top side facing down.
[0081] In the release mode, the finger 105 lies in the plane of the hand 101 . Positioning of the finger 105 is accomplished through the controlling mechanics at the ‘wrist’ (or proximate) end of hand 101 . In particular, a voice coil or motor/encoder combination is used to position finger 105 .
[0082] Hand 101 , while in the release mode, is positioned under the wafer selected using electronics positioning systems or an optics system shown schematically at 117 . At this point, the finger 105 is rotated so as to present a surface to the wafer edge. The controlling mechanics then pulls the finger 105 towards the center of the wafer thereby pushing the wafer against the fixed diametrically opposed posts 103 . Pressure is accurately maintained through precise control of the electrical current applied to the coil driving translator solenoid or voice coil 117 , which, in turn, causes the actuating rod 111 to move along the length of the hand 101 . Leads 123 to the controls communicate information from a central processor (not shown) to the hand 101 . It has been found that supplying a current of about 310 mA to about 360 mA to a solenoid supplied (Model B LA13-12-00A) exerts the appropriate grasping pressure on a 200 nmg (approx. 12″) wafer held in the device.
[0083] Typically, finger movement as effected by finger translator means 117 and finger rotator device 109 is programmed on an application specific basis. Likewise, the same can be accomplished by accurately controlling the current through voice coils and employing stops and cams where necessary. However, any of the mechanisms used in the field of motion control could be used when applicable. Once the wafer is grasped, the hand 101 can now transport the wafer to any location directed by the robotics. The exemplary feature of this grasping method is that it allows the hand to completely rotate the wafer through 360 degrees without dropping it, permitting the wafer to be placed in a variety of carrier mechanisms. The ability to rotate as such will allow processing of both sides of the wafer. In addition, since the wafer is trapped between the posts 103 and finger 105 , it can be moved at greater accelerations and speeds than possible with vacuum pickups, thereby reducing processing time. As an added benefit, the wafer surface is not contaminated since only the edges come in contact with the hand. This will enhance production yields.
[0084] Referring to FIGS. 9 and 10, a further embodiment of the wafer handling assembly 201 includes a stiff member or paddle 200 with a single moveable post 203 centrally located at the control end 204 of the paddle 200 and two rotatable fingers 205 at the opposite end of the paddle, to form the three corners of a triangle for grasping a wafer 222 there between. Mounted to the wafer handling assembly 201 are two rotation coils 209 , each connected to a finger 205 , and a translational coil 217 for moving the post 203 a sufficient distance along the central axis 206 of the assembly 201 to grasp a wafer 222 with the desired tension between the post 203 and the fingers 205 . As in the previously described embodiments the assembly 201 may also carry locating and positioning optics and related controls.
[0085] In contrast to the previous embodiment, in the embodiment of FIGS. 9 and 10 the two spaced apart fingers 205 rotate from the plane of the paddle 200 as a result of a rotational force applied to actuating rod 211 to a position perpendicular to the paddle surface. However, they do not translate lengthwise. Instead, the single post 203 is moved along the central axis 206 of the paddle 200 to grasp the wafer, the tension on the wafer 222 being controlled by the current applied to the translational coil or solenoid 217 , operating through the translational rod 218 , which moves the post 203 to apply grasping pressure to the wafer 222 . Otherwise, this embodiment operates in a similar manner to the previous described embodiment. The paddle 200 is positioned next to a wafer 222 . The rotational solenoids 209 , operating through actuating rod 211 , causes the finger 205 to move into its perpendicular position with the wafer against the fingers 205 .
[0086] One skilled in the art based on the foregoing description will recognize that all of the supplemental features of the first described embodiment, including the optical sensing and positioning devices can be used on the further embodiment described above.
[0087] [0087]FIG. 11 is a wafer handling system 301 which is a modification of the embodiment of FIGS. 9 and 10 having the rotation of the fingers caused by a rotational force applied to a flexible actuating rod 311 . As shown in FIG. 11, rather than the rod 311 being straight is flexible and therefore capable of maintaining the same alignment from rotational solenoid 209 (not shown in FIG. 11) to the finger 205 . Otherwise, the modification of FIG. 11 operates in the same manner as the embodiment of FIG. 9.
[0088] FIGS. 12 - 16 show two embodiments of the drive components assembly 300 , 400 for the rotatable finger and translational finger or post which incorporate a biasing spring. When power is not delivered to the coil 301 or solenoid 401 which controls the translational movement of the finger 105 or post 103 the spring 31 provides a biasing movement to that finger or post. The tension of that spring, whether it is operating to expand or contract, is selected so that the tension applied to the disk 122 being grasped does not exceed a predetermined maximum level needed to grasp the disk 122 without damaging it and is not less than a tension level necessary to hold the disk. Because the assembly can be constructed so that the translational post or finger is at its further-most position (i.e., always open) when powered but at rest (not grasping a disk), or at its nearest most position (i.e., always closed) in the same rest mode the spring can be alternatively placed in the drive components assembly in tension or compression.
[0089] [0089]FIGS. 12 and 13 show a top and end view of the drive components assembly 300 incorporating a voice coil 301 to provide movement to the translational post or finger 105 . FIGS. 14 and 15 show the drive components assembly 400 with the voice coil 301 replaced by a solenoid 401 . The main difference between the voice coil and the solenoid is that in use of the voice coil, the tension on the disk applied by the translational post or finger is proportional, over the operating range of the coil, to the current applied to the coil. While some tension differential can be provided by adjusting the current to the solenoid, it generally operates in an on/off condition with the tension applied to the disk being dictated by the particular solenoid chosen and its operating characteristic at the prescribed current feed.
[0090] An additional feature of the embodiments in FIGS. 12 - 15 are that they are all provided in an insertable frame or assembly base 308 so the drive components assembly can be reassembled and then inserted into any of several different configurations of the wafer grasping hands. It can be seen, by comparing the embodiments of FIGS. 12 - 15 with the embodiments of the other Figures, that in the prior embodiments the translational and rotational drive components were mounted directly to the hand assembly, and had to be individually assembled to the unit, rather than being attached to the hand assembly as a single unit. Incorporation of the embodiments of FIGS. 12 - 14 requires only that the drive components assembly 300 , 400 be mounted to the hand assembly and the actuating rod 111 be attached to the finger shaft coupling 305 in the drive components assembly. It should be noted that while FIGS. 12 - 15 show only a single finger which both rotates and translates, the drive components assembly can be configured to include drives for attachment to additional fingers or to separate rotational fingers and translational posts.
[0091] Another problem with prior available devices is that it is difficult for the operator, or electronics controlling the operation of the disk handling assembly, to determine during operation if the finger was in an up or down position, was in its extended (open) position or withdrawn (grasping) position or whether a disk was being held or the hand failed to grasp a disk. The latter problem may be caused by several operational deficiencies, such as a disk
[0092] c) a fixed rotation stop 312 which can be set to limit the rotation of the finger from horozontal to vertical (i.e., 90°)
[0093] d) a rotation sensor 313 to detect if the finger is up or down, and
[0094] e) and an in-or-out sensor 314 to detect if the finger is in its extended or retracted position.
[0095] These components are fixedly or moveably mounted, as required by their operation, to an assembly base 308 which is, in turn mounted to the hand assembly 101 as shown in FIG. 15. The spring 311 may be replaced by other similarly acting devices such a magnetic break.
[0096] The drive component assembly 400 of FIGS. 14 and 15 is assembled and operates substantial the same as the assembly of FIGS. 12 and 13 with the exception that the voice coil 301 is replaced by a solenoid 401 mounted to the assembly base 308 . The movement of the solenoid plunger 402 provides longitudinal movement of the finger 105 which was provided by the magnet assembly 309 of the voice coil.
[0097] Wafers are normally loaded in cassettes or caddies and are stacked in grooves that hold the wafer on the sides. The present system will locate the position of each wafer to a high degree of accuracy by employing light beams and photo sensors to detect the wafer edge. Changes in the reflections from the edge allows the optical sensing equipment to determine the wafer edge and, therefore, the position of the hand with respect to the wafer. The entire caddie can be scanned and all positions determined, including missing wafers, as a missing wafer will generate an anomaly in the spacing sequence.
[0098] Sensing optics mount 107 is centrally mounted on the ‘wrist’ end of hand 101 as shown in FIGS. 1 and 4 or off to one side as shown in FIG. 6. The optics system in preferred embodiments is comprised of optical transmitters such as lasers and IR diodes, optical receivers such as photo diodes, CCD'S, photo transistors, and similar devices and the associated mechanical devices needed to direct an illuminating beam(s) at the edge of the wafer and receive the reflections. The beam(s) are focused at an optimal distance from the finger end of the hand that will permit accurate and reliable position determination. The beam(s) can be modulated in intensity and position to reduce the effects of background noise and to enhance edge detection. More than one sensing optics mount 107 can be used, such as a second unit (not shown) at a similar location on the other edge of the face of the assembly to aid in positioning. Also, additional optical sensors 130 can be located on the hand 101 at various locations to aid in accurately measuring the size of wafer 122 .
[0099] Panning the small focal point across the face of the edge will allow an accurate location of the edge vertices and consequently the wafer itself. Since the edge of the wafer represents a compound surface, reflections from the surface may or may not reach the receivers. Panning the beam(s) along the edge will increase the probability of detection and increase accuracy since the wafer radial line aligned along the long axis of the hand will produce the greatest reflection. This information will allow the robotics to generate the best hand alignment with reference to the wafer.
[0100] This system is driven by robotics of the form necessary to the application or process. Any of the digital/analog techniques used for determining position, speed, acceleration, and, in general, all parameters associated with displacement and motion may be used as applicable to the specific process. The system of the present invention further embodies the use of computer equipment in conjunction with process specific electromechanical, pneumatic, and hydraulic systems to attain the desired operation.
[0101] The control system which is contemplated as within the scope of the instant teachings likewise serves to direct and modulate the photo sources, position the photo detectors, analyze the data from the detectors representing the variations in reflections, use the processed data to direct the motion control units to position the equipment as desired, and to process the feedback data from the motion control units to determine correction signals.
[0102] Further mechanisms used in conjunction with this system generate any alarms, signals and/or bells required, and format and output required data as video, print, audio, telephony, telemetry or as any of the other communications technologies necessary.
[0103] Since the system of the present invention has a wide range of applications, material used in the fabrication of this system will necessarily be diverse. This is to include, but not be limited to, metals, plastics, ceramics, glass, wood and all the various alloys, grades, tempers, compounds, and varieties of such, including compounds and combinations. The specific application and environment will dictate the actual materials used.
[0104] As discussed, related improvements according to the teachings of the present invention include replacement of conventional teachings with dynamic automated system employing laser-measuring equipment. Likewise, it is contemplated by the present invention to replace existing vacuum pickup technology with an electromechanical or gas actuated system that does not rely on a vacuum and provides a positive lift and retention system.
[0105] Modern laser distance measuring equipment is capable of making very precise measurements. Suitably locating one or more laser reading heads will provide all the information necessary to accurately locate and size each wafer in the processing system. Typically, a laser head located as reference on a two-axis mount would sweep the column of wafers in a cassette.
[0106] The shown locations are not intended to limit the location or number of optical sensors. The reflection from the individual disks provide the line-of-sight distance from the reference. Further, a reading from the second optical sensor 130 located on the center line of the hand 101 , when taken in conjunction with the known position of the posts 103 , can be used to sense the exact location of the edge of a circular wafer disc and in turn determine the exact diameter of the disc for use in setting the current delivered to the tensioning device.
[0107] Encoders in the axis mounts likewise are effective for supplying azimuth information, as is known to artisans. From the combined information, sent to a central processor, the exact position of each wafer relative to the reference can be determined to a high degree of precision. This same process is applied to the destination locations of each wafer. The processor then utilizes the information to exactly place the wafers, as needed in cassettes or caddies.
[0108] Different metals and plastics are used according to the teachings of the present invention. The environment where the unit is used will determine the materials of construction. Mechanical interface to the different types of robots requires many different mechanical designs. However, this does not effect the smooth operation of the intelligent integrated wafer handling system. For example, all the different mechanical designs can utilize the modular assemblies of FIGS. 12 - 15 .
[0109] To avoid bending or cracking of a wafer being grasped, the amount of pressure applied by the moveable finger 105 must be controlled precisely. The embodiment of the present invention described above utilizes an actuator of the voice coil type to provide the required amount of hold on the disk. This is accomplished by closely controlling the current through the coil. Again, the correct parameters for a particular type of and size of wafer is entered into the central controller. This provides a highly accurate and repeatable method to lifting the wafers without breakage. In addition, since the wafers are ‘trapped’ within the two posts and finger, no movement can result because of high accelerations during the transportation of the from one processing point to another.
[0110] Likewise, according to the instant teachings the system can also be implemented using hydraulics with a gas (e.g.; dry air or dry nitrogen) or liquid driven mechanism. The clinching finger motion can be controlled through a device such as a variable needle valve and associated valving, such as by varying the electric current fed to the valve driver or controlling the percent opening of the valves.
[0111] Overall system control is through a main central processing unit (CPU) which contains the software that defines the actual operations performed. The CPU interfaces with various handling and processing mechanisms through specially designed inter-+faces optimized for the function required. The system as a whole is made up of individual sections representing the various processes. Each section is arranged so as to allow the handling system access.
[0112] Different environments will, naturally, dictate different arrangements of the various processing sections. This in turn would require different software. To meet the numerous changes in software likely to result, each processing section runs a subprogram in an overall controlling shell. The unique date required by each section is then entered as ‘calibration data’ that is easily passed between the individual sections and the main shelf. This allows total flexibility and ease of use since each section is running autonomously with respect to the others.
[0113] The system above utilizes individual wafer processing sections controlled by a central CPU. Since each section runs autonomously under overall supervision of the shell software, different system arrangements are allowed to meet the needs of the physical environment.
[0114] The foregoing is meant to illustrate, but not to limit, the scope of the invention. Indeed, those of ordinary skill in the art can readily envision and produce further embodiments, based on the teachings herein, without undue experimentation.
[0115] For example, while the various components of the system are shown mounted on one side of, or within, the assembly, the invention contemplates locating same on either side or extending off the robot arm end of the assembly.
[0116] Also, as indicated above, while the invention has been described in relationship to semiconductor wafers, it can be used to handle any flat, stiff sheet like structures of defined dimensions, such as ceramic or glass dishes or plates, petric dishes containing growth media, compact disks in a CD player, removable storage media in a computer system or any other mechanical system which requires removal, transport or handling of disc like articles. Also, various techniques can be used to control the grasping pressure on the wafer. However, the tension is controlled by varying and setting the driving force to the finger 105 and does not require measuring the force actually applied.
[0117] While the invention is described as having one or two rotating fingers and one or two fixed or moveable (translational) posts, other combinations, or additional posts and or fingers are contemplated.
[0118] The present invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiment is to be considered in all respects only as illustrative and not as restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of the equivalence of the claims are to be embraced within their scope.
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A system for handling stiff but flexible discs, particularly semiconductor wafers, including fail safe mechanisms that prevent the disc from being dropped if power to the unit is interrupted. Also, the electronics controlling operation resumes functioning at the point in the operation cycle existing when power was interrupted. A wafer hand assembly member is slipped under a wafer, or between parallel stacked but spaced wafers, and one or more fingers are rotated 90° to a position perpendicular to the plane of the stiff hand assembly member. The hand assembly also has one or more posts positioned perpendicular to the surface of the hand assembly. The finger(s) and post(s)or rear barrier constitute three upright projections or points forming the corners of a triangle with the wafer to be grasped there between. A translator solenoid or voice coil, controls the lateral location of one finger or post, moving that finger or post toward the other two stationary fingers or post(s) causing the wafer to be grasped with controlled traction force between the fixed posts and the moveable finger. The traction force is controlled by the amount of driving energy fed to the translator solenoid. If the power to the solenoid or voice is interrupted, springs in the system cause the disk to be held between the posts or barrier and fingers until power is restored.
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This application is a continuation of and claims the benefit of U.S. patent application Ser. No. 09/082,616, filed May 20, 1998 now U.S. Pat. No. 6,035,981, which itself claims the benefit of U.S. Provisional Application No. 60/047,201, filed May 20, 1997, and U.S. Provisional Application No. 60/050,516, filed Jun. 23, 1997.
TECHNICAL FIELD
The present invention generally relates to a device for controlling vibration. More particularly, the present invention relates to a passive mass damper for conservative broadband suppression of vibrations.
BACKGROUND
In general, vibration originating from machines or other sources is most often undesirable and detrimental. For example, vibration in a precision machining tool may lead to faults and imperfections in work pieces produced on the tool. The vibration also may be transmitted through the floor and disrupt other tools. Additionally, the noise generally associated with machine vibration may be disruptive to workers.
Various methods and devices exist to reduce undesirable vibrations and may be generally categorized as vibration isolators or suppressors. Typically, vibration isolation devices operate locally to reduce transmissibility, wherein transmissibility is typically defined as the ratio of the transmitted force to the disturbing force. As such, vibration isolation devices are particularly suitable for reducing discrete and transient vibrations. For example, various reflexive and absorptive material, such as rubber, cork, foam and the like, may be placed in connective elements of a stamping machine, such as the stamping table and legs, to isolate the discrete vibrations associated with the stamping action of the machine.
In contrast, vibration suppression devices typically operate globally to suppress vibration. As such, vibration suppression devices are particularly suitable for reducing cyclic vibrations or vibrations which may be difficult to isolate to a particular element of a machine. For example, the motor of a machine generates cyclic vibrations. Rather than attempting to isolate the vibration transmitted through various connective elements of the machine, the entire machine may be mounted on a vibration suppression base. While the vibration suppression base may reduce the global vibration generated by the machine, local transmission of vibration may not be altered. In fact, certain vibration suppression devices may actually amplify local transmission of vibration.
Vibration mitigation devices may be categorized further as active or passive devices. Typically, active devices incorporate a feedback system which detects the amplitude and/or frequency of the disrupting vibration and responds accordingly to reduce or eliminate the vibration. Therefore, active devices are capable of broadband reduction of vibration. However, the complexity and cost of typical active devices often make them impractical for many applications.
In contrast, passive devices are typically mechanical devices which generally use various spring elements and damping elements to reduce or eliminate vibrations. However, conventional passive devices generally operate to reduce vibrations only in a fairly narrow bandwidth. Additionally, certain materials used in conventional passive devices, such as rubber and lubricating fluid, may be inappropriate for use in certain environments, such as clean room environments.
A spring damper device is one conventional passive vibration suppression device which is described in various mechanical textbooks and handbooks. In a spring damper device, a spring element and a damper element reduce vibration by removing the energy of a vibrating system through the damper element. However, the spring damper device typically operates at a narrow bandwidth determined by the stiffness of the spring element and the damper coefficient of the damper element. Typically, vibrations outside of this narrow preset bandwidth will not be effectively reduced. In fact, vibrations at certain frequencies will often produce increased responses with a peak response occurring when the frequency of the vibration is equal to the natural frequency of the spring damper system. Consequently, a spring damper device must often be precisely calibrated to match the frequency of the vibrating system.
In another conventional device, a spring element is used in combination with a beam-column element to reduce the transmission of vibration. See U.S. Pat. No. 5,178,357, issued on January 1993, to Platus and related U.S. Pat. No. 5,549,270, issued on August 1996, to Platus et al. More particularly, a spring and a beam-column are calibrated such that one element has a positive stiffness and the other element has an equal negative stiffness. In this manner, an object is supported with net-zero effective stiffness. However, a spring and beam-column pair is required for each axis to be isolated from vibration and each spring and beam-column pair must be precisely calibrated to achieve a net-zero effective stiffness in each axis. As such, this method is fairly complicated and difficult to calibrate and adjust. Additionally, as the requisite negative and positive stiffness are achieve through two separate elements, if one element wears at a rate different than that of the other, their stiffness will no longer match and a net-zero effective stiffness will not be achieved.
SUMMARY OF THE INVENTION
The present invention relates to a device for broadband suppression of vibrations. According to a preferred embodiment of the present invention, a mass damper device includes a mass element and a plurality of nonlinear spring elements with high secant stiffness and low tangent stiffness. The mass damper is mounted on a vibration source which induces vibration of the mass element on the spring elements. The mass element vibrates off phase from the inducing vibration to suppress the inducing vibration.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The present invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals generally denote like elements, and:
FIG. 1 is perspective view of a mass damper in accordance with the present invention;
FIG. 2 is an exploded perspective view of a portion of the device shown in FIG. 1;
FIG. 3 is a cross-sectional view of another portion of the device shown in FIG. 1;
FIG. 4 is a cross-sectional view of a ball-in-recess assembly used in the device shown in FIG. 1;
FIG. 5 is a cross-sectional view of another ball-in-recess assembly used in the device shown in FIG 1 ;
FIG. 6 is a perspective view of a bob used in the device shown in FIG. 1;
FIG. 7 is a top view of another mass damper in accordance with the present invention;
FIG. 8 is a side view of a portion of the device shown in FIG. 1;
FIG. 9 is a cross-sectional view of a ball-in-recess assembly used in the device shown in FIG. 1;
FIG. 10 is another cross-sectional view of a ball-in-recess assembly used in the device shown in FIG. 1;
FIG. 11 is a perspective view of another mass damper in accordance with the present invention;
FIG. 12 is a top view of the device shown in FIG. 11;
FIG. 13 is a perspective cross-sectional view taken through line 1 — 1 of the device shown in FIG. 11;
FIG. 14 is a perspective view of yet another mass damper in accordance with the present invention; and
FIG. 15 is a perspective cross-sectional view taken through line 15 - 15 of the device shown in FIG. 14 .
DETAILED DESCRIPTION OF THE INVENTION
The present invention is preferably configured to reduce vibrations in systems such as machines, plants, tools, platforms, and the like which have multi-rotary or reciprocating parts and impact sources, particularly those with parts and sources which cannot be effectively isolated, which have less vibration modes than vibration sources, which require global rather than local transmission reduction, or in which the open loop vibration is substantially dominated by resonance.
For example, a mass damper in accordance with a preferred embodiment of the present invention is configured to operate with a Chemical Mechanical Planarization (“CMP”) tool used in the semiconductor industry to planarize and polish wafers to an extremely planar and smooth surface. As background, wafers in a CMP tool are typically held by carrier heads then lowered and pressed against a polishing pad, while a slurry is often added to aid in the CMP process. Additionally, the polishing pad and carrier heads are typically rotated at differential speeds while the carrier heads are typically oscillated back and forth. The multiple directional movement, the unmatched motor speeds and hydrodynamic fluctuation of the entrapped slurry typically creates a combination of high and low frequency vibrations which may result in wafer loss. Also, the resulting vibrations are commonly transmitted through the floor to other vibration sensitive machines and tools while the resulting noise may be detrimental to nearby workers. Although the present invention may be used in a CMP environment, the present invention also is configured to reduce vibration in various environments and systems.
With respect to the details of the device, FIG. 1 shows a mass damper in accordance with one embodiment of the present invention. Mass damper 10 has 6 degrees-of-freedom (“DOF”); 3 translational modes along x, y, and z axes, and 3 rotational modes about x, y and z axes. In a preferred embodiment, mass damper 10 preferably includes a plurality of ball-in-recess assemblies as nonlinear spring elements in combination with mass elements to substantially achieve broadband suppression of vibrations.
Base assembly 20 is preferably rigidly connected to a source of vibration, such as a machine tool. Base 20 preferably includes base plate 22 and a plurality of anchor bolts 24 and nuts 26 . Base plate 22 is preferably rigidly attached to the source of vibration by anchor bolts 24 and nuts 26 such that vibration is suitably transmitted to base plate 22 without substantial distortion. Base plate 22 is preferably formed from metal, ceramic, or other suitable rigid material.
Assembly 30 is preferably rigidly mounted on base plate 22 . Leveler studs 28 are preferably configured to level assembly 30 thereby defining the x-y plane of mass damper 10 . Assembly 30 preferably includes a plurality of ball-in-recess assemblies disposed between bottom plate 32 and top plate 34 . More particularly, with additional reference to FIG. 2, cone-shaped recesses 38 , 40 , 44 are suitably formed by known methods in bottom plate 32 . Substantially matching cone-shaped recesses 36 , 42 and 46 are suitably formed by known methods in top plate 34 (recesses in top plate 34 are not shown). Balls 37 , 41 and 45 are preferably disposed between recesses 36 , 38 , 40 , 42 , 44 and 46 , respectively. Balls 37 , 41 and 45 preferably lie within holes formed in spacer 39 disposed between bottom plate 32 and top plate 34 to substantially ensure constant relative distance between balls 37 , 41 , and 45 . Spacer 39 is preferably formed from TEFLON® or other suitable low friction material to facilitate movement of bottom plate 32 relative to top plate 34 .
With additional reference to FIG. 3, tower 50 is preferably threaded into top plate 34 and counter locked by nut 52 . Various methods are known in the art for securing tower 50 to top plate 34 . For example, tower 50 can be welded to top plate 34 .
Coil spring 54 is preferably disposed within the vertical centerline of tower 50 to define the z axis of mass damper 10 . One end of coil spring 54 is preferably attached to bottom plate 32 and the other end is preferably attached to the top of tower 50 . More particularly, coil spring 54 is preferably attached to bottom plate 32 using spring anchor 64 and nut 66 . Coil spring 54 is preferably attached to dowel pin 60 by spring anchor 56 and nut 58 . Dowel pin 60 is preferably attached to the top of tower 50 by cotter pin 62 . The tension in coil spring 54 may be adjusted by adjusting either nut 52 or nut 66 . Coil spring 54 may be attached to bottom plate 32 and top of tower 50 using various methods known in the art.
Coil spring 54 exerts a compressive force on bottom plate 32 and top plate 34 through tower 50 to suitably pre-compress the ball-in-cone assemblies in assembly 30 . However, various methods are known in the art for suitably pre-compressing ball-in-cone assemblies.
With reference to FIG. 4, when mass-damper 10 is undisturbed by external vibrations or forces, ball 37 rests at the vertices of cone-shaped recesses 36 and 38 (for clarity only one ball-in-recess assembly is described). Similarly, balls 41 and 45 rest at the vertices of recesses 40 , 42 , 44 and 46 , respectively. Therefore, the weight of top plate 34 and assemblies attached to top plate 34 and the compressive force of coil spring 54 are substantially distributed between balls 37 , 41 and 45 . Accordingly, balls 37 , 41 and 45 are preferably formed from metal or other high strength material. Although three ball-in-recess assemblies have been described, one skilled in the art will appreciate that any number of ball-in-recess assemblies may be used without deviating from the spirit and scope of the present invention.
Referring again to FIG. 1, assembly 70 preferably includes a first bob 72 and a second bob 74 suspended over assembly 30 on cover plate 68 . Cover plate 68 is preferably threaded on tower 50 and counter locked from underneath with a nut (not shown). Various methods are known in the art for securing cover plate 68 to tower 50 . For example, cover plate 68 can be welded to tower 50 .
Coil spring 76 is preferably disposed along a channel formed along the vertical center line of first bob 72 . The top end of coil spring 76 is preferably attached to spring anchor 78 which is preferably placed through a hole formed in cover plate 68 and secured by nut 80 . The bottom end of coil spring 76 is preferably attached to the bottom of first bob 72 by a spring anchor (not shown) and nut 52 . Second bob 74 is preferably secured to cover plate 68 in a substantially similar manner. Alternatively, bobs 72 and 74 may be secured to cover plate 68 using various methods known in the art.
With reference to FIGS. 5 and 6, a plurality of ball-in-recess assemblies are preferably disposed between tower 50 and bobs 72 and 74 . More particularly, cone-shaped raceways 82 and 86 are suitably formed around the circumference of tower 50 . Substantially matching cone-shaped raceways 80 and 84 are suitably formed around the inner surface of bob 72 . Balls 88 and 90 are preferably disposed between raceways 80 , 82 , 84 and 86 , respectively. Additionally, balls 88 and 90 lie within holes formed in curved spacer 92 to ensure constant relative distance between balls 88 and 90 . Spacer 92 is preferably formed from TEFLON® or other suitable low friction material to facilitate movement of bob 72 relative to tower 50 . In a similar manner, Bob 74 is suitably configured with cone-shaped raceways, balls, and curved spacer to facilitate movement of bob 74 relative to tower 50 .
Although bob 72 and 74 have been described as two mass elements, any number of mass elements may be used in accordance with the present invention. For example, with reference to FIG. 7, a mass damper is shown with three mass elements.
With reference to FIG. 1, a plurality of spring anchors 94 are preferably rigidly attached to tower 50 and a plurality of anchors 98 are preferably rigidly attached to bobs 72 and 74 . A plurality of springs 96 are preferably held in tension between spring anchors 94 on tower 50 and anchors 98 on bobs 72 and 74 . More particularly, with additional reference to FIG. 8, one of the plurality of springs 96 is preferably suitably attached to one of the plurality spring anchors 94 and to one of the plurality of spring anchors 98 by anchor 102 and nut 100 . A plurality of springs 104 held in compression between bores 106 formed in bobs 72 and 74 offset, in part, the force exerted by springs 96 . Bobs 72 and 74 may be suitably pressed against tower 50 using various methods known in the art.
Housing 120 substantially encloses assemblies 30 and 70 to protect these assemblies from corrosion or undesired access. Seal 122 substantially hermetically seals housing 120 , except for a hole in bottom plate 32 for coil spring 54 to pass. A plurality of bolts through tapped holes 124 suitably attach housing 120 to assembly 30 .
With additional reference to FIG. 9, vibration in the x-y plane suitably translates bottom plate 32 relative to top plate 34 . In response, ball 37 moves from the vertices of recesses 36 and 38 and onto the sloped perimeters of recesses 36 and 38 (for clarity, only one ball-in-recess assembly is described).
When ball 37 moves from the vertices of recesses 36 and 38 , a portion of the weight of top plate 34 and the assemblies attached to top plate 34 and the compression force of coil spring 54 is exerted as force P 1 normal to the sloped perimeters of recesses 36 and 38 . Force P 1 may be resolved into a vertical component V 1 and horizontal component H 1 . The horizontal component H 1 acts as a restorative force to translate top plate 34 and the assemblies attached to top plate 34 off phase relative to bottom plate 32 .
Moreover, as the slope of recesses 36 and 38 is substantially constant, the restorative force, horizontal component H 1 , is substantially constant for varying displacements of bottom plate 32 . As such, ball 37 and cone-shaped recesses 36 and 38 operate essentially as a nonlinear spring element with low tangential stiffness and high secant stiffness. Therefore, assembly 30 substantially provides broadband suppression of vibration in the x-y plane in the displacement range of the vibration source. Additionally, assembly 30 suitably provides soft support for small displacements in the x-y plane and stiff support for large displacements in the x-y plane.
The stiffness required to substantially achieve a broadband suppression of vibration in the x-y axis is a function of the mass of top plate 34 and the assemblies attached to top plate 34 , the mass of the vibration source, and the stiffness coefficient of the source. More particularly, the requisite stiffness is approximately the stiffness coefficient of the source times the ratio of the mass of top plate 34 and the assemblies attached to top plate 34 to the mass of the source. The mass of top plate 34 and the assemblies attached to top plate 34 largely consists of the mass of bobs 72 and 74 . The mass and stiffness coefficient of the vibration source may be measured using methods well known in the art. Alternatively, in the case of machine tools, the mass and stiffness coefficient may be provided by the manufacturers.
The effective stiffness provided by the ball-in-recess assemblies in assembly 30 is substantially a function of the forces applied to the balls, the diameter of the balls, and the geometry of the recesses. More particularly, the effective stiffness of a ball-in-recess assembly is approximately equal to the magnitude of the force applied to the ball divided by twice the difference between the radius of the rolling surfaces abutting the ball and the diameter of the ball.
The effective stiffness of the ball-in-recess assemblies in assembly 30 is sufficiently tuned such that the broadband response of assembly 30 is substantially centered on the frequency of the vibration. The stiffness of the ball-in-recess assemblies may be suitably tuned by appropriately altering the weight of top plate 34 and the assemblies attached to top plate 34 . Alternatively, the stiffness of the ball-in-recess assemblies may be suitably tuned more easily by appropriately altering the tension in coil spring 54 by adjusting nut 58 or nut 66 thus facilitating easy field tuning of the broadband response of assembly 30 .
With reference to FIG. 10, vibration in the x-z or y-z plane translates tower 50 vertically relative to bob 72 . Ball 88 moves from the vertex of cone-shaped raceways 80 and 82 and onto the sloped perimeter of raceways 80 and 82 (for clarity only one ball-in-recess assembly is described).
Springs 96 and 104 combine to exert a force P 2 normal to the sloped perimeters of raceways 80 and 82 . Force P 2 may be resolved into a horizontal component H 2 and vertical component V 2 . Vertical component V 2 operates to translate bob 72 off phase from tower 50 .
As the slopes of the perimeters of raceways 80 and 82 are substantially constant, vertical component V 2 is substantially constant for varying displacements. As such, ball 88 and raceways 80 and 82 operate essentially as a nonlinear spring element with low tangential stiffness and high secant stiffness. Therefore, assembly 70 substantially provides broadband suppression of vibration in the x-z and y-z planes for the displacement range of the vibration source. The broadband response of assembly 70 is suitably tuned to center the frequency of the vibration in a manner substantially similar to assembly 30 . Additionally, assembly 70 suitably provides soft support for small displacement in these planes and stiff support for large displacements in the x-z and y-z planes.
If vibration is substantially restricted to the x-z or y-z planes then bob 74 responds substantially synchronously with bob 72 . Bob 72 may suitably translate off-phase from bob 74 to oppose rotational vibration which may tend to rock tower 50 . Additionally, bobs 72 and 74 may suitably translate horizontally to oppose rotational vibration which may tend to roll tower 50 .
Multi-modal translational vibrations will result in multi-modal response by mass damper 10 . For example, vibration in the x-y plane combined with vibration in the x-z plane will be suitably opposed by multi-modal off phase vibration of mass damper 10 induced by the translational motion of bottom plate 32 relative to top plate 34 and translation motion of tower 50 relative to bobs 72 and 74 .
The requisite mass of bobs 72 and 74 largely is largely dependent on the specific application. The combined mass of bobs 72 and 74 , however, should be within a range of about 0.5 to 25 percent of the mass of the vibration source. A mass of less than about 0.5 percent of the mass of the source provides insufficient energy to effectively suppress the vibration. A mass of greater than about 25 percent, however, results in overshooting.
Friction associated with the various ball-in-recess assemblies does not contribute significantly to the response characteristic of mass damper 10 . Accordingly, mass damper 10 is a substantially conservative device.
With reference to FIGS. 11, 12 and 13 , a mass damper in accordance with another embodiment of the present invention is shown. Mass damper 200 also has 6 degrees-of-freedom (“DOF”); 3 translational modes along x, y, and z axes, and 3 rotational modes about x, y and z axes. Mass damper 200 , however, suitably incorporates known Bellevilles as nonlinear spring elements in combination with a mass element to substantially achieve broadband vibration suppression.
Mass damper 200 is preferably mounted on a vibration source, such as a machine tool, with cover 201 in contact with the source. Vibration is transmitted through housing 230 and base plate 202 to bob 208 suitably disposed within housing 230 . Various Belleville assemblies suitably vibrate bob 208 off phase from the vibration source to substantially suppress the vibration.
More particularly, bob 208 is preferably suspended on base plate 202 by a plurality of Belleville assemblies. In a preferred embodiment, three Belleville assemblies are preferably disposed at 120 degree increments around the bottom of bob 208 (for clarity only Belleville assembly 205 is described).
Belleville assembly 205 preferably includes seat 204 , needle support 206 , piston 214 , plurality of springs 222 and plug 216 . Seat 204 is preferably disposed within a recess formed in base plate 202 . The bottom end of needle support 206 suitably pivots on seat 204 . Similarly, piston 214 suitably pivots on the top end of needle support 206 . As bob 208 moves, piston 214 suitably slides within chamber 209 formed in bob 208 . Plug 216 , however, moves with bob 208 . Plurality of springs 222 are appropriately disposed between piston 214 and plug 216 such that relative motion between piston 214 and plug 216 suitably compresses and elongates springs 222 .
Additionally, bob 208 is suitably supported against housing 230 by a plurality of Belleville assemblies. In a preferred embodiment, three Belleville assemblies are preferably disposed at 120 degree increments around bob 208 (for clarity only Belleville assembly 211 is described).
Belleville assembly 211 preferably includes bolt 220 , plunger 212 , plurality of springs 224 and plug 210 . Bolt 220 is preferably threaded through housing 230 . Plunger 212 suitably pivots on bolt 220 . Plug 210 rests against recess 232 formed in bob 208 . Plurality of springs 224 are appropriately disposed between plunger 212 and plug 210 such that relative motion between plunger 212 and plug 210 suitably compresses and elongates springs 224 .
In a preferred embodiment, springs 222 and 224 are preferably Bellevilles appropriately configured to exhibit low tangential stiffness and high secant stiffness. Bellevilles are well known in the art and may be manufactured to provide the requisite stiffness characteristics. Alternatively, standard Bellevilles may be suitably configured in parallel and/or series to provide the requisite stiffness characteristics. However, various nonlinear spring elements may be used in mass damper 200 to provide broadband suppression of vibrations. For example, suitable EPDM rubber may be used to suitably provide the requisite stiffness characteristics.
The requisite mass of bob 208 and requisite stiffness of springs 222 and 224 are determined in substantially the same manner as in the prior embodiment. However, both parameters largely are dependent on the specific application.
With reference to FIGS. 14 and 15, a mass damper in accordance with yet another embodiment of the present invention is shown. Mass damper 300 has one degree-of-freedom (“DOF”) along the z axis. Mass damper 300 also uses Bellevilles as nonlinear spring elements in combination with a mass element to substantially achieve broadband suppression of vibration.
Mass damper 300 preferably includes base 302 , plurality of springs 304 and 306 , bob 308 and plug 310 . Housing 312 is preferably attached to base 302 by bolt 314 . Bob 308 is preferably suspended on springs 304 and 306 between base 302 and plug 310 . Vibration from a source is transmitted through housing 312 to base 302 . Springs 304 and 306 suitably vibrate bob 308 off phase from the vibration source to substantially suppress the vibration.
In a preferred embodiment, springs 304 and 306 are preferably Bellevilles with low tangential stiffness and high secant stiffness. However, as with the prior embodiment, various springs elements may be used with mass damper 300 to substantially achieve broadband suppression of vibration.
In a most preferred embodiment, a plurality of mass dampers 300 are preferably used to reduce planetary wobbling related to rotation of a heavy, large diameter, thick grinding head. Mass of bob 308 is about 2 to 8 percent of the grinding head. Ten mass dampers 300 are preferably disposed at about 36 degree increments around the grinding head. When the grinding head rotates at about 30 to 40 RPM, the wobbling vibration of the grinding head is substantially suppressed.
Although specific embodiments and parameters have been described, various modification may be apparent to one of ordinary skill in the art upon reading this disclosure. Therefore, it is to be understood that the embodiments described in this disclosure are merely illustrative of and not restrictive on the broad invention and that this invention is not limited to the specific embodiments shown and described herein.
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The present invention relates to a passive mass damper for broadband suppression of vibrations. The mass damper preferably includes a bob supported by nonlinear springs with high secant stiffness and low tangent stiffness. The mass damper is mounted on a machine or other source of vibration. The vibration generated by the machine is transmitted to the mass damper and induces off phase vibration of the bob which suppresses the inducing vibration.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method and means for interconnecting two insulated conductors in subsea environments and in particular for use with conductors having non-compatible insulation material such as PE and a rubber.
2. Background Information
High water pressures and with time it is difficult and nearly impossible to prevent water from entering joint compartments. One entrance to a joint compartment is along the cable conductor underneath the conductor insulation. Remedies have been proposed for filling all spaces within a multifilament conductor and good effects have been obtained at low outer water pressure.
In conventional joints the whole joint is covered with a common insulation sleeve. The problem is however to obtain sufficient bonding between the conductor insulations and the common insulation sleeve. When the two conductors to be jointed have identical or compatible insulation sheaths, sufficient bonding will be obtained with a common joint sleeve. This is, however, not possible when one conductor has PE insulation and the other has rubber (e.g. Hypalon, Neoprene) insulation.
SUMMARY OF THE INVENTION
One object of this invention is to improve subsea cable conductor joints. In particular the object is to improve an interconnection between the conductor insulation of an umbilical cable and the conductor insulation of the interfacing subsea equipment according to the invention. With a conductor joint as defined there is obtained a unique waterproof connection between two insulated conductors, in particular between conductors having sheaths of different insulation material.
BRIEF DESCRIPTION OF THE DRAWING
Above mentioned and other features and objects of the present invention will clearly appear from the following detailed description of embodiments of the invention taken in conjunction with the drawing which shows a splice between conductors schematically.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the figure is schematically illustrated a splice or joint 1 between two conductors 2 and 3 having insulation sheaths 4 and 5. The conductor insulation 4 is polyethylene (PE) which is commonly used in umbilical cables and the conductor insulation 5 may be Hypalon, Neoprene or some other suitable rubber material which is used for wiring within offshore installations.
As mentioned the main object of the invention is to provide a waterproof splice between a PE insulated conductor and a conductor with a rubber (e g Hypalon, Neoprene) insulation. A secondary object is to prevent water which may have entered the umbilical cable and the PE conductor insulation from entering the offshore installation. The two conductors 2 and 3 are therefore joined with a splice pin arrangement 6 and 7 so that water within the multifilament conductor 2 cannot penetrate to the multifilament conductor 3.
The splice pin arrangement 6,7 which is preferably made of brass is covered by an insulator 8 of, for example, glass fiber reinforced epoxy material. Part of the outer surface of the pin arrangement 6,7 is provided with grooves 18,19 in order to provide good bonding to the joint compounds. Over the insulator 8 there is arranged a tube 9 of metal such as stainless steel. The tube 9 is advantageously provided with corrugated outer surfaces 10,11 in order to obtain good bonding and increase the bonding surface to the insulation material used in the joint.
In the case where the two conductors have different conductor insulation, it may be necessary to pretreat the surface of the pin 6 and the surface 10 of the tube 9 up to the flanged section, differently from the treatment of the surface of the pin 7 and the surface 11 of the tube 9. Low density polyethylene is baked into the surface on the PE side of the tube and pin, whereas the rubber side of the tube/pin is treated with a two component primer compatible with the rubber.
Application of joining compounds may involve heating to different temperatures and one feature of the invention is therefore to separate the surfaces 10 and 11 by a partition 12. The partition 12 can have a U-shaped cross-section including an airspace 15 between two partition walls 16,17 for separating the two sheath moldings 13,14.
The PE sheathed conductor 2,4 is molded to the surface of the pin 6 and to the corresponding side of the tube 9 by using a compound consisting 13 of low density polyethylene which is applied at a temperature of some 180° C. for a period of some 10 minutes after a soaking period.
The rubber sheathed conductor 3,5 is molded to the surface of the pin 7 and to the corresponding side of the tube 9 by using a compound 14 consisting of a compatible rubber compound which is applied at a temperature of 150°-170° C. for a period of 30 to 60 minutes.
The PE sheathed conductor 2,4 which requires higher molding temperature, is molded to the tube/pin 9,6,7 prior to molding of the rubber sheathed conductor 3,5 in order to prevent melting of the insulation material. This problem is also minimized by the unique design of the partition of the tube 9.
With such a design of the joint, the insulation 4 of the conductor 2 may be bonded or molded to the pretreated surface 10 of the tube 9 with an insulation compound 13 which is compatible with the material 4 (and not with the insulation material 5). The arrangement can be similar on the other side of the joint where insulation compound 14 compatible with the insulation material 5 is bonded or molded to a pretreated surface 11 of the tube 9.
The molding compounds 13 and 14 must also be capable of bonding to the pretreated surfaces of the splice pin arrangement 6,7.
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Interconnecting two insulation sheathed conductors in subsea environments is done using a subsea connector including a metal conductor splice pin arrangement and a splice insulation sleeve. A metal tube is placed over the splice insulation sleeve. The conductor insulation sheaths are molded to respective opposite sides of the metal tube.
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FIELD OF THE INVENTION
[0001] The present invention in general, relates to a subsea leak detection system and to a method for installation thereof.
[0002] More specifically, the present invention relates to a subsea leak detection system which is adapted to be precisely, securely and conveniently positioned at an appropriate sub sea location. This facilitates precise detection of hydrocarbon and other leakage from a subsea assembly, such as a X-mas tree. Hence, is achieved triggering of a message to the well supervising team for initiating corrective steps.
[0003] More particularly, the present invention relates to a subsea leak detection system according to the preamble of claim 1 and to a method of positioning such leak detection system appropriately in a subsea location, according to the preamble of claim 8 .
TECHNICAL BACKGROUND OF THE INVENTION
[0004] It is known in the art that various subsea assemblies are applied in the exploration and production of hydrocarbons such as oil and gas. These include complex installations with various equipment and assemblies. Such assemblies may be X-mas trees, BOPs, production manifolds and so on, as known to persons skilled in the art.
[0005] Small and large scale leakages of hydrocarbons and other undesirable materials such as injecting fluids and chemicals are known to occur from such subsea assemblies, particularly during production, resulting in discharge of hydrocarbons or other chemicals to the surrounding water.
[0006] Environmental impact analysis of hydrocarbon leakage is today a matter of concern all over the world. Hence, hydrocarbon exploration and production agencies are now attaching immense importance on regulating and substantially preventing hydrocarbon and other leakage from subsea units, not only from economic points of view, but in particular due to environmental concerns.
[0007] In the above context, it is hereby clarified that hereinbefore and hereinafter, the present invention as well its technical background, prior art already known, are explained with reference to hydrocarbons, X-mas trees, production units/equipments. It should be understood that these are all limitations for the sake of explanation. The present invention pertains to all types of leakage detection under water such as hydrocarbons, hydraulic fluids and chemicals and so on. Further, the present invention is applicable in respect of all types of units, installations, equipment and subsea assemblies such as X-mas tree, production manifolds and so on, as known to persons skilled in the art, involved in hydrocarbon recovery by offshore operations. Reference to subsea hydrocarbon production units and operations, is purely exemplary and non-limiting.
[0008] Application of acoustic methods for subsea leak detection has found applicability for quite a long time, but has suffered from the disadvantage of sensitivity to shadowing of signals by subsea structures and units. However, it is known that such disadvantages are effectively overcome by deploying a plurality of detectors around potential leakage zones.
[0009] Biosensors, depending on study of the behaviour of the aquatic animals to pollution are known to be effective at shallower levels. However, such sensors are now mainly under experimentation.
[0010] Capacitive sensors measure the change in dielectric constant of the medium surrounding the sensor and are found to be fairly and reasonably reliable in precise detection of hydrocarbon and other leakages from subsea production units.
[0011] Prevention of hydrocarbon leakage of any scale during subsea production has become increasingly more important. The earlier a small leak can be detected the easier it will be to prevent any major leakage. A significant problem encountered in this respect is toe position the leak detector so that it will correctly detect a leakage.
[0012] Proper positioning of the leak detection system is required not only for precise detection of leakage, but also for ensuring that detection of natural seepage from the sea bed does not trigger the detector. Natural seepage may trigger wrong signals to the leakage management team. Further, retaining the position of the leak detector after it has been installed is another challenge.
[0013] In other words, the leak detection systems known in the art are not suitably adapted to be precisely and securely positioned.
[0014] U.S. Pat. No. 7,918,126 discloses a leak detection system for precise detection of leakage of subsea materials such as hydrocarbons, hydraulic fluids, chemicals. It includes a plurality of sensors and a controller for receiving leak detection data from such sensors. It directs the sensing activities of the sensors, based on the data. However, it does not teach precisely and securely location of the system for leak detection, because it is not adapted to be so positioned and moreover it involves complex constructional network.
[0015] Similarly, U.S. Pat. No. 4,282,487 discloses a hydrocarbon detection system, but here again is not disclosed how the system is adapted to be precisely and securely positioned for precise detection of leakage. Rather, it generally states under “Background of the invention” that it is desirable that a plurality of detection units should be located at potential locations of hydrocarbon escape.
[0016] To take care of the concerns as stated in the preceding paragraphs, it has been common knowledge that leak detection systems are often located in the ceiling of subsea assemblies such as X-mas trees. The motive is to arrest all leak detections coming out from such units. However, such positioning results in faulty detection, in as much as leakage of hydrocarbons such as oil and gas above the X-mas tree are not detected.
[0017] Further, the construction of such prior art leak detection systems does not allow for suitable and secure location for precise detection. Additionally, due to their constructional disadvantage, prior art subsea leak detection systems cannot be easily installed, or for that matter retrieved after installation, for maintenance or replacement. This is for example, due to the limited space between the X-mas tree roof and X-mas tree, the desired location of installation.
[0018] Accordingly, there is a need for a subsea leak detection system, which by virtue of its simple construction is adapted to be suitably and securely located/installed for precise detection of leakage of hydrocarbons.
[0019] The present invention meets the above long felt need and other associated needs as will be clear to persons skilled in the art from the following.
OBJECTS OF THE INVENTION
[0020] The principal object of the present invention is to provide a subsea leak detection system which Is adapted to be precisely and securely Installed at a suitable subsea location, by virtue of its simple and unique construction, for precise detection of leakage of hydrcrabons and other materials.
[0021] It is another object of the present invention to provide a subsea leak detection system which is simple in construction comprising mutually balanced components, easy to Install and very cost effective, without compromising on accuracy.
[0022] A further object of the invention is top provide a leak detection system that is less (if at all) depending on tolerances in distance between the subsea structure and the protective structure.
[0023] It is also an object for the present invention to provide a leak detection system that will not transfer impact forces to the subsea structure of the protective structure is hit by falling objects or otherwise subject to excessive forces.
[0024] Another object of the present invention is to provide a subsea leak detection system which can be easily accessed for example by an ROV, for installation and for retrieval after completion of operation or for maintenance/replacement.
[0025] It is another object of the present invention to provide a subsea leak detection system which is adapted to send a signal to the leak management team for Initiating rectifying steps, in the event of detection of leakage.
[0026] It is a further object of the present invention to provide a subsea leak detection system which is adapted to ignore natural seepage from sea bed.
[0027] It is a further object of the present invention to provide a method for suitably installing a subsea leak detection system having all advantages as stated hereinbefore under the heading “Objects of the invention” for precise detection of leakage of hydrocarbon and other materials, during subsea operation.
[0028] How the foregoing objects are achieved and some other advantageous features, still not disclosed in prior art will be clear from the following non-limiting description.
[0029] All through the specification including the claims, the words, “subsea”, “connector”, “subsea assembly”, “X-mas tree”, “floating unit”, “hatches”, “anchor”, “hydrocarbon (including oil and gas)”, “subsea material”, “leak detection system”, “production operation”, “subsea operation”, “buoy” are to be interpreted in the broadest sense of the respective terms and includes all similar items in the field known by other terms, as may be clear to persons skilled in the art. Restriction/limitation, if any, referred to in the specification, is solely by way of example and understanding the present invention.
SUMMARY OF THE INVENTION
[0030] According to a first aspect of the present invention there is provided a subsea leak detection system for an off-shore operation facility, comprising at least a leak detector operatively connected to a controller located on a subsea assembly. According to the invention, the system is provided with a floating member on which the leak detector is suitably attached. The floating member is adapted to be installed and stably positioned, above the assembly
[0031] In accordance with a preferred embodiment of the first aspect of the present invention the assembly is an X-mas tree having a template hatch above its roof for collection of hydrocarbon leakages and the controller is a subsea control module unit on the X-mas tree, connected by connectors such as cables, with said detector.
[0032] More preferably, the detector is a capacitive sensor type detector.
[0033] According to another preferred embodiment of the first aspect of the present invention the floating member is a buoy secured to a locking unit by means of wires on said X-mas tree roof, such that the detector is positioned above said X-mas tree roof and beneath said template hatch.
[0034] Preferably, the locking unit is securely received on a guide post receptacle, on said X-mas tree roof.
[0035] According to a second aspect of the present invention there is provided a method for installation of a subsea leak detection system for an off-shore operation facility, the system comprising at least one leak detector operatively connected to a controller located on a subsea assembly, said system being provided with a floating member on which said leak detector is suitably attached. According to the method of the present invention the floating member retaining the detector Is installed and stably positioned by appropriate means, above the assembly.
BRIEF DESCRIPTION OF THE ACCOMPANYING FIGS.
[0036] Having described the main features of the invention above, a more detailed and non-limiting description of a preferred embodiment will be given In the following with reference to the drawings, in which
[0037] FIG. 1 is a perspective view of a preferred embodiment of the leak detection system according to the present invention.
[0038] FIG. 2 illustrates an enlarged view of the leak detection system shown in FIG. 1 .
[0039] FIG. 3 illustrates the leak detection system shown in FIGS. 1 and 2 in installed position.
[0040] FIGS. 4( a ) and 4 ( b ) illustrate two consecutive stages of installation of the leak detection system shown in FIGS. 1 , 2 and 3 .
[0041] FIG. 5 illustrates a step of installation immediately consecutive to the step shown in FIG. 4( b ), when the leak detection system of the present invention is almost installed in position.
DETAILED DESCRIPTION OF THE INVENTION
[0042] The following provides a detailed non-limiting description of a preferred embodiment of the leak detection system according to the present invention which is purely exemplary and non-limiting.
[0043] In the above context, it is hereby clarified that hereinbefore and hereinafter, the present invention as well its technical background, prior art already known, are explained with reference to hydrocarbons and X-mas trees. It should be understood that these are all limitations for the sake of explanation. The present invention pertains to all types of leakage detection under water such as hydrocarbons, hydraulic fluids/chemicals and so on, or any fluid whose Specific Gravity is lower than sea water. Further, the present invention is applicable in respect of all types of units, installations, equipments and subsea assemblies such as X-mas trees, production manifolds and so on, as known to persons skilled in the art, Involved in hydrocarbon recovery by offshore operations. Reference to subsea hydrocarbon production operations, is purely exemplary and non-limiting.
[0044] As stated before, the present invention proposes a simple subsea leak detection system, which, unlike the leak detection systems hitherto known, can be precisely and securely located in subsea, for optimal detection of hydrocarbon leakage, during subsea operation.
[0045] FIG. 1 is a perspective view of the leak detection system. It comprises of a floating unit or buoy 1 , which is connected to a locking unit 8 , by means of wires 7 . FIG. 2 is a further enlarged view of the system shown in FIG. 1 , where like reference numerals represent like features. It shows the capacitive leak detector with jumper 5 , positioned on the distance ring 3 of the buoy 1 . Attached to the leak detector 5 is a cable 6 , which connects the detector 5 with a plug 15 (se FIG. 3 ). The buoy is also provided with impact absorbing pads 4 , preferably made of rubber on its top portion. The buoy also has a buoyancy element 2 beneath the ring 3 . The buoyancy element 2 provides positive upward buoyancy to the buoy.
[0046] The locking unit 8 is provided with a lower lock plug 8 ″ and a slot 8 ′. The functions of these and also the other parts are explained with reference to the subsequent figures, where like reference numerals represent like constructional features.
[0047] It is common knowledge that templates involves protective structures for subsea assemblies such as X-mas trees and manifolds and template hatches are designed to protect the equipment below. Template hatches may also be used to collect small amounts of oil and gas from leakages. Further, such template hatch is particularly helpful to arrest the leakages which escape upwards undetected, so that such leakages may be redetected.
[0048] FIG. 3 illustrates a position where the leak detection system is optimally installed. This figure, illustrates how the leak detection system according to the present invention is beneficial. A close look at FIG. 3 will reveal that the buoy 1 is located beneath the X-mas tree template hatch 10 and above the X-mas tree roof 11 . This position is beneficial, because the oil and gas leakage above the X-mas tree roof 11 will be detected by the detector unit 6 , positioned on the floating buoy 1 . Of course, the detector 6 identifies all leakages coming out from beneath it, barring the natural seepages from the sea bed.
[0049] The buoy 1 is guided, preferably, by an ROV, so that the detector 6 is placed just beneath the X-mas tree template hatch 10 but above the X-mas tree roof top 11 . This is explained in detail later, with reference to FIGS. 4 a , 4 b and 5
[0050] The location of the detector 5 , beneath the ceiling of the hatch 10 ensures detection of leakage from any equipment below the hatch 10 . Further, the detector 5 is located about 5 cm below the ceiling of the hatch 10 . Natural leakage from sea bed, being low in volume, if allowed to accumulate, take some time to fill this gap. So the spill from natural leakage has enough time to pass through small openings 10 ′ (best shown in FIG. 4( a )) in the hatch 10 , without being accumulated in a sufficient amount to reach the level of the capacitor 6 .
[0051] Thus a false signal being is sent to the leakage management team due to natural leakage is largely prevented. This is also facilitated by the fact that the minor seepages from the seabed do not cause significant change in the dielectric constant of the surrounding sea water. The detector 6 is set at a certain threshold value adapted to ignore such insignificant changes in the dielectric constant of the surrounding media. Hence, such natural seepages escape undetected through the openings 10 ′ (best shown in FIG. 4 a ).
[0052] Now the different units of the leak detection system will be explained. It is clear from FIG. 3 that the wires 7 attach the buoy 1 to the locking unit 8 . The locking unit is attached in an anchored manner on the X-mas tree roof top 11 . For that purpose, the lower plug unit 8 ″ of the locking unit 8 is adapted to mate with a guide post receptacle 16 on the X-mas tree roof 11 . Thus, the locking unit 8 being securely locked on the roof 11 anchors the buoy 1 .
[0053] The buoy 1 has a conical top portion 17 which is adapted to mate with a funnel shape opening 10 ′ in the hatch 10 .
[0054] The template hatch 10 , as explained hereinbefore facilitates collection of oil and gas leakages and is particularly helpful to arrest the leakages which escape upwards undetected, so that such leakages may be redetected.
[0055] The buoy is held in position on installation beneath the template hatch 10 by its positive upward buoyancy and by the mating of the conical portion 17 with the opening 10 ′. The locking unit 8 is heavier than the buoyancy of the buoy 1 and is locked to the guide post receptacle 16 , thus preventing unintentional drift off of the leak detection device.
[0056] The detector 5 is connected by the cable 6 and the plug 15 to a sub sea control module 9 (hereinafter referred to as SCM) located on the X-mas tree. The slot 8 ′ of the locking unit 8 acts as a secured parking space for the free end of the connector 15 when not in use, for example during removal of the whole unit.
[0057] In the preferred embodiment hereinbefore and hereinafter described, the detector 56 is a phase capacitive leak detector probe. But this is not consequential to the present Invention and other types of sensors may be applied as well, as known to persons skilled in the art.
[0058] The detector 5 thus applies capacitive sensing for identifying change in the dielectric constant in the surrounding medium. So, it has to remain in physical contact with the media to detect. This is not consequential to the present invention as explained in the preceding paragraph and further elaboration is not provided, as it Is known to persons skilled in the art. Due to similar reasons, the role of the SCM 9 is not elaborated. Obviously, the leak detector 5 is connected to the SCM 9 , which sends signals to the surface so that the leak management team can initiate rectifying measures, in the event of detection of leakage.
[0059] It is the judicious construction of the leak detection system, involving the floating unit 1 , anchored by the locking unit 8 on a X-mas tree roof top 10 , such that the detector 5 is beneath the template hatch 10 but above the X-mas tree roof top 11 , which constitutes the crux of the invention. The objective of securely placing the detector 5 below the template hatch 10 but above the X-mas tree roof top 11 is achieved by this unique but simple construction. The leak detector 5 is adapted to be installed approximately 5 cm below the template hatch 10 .
[0060] How the installation takes place will now be elaborated with reference to FIGS. 4 a , 4 b and 5 .
[0061] As shown in FIG. 4 a the buoy 1 is guided by an arm 12 ′ of an ROV 12 beneath the X-mas tree template hatch 10 , so that the detector 6 is placed just beneath the X-mas tree template hatch 10 , but above the X-mas tree roof top 11 . One arm 12 ″ of the ROV 12 is firmly attached to a fixed handrail 11 ′ on the body of the X-mas tree 14 . The whole unit is so constructed such that the unit in its entirety is adapted to be installed say, just 5 cm below the template hatch 10 and the unit by virtue of the buoyancy and unique balancing between components retains its position.
[0062] The installation is being shown at a stage when the hatch 10 is closed. This figure also shows the openings 10 ′ in the hatch ceiling, through which the seepages from the sea bed escape can without being detected by the detector 6 . As clearly shown in FIG. 4 a , the floater 1 is secured by wires 7 to the locking unit 8 , during ROV operations subsea (for transport and positioning).
[0063] The wire 7 prevents unintentional drift-off, should the template hatch 10 be opened without prior removal of the buoy 1 and the associated components namely, the detector 5 , the cable 6 , the wires 7 and the locking unit 8 . During transport, the free end of the plug 15 is securely docked into the slot 8 ′ (best shown in FIGS. 1 and 2 ) of the locking unit 8 .
[0064] FIG. 4 b shows the next stage where the leak detection system is brought further towards the desired location in the opening 10 ′ below the hatch 10 . FIG. 5 shows the next stage when the buoy 1 is installed at the desired location. The pads 4 rest against the hatch ceiling 10 . Hence, the ROV 12 is retracted back.
[0065] The buoy does not need to be fixed to the hatch ceiling, but may be allowed to float within the boundaries of the ceiling.
[0066] If a hatch is opened without first removing the leak detector system, the buoy 1 will float up until the wires 7 are taut. The locking unit 8 will prevent the buoy from ascending further. Ideally, the leak detection system should then be removed and not installed again until the hatch 10 is closed. However, if the hatch 10 is closed again without the leak detection system first being removed, the buoy 1 will be pushed down by the hatch and lie under the hatch quite safely. It will likely not be in a correct position, but it is a simple task for an ROV to reposition the buoy 1 to one of the openings 10 ′. This means that the leak detection system will be kept safe irrespective of the movement of the hatch 10 .
[0067] When, FIGS. 3 , 4 a , 4 b and 5 are construed with reference to the preceding description, it would be clear to persons skilled in the art that the unique construction of the leak detection system according to the present invention makes it possible to install the detector unit beneath the hatch ceiling 10 and above the X-mas tree roof 11 , which was hitherto not possible. The other advantages as stated before, are derived from this unique construction as well, particularly the retaining of position of the detector unit when installed.
[0068] The position of the leak detector 5 ensures that it detects leakage as early as possible; simultaneously ensuring that false detection of seepages from sea bed is avoided. The construction facilitates easy installation and retrieval of the entire system for replacement and maintenance. The leak detection system may be installed or removed while performing operations such as well intervention and so on.
[0069] From the foregoing description and also from the appended claims it would be clear to persons skilled in the art, that all the objectives of the present Invention are achieved. The technology in accordance with the present invention can be applied both in deep sea and shallow sea and can function irrespective of the underwater condition. Further, it should be understood that only one leak detection system located above an X-mas tree is shown. Ideally, there should be a plurality of such leak detection systems installed above subsea assemblies during subsea operation, so that leak detection is done in a reliable manner and appropriate signals are sent to the leak management team, for effecting corrective measures. The present invention encompasses this aspect as well.
[0070] The present invention has been described with reference to a preferred embodiment and drawings for the sake of understanding only and it should be clear to persons skilled in the art that the present invention includes all legitimate modifications within the ambit of what has been described hereinbefore and claimed in the appended claims.
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A subsea leak detection system for an off-shore operation facility, comprising at least a leak detector ( 6 ) operatively connected to a controller ( 9 ) located on a subsea assembly ( 14 ). The system is provided with a floating member ( 1 ) on which the leak detector ( 6 ) is suitably attached. The floating member ( 1 ) is adapted to be installed and stably positioned, above the assembly ( 14 ).
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This application is a divisional application of application Ser. No. 07/701,925, filed May 17, 1991, now U.S. Pat. No. 5170,226
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a method for fabricating semiconductor structures which contain at least a doped region in a compound semiconductor layer of III-V or II-VI elements with Group V or Group VI elements introduced therein, in excess amount, to form either microcrystals or point defects in the doped region and, more particularly, it relates to the fabrication of quantum structures in III-V compound layer such as GaAs. This invention is also directed to the fabrication of an improved FET structure which has a gate length less than 0.1 micron.
2. Description of the Prior Art
Electrons confined in a potential well whose size is comparable to that of the de Broglic wavelength of an electron behave quite differently from those in free space. This special behavior is called the quantum confined effect. One-dimensional plane. Two-dimensional confinement allows only one-dimensional motion of carriers: a structure with this feature is called a quantum wire or quantum well wire. Three-dimensional confinement does not allow kinetic motion of electrons, for example, in any direction. This electronic state is similar to those in atoms. An electron in this state is called a zero-dimensional electron and a structure that gives rise to this state is called a quantum dot or quantum box.
The difference in the dimensionality of these electrons causes quite a big difference in their density of states and electronic energy levels. Moreover, a remarkable improvement can be expected in the performance of devices that use the feature of electron kinematics in quantum structures of less than three dimensions. For example, an electron's mobility is related to the speed of an electronic feature of electron kinematics in quantum structures of less than three-dimensions. For example, an electron's mobility is related to the speed of an electronic device and its power consumption. This mobility is subject to electron scattering processes in semiconductors.
A quantum wire in which an electron has only one-dimensional freedom of kinetic motion allows only forward and backward scattering. Only backscattering reduces the mobility, but the probability of such scattering can be expected to be very low. Extraordinarily high mobility (10 7 -10 8 sqcm/Vs) is predicted in the Japanese Journal of Applied Physics, Vol.19, No.12, December, 1980, pp.L735-L738 in an article entitled "Scattering Suppression and High-Mobility Effect of Size-Quantized Electrons in Ultrafine Semiconductor Wire Structures" by H. Sakaki. It is easy to understand the improvement, if we compare this value with that of bulk GaAs (10 3 sqcm/Vs).
There have been many attempts to make quantum wires and quantum boxes, in the hope of effecting a remarkable improvement in the device performance of electronic devices. However, these attempts have hitherto resulted only in rather large quantum wires whose quantum size effect is insufficient for practical purpose. These quantum wires also present many problems: lack of uniformity, low packing density and difficulty in obtaining a multi-layered structure and cleanliness in the fabrication process, which is important for subsequent crystal growth. Even if a quantum wire has high electron mobility, the current per quantum wire is so small that a large bundle of quantum wires is required to operate an actual electron device. This means that the size uniformity, high packing density, and multi-layered structure are indispensable for quantum wires.
Prior methods of fabricating quantum wires can be classified into four types, as summarized below. Except for molecular beam epitaxy (MBE), or metal organic chemical vapor deposition (MO-CVD), described at 4 below, grown quantum wells or superlattices are used for one-dimensional quantum confinement. Many different methods are used for additional confinement.
1. Etching Methods
1) Chemical Etching Method
A preferential chemical etching method used for making quantum wires was proposed in the Applied Physics Letter Vol.41 No.7, Oct. 1, 1982, pp.635-638 in an article entitled "Toward Quantum Well Wires: Fabrication and Optical Properties" by P. M. Petroff et al. The surfaces of a (111) Ga plane of GaAs have strong resistance to the etchant (H 2 SO 4 :H 2 O 2 :H 2 O). This characteristic has been used to obtain a 200 Å quantum wire stripe-width from a two-micron mask pattern. However, this method lacks uniformity of quantum well size, high packing density structure, and the ability to process a multi-layered structure. A similar method was disclosed in the Journal of Crystal Growth 93, 1988, pp.365-369 in an article entitled "Fabrication Technique for GaInAsP/InP Quantum Wire Structure by LP-MOVPE" by P. Daste et al for making a GaInAsP quantum wire which has a 500 Å quantum wire stripe-width. This method is, however, subject to the same problems as the first mentioned approach.
2) Dry Etching Method
K. Kash et al applied a conventional dry etching method to MBE grown quantum well structures and obtained 400 ű50 Å quantum wires, as reported in the Applied Physics Letter Vol.49 No.16, Oct. 20, 1986, pp.1043-1045 in an article entitled "Optical Spectroscopy of Ultrasmall Structures etched from quantum wells". A. Scherer et al also made quantum wires of 300 Å-400 Å stripe-width, as reported in an article entitled "Fabrication of Small Laterally Patterned Multiple Quantum Wells" in the Applied Physics Letter Vo.49 No.19, Nov. 10, 1986, pp.1284-1286. However, these dimensions are still insufficient to obtain a practical quantum size effect. In addition, the dry etching process causes damage and contamination to the semiconductor crystal. The fluctuation of the quantum well size, which originates from the dry etching resist, is also a problem.
2. Use of a Hetero-Interface or Metal-Oxide-Semiconductor (MOS) Structure Fabricated on an Edge of a Crystal
The above-mentioned article by Sakaki et al proposed a conductive wire, that is electrostatically formed by a positive gate voltage, which induces an n-type inversion layer on a modified V-groove surface of a p-type quantum well structure. This method was extended to a quantum wire fabrication technique that relies on the MBE overgrowth of a cleaved multilayer MBE sample with modulation doping. L. Pfeiffer et al obtained a quantum wire, whose mobility is 4.8×10 5 sqcm/Vs, as reported in an article entitled "Formation of a High Quality Two-dimensional Electron Gas on Cleaved GaAs", in the Applied Physics Letter Vol.56, No.17, Apr. 23, 1990 pp.1697-1699. Although this value is quite high compared with that of a conventional semiconductor bulk crystal, only one cleaved facet can be used to make a quantum wire array. The disadvantage of the fabrication process, which requires formation on a wafer edge, makes it difficult to fabricate actual devices.
3. Partial Intermixing of the Micro-Hetero Structure
Impurity-induced disordering is a patternable process for locally mixing a compound semiconductive micro-hetero structure without losing its crystal quality. Under conditions of thermal diffusion or thermal annealing after ion implantation, impurity ions such as Zn or Si causes interdiffusion between Ga and Al atoms, which are component atoms in a III-V compound semiconductor. The intermixing of atoms forming the quantum structure makes the band gap larger than that without intermixing.
This intermixing was extended and combined with Ga focused ion beam implantation to make quantum wires or quantum boxes, as disclosed in Japanese Published Unexamined Patent Application (PUPA) 61-18192 and Japanese PUPA 62-36886, and in an article entitled "Optically Detected Carrier Confinement to One and Zero Dimension in GaAs Quantum Well Wires and Boxes" by J. Cibert et al in the Applied Physics Letter Vol.49, No.19, Nov. 10, 1986. In these prior art techniques, quantum structures, which are implanted with a pattern of linear arrays of focused Ga ion beams, change to linear arrays of mixed crystals, which act as barriers for linear arrays of quantum wires. Although this method preserves good crystal quality during the process, the thus obtained quantum wires or quantum dots have quite vague patterns in comparison with the original ion implanted patterns. This results from diffusion, which is the main cause of intermixing in this system. According to J. Cibert, there was no apparent formation of quantum wires when the mask pattern was smaller than 500 Å. This method is thus not appropriate process for making good quantum wires.
4. Crystal Growth on a Tilted Substrate
MBE or MO-CVD growth on a (001) GaAs substrate mis-oriented by several degrees from (110) gives direct growth of quantum wires. The crystal surface of the tilted substrate has many staircase-like steps with an atomic scale, which can act as nucleation centers for crystal growth. The crystal growth of each epitaxy layer starts from these steps.
Alternation between GaAs and AlAs molecular beams gives a lateral superlattice that is similar to a kind of quantum wire. The ratio between the GaAs and AlAs stripe-width can be controlled by the exposure time of each molecular beam. The size of the stripe-width can be controlled by selecting the tilted angle of the substrate, but the actual step size varies broadly. Although this method gives quantum wires with a stripe-width of 100 Å or less and also allows the integration of multilayers of quantum wire arrays, the well width fluctuation reduces the advantage of the quantum wire. M. Tsuchiya et al measured the spectral linewidth of photoluminescence from quantum wells and quantum wires, grown by this method at 3.7 meV and 7.7 meV, respectively, as reported in an article entitled "Optical Anisotropy in a Quantum-Well-Wire Array with Two-Dimensiona Quantum Confinement" in the Physical Review Letters, Vol.62, No.4, Jan. 23, 1989, pp.466-469. This line-width-broadening mechanism originates from the well-width fluctuation in the lateral direction of quantum wires.
In summary, all prior art techniques for making quantum wires or quantum dots involve difficulties in either the well size, the packing density, the direction of the substrate, or uniformity, thus reducing their effectiveness for actual usage in electronic devices or optical devices.
SUMMARY OF THE INVENTION
There is disclosed herein a novel fabrication method for semiconductor structures which allow several advantages over prior art methods. The use of structures fabricated by this method in various electronic devices is expected to result in a greatly enhanced performance.
It is known that epitaxial GaAs films grown at relatively low substrate temperatures 200°-250° Centigrade by molecular beam epitaxy exhibit high resistance and therefore very favorable insulating characteristics for buffer layers in metal-semiconductor field effect transistors, as disclosed in an article entitled "New MBE Buffer Used to Eliminate Backgating in GaAs MESFET's" by F. W. Smith et al in the IEEE Electron Device Letters, Vol.9, No.2, February 1988. pp.77-80. A mechanism for the high resistance is considered to be attributed to the presence of excess Arsenic (As) microcrystals imbedded in the GaAs single crystal layers, as reported in an article entitled "Arsenic Precipitates and the Semi-insulating Properties of GaAs Buffer Layers Grown by Low-Temperature Molecular Beam Epitaxy" by A. C. Warren et al in the Applied Physics Letter Vol.57 No.13, Sep. 24, 1990, pp.1331-1333 and in another article entitled "Formation of Arsenic Precipitates in GaAs Buffer Layers Grown by Molecular Beam Epitaxy at Low Substrate Temperatures" by M. R. Melloch in the Applied Physics Letter Vol.57 No.15, Oct. 8, 1990, pp.1531-1533. Each As microcrystal acts as a small metal particle, forming a Schottky barrier at the As/GaAs boundary and thus a carrier depletion region surrounding the microcrystal. Consequently, the entire GaAs layer becomes free from carriers under the condition at which the average As crystallite distance is close enough to let the depletion regions overlap each other. For example, the carrier concentrations that can be depleted have been estimated to be less than or equal to 2.2×10 18 /cc for n-type and less than or equal to 1.6×10 18 /cc for p-type with the As microcrystal concentration of 2×10 16 /cc, assuming the barrier heights of 0.8 eV and 0.6 eV for electrons and holes respectively.
The concentration of As microcrystals or point defects in the form of vacancies or arsenic antesites is controllable by the MBE growth parameters, such as substrate temperature and As/Ga flux ratio. A highly resistive GaAs layer thus prepared shows more favorable insulating features than that of a Cr doped semi-insulating GaAs substrate, and is currently considered to be a promising material for device application. However, a method to permanently recover electronic conduction in the highly resistive layer has not yet been found in the prior art techniques.
The present invention provides an approach for recovering permanently the electronic conduction at an arbitrary area specified by the implantation of appropriate amounts of group III elements, that is, Ga + ions, in the highly resistive layers which may be doped or undoped. At the area of implantation, the As microcrystals change into a GaAs single crystal phase through the reaction Ga+As→GaAs after an appropriate annealing step, resulting in the elimination of carrier depleted regions. This makes it possible to generate and confine carriers inside of the implanted regions in doped but highly resistive target GaAs layers which contain excess As microcrystals or point defects.
Co-implantation of ions of Group III elements and Group II elements provides semiconductor single crystal regions which have holes, and co-implantation of ions of Group III elements and Group IV elements provide a region with electrons as carriers after an appropriate annealing step. This makes it possible to generate and confine both p- and n-type carriers inside of the implanted regions even if the target III-V semiconductor layer is undoped. Use of this technique can provide devices such as GaAs short channel devices which have high-speed performance and which can be integrated in both lateral and vertical directions. At this point, it should be appreciated, that while GaAs has been discussed by way of example, other compound semiconductors such as semiconductors, made from the II-VI elements may also be utilized. In addition, binary, ternary and quaternary compounds of both III-V and II-VI elements may be used in the practice of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A through 1C show fabrication process of GaAs wires.
FIG. 2 is a top view of a wire structure with electrical contacts.
FIG. 3 is a cross section view of contact region.
FIG. 4 is an illustration of depletion region caused by Arsenic microcrystal and quantum wire fabricated therein.
FIG. 5 shows fabrication process for stacked GaAs wires structure.
FIG. 6 is a side view of a stacked wire structure with side contacts.
FIG. 7 is a top view of Ga implanted regions in forms of dots.
FIGS. 8A through 8E show fabrication process of short channel GaAs FET.
FIGS. 9A and 9B show alternative fabrication process of short channel GaAs FET.
FIG. 10 is a graph showing a transient response of electron drift velocity in Si.
FIGS. 11 and 12 are graphs showing a transient response of electron drift velocity in GaAs.
FIGS. 13A and 13B show fabrication process of short channel GaAs FET for normally-off and on devices.
FIG. 14 is a cross section view of multi-layered integrated circuits.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Throughout the following description, the same reference numbers refer to the same elements in all the figures.
EXAMPLE 1
Quantum Wires
The first example is the fabrication of quantum wires, which is schematically illustrated in FIG. 1A-FIG. 1C. A 1-micron thick, highly resistive GaAs (doped with Si=1×10 17 /cc) layer 2 is first grown on a semi-insulating GaAs (100) substrate 1 by molecular beam epitaxy (MBE) at a substrate temperature of 200° Centigrade with As 4 /Ga flux ratio of less than 16, as illustrated in FIG. 1A. The growth rate is 1 micron/hr. The estimated concentration of As microcrystals in bulk layer 2 is 10 16 -10 17 atoms/cc. A microcrystal, typically a 50 Å cluster, consists of 2×10 3 As atoms on average. The sample is then transferred through ultrahigh vacuum transfer modules to a focused ion beam (FIB) chamber for the Ga writing from which quantum wires are ultimately formed. The Ga writing is performed by using a Ga + focused ion beam having a beam diameter of 0.25 micron to form an array of straight Ga regions 3. The array may consist of 100 such regions 3. The dose is 10 14 Ga + /sqcm. The acceleration voltage and beam current are 150 keV and 100 pA, respectively, so that the ion-implantation depth is 0.15 micron. The concentration of implanted Ga is 2×10 19 -2×10 20 atoms/cc. A cross-sectional view of such Ga-implanted region is shown as region 3 in FIG. 1B. A top view of the array of Ga regions 3 can also be seen in FIG. 2. The length of each Ga-implanted region 3 is 50 microns, and the spacing between two consecutive regions 3 is 0.1 micron.
After the Ga writing is completed, the sample is transferred back to the MBE growth chamber where a second low temperature GaAs layer 4 (FIG. 1C) of 0.1 micron thickness is grown on top of the layer 2 at the same growth conditions as specified for the growth of layer 2. Note, however, that the layer 4 is intentionally undoped. This is followed by the growth of a 0.1 micron thick undoped GaAs cap layer 5 (FIG. 1C). This step is performed at a substrate temperature of 580°-600° Centigrade.
Finally, the sample is again transferred to the FIB chamber, and Si + and Ga + ions are co-implanted in a pattern 6 at both ends of the array of regions 3 as shown in FIG. 2. The alignment between the array of regions 3 and pattern 6 viewed from the sample surface is also shown in FIG. 2. Note that the array of regions 3 is embedded in highly resistive GaAs as shown in FIG. 1C, which corresponds to a cross section A-A' in FIG. 2. The implantation depth has to be deep (about 0.2 micron) enough to reach the embedded array of regions 3. A cross section of the implanted region B-B' is also shown in FIG. 3 for comparison. The purpose of this process is to establish electrical contact from the top surface to the array of regions 3, so the beam size can be rather large (about 1 micron) compared to the previous Ga writing process. The co-implantation step is followed by either laser flash annealing or other rapid thermal annealing step to recover the crystal quality of regions 3 and co-implanted regions 6, and then by the formation of n-type ohmic contact pads 7 (FIG. 3) on top of regions 6. After annealing, regions 3 and 6 have been recovered or converted to conductive regions of GaAs in the form of quantum wires. The steps involved in the electrical contact fabrication are similar to those used in conventional semiconductor device processing.
The resulting structure is then subjected to transport measurements to determine its characteristics. Finite conductance (2×10 -4 mho) is observed together with characteristic magnetotransport behavior, both indicative of the presence of electrons in the recovered GaAs wires. An effective wire diameter is estimated to be about 30 nm, taking account of a depletion region which extends from outside to inside of the GaAs wires. 30 nm is sufficiently less than the de Broglie wavelength of electrons or holes to permit the quantum size effects such as high electron mobility.
The formation mechanism of quantum wires in highly resistive GaAs can be understood by considering FIG. 4. Note that FIG. 4 is an enlargement of the tube-like shape of ion-implanted regions 3 and As microcrystals 8 after GaAs layer 4 is grown. The solid state reaction Ga+As→GaAs occurs in the regions 3 where Ga + ions are implanted in a concentration of As microcrystals 8 so as to return regions 3 to stoichiometry. This results in the appearance of a specific region 9 which is undepleted as compared with depleted region 10. Thus, carriers which are electrons for Si-doped GaAs are confined in region 9. Annealing effects during the cap layer growth (at 580°-600° Centigrade) and after the second ion implantation also promote reactions for GaAs formation and recrystallization which results in conductive regions 9.
Note that the width or diameter of a region 3 is determined by not only the ion beam diameter but also by the extension of the depletion regions 10 from the surrounding As microcrystals 8. The latter is determined by the concentration of microcrystals 8 which is controllable by the substrate temperature, the As 4 /Ga flux ratio during the MBE-growth step and the silicon concentration. Similarly, the wire depth, or the size in a vertical direction of FIG. 4 is determined by the ion-implantation depth and the above MBE parameters. The former is controlled by ion-implantation parameters such as beam acceleration voltage and current.
EXAMPLE 2
Stack of Wire Arrays
The second example of wire arrays is schematically illustrated as an end view in FIG. 5. The first row of the array of Ga wires 3 is fabricated in the same fashion as described in example 1. A second GaAs layer 11 is then grown on top of layer 2, embedding first row of wires 3 underneath it, followed by the successive fabrication of a second row of Ga wires 3 on top of layer 11. Layer 11 is grown under the same growth condition as layer 2. The fabrication process of Ga wires 3 is repeated six times in total forming structure 17, and then, undoped low temperature (200° Centigrade) and high temperature (600° Centigrade) GaAs cap layers 12 and 13 are grown on top of layers of wires 3. The quantum wire structure 17 composed of six rows of GaAs wires 3 prepared as above, is shown in FIG. 6 as a side view of FIG. 5. In this case, the electrical contact is achieved by side wall contacts 19 in a mesa structure fabricated by conventional lithography techniques. An edge of the top of the mesa is aligned perpendicular to the axis of wires 3. The contact formation is done at the mesa edges 18 (FIG. 6) by co-implantation of Ga + and Si + ions by FIB, followed by rapid thermal annealing and n-type metallurgy 19. Magnetotransport behavior through two contact probes shows the existence of electrons confined in the GaAs wires 3, and, thus, confirms the formation of quantum wires.
EXAMPLE 3
Quantum Dots
An array of Ga dots 20 is fabricated in a low temperature grown GaAs layer 21, as seen on the top view of the sample surface of layer 27 (FIG. 7). Ga + ions are implanted in the form of an array of dots each with a diameter of 0.2 micron. Repetition of the growth and dot fabrication process like Example 2 yields a stack of arrays of dots (15,000 dots). After an annealing step, the sample is evaluated by infrared reflection spectroscopy in which reflectance modulation is observed at the photon energies corresponding to those of confined states in a quantum dot of about 30 nm diameter. Such a structure can transform electromagnetic waves from one frequency to another and also act as a polarizer.
EXAMPLE 4
p-type Wires
An array of Ga wires 3 is fabricated in a same way as described in connection with Example 1. The host GaAs layer (layer 2 in FIG. 1) in this case, however, is intentionally doped with an acceptor impurity Be. The GaAs:Be layer is grown by MBE at the substrate temperature 200°-250° Centigrade with As 4 /Ga flux ratio of less than 16; the same as the GaAs layer 2 in Example 1. In the electrical contact process, Be + ions are used instead of Si + ions because of the p-type contacts. A conductance of about 10 -5 mho/100 wires is observed together with characteristic magnetotransport behavior indicative of the carrier confinement.
The resulting quantum wire and dot structures have a wide range of application. For example, p- or n-type wires are used for channel regions for ultrasmall and fast FETs which are smaller than FETs described below in Examples 5 to 8. A quantum dot array may be used as a micro switching device, as described in Scientific American, March, 1988, pp. 96 to 100, in an article entitled "The Quantum-Effect Device: Tomorrow's Transistor" by R. T. Bate.
EXAMPLE 5
Short Channel FETs
The fifth example shows the fabrication of a short channel GaAs FET, which is schematically illustrated in FIGS. 8A-8E. A 1-micron thick, highly resistive GaAs (Si=1×10 17 /cc) layer 22 is first grown on a semi-insulating GaAs (100) substrate 21 by molecular beam epitaxy (MBE) at the substrate temperature of 200° Centigrade with As 4 /Ga flux ratio less than 16, as illustrated in FIG. 8A. The growth rate is 1 micron/hr. The estimated concentration of As microcrystal in layer 2 is 10 16 -10 17 atoms/cc. The sample is then transferred through ultrahigh vacuum transfer modules to a focused ion beam (FIB) chamber for the Ga pattern writing. Pattern 23 (which may be rectangular) is written by using a Ga + focused ion beam of a beam diameter of 0.25 micron to form an n-type region. The dose is 1×10 14 Ga + /sqcm. The concentration of the implanted Ga is 10 19 -10 20 atoms/cc. A cross-sectional view of such Ga-implanted region 23 is shown in FIG. 8B. The length of region 23, indicated as L1 in FIG. 8B, is 5 microns and the implantation depth, indicated as D1, is 150 nm (0.15 micron). The remaining dimension of region 23 is 50 micron. In a subsequent step, writing of rectangular pattern 24 is carried out by using a Ga + and Si + focused ion beam of a beam diameter 0.25 micron to form n + type source and drain regions. In this FIB process, the density of Si is controlled to obtain a constant value (Si=10 18 atoms/cc) for the region 24. The density of implanted Ga is also controlled to obtain a constant value of (Ga=2×10 19 -2×10 20 atoms/cc) for the region 24. The achieved ion-implantation depth, indicated as D2, is 250 nm. The remaining portion of region 23 shown as n-type region 26 between two regions 24 becomes channel for the FET as shown in FIG. 8C. The effective n-type channel length of region 26, indicated as L2 in FIG. 8C, is 0.09 micron.
After the writing is completed, the sample is transferred back to the MBE growth chamber where a second low temperature GaAs layer 27 (FIG. 8C) of 0.1 micron thickness is grown on top of the layer 22 under the same growth conditions as layer 22. Note, however, that the layer 27 is intentionally undoped.
Finally, the sample is again transferred to the FIB chamber, and Si + and Ga + ions are co-implanted in pattern 28 at both ends of n + region 24 as shown in FIG. 8D. Be + and Ga + ions are co-implanted to form gate region 29, which has a 0.05 micron effective gate length.
The implantation depth has to be deep enough (about 0.11 micron) to reach the embedded regions 24 and 26. This is followed by either laser flash annealing or other rapid thermal annealing techniques to recover the crystal quality of the implanted regions 24 and 26 and n-type ohmic contact pads 28 and p-type gate 29 on top of the region 26. Thus, the channel, source, drain and gate regions are fabricated using a maskless FIB technique.
The subsequent processes involved in the electrical contact fabrication are similar to those used in a conventional semiconductor device fabrication process. In FIG. 8E, ohmic electrodes 31 for n-type regions 28 are made of Au/Ge/Ni and contact 32 made of p-type WN x to gate 29 are deposited through holes in insulating layer 30. Thus, the obtained FET has a planar structure suitable for various kinds of subsequent processes.
The annealing step should be performed before ohmic electrodes 31, 32 are fabricated. Preferably the annealing should be done after insulating layer 30 is formed over layer 27, but it can be done before layer 30 is formed if it is carried out in an arsenic atmosphere.
The fabrication steps shown in FIGS. 8B and 8C have an alternative as shown in FIGS. 9A and 9B. In this alternative process, n-type region 23a is first formed in GaAs layer 22. Region 23a is formed in a same manner as region 23 except that the length L1 is 0.09 micron (FIG. 9A). Then regions 24 are formed on both sides of the region 23a (FIG. 9B).
Formation of the short channel GaAs FET is attributable to the solid reaction Ga+As→GaAs occurring in the regions 23, 24, 28 and 29 where Ga + ions are implanted in such concentration that the As microcrystals are converted to crystalline GaAs.
The resulting normally-off, junction FET is characterized by current-voltage measurements for various gate biases. The transconductance 1.2S/mm is observed without hysterisis in its I-V characteristics.
The performance of an FET fabricated according to the above-mentioned steps is explained below. In electronic devices, a drift velocity of carriers under electric field has significant meaning to determine the device performance, especially its speed and power consumption. The drift velocity in semiconductors depends on the electronic structures of the channel which transports the carriers. FIG. 10 shows a transient response of electron drift velocity of n-type silicon obtained by the Monte Carlo method. A similar transient response for n-type GaAs is shown in FIG. 11.
From these figures it should be clear that GaAs electronic devices can be expected to have switching speeds on the order of half a picosecond. If the transit time of electrons exceeds several picoseconds, the relationship shown in FIG. 11 need not be used. Alternatively, FIG. 11 may be recast as FIG. 12 which shows the electron drift velocity change along the channel distance which is obtained by using the Monte Carlo technique.
The shortest channel length in FET devices is 0.1 micron in Si metal-oxide-semiconductor (MOS) FET structures as reported by G. A. Sai-IIalasz in an article entitled "Experimental Technology and Performance of 0.1 micron Gate-Length Low Temperature Operation MOSFETs", in the Extended Abstracts of the 20th Conference on Solid State Devices and Materials, Tokyo, 1988, pp. 5-8. This extremely short channel was obtained not in GaAs but in silicon. This indicates that for the same channel length, higher switching speed can be obtained in GaAs.
In GaAs devices, such as metal-semiconductor (MES) FET, a more complicated fabrication process is required, even for 0.5 micron length, compared to Si MOS-FET technology, as described by K. Ishida ct al in an article entitled "A 5 Gb/s 4 Bit Shift Register with 0.5 micron WN x -gate GaAs MESFETs", in the Extended Abstracts of the 20th Conference on Solid State Devices and Materials, Tokyo, 1988, pp. 129-132. In the case of GaAs, high speed, reliable device was not achieved by the prior art techniques because (1) the short channel effect could not be fully utilized and (2) punch-through effects could not be prevented.
In contrast, the GaAs device obtained by the above-mentioned method has a very short channel and thus has high-speed performance. High resistivity layer 22 prevents punch-through effects from which the conventional GaAs FETs with short gate length suffered. In addition, a gate region less than 0.1 micron in length can be fabricated easily using a maskless FIB technique.
EXAMPLE 6
Normally-On and Off Type FETs
The sixth example of short channel FETs are schematically illustrated in FIGS. 13A and 13B. The n-type region 33 for a normally-off FET is fabricated in the same fashion as described in Example 5, and the n-type region 34 for a normally-on FET is fabricated by increasing both the beam acceleration voltage and current. The depth of region 33 is 150 nm and that of region 34 is 250 nm. The following fabrication process is the same as that described in connection with Example 5. Source and drain regions 35 are formed in a similar way for normally-on and normally-off FETs. An integrated circuit is obtained with this normally-off and on FET combination. The advantage specific to this example is that the source, drain and channel regions for both normally-on FET and a normally off FET is that they are fabricated on the as-formed surface of a GaAs crystal layer, as shown in FIG. 13.
EXAMPLE 7
Three-Dimensional Integration of Short Channel FETs
The three dimensional integration, in both lateral and vertical directions, of short channel FETs is schematically shown in FIG. 14. GaAs layer 37 is formed under the same conditions as layer 22 of Example 5 and is intentionally undoped. The first level of an n-type active region 38 for an n-FET and a p-type active region 39 for a p-FET are fabricated in the same fashion as described in Example 5. Here, active region means the source, drain and channel of the FET. For an n-type active region, the channel region is fabricated by co-implantation of Ga + and Si + and source and drain regions in a similar way except that the Si ion dose is increased. For p-type region 39, the only alteration is that Si is substituted for the Be ion. The second undoped-GaAs layer 40 is then grown on top of layer 37, embedding the active regions 38 and 39. Layer 40 is grown under the same growth condition as layer 27 in Example 5.
The structure is transferred to the FIB chamber and a p-type gate region 41 and n-type gate region 42 are made in a manner similar to that shown in Example 5. Then, the third undoped-GaAs layer 43 is grown under the same conditions as layer 37. The second level of an n-type active region 47 for an n-FET and a p-type active region 46 for a p-FET are fabricated in the same way as for regions 38, 39. The contact region 44, which connects between gate region 42 and n-type active region 47, and region 45 which has opposite conductivity to that of region 44 are made by co-implantation of Ga and Si ions or Ga and Be ions.
This process is repeated for making undoped-GaAs layers 48, 51 and 56 and making n-type gate regions 49 and 59, p-type gate regions 50 and 57, n-type active region 55 and contacts 53 and 58, and p-type active region 54 and contacts 52 and 60. Electrical contacts 61 to 64 are formed through insulating layer 65 in the same manner as described in connection with Example 5.
The method described here can be repeatable for many more levels if it is required. In such integrated circuits, the size of each FET is quite small compared to FETs in conventional integrated circuits, because many bonding pads, which have 100 micron square areas, can be extremely reduced by adopting the three dimensional internal connections described above which may only be 1 micron square in area.
In three dimensional structures, low-power consumption is indispensable because it is very difficult to obtain good heat sinking in such structures. In this connection, another benefit of this structure is the low-power consumption of complimentary FET circuits. In this fabrication method, to obtain n- and p-type channels is quite simple; just change the source of ions to be implanted.
As mentioned in the above three examples, this invention provides a practical method for fabrication of short-channel FETs, of the normally-on and off varieties as well as complimentary FET circuits.
As also mentioned in the above examples, this invention provides a practical method for fabrication of micro structures such as quantum wire and dot structures and FETs of less than 0.1 micron gate length. Besides GaAs, similar effects are expected to occur in other III-V compound semiconductors and alloys, such as GaAlAs, (In,Ga)As and InP. For example, implantation of In + ions also results in the elimination of As or P microcrystals and the consequent recovery of the original III-V compound.
While III-V compounds have been utilized herein to fabricate the various structures shown, it should be appreciated that other compound semiconductors such as II-VI compounds and their usual dopants may also be used in the practice of the present invention. For example, ZnSe containing Se microcrystals and/or point defects (doped with Al for n-type and N for p-type) may be implanted with Zn in specific regions to reform ZnSc upon annealing as an electronically active region. Other combinations including ternary and quaternary II-VI compounds will easily come to the minds of those skilled in the semiconductor arts.
In the above exposition, it should be noted that in most instances, it is the presence of excess amounts of the anionic component of a doped or undoped compound semiconductor which results in the formation of microcrystals and/or defects and that the cationic component of the compound semiconductor, in most instances, is ion implanted to compensate for the presence of the anionic microcrystals and/or defects. These components are then annealed to reform the original compound semiconductor. However, in some instances, either the anion or the cation may appear as the microcrystal and/or defect by depositing the compound semiconductor with an excess of either ion. In this instance, the element not in excess in the deposited layer would be implanted and annealed to reform the compound semiconductor. Cadmium Telluride is one such compound semiconductor material.
In connection with the formation of layers of high resistivity, the terms microcrystals and point defects have been used when one of the elements of a compound semiconductor appears in excess in a deposited layer of compound semiconductor. To the extent that microcrystals and point defects appear to differ only in the number of atoms of a particular atomic species with micro-crystals having a much greater number of atoms, both of these entities may be characterized as clusters of atoms. Thus, as claimed hereinbelow, the terms "clusters of atoms" or "clusters of one of the compound semiconductor elements" are intended to cover both microcrystals and point defects.
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Disclosed is a new method suitable for making highly integrated quantum wire arrays, quantum dot arrays in a single crystal compound semiconductor and FETs of less than 0.1 micron gate length. This makes it possible to construct a high-performance electronic device with high speed and low power consumption, using a combination of low-temperature-growth molecular beam epitaxy (LTG-MBE) and focused ion beam (FIB) implantation. The compound semiconductor (GaAs) epitaxial layers, which are made by LTG-MBE, are used as targets of Ga FIB implantation to make Ga wire or dot arrays. Precipitation of arsenic microcrystals, which are initially embedded in a single crystal GaAs layer and act as Schottky barriers, are typically observed in an LTG GaAs layer. A thermal annealing process, after implantation, changes the arsenic microcrystals to GaAs crystals if the arsenic microcrystals are in the region in which the Ga ions are implanted. A wire-like shape free of As microcrystals then acts as a quantum wire for electrons or holes whereas a dot-like shape free of As microcrystals acts as a quantum dot. The co-existence of Ga ions and dopant ions, which provides conductivity type carriers opposite to the conductivity type of the majority carriers of a channel region of an FET, provides the fabrication of very narrow junction gate region for any FET.
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RELATED APPLICATIONS
None
FIELD OF THE INVENTION
The present invention relates to an educational multi-player board-based game especially suited to preschool children players that utilizes a playing board, a plurality of cards, a die and a die launcher.
BACKGROUND OF THE INVENTION
During the educational process of a child, it is often necessary to determine how a child is performing in relation to his or her peers, and/or to determine if he or she is ready for school, or the next step in their educational process. Such benchmarking processes are often a one on one process with an adult/teacher which can be scary for the child, causing inaccurate results. While games can be adapted to determine such benchmarking levels, the randomness of the game can also cause errors. Additionally, children may react better in a group environment rather than individually, which most typical games do not excel at. Accordingly, there exists a need for a means by which a child's game can be developed which is not only fun to play, but aids in determining learning benchmarks as well.
SUMMARY OF THE INVENTION
The disadvantages of the prior art are overcome by the present invention in providing an educational multi-player board-based game especially suited to preschool children players comprises a playing board, a plurality of cards, a die and a die launcher. The game can also be used to establish general knowledge benchmarks of the players. The game utilizes a game board assembly that facilitates a question and answer process within various subjects. The die is placed on the launcher and a pedal is depressed launching the die. The color displayed by the die represents the category of card to choose from. Each card has a question disposed thereon which a user has to answer. If the user answers the question correctly a game piece is moved on the playing board. The first game piece to advance through the playing board is the winner.
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 exploded view of an educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 2 is an environmental view of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 3 a is a top view of a first language card portion 40 a of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 3 b is a top view of a second language card portion 40 b of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 4 a is a top view of a first letter identification card portion 42 a of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 4 b is a top view of a second letter identification card portion 42 b of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 5 a is a top view of a first logic card portion 44 a of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 5 b is a top view of a second logic card portion 44 b of the educational board game 10 , according to a preferred embodiment of the present invention;
FIG. 6 a is a top view of a first physical card portion 46 a of the educational board game 10 , according to a preferred embodiment of the present invention; and,
FIG. 6 b is a top view of a second physical card portion 46 b of the educational board game 10 , according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 educational board game
20 game board assembly
22 board
24 playing surface
25 game path
26 game steps
28 starting point
30 ending point
35 card deck
36 challenge question cards
40 language card set
40 a first language card
40 b second language card
42 letter identification card set
42 a first letter identification card
42 b second letter identification card
44 logic card set
44 a first logic card
44 b second logic card
46 physical card set
46 a first physical card
46 b second physical card
50 game token set
70 path advance device
72 base
73 mounting tube
74 bellows
75 air hose
76 die
78 aperture
100 player
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 6 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 of the referenced items.
The present invention describes an educational board game (herein described as the “game”) 10 , which provides an educational multi-player board-based game especially suited to preschool children players 100 . It is envisioned that the game 10 can also be used to establish general knowledge benchmarks of the players 100 . The game 10 utilizes a game board assembly 20 which facilitates a question and answer process of various subjects. Generally speaking, the player 100 moves a token forward along the game increments or steps, lands on a step with a correspondingly categorized challenge question card, advances with a correct answer, and competes with the other players to finish first.
Referring now to FIG. 1 , an exploded view of the game 10 , according to a preferred embodiment of the present invention, is disclosed. The game 10 comprises a game board assembly 20 , a card deck 35 that includes a plurality of question or challenge cards 36 that are organized into different categories or sets 40 , 42 , 44 , and 46 , a set of player tokens 50 , and a path advance device 70 . The game board assembly 20 comprises a conventional rectangular pressed paper game board 22 , being printed upon one (1) side with a serpentine path of a plurality of geometric game increments or steps 26 having a starting point 28 and an ending point 30 . The game steps 26 are envisioned to comprise sequentially arranged geometric shapes such as diamonds, squares, and the like, which form a route from the starting point 28 to an ending point 30 . The geometric shapes of the steps 26 additionally have a specific color assigned to them that relates to the categories of the challenge cards 36 . It is envisioned that the game path 25 is arranged in a serpentine pattern over the board 22 with sufficient space along the path of game steps 26 for placement of stacks of the card sets 40 , 42 , 44 , and 46 . It is further envisioned that the board 22 provides at least one (1) folding feature allowing for folding for compact storage.
In the preferred embodiment, the deck 35 of challenge question cards 36 present various questions to the players 100 and are organized and separated into four (4) different categories or subjects 40 , 42 , 44 , and 46 . It should be appreciated that the categories are not limited to only four (4) and may be of any number based on the desired complexity and difficulty desired by the game producer. Of the deck 35 illustrated herein, a question or challenge is printed upon the obverse or face side of the card 36 and a solid color corresponding to the categories established is printed upon the reverse side. The game 10 is illustrated here having four (4) categories of card sets 40 , 42 , 44 , and 46 within the deck 35 . As an example, a language card set 40 (see FIGS. 3 a and 3 b ) is designated by the color blue, a letter identification card set 42 (see FIGS. 4 a and 4 b ) is designated by the color white, a logic card set 44 (see FIGS. 5 a and 5 b ) designated as red, and a physical card set 46 (see FIGS. 6 a and 6 b ) designated as yellow. Again, it should be understood that the game 10 may comprise various types and numbers of categories and corresponding question cards without deviating from the teachings of the invention 10 , and as such this example should not be interpreted as a limiting factor of the game 10 .
At beginning of play, the players 100 start with their tokens 50 on the starting point 28 and move, in turn, along the serpentine game path 25 . The move of the token 50 is to the next colored step 26 along the path 25 that corresponds to the color revealed by the path advance device 70 . In landing on a game step 26 , it is determined which card category that particular step 26 represents, and the player 100 draws a corresponding card 36 from the respective stack of categorized cards 40 , 42 , 44 , and 46 . The player 100 then attempts to correctly answer the question or performs the task printed upon the card 40 , 42 , 44 , and 46 . If successful, the player advances their game token 50 to the next game step 26 of that color. If unsuccessful, the turn is over and play proceeds to the next player 100 . The player 100 that first reaches the ending point 30 wins. In addition to the educational enhancement and game playing skills developed in the use of the present invention, it is also envisioned to provide a means to benchmark a child's individual skill level.
Referring now to FIG. 2 , an environmental view of the game 10 , according to a preferred embodiment of the present invention, is disclosed. During game play, a specific path advance device 70 is utilized to provide the players 100 with entertaining manner of determining to which game steps 26 the players 100 are allowed to move in turn. More specifically, in the preferred embodiment, the path advance device 70 is a pneumatic launcher that comprises a large scale, lightweight cube-shaped die 76 that is launched into the air. The pneumatic launcher 70 is envisioned to be similar to products sold by the SPIN MASTER CO.® comprising a base 72 having an integral upwardly directed mounting tube 73 and a foot-actuated bellows 74 . An air hose 75 connects the bellows 74 to the base 72 and provides pneumatic communication between the two (2). The path advance device 70 includes a die 76 . Rather than convention pips on the side of the die 76 representing numbers, the die of the present invention has colored sides that relate to the categories determined in the card deck 35 . The randomly colored cubical die 76 is launched as a projectile by player 100 who steps upon the bellows portion 74 which in turn provides a flow of air through the air hose 75 and mounting tube 73 portions. Formed into one (1) side of the die 76 is an aperture and bore 78 that corresponds to the upwardly directed mounting tube 73 of the launcher 70 . To prepare the die 76 for launch, its aperture 78 is placed down upon the mounting tube 73 of the launcher 70 . The a blast of air from the bellows 74 propels the die 76 upwardly from the mounting tube 73 causing it to become airborne and subsequently return to the floor surface where it rolls and comes to rest. Based upon the resulting color displayed upon the upper surface of the die 76 , a player 100 moves the token 50 to the selects and responds to a correspondingly colored card 40 , 42 , 44 , and 46 .
It should be noted, in the present example, the cube-shaped die 76 has six (6) sides and only four (4) categories of challenge question are used for illustration. In this case, the two (2) sides of the cube that are available beyond the four (4) used to specifically color relate to the challenge categories, may be used as a “wild card” or “free space” in which the player is allowed to choose the next game step and corresponding challenge category. Likewise, if it is desirable to have more than six (6) challenge categories, another geometric shape having greater than six (6) sides may be substituted for the cube shaped die 76 .
The game token set 50 comprises a plurality of unique game pieces being illustrated here as molded plastic or metal disc-shaped poker chip-like pieces having different colors to be used by respective players 100 to mark their progress during participation in the game 10 . However, it should be understood that the game token set 50 may be introduced having various other visual appearances including themes such as animals, pets, miscellaneous household objects, and the like, with equal benefit and, as such, should not be interpreted as a limiting factor of the game 10 .
Referring now to FIGS. 3 a through 6 b , the challenge question cards 36 are disclosed. The categories of challenge may include physical acts, mental calculations, logical analysis, and factual recall or the like. In the preferred embodiment, they are defined by language, letter identification, logic, and physical challenges. As shown in FIGS. 3 a and 3 b , top views of first language card 40 a and second language card 40 b portions of the game 10 , according to a preferred embodiment of the present invention, are disclosed. The first language card 40 a and second language card 40 b depict examples of language questions by utilizing pictures, text, and the like to communicate the question and answer process; however, it is understood that any number of language questions may be introduced being illustrated in a similar manner to these examples to improve a player's 100 language skills while playing the game 10 .
Referring now to FIGS. 4 a and 4 b , top views of first letter identification card 42 a and second letter identification card 42 b portions of the game 10 , according to a preferred embodiment of the present invention, are disclosed. The first letter identification card 42 a and second letter identification card 42 b depict examples of letter identification questions by utilizing pictures, text, and the like; however, it is understood that any number of letter identification questions may be introduced being illustrated in a similar manner to these examples improve a player's 100 letter identification skills while playing the game 10 .
Referring now to FIGS. 5 a and 5 b , top views of first logic card 44 a and second logic card 44 b portions of the game 10 , according to a preferred embodiment of the present invention, are disclosed. The first logic card 44 a and second logic card 44 b depict examples of logic questions by utilizing pictures, text, and the like; however, it is understood that any number of logic questions may be introduced being illustrated in a similar manner to these examples to improve a player's 100 logic skills while playing the game 10 .
Referring now to FIGS. 6 a and 6 b , top views of first physical card 46 a and second physical card 46 b portions of the game 10 , according to a preferred embodiment of the present invention, are disclosed. The first physical card 46 a and second physical card 46 b depict examples of physical questions by utilizing pictures, text, and the like; however, it is understood that any number of physical questions may be introduced being illustrated in a similar manner to these examples to improve a player's 100 physical skills while playing the game 10 .
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 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 game 10 , it would be installed and utilized as indicated in FIGS. 1 and 2 .
The method of utilizing the game 10 may be achieved by performing the following steps: procuring a model of the game 10 comprising desired numbers of and types of categories; unfolding and placing the board 22 onto a flat surface such as a table; placing the card sets 40 , 42 , 44 , and 46 upon the board 22 at appropriate locations; placing the game tokens 50 at a starting point portion 28 of the board 22 ; selecting a player 100 to roll the die 76 by stepping upon the bellows portion 74 of the pneumatic launcher 70 to motion the die 76 ; observing a color of an upwardly-facing side of the die 76 upon coming to rest; selecting a card from a correspondingly colored card set 40 , 42 , 44 , 46 . reading the question printed upon the card 40 , 42 , 44 , 46 ; correctly answering the question or performing the task printed upon the card 40 , 42 , 44 , 46 ; advancing the player's 100 game token 50 to the next game step 26 having that color; repeating the above steps for the remaining players 100 ; continuing the rolling of the die 76 and moving of the game tokens 50 for all players 100 until a player 100 reaches the ending point 30 to win the game 10 . The game 10 provides a fun and entertaining board game for groups of children players 100 , but also allows for easy benchmarking of the child's individual skill level.
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 to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, 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.
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An educational board game includes a playing board, a plurality of cards, a die and a die launcher. The playing cards are separated into categories and the die has a plurality of colored faces, each color corresponding to a particular category. The die is placed on the launcher and a bellows-type pedal is depressed, thereby launching the die. The color displayed by the die represents the category of card to be taken. Each card has a challenge question or task disposed thereon which a user has to answer or perform. If the user answers the question correctly a game piece is moved on the playing board. The first game piece to advance through the playing board is the winner.
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FIELD OF THE INVENTION
The present invention relates generally to rod/piston assemblies of a type capable of use in non-commercial air compressors and, more particularly, to rod/piston assemblies comprising unitary rod members and to a method for affixing compression rings to such bodies.
BACKGROUND OF THE INVENTION
One type of conventional oil-free rod/piston assembly comprises an aluminum rod die casting, a preformed polytetrafluoroethylene [“PTFE”] compression ring, an aluminum die cast retaining ring and a metal retaining screw or rivet. The aluminum rod die casting includes a crank bore and a lower bezel connected by an I-section rod. When assembled, the PTFE compression ring is clamped between the retaining ring and the lower bezel to form a piston head. Similar structures are proposed in Droege et al. U.S. Pat. No. 3,961,869 and Droege et al U.S. Pat. No. 3,961,868.
Typically, the rod/piston assembly is fitted into a cylinder such that reciprocation of the piston draws air into the cylinder through an intake port and expels the air from the cylinder through an outlet port under pressure. The compression ring presses against the inner surface of the cylinder to provide a pressure-tight seal about the piston head. Conventional PTFE compression rings comprise annuli sufficiently thin to flex against the inner surfaces of the cylinder so as to enhance the seal between the rod/piston structure and the cylinder.
The use of flexible PTFE in forming compression rings has numerous advantages, including high strength and low friction against the inner surface of the cylinder. Nevertheless, cast or sintered PTFE generally is too stiff and brittle to flex in the manner of the compression ring described above without further processing steps, such as stretching. One desirable feature of the prior art rod/piston assembly is that the PTFE ring can be cast or sintered and then processed before it is combined with the aluminum rod die casting to form the assembly.
One drawback to the prior art rod/piston structure is the relatively large number of pre-formed or pre-cast parts which go into its assembly. The number of pre-formed or pre-cast parts required to assemble the finished structure increases the cost of manufacturing the structure. Likewise, separately fitting the compression ring over the lower bezel of the aluminum rod die casting; fitting the retaining ring over the lower bezel; and fastening the retaining ring to the lower bezel with the retaining screw or rivet adds to the time and cost of assembling the structure.
The number and arrangement of the parts also affects the dimensional repeatability of the structure. That is, the overall length of the rod/piston assembly depends on several factors, including cumulative variations in the lengths of the aluminum rod die casting, the PTFE compression ring and the retaining ring; the elasticity of the compression ring; and the torque or force used in tightening the retaining screw or rivet to clamp the parts together. Controlling all of these factors would be difficult and any steps taken to do so would increase further the cost of the finished assembly.
Dinkel et al. U.S. Pat. No. 6,200,109 proposes an electric motor/pump assembly including a motor shaft and a sealing element which acts upon the motor shaft radially. The sealing element is made of an elastic material, for example, silicone plastics, which is injected into a groove to seal a gap where the sealing lip of the sealing element abuts on the motor shaft side.
Heine et al. U.S. Pat. Nos. 6,139,023; 5,874,170; and 5,756,025, the disclosures of which are incorporated by reference, propose a method for injection molding a seal carrier to a sealing member. The sealing member is modified by admixture or surface treatment with a material compatible with the seal carrier. The modified sealing member then is placed in an injection mold. The mold is closed and plastic material which will form the carrier body is injected into the mold. The sealing member fuses to the plastics of the carrier body as the carrier body cools, thereby providing a durable connection in substance lock.
Ebbing U.S. Pat. No. 5,282,412 proposes an angulating piston assembly for a vehicle air conditioning system compressor. The proposed angulating piston assembly is made up of two components: namely, a composite piston and a piston ring subassembly that includes a rigid annular support collar and a stretched piston ring on the collar. A proposed method for making the angulating piston assembly includes the steps of cutting or skiving an elastomeric ring if desired width from an extruded tube of mineral or graphite filled PTFE, stretching the elastomeric ring, sliding the elastomeric ring onto the support collar to form the piston ring subassembly; placing the piston ring subassembly into one half of a mold cavity for forming the molded head of the composite piston; positioning a distal end of a piston rod so as to extend into the same half of the mold cavity; closing the other half of the mold cavity to fully capture the piston ring and the subassembly; and injecting high temperature, high strength glass-reinforced resin into the cavity in order to form the piston head.
Preston et al. U.S. Pat. No. 4,986,553 proposes a shaft seal comprising a rigid case ring and a PTFE sealing ring component which is secured to a radial flange of the case ring by being bonded to a molded elastomeric sealing ring component.
Various patents, including Kanari et al. U.S. Pat. No. 5,611,260; Holtzberg U.S. Pat. No. 4,432,925; and Dorsch U.S. Pat. No. 4,462,767, propose mechanical techniques for securing PTFE rings to piston heads.
Thus, there remains a need in the art for an improved rod/piston assembly comprising relatively few pre-formed or pre-cast parts and an improved method for manufacturing such an assembly requiring relatively few production steps. In particular, there is a need in the art for an improved method which is particularly, though not exclusively, suited for use in manufacturing rod/piston assemblies comprising pre-formed PTFE compression rings and pre-formed or pre-cast metal rod members having repeatable dimensions.
SUMMARY OF THE INVENTION
These needs and others are addressed by a rod/piston assembly comprising a unitary rod member and a compression ring. The preferred unitary rod member is composed of a rigid material, most preferably a metal such as aluminum or an aluminum alloy. The preferred compression ring is composed of flexible PTFE.
The preferred unitary rod member includes a lower bezel portion, a connecting rod portion and a knob portion. The preferred lower bezel portion defines first and second sides. The preferred connecting rod portion terminates along the first side of the lower bezel portion. The preferred knob portion extends from the second side of the lower bezel portion. Most preferably, the knob portion has an outer diameter less than an outer diameter of the lower bezel portion so as to define a shoulder or flange along the second side of the lower bezel portion. The preferred knob portion defines opposed inner and outer sides and a peripheral surface connecting the inner and outer sides. The inner side of the preferred knob portion coincides with the second surface of the lower bezel portion.
The preferred compression ring defines a hole fitting about the knob portion of the unitary rod member. Most preferably, the compression ring comprises a thin annulus having an outer diameter greater than the outer diameter the lower bezel portion.
In accordance with a first especially preferred embodiment, the outer side of the knob portion defines a free or exposed surface. The compression ring defines a securing surface facing the second surface of the lower bezel portion of the unitary rod member. The compression ring is secured to the unitary rod member along the second surface of the lower bezel portion such that a peripheral portion of the compression ring extends radially beyond the lower bezel portion for contact with an inner surface of a cylinder. Optionally, a plastic filler ring or collar is secured around the peripheral surface of the knob portion to promote engagement between the peripheral portion of the compression ring and an inner surface of a cylinder when the rod/piston assembly is in use, and to control the cylinder volume.
In accordance with a first preferred method of manufacture, the compression ring is secured to the unitary rod member by means of a combination of elevated temperature and pressure in a mold or press. In accordance with this method, the second surface of the lower bezel portion, the securing surface of the compression ring, or both, are chemically treated, and a bonding agent is applied, to promote coupling of the compression ring to the lower bezel portion. The unitary rod member and the compression ring are positioned in the mold or press with the compression ring and, optionally, the plastic filler ring, fitted over the knob portion of the unitary rod member. Elevated temperature and pressure are applied to secure the compression ring and, optionally, the plastic filler ring, to the lower bezel portion.
In accordance with one preferred option, the unitary rod member and the compression ring are placed in a mold having a recess adjacent the knob portion of the unitary rod member and the compression ring. Resin is injected into the recess and solidified to form the plastic filler ring or collar.
In accordance with a second especially preferred embodiment, a preformed plastic filler ring or collar is positioned over the knob portion of the unitary rod member before the compression ring is secured to the unitary rod member. This preferred plastic filler ring includes an inner bead or lip which cooperates to secure the plastic filler ring to the peripheral surface of the knob portion.
Thus, in accordance with a second especially preferred method of manufacture, the compression ring and the plastic filler ring are secured to the unitary rod member by means of a combination of elevated temperature and pressure in a mold or press. More specifically, the lower bezel portion of the unitary rod member, the compression ring and the plastic filler ring, or a combination of those parts, are chemically treated and at least partially coated with a bonding agent. The unitary rod member, the compression ring and the plastic filler ring are positioned in the mold or press with the compression ring and the plastic filler ring fitted over the knob portion. Elevated temperature and pressure are applied in the mold or press to secure the compression ring and the plastic filler ring to the unitary rod member.
In accordance with a third especially preferred embodiment, the unitary rod member further includes an upper bezel portion extending from the outer side of the knob portion toward a free or exposed surface of the upper bezel portion. The preferred upper bezel portion has an outer diameter greater than that of the outer diameter of the knob portion such that the lower bezel portion, the knob portion and the upper bezel portion cooperate to define a peripheral channel between the upper and lower bezel portions. Most preferably, the hole through the compression ring has an inner diameter at least as large as the outer diameter of the upper bezel portion so as to permit the compression ring to slide over the upper bezel portion during assembly.
In accordance with a third preferred method of manufacture, the compression ring is secured to the unitary rod member by means of a polymeric filler or bonding agent, which is injected into the peripheral channel defined in the unitary rod member while the unitary rod member and the compression ring are seated in a mold or press. In accordance with this method, the unitary rod member and the compression ring are positioned in the mold or press with the compression ring fitted over the knob portion of the unitary rod member. Resin is injected into the mold or press and solidified to form the polymeric filler.
Thus, the preferred structures minimize the number of parts which must be supplied to form a rod/piston assembly and simplify the processes for their construction. The preferred rod/piston assemblies each comprise no more than three parts: the unitary rod member, the compression ring and, optionally, the preformed plastic filler ring or collar. Each of the preferred rod/piston assemblies is susceptible of assembly by means of a relatively simple pressing or injection molding process. No rivets or threaded fasteners are required to retain the compression rings on the unitary rod members.
Furthermore, the preferred structures are adapted for a high level of dimensional repeatability. In each of the preferred rod/piston assemblies, the unitary rod assembly defines a free or exposed surface extending beyond the region where the compression ring is secured to the unitary rod member. Consequently, the overall length of the rod/piston assembly depends solely on the length of the unitary rod member. Since the length of the unitary rod member is the primary factor affecting the overall length of the assembly, the repeatability of the overall length is promoted.
Furthermore, it is believed the unitary rod member will be susceptible of casting in a die of relatively simple construction. This will allow an increase in the number of cavities which can be formed in such a die, therefor reducing the cost of parts for the rod/piston assembly.
Therefore, it is an object of the invention to provide an improved rod/piston assembly requiring a relatively small number of parts. It is a further object of the invention to provide a relatively simple method for manufacturing the assembly. The invention will be further described in conjunction with the appended drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a rod/piston assembly in accordance with the prior art;
FIG. 2 is a side elevational view of a first embodiment of a rod/piston assembly in accordance with the present invention;
FIG. 3 is a front elevational view of the rod/piston assembly of FIG. 2 ;
FIG. 4 is a side sectional view of the rod/piston assembly of FIG. 2 , taken along the line 4 — 4 in FIG. 3 ;
FIG. 5 is a plan view of a compression ring for use in the rod/piston assembly of FIG. 2 ;
FIG. 6 is a flow chart illustrating a preferred method for manufacturing the rod/piston assembly of FIG. 2 ;
FIG. 7 is a side elevational view of a second embodiment of a rod/piston assembly in accordance with the invention, partially broken away through a lower bezel portion and a knob portion thereof;
FIG. 8 is a flow chart illustrating a preferred method for manufacturing the rod/piston assembly of FIG. 7 ;
FIG. 9 is a schematic view, showing the rod/piston assembly of FIG. 2 positioned in a cylinder of an air compressor or the like;
FIG. 10 is a side elevational view of a third embodiment of a rod/piston assembly in accordance with the present invention;
FIG. 11 is a side elevational view of the rod/piston assembly of FIG. 10 , partially broken away through lower bezel, knob and upper bezel portions thereof; and
FIG. 12 is a flow chart illustrating a preferred method for manufacturing the rod/piston assembly of FIG. 10 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a prior art rod/piston assembly 10 comprising an aluminum rod die casting 12 , a pre-formed PTFE compression ring 14 , an aluminum die cast retaining ring 16 and a metal retaining screw or rivet 18 . The aluminum rod die casting 12 includes a crank bore 20 and a lower bezel 22 connected by an I-sectioned rod 24 . When assembled, the PTFE compression ring 14 is clamped between the retaining ring 16 and the lower bezel 22 to form a piston head 30 .
As noted earlier, the prior art rod/piston assembly 10 is constructed from at least four separate pre-formed or pre-cast parts. The overall length of the rod/piston assembly depends on several factors, including cumulative variations in the dimensions of the aluminum rod die casting 12 , the PTFE compression ring 14 and the retaining ring 16 ; the elasticity of the compression ring 14 ; and the torque or force used in tightening the retaining screw or rivet 18 to clamp the parts together
As shown in FIG. 2 , a first preferred embodiment of a rod/piston assembly 50 in accordance with the present invention comprises a unitary rod member 52 , a compression ring 54 and a polymeric filler or plastic filler ring 56 . The unitary rod member 52 includes a connecting rod portion 60 terminating in a lower bezel portion 62 . The connecting rod portion 60 is I-sectioned over much of its length, except where it defines a crank bore 64 opposite the lower bezel portion 62 .
As shown in FIG. 3 , the unitary rod member 52 ( FIG. 2 ) further includes a knob portion 66 having a peripheral surface 70 and an outer side 72 defining a free or exposed surface. More specifically, as shown in FIG. 4 , the lower bezel portion 62 has a first side 80 and a second side 82 . The connecting rod portion 60 terminates along the first side 80 of the lower bezel portion 62 . The knob portion 66 extends from the second side 82 of the lower bezel portion 62 . The knob portion 66 has an inner side 84 as well as the outer side 72 and the peripheral surface 70 . The inner side 84 of the knob portion 66 coincides with the second side 82 of the lower bezel portion 62 .
The lower bezel portion 62 defines an outer diameter 90 along its second side 82 and the knob portion 66 defines an outer diameter 92 along its inner side 84 . The outer diameter 90 of the lower bezel portion 62 preferably is greater than the outer diameter 92 of the knob portion 66 such that the unitary rod member 52 defines a shoulder or flange 94 where the knob portion 66 extends from the lower bezel portion 62 .
As shown in FIG. 5 , the compression ring 54 preferably comprises a PTFE annulus having a hole 100 defining an inner diameter 102 at least as large as the outer diameter 92 ( FIG. 4 ) of the knob portion 66 (FIG. 4 ). The preferred compression ring 54 also defines an outer diameter 104 . Most preferably, the compression ring 54 defines a securing surface 106 and a peripheral portion 108 spaced radially outwardly from the securing surface 106 . The compression ring 54 is relatively flat and annular in its natural state as seen in FIGS. 4 and 5 , for example. Upon insertion into cylinder 120 and during use, the peripheral portion 108 is bent upwardly to remain in contact with inner surface 122 . The peripheral portion 108 is of a sufficient radial length to remain in contact throughout the stroke of the rod/piston assembly 50 and thus expands and contracts to conform to the shape needed to provide the seal with the inner surface 122 . For example, as the piston/rod assembly 50 moves, the peripheral portion conforms to fit circular and oval surface configurations depending upon the stroke position.
In accordance with a preferred method of manufacture, the compression ring 54 ( FIGS. 4 and 5 ) is secured to the unitary rod member 52 ( FIG. 4 ) by means of a combination of elevated temperature and pressure in a conventional mold or press (not shown). As illustrated in FIG. 6 , a step 110 includes chemically treating, and applying a bonding agent to, at least a section of the second side 82 ( FIG. 4 ) of the lower bezel portion 62 (FIG. 4 ); at least a section of the securing surface 106 ( FIG. 5 ) of the compression ring 54 (FIGS. 4 and 5 ), or both, to promote coupling of the compression ring 54 ( FIGS. 4 and 5 ) to the lower bezel portion 62 (FIG. 4 ). A step 112 includes positioning the unitary rod member 52 ( FIG. 4 ) and the compression ring 54 ( FIGS. 4 and 5 ) in the mold or press (not shown) with the compression ring 54 ( FIGS. 4 and 5 ) fitted over the knob portion 66 ( FIG. 4 ) of the unitary rod member 52 ( FIG. 4 ) such that the securing surface 106 ( FIG. 5 ) of the compression ring 54 ( FIGS. 4 and 5 ) faces the second side 82 ( FIG. 4 ) of the lower bezel portion 62 (FIG. 4 ). A step 114 includes applying elevated temperature and pressure in the mold or press (not shown) to secure the compression ring 54 ( FIGS. 4 and 5 ) to the lower bezel portion (FIG. 4 ).
In accordance with one option, the mold (not shown) includes cavity (not shown) shaped to receive the unitary rod member 52 ( FIG. 4 ) and the compression ring 54 (FIGS. 4 and 5 ). The cavity (not shown) defines a recess (not shown) adjacent the knob portion 66 ( FIG. 4 ) of the unitary rod member ( FIG. 4 ) and the compression ring (FIGS. 4 and 5 ). The preferred recess (not shown) is configured to form the polymeric filler 56 (FIG. 4 ). A step 116 of the preferred method of manufacture includes injecting resin into the recess (not shown) and solidifying the resin to form the polymeric filler 56 (FIG. 4 ).
In accordance with another option, illustrated in FIG. 7 , the assembly 50 ′ includes a polymeric filler or plastic filler ring 56 ′ which is preformed and positioned over a peripheral surface 70 ′ of a knob portion 66 ′ of a unitary rod member 52 ′ before the compression ring 54 ′ is secured to the unitary rod member 52 ′. As shown in FIG. 7 , the preferred plastic filler ring 56 ′ includes an inner bead or lip 58 ′ which cooperates to secure the plastic filler ring 56 ′ to the peripheral surface 70 ′ of the knob portion 66 ′. The preferred plastic filler ring 56 ′ also includes a fillet 59 ′ adjacent the compression ring 54 ′ for facilitating bending of the compression ring 54 ′.
During assembly, the compression ring 54 ′ and the plastic filler ring 56 ′ are secured to the unitary rod member 52 ′ by means of a combination of elevated temperature and pressure in a mold or press (not shown). The method, as illustrated in FIG. 8 , includes the step 110 ′ of chemically treating, and applying a bonding agent to, one or more of a lower bezel portion 62 ′ ( FIG. 7 ) of the unitary rod member 52 ′ (FIG. 7 ), the compression ring 54 ′ ( FIG. 7 ) and the plastic filler ring 56 ′ (FIG. 7 ); the step 112 ′ of positioning the unitary rod member 52 ′ (FIG. 7 ), the compression ring 54 ′ ( FIG. 7 ) and the plastic filler ring 56 ′ ( FIG. 7 ) in the mold or press (not shown) with the compression ring 54 ′ ( FIG. 7 ) fitted over the knob portion 66 ′ ( FIG. 7 ) of the unitary rod member 52 ′ ( FIG. 7 ) and the plastic filler ring 56 ′ ( FIG. 7 ) fitted over the knob portion 66 ′ ( FIG. 7 ) adjacent the compression ring 54 ′ (FIG. 7 ); and the step 114 ′ of applying elevated temperature and pressure in the mold or press (not shown) to secure the compression ring 54 ′ ( FIG. 7 ) and the plastic filler ring 56 ′ ( FIG. 7 ) to the lower bezel portion 62 ′ (FIG. 7 ).
A preferred application for the rod/piston assembly 50 of FIGS. 2-4 (as well as the assembly 50 ′ of FIG. 7 ) is in an air compressor (not shown). More specifically, as suggested by FIG. 9 , the preferred rod/piston assembly 50 is positioned in a cylinder 120 of such compressor (not shown) so that the peripheral portion 108 ( FIG. 5 ) of the compression ring 54 brushes against an inner surface 122 of the cylinder 120 . Most preferably, the inner surface 122 defines an inner diameter slightly less than the outer diameter 104 ( FIG. 5 ) of the compression ring 54 and the compression ring 54 has sufficient flexibility such that the peripheral portion 108 ( FIG. 5 ) of the compression ring 54 engages the inner surface 122 over a finite contact surface so as to define a moveable, air tight seal between the rod/piston assembly 50 and the cylinder 120 . The preferred polymeric filler 56 serves to constrain the flexure of the peripheral portion 108 ( FIG. 5 ) of the compression ring 54 so as to promote engagement of the peripheral portion 108 ( FIG. 5 ) against the inner surface 122 of the cylinder 120 to form this seal and to control the volume of the cylinder. It is believed that the overall design of the preferred rod/piston assembly 50 , including the features highlighted herein, will improve the performance of such air compressors (not shown).
As shown in FIG. 10 , a third preferred embodiment of a rod/piston assembly 150 in accordance with the present invention comprises a unitary rod member 152 and a compression ring 154 . As shown in FIG. 11 , a plastic filler ring or collar 156 ( FIG. 11 ) secures the compression ring 154 to the unitary rod member 152 .
The unitary rod member 152 includes a connecting rod portion 160 terminating in a lower bezel portion 162 . The connecting rod portion 160 defines a crank bore 164 . The unitary rod member 152 further includes a knob portion 166 and an upper bezel portion 168 . The knob portion 166 has a peripheral surface 170 and an outer side 172 .
The preferred geometry of the unitary rod member 152 is arranged as follows. The lower bezel portion 162 has a first side 180 and a second side 182 . The connecting rod portion 160 terminates along the first side 180 of the lower bezel portion 162 . The knob portion 166 extends from the second side 182 of the lower bezel portion 162 . The knob portion has an inner side 184 as well as the outer side 172 and the peripheral surface 170 . The inner side 184 of the knob portion 166 coincides with the second side 182 of the lower bezel portion 162 . The upper bezel portion 168 extends outwardly from the outer side 172 of the knob portion 166 . The upper bezel portion 168 defines a free or exposed surface 186 opposite the knob portion 166 .
The lower bezel portion 162 defines an outer diameter 190 along its second side 182 and the knob portion 166 defines an outer diameter 192 along its inner side 184 . The outer diameter 190 of the lower bezel portion 162 is greater than the outer diameter 192 of the knob portion 166 such that the unitary rod member 152 defines a peripheral channel 194 aligned with the knob portion 166 . The upper bezel portion 168 defines an outer diameter 196 greater than the outer diameter 192 of the knob portion 166 so as to provide an outer bound for the peripheral channel 194 .
In accordance with a third preferred method of manufacture, the compression ring 154 is secured to the unitary rod member 152 by means of the polymeric filler 156 , which is injection molded in the peripheral channel 194 while the unitary rod member 152 and the compression ring 154 are seated in a mold (not shown). As shown in FIG. 10 , a step 200 of the third preferred method of manufacture includes positioning the unitary rod member 152 ( FIGS. 10 and 11 ) and the compression ring 154 ( FIGS. 10 and 11 ) in a cavity (not shown) of the mold (not shown) with the compression ring 154 ( FIGS. 10 and 11 ) fitted over the knob portion 166 ( FIG. 11 ) of the unitary rod member 152 (FIGS. 10 and 11 ). The preferred compression ring 154 ( FIGS. 10 and 11 ) is a PTFE annulus having a configuration similar to that of the compression ring 54 (FIG. 5 ). Most preferably, the compression ring 154 ( FIGS. 10 and 11 ) has a hole (not shown) defining an inner diameter (not shown) at least as great as the outer diameter 196 ( FIG. 11 ) of the upper bezel portion 168 ( FIG. 11 ) so as to permit the compression ring 154 ( FIGS. 10 and 11 ) to slip easily over the upper bezel portion 168 ( FIG. 11 ) into position adjacent the peripheral channel 194 (FIG. 11 ).
As shown in FIG. 12 , a step 202 of the preferred method of manufacture includes injecting resin (not shown) into the cavity (not shown) of the mold (not shown). The resin (not shown) is solidified to form the polymeric filler 156 ( FIG. 11 ) to secure the compression ring 154 ( FIGS. 10 and 11 ) onto the unitary rod member 152 (FIGS. 10 and 11 ).
From the foregoing description, it will be apparent that the preferred rod/piston assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 (FIGS. 10 and 11 ), and the preferred methods of manufacture ( FIGS. 6 , 8 and 12 ), provide a number of advantages over the prior art. The preferred methods use relatively small numbers of pre-formed or pre-cast parts, namely, just the unitary rod assemblies 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 (FIG. 11 ); the compression rings 54 (FIGS. 4 and 5 ), 54 ′ (FIG. 7 ); 154 ( FIG. 11 ) and, optionally, preformed plastic filler rings 56 ′ (FIG. 7 ), although it is within the scope of the invention to include additional pre-formed or pre-cast parts for purposes apparent to those of ordinary skill in the art. The preferred methods ( FIGS. 6 , 8 and 12 ) themselves are relatively simple, although it is again within the scope of the invention to include additional method steps for various purposes apparent to those of ordinary skill. In particular, since the compression rings 54 (FIGS. 4 and 5 ), 54 ′ (FIG. 7 ), 154 ( FIG. 11 ) are pre-formed, they can be cast or sintered and then processed before they are secured to the unitary rod members 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 (FIG. 11 ).
Preferably, the unitary rod members 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 ( FIG. 11 ) are each formed from a single integral die casting of a metal such as aluminum or an aluminum alloy. The preferred compression rings 54 (FIGS. 4 and 5 ), 54 ′ (FIG. 7 ), 154 ( FIG. 11 ) are formed from PTFE annuli having sufficient flexibility to form temporary seals against the inner surfaces 122 ( FIG. 9 ) of cylinders 120 ( FIG. 9 ) in which the rod/piston assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) are placed. Preferably, the polymeric fillers 56 (FIG. 4 ), 56 ′ (FIG. 7 ), 156 ( FIG. 11 ) are formed from castable resins capable of forming polymers resistant to conditions which the rod/piston assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) are likely to encounter during use. The selection of such materials, and suitable methods for forming or casting of the materials to form the aforementioned parts, is within the ordinary skill in the art.
It will be apparent from FIGS. 4 , 7 and 11 that the overall lengths of the preferred assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) depend solely on the lengths of the unitary rod members 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 (FIG. 11 ). This implies that, where the unitary rod members 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 ( FIG. 11 ) are formed from integral die castings, the repeatability of the overall lengths of the assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) will depend primarily on the care with which the castings are prepared. As such, the preferred assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) will have improved dimensional repeatability. In addition, it is believed that the preferred unitary rod members 52 (FIG. 4 ), 52 ′ (FIG. 7 ), 152 ( FIG. 11 ) can be shaped in relatively simple dies (not shown), such that a relatively large number of die cavities (not shown) may be formed in a single die (not shown). This will serve to further reduce the cost of manufacture.
From the foregoing description, those skilled in the art will appreciate that the present invention is directed toward improved rod/piston assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) having relatively few pre-formed or pre-cast parts and to improved methods ( FIGS. 6 , 8 and 11 ) for manufacturing such assemblies 50 (FIGS. 2 - 4 ), 50 ′ (FIG. 7 ), 150 ( FIGS. 10 and 11 ) requiring relatively few manufacturing steps. While the form of apparatus herein described constitutes a preferred embodiment of this invention, it is to be understood that the invention is not limited to this precise form of apparatus, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
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Preferred rod/piston assemblies ( 50, 50′, 150 ) comprise unitary rod members ( 52, 52′, 152 ) and compression rings ( 54, 54′, 154 ). In accordance with one preferred embodiment ( 50 ), the unitary rod member ( 52 ) comprises a connecting rod portion ( 60 ), a lower bezel portion ( 62 ) and a knob portion ( 66 ). The lower bezel portion ( 62 ) and the compression ring ( 54 ) define facing surfaces ( 82, 106 ) along which the compression ring ( 54 ) is secured to the unitary rod member ( 52 ). In accordance with a preferred method of manufacture, one or both of the facing surfaces ( 82, 106 ) are chemically treated to promote coupling of the compression ( 54 ) ring to the lower bezel portion ( 62 ). The unitary rod member ( 52 ) and the compression ring ( 54 ) are positioned in the mold or press with the compression ring ( 54 ) fitted over the knob portion ( 66 ) of the unitary rod member. Elevated temperature and pressure are applied to secure the compression ring ( 54 ) to the lower bezel portion ( 62 ). Among the advantages of the preferred structure are minimization the number of parts which must be supplied to form the preferred rod/piston assemblies ( 50, 50′, 150 ) and simplification of the processes for their construction.
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FIELD OF THE INVENTION
The present invention relates to a hearing aid system comprising a hearing implant and method of powering a hearing implant.
BACKGROUND OF THE INVENTION
Sensorineural deafness is by far the most common type of hearing loss. Deafness affects 9 million people in the United Kingdom, of which about 95% have sensorineural deafness (source Defeating Deafness, United Kingdom). Causes include congenital, bacterial, high intensity noise and, especially, the ageing process, with 30 percent of those affected being over 60 years. Hearing impairment is the third most common chronic problem affecting the ageing population—and one of the least diagnosed. There is also an increased prevalence in some sections of the younger age group, due to exposure to loud noise.
There are currently no effective means of repairing the cochlea or the nervous pathways to the brain. For most patients, hearing can be restored adequately by sufficient amplification of sound with a hearing aid. Hearing aids have a number of problems: acoustic feedback (because the microphone is very close to the speaker), inadequate sound quality, and discomfort due to occlusion of the ear canal. They also are undesirable from the social point of view, in that the appearance of wearing a hearing aid can cause users to feel that they are seen to be handicapped. The alternative is an implantable device.
Middle ear implants provide mechanical amplification by vibrating the ossicular chain. They are intended for patients with moderate to severe sensorineural hearing loss, who still have residual hearing. They could potentially benefit up to 50% of all people with hearing loss. Cochlear implants, the alternative, provide electrical stimulation to the nerves of the inner ear, but are suitable only for the profoundly deaf, as all residual hearing is destroyed during their implantation. They are not favoured where there are alternative solutions.
Middle or inner ear implants however require a power supply. A few use incorporated batteries, which although last several years, require replacement. This undesirably necessitates a further operation for the patient. Other implants use wires through the skull and the rest use radiofrequency or inductively coupled methods. Nevertheless, radio frequency modulated transmission uses complicated circuitry, is cumbersome and costly, and the implanted receiver module itself has a heavy demand on power. It also has to be approved under each country's radiofrequency regulations. Inductively coupled transmission methods use two coils or one coil and one magnet separated in close proximity. However, problems include high power consumption, signal variations and background noise. Moreover, MRI compatibility can also be a problem with some components.
It is an object of the present invention to obviate and/or mitigate at least one of the aforementioned disadvantages and/or problems.
SUMMARY OF THE INVENTION
Broadly speaking the present invention is based on powering a middle or inner ear implant using a light signal.
In a first aspect the present invention provides a hearing aid system comprising an external ear canal module and an implant;
the external ear canal module comprising a microphone, a light source, a power source and necessary electronic circuitry;
the implant comprising a photoreceiver actively coupled to a hearing actuator; and
wherein in use, sound detected by the microphone of the external ear canal module is converted and transmitted by the light source as a modulated light signal, the modulated light signal being detected by the photoreceiver of the ear implant and converted to an electrical signal for driving the hearing actuator.
The implant it will be understood is located within the middle or inner ear, i.e the body side of the ear drum.
Advantageously the present system is such that the light signal may be sufficient to not only provide the sound information, but also power the ear implant. In this manner, the ear implant need not have its own internal power source. Alternatively or additionally a further light source may be used to charge a battery within the ear implant so as to provide additional power to the implant.
Thus, in a further aspect, the present invention provides a method of powering and/or signalling an ear implant comprising transmitting a light source, or sources through a patients ear drum, such that said light source(s) is/are received by the ear implant and wherein said light source(s) is/are capable of powering and/or signalling the ear implant.
The components of the external ear canal module are typically contained within a single housing which is shaped to fit within the external ear canal. The microphone is positioned within the housing such that in use it can easily detect sounds. Thus, the microphone is generally arranged to be directed towards the outside of the ear for receiving sound. The sound received by the microphone is transduced by appropriate means known to those skilled in the art, into an electrical signal which in turn is converted into a modulated signal by suitable modulating means. The modulated signal is then output as a modulated light signal from the light source.
The light source may be for example a light emitting diode (LED) and the light signal itself may be visible light or preferably near infrared (NIR) light or infrared (IR) energy. Studies have shown that IR light can penetrate over 15 mm of tissue at frequencies up to 30 KHz. The light which is output by the module is to be received by the middle-ear implant. Thus, the light source is arranged in use so as to emit the light in the direction of the photoreceiver. The light source therefore emits the light towards and through the ear drum for detection by the photoreceiver.
The skilled addressee is well aware of the electrical circuitry required for the module and a power source, typically a battery, rechargeable or otherwise, is required to power the components of the module.
Although generally designed to fit snugly within the external ear canal so as to not easily fall out, the module should conveniently not completely occlude the ear canal. In this manner a channel, valve or the like may be provided in the module so as to provide a passage through the module thereby preventing blockage of the ear canal. It is understood that such a channel valve or the like could be associated with the housing of the module and, for example, a channel could be cut into the external surface of the module.
The implant may be an integrated photoreceiver/actuator unit such as a micro electromechanical system (MEMS)-integrated photoreceiver/actuator. The photoreceiver/actuator may be a single unit, or the photoreceiver and actuator may be separate and electrically connected by wiring. The photoreceiver may be a photo-sensitive diode, photo voltaic cell or other type of photoreceiver which may be located anywhere in the middle ear, providing it can receive light generated from the light source of the ear canal module. It may be covered by a biocompatible coating, which could include coverage of the photoreceiver.
In order that a patient suffers no or minimal residual hearing loss, the implant may sit on the ossicular chain, rather than linking to it from a remote fixation, such that the only additional mechanical impedance is due to the small mass of the actuator itself. Locating the actuator on the ossicular chain may also help to eliminate any post-operative alterations to implant performance from tightening or loosening of the actuator-ossicle coupling during the healing of swollen tissues, and from small displacements arising from the altered gravitational effects of lying down during the operation and sitting/standing up afterwards.
The actuator may, for example, be located on the incus long process, the incudostapedial joint (which could be disarticulated temporarily without damage for the fitting of an annular shaped actuator) or the stapes. The actual design of the actuator will be determined by the skilled addressee according to the location selected, an important aim being to reduce acoustic feedback An alternative position may be in the inner ear, for example the promontory, where coupling may be direct, via fenestration: a surgical technique to create a window in the inner ear in order to contact the inner ear fluid directly, or using an external anchoring support.
The actuator may be secured in place by methods such as cementing, grafting or mechanical means, for example screws or barbs. It could be osseointegrated with the ossicular chain.
Actuation may be mechanically driven or electrical. In the middle ear, actuation will generally be mechanical vibration of the ossicular chain, or more specifically individual bones thereof. If the actuator is placed in the inner ear, actuation may be carried out mechanically by for example direct or indirect vibration of the perilymph fluid in the inner ear, or electrically to an electrode or electrode array, coupled for example to the cochlea.
In order to drive a mechanically operated actuator, light is received by the photoreceiver, which is in turn converted into an electrical output which drives the actuator resulting in vibrations. Typically the actuator may be a thin disk made of piezo ceramic material such as lead zirconate titanate (PZT), or lead lanthanum zirconate tibanate PLZT. This is desirable because the materials are magnetic resonance imaging (MRI) compatible, as well as being efficient transducers. Additionally more than one disk may be provided in a desired configuration and/or disk may be more than one layer thick. The vibrations may also be generated using for example a disk(s) of piezo ceramic in conjunction with a flexible diaphragm of for example stainless steel, titanium, or aluminium.
Furthermore, the use of a flexible diaphragm permits hydraulic amplification to increase the displacement of the flexible diaphragm. For example, an increase in the displacement of the flexible diaphragm can be obtained using a simple fluid-filled tube coupled to a larger diameter disk actuator which is located at the opposite end of the tube from the flexible diaphragm and may contact for example the perilymph. Such a tube structure allows the actuator module to be placed in the middle ear cavity which provides more space for accommodation and support.
BRIEF DESCRIPTION OF THE DRAWINGS
As an example, a PZT disc actuator now in use in an incus-driven middle ear implant operates at 1V and 100 μA. This power requirement could be generated from the photodetector without the need for further electronic amplification. Passive RC filtering could be used for demodulation. In case a higher voltage or current is needed to drive the actuator, a simple op-amp would be sufficient which will consume very little extra power other than to drive the actuator. The additional power could come from another modulated source or a DC frequency in the light signal.
An embodiment of the present invention will now be described in more detail and with reference to the following FIG.:
FIG. 1 shows the possible locations of an ear canal module and ear implant according to the present invention;
FIG. 2 shows a block diagram identifying the components of the ear canal module and ear implant of the present invention;
FIG. 3 is a schematic depiction of a testing system used to evaluate the present invention; and
FIG. 4 is a graphic depiction of displacement versus frequency as measured using the test apparatus of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows somewhat schematically the relative locations of the external ear canal module 1 and ear implant 20 . As can be seen, the ear module 1 is located in the ear canal 3 . The ear module 1 has a channel 5 through the module 1 in order to prevent occlusion of the ear canal 3 . A modulated IR light signal, represented by the dashed lines 7 , is emitted by an LED 9 , through the ear drum 12 , so as to be detected by an implant 20 . In this embodiment, the implant 20 sits on the incudostapedial joint, so as to oscillate the stapes, although the implant could be located elsewhere, for example in the promontory.
FIG. 2 shows in more detail the components of the ear module 1 and implant 20 of the present invention. The ear module 1 comprises a microphone 11 , and associated electronic circuiting 13 for transducing sound into an electrical signal which is in turn converted and transmitted as the modulated light signal 7 (shown as broken arrows) by the LED 9 . Power for the ear module is provided by a battery 15 . The modulated light signal 7 passes through the ear drum 12 and is detected by a photodiode 22 of implant 20 . The photodiode 22 converts the light signal 7 into an electrical signal for driving/oscillating a disk actuator 24 made of PZT piezo ceramic material.
Advantageously the hearing system features surgical simplicity, safety and life-long durability (no implanted battery needs to be replaced), easy updating of signal processing (external module) algorithms, minimum or no deterioration (destruction) of the residual hearing level, minimum or no acoustic feedback and canal occlusion problems which are inherent with conventional hearing aids, low-cost and acceptability for both the surgeons and the patients.
To illustrate the efficacy of the present invention, the inventors have tested the feasibility of two components of the invention ie. the ossicular mounted piezoelectric actuator and the infrared telemetry system.
We have tested the feasibility of the two key innovations in this project, i.e. the ossicular mounted piezoelectric actuator and the infrared telemetry system.
(a) Ossicular mounted piezoelectric actuator. An ossicular mounted actuator is used in the Soundbridge implant [1], but it has an electromagnetic actuator with a moving mass component, so the vibrating mechanism is not directly comparable with the presently proposed design. The piezoelectric actuator used for the pilot study was an 8 mm diameter single layer disk bender, of the type used in the TICA hearing implant (2). The output vibration level of the TICA actuator is well documented and has been shown clinically to satisfy the requirements of a hearing implant [2]. This makes it suitable for demonstrating the ossicular mounted concept. The actuator is available commercially (American Piezo Company). Its total thickness is 0.22 mm and its mass is less than 150 mg.
FIG. 3 shows a schematic of the test configuration, which was designed to be a more demanding load than the real ossicular chain. A copper wire was used to simulate the ossicular chain. It was glued at one end to a 17 mm long section of flexible plastic sleeving (polyolefin, 12.7 mm bore, 0.3 mm thick, weight 0.36 g), giving a crude representation of the eardrum. The wire weighed 60 mg, which is about 10% heavier than the ossicular chain [3]. The other side of the tube was glued to a solid framework. The wire passed through the centre of the actuator, with a tight fit to hold it in place. The protruding wire weighed about 8 mg, twice the weight of the stapes. Reference data were obtained for an unloaded actuator, which was attached around its circumference to a solid framework, FIG. 3( b ). Vibration was measured with a laser vibrometer. FIG. 4 shows the measured displacements.
The TICA is reported as producing 22 nm at 2.83V peak to peak [2], which was found to be equivalent to around 100 dB SPL at 1 kHz and more than 130 dB SPL (Sound Pressure Level) at higher frequencies [2]. The ‘ossicular mounted’ actuator of the present invention gave a nearly flat response of 47 nm below 4 kHz at 1V excitation, considerably higher than the TICA, and a similar resonant frequency of 7-10 kHz.
(b) Infrared light transmission. Light transmission was tested through a chicken skin, which is more opaque than the eardrum and at least twice as thick. The simulation was otherwise as realistic as possible, in terms of the likely size of the light emitting diode (LED) source and the distances for the light path. The energy detected by a photodiode was used to drive the disk bender actuator and could produce a vibration displacement level equivalent to 100 dB SPL, which is more than adequate for an implant, using 2.1 mW optical power. A custom made actuator is envisaged to perform much better. The level of infrared energy used was less than 1% of the level that could cause tissue damage, according to British Standard EN 60825-1: 1994 Safety of Laser Products. This demonstrates the viability of the trans-eardrum telemetry concept.
REFERENCES
[1] Lenarz T, Weber B P, Mack K F, Battmer R D, Gnadeberg D. The Vibrant Soundbridge System: a new kind of hearing aid for sensorineural hearing loss. 1: Function and initial clinical experiences. Laryngorhinootologie. 1998; 77: 247-55. (In German).
[2] Zenner H P, Leysieffer H, Maassen M, et al. Human Studies of a Piezoelectric Transducer and a Microphone for a Totally Implantable Electronic Hearing Device. American Journal of Otology, 2000; 21: 196-204.
[3] Kirkae I. The structure and function of the middle ear. University of Tokyo Press, Tokyo, 1960.
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The present invention relates to a hearing aid system comprising a hearing implant and a method of powering a hearing implant, the system comprising an external ear canal module and an implant, wherein the signalling and/or powering of the ear implant is by way of a light signal being provided to the implant through the ear drum from, for example, the ear canal module.
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This Application is a continuation-in-part of application Ser. No. 08/340,907 filed Nov. 15, 1994, now abandoned.
BACKGROUND OF THE INVENTION
This Invention relates to the magnetic conditioning of fluids and specifically relates to devices for separating metals and organic or inorganic materials from water or other fluids.
It is known that a magnetic flux can prevent the buildup of scale and other materials in pipes utilized to transport fluids. For example in U.S. Pat. No. 5,269,915 by Clair a magnet is placed outside a ferrous pipe for inducing a magnetic flux within the pipe for prevention of calcium carbonate on the pipe wall. The patent also describes how oil and other materials such as the precious metals cause problems in flow lines. As therein discussed, chemical treatment is expensive and necessitates collateral equipment and processes. Clair discusses deficiencies of the prior art relative to inducing a sufficient magnetic flux into the water flowing in the pipe for separation of undesirable materials from water. In the Clair patent a magnetic flux is created in an area G on the inside of the pipe utilizing magnets on the outside of the pipe. The magnetic flux ionizes the fluid and also the dissolved and suspended solids in the fluid for separation of undesirable materials.
In U.S. Pat. No. 4,755,288 by Mitchel a system is shown to create a magnetic flux within the pipe which includes cooling units for the magnets. The patent describes how many devices do not provide sufficient magnetic flux within the pipe for treatment of the water or other fluid.
In U.S. Pat. No. 5,030,344 by Ambrose there is disclosed a magnetic fluid conditioner arranged on the outside of the pipe with several magnets positioned so that the south magnetic pole faces the pipe. An elaborate system is utilized to strengthen the magnetic flux for separation of undesirable materials from water.
In U.S. Pat. No. 5,186,827 by Liberti, et al. four magnets are placed at a distance from the fluid carrying pipe for separating materials from water.
There are many other devices designed for increasing the magnetic flux within the fluid carrying pipe such as those disclosed in U.S. Pat. Nos. 4,417,985 by Keane; 5,024,759 by McGrath, et al.; 5,074,998 by Doleman, et al.; 5,198,106 by Carpenter; 5,161,512 by Adam; 5,178,757 by Corney; 5,227,683 by Clair; 5,122,277 by Jones; 4,428,837 by Kronenberg; 4,407,719 by Van Gorp; 4,552,664 by Benner and 2,652,925 by Vermeiren.
In Vermeiren, for example, the pipe is surrounded by several solenoids supplied by alternating current or direct current whereunder different solenoids have the same polarity.
As is obvious from the foregoing discussion and a simple inspection of prior art, extensive research has been conducted for the purpose of increasing the magnetic flux within the fluid carrying pipe.
Furthermore, research to date has not revealed the exact mechanism whereunder various metals and organic or inorganic materials are separated from water during the process utilizing a magnetic flux.
Accordingly, the object of the Invention is to improve the separation process whereunder a magnetic flux created inside a pipe carrying fluid for treatment. Another object of the Invention is to increase the magnetic flux within a fluid carrying pipe for separation of metals and organic or inorganic materials from water or other fluids. Further objects of the Invention will be apparent from the following discussion.
DISCLOSURE OF THE INVENTION
The Invention herein comprises a plurality of magnets placed about a fluid-carrying pipe; a core placed within the flow line of the pipe and approximately at the center line of the pipe; a controlled electrical return path, such as a metal wire or conduit, connected electrically to the core, but not in electrical contact with the pipe, and which runs to a lower electrical potential. A low reluctance shield encloses the above magnet structure. The core is supported within the pipe by one or more support pieces running from the core and to the interior of the pipe, and arranged so that the core may be easily removed from the pipe. The controlled electrical return path (CERP) is, in essence, an electrically conductive means, such as a metal piece, wire or conduit, which is in electrical contact with the core so that electrical charges of the core flow to a lower electrical potential. A preferred lower electrical potential is ground, substantially ground, or a structure such as a pipe which itself is connected electrically to ground.
As stated, the core is placed in the center line of the pipe. Such center-line is essentially in a zero gauss region. In such position there is a maximum influence by the magnetic field on the fluid flowing through the pipe.
As stated, the controlled electrical return path (CERP) is in electrical contact with the core, but not with the pipe. In one embodiment shown, the CERP is in electrical communication with a shaft which itself is in electrical communication with the core. Such shaft is electrically insulated from the pipe. Thus, there is an electrical flow from the core only through the CERP and into a lower electrical potential.
The invention also includes an embodiment whereunder the CERP is connected to a prior art variable resistor prior to contact with the lower potential so that the electrical flow to ground can be controlled and that there can be a control of the intensity of the separation.
Applicant has discovered that the magnetic field placed on the fluid within the pipe can be controlled by the variable resistor, which controls the electrical flow through the CERP.
The lower potential can be any lower potential, but is preferably ground or substantially ground or a structure such as a pipe which itself is connected electrically to the ground.
For reasons unknown to the Inventor, the CERP enhances the separation process wherein a magnetic flux is placed into fluid flowing within a pipe.
Each magnet arranged outside and about the pipe has several magnet sections. The number of magnet sections depend upon the particular application. In the embodiment herein, there are four magnet sections, each of which have six separate magnets. Each magnet is polarized so that the portion of the magnet facing the pipe is either of a north or south polarity with the portion of the magnet section facing away from the pipe is of the opposite polarity. For purposes of discussion herein, a magnet is considered north, when the portion of the magnet facing the pipe is of north polarity. A magnet is referred to herein as being south, when the portion of the magnet facing the pipe is of south polarity. Each magnet section of each magnet is either of north or south polarity (that is, the polarity of the section facing the pipe). Each magnet section has a different polarity from the adjacent section. Furthermore, each magnet section opposite to the magnet section on the other side of the pipe has the same polarity as such opposite magnet section. For example, in one embodiment, four magnets are placed about the pipe equal distance from one another. In such embodiment, each magnet has six sections. A first section is magnetically north, the second section magnetically south, the third section magnetically north, the fourth section magnetically south, the fifth section magnetically north, and the sixth section magnetically south. The magnet on the opposite side of the pipe likewise has a first section in which is magnetically north, a second adjacent section magnetically south, a third section magnetically north, a fourth section magnetically south a fifth section magnetically north, and a sixth section magnetically south. Accordingly, all magnets of a first section are magnetically north. Thus, the polarity of the magnet section opposite to each magnet is identical. Accordingly, each section has magnetic fluxes flowing between them and repelled by the magnet section on the opposite side of the pipe.
In some applications, it is preferred that the polarity of the magnet sections near the inlet where fluid enters the pipe of the Invention be north. In other applications, the magnet section near or adjacent to the inlet section is preferably south.
A shield which has a low magnetic reluctance is provided exterior to the pipe and the magnets so that magnetic fluxes do not escape from the pipe but are retained within the pipe.
As stated, it is unknown why the above-described system results in a high efficiency of removal of metals and chemicals, as well as hydro-carbon materials from water or other fluids. Prior art devices which show metal pieces within the pipe disclose no elements whereunder electron flow from such inner pieces or cores are dispelled to a lower potential such as ground.
Additionally, prior art devices do not disclose applicant's novel magnetic section arrangement whereunder sections of different polarity are made part of magnets placed about the pipe and in the arrangement described hereinabove.
In any event, the subject Invention results in a high efficiency of separation of materials from aqueous and other solutions.
THE DRAWINGS
FIG. 1 shows a cut-away and perspective view of the Invention.
FIG. 2 shows an end-view of the Invention.
FIG. 3 shows the perspective view of enclosing caps.
FIG. 4 shows a perspective view of the enclosing caps.
FIG. 5 shows a perspective view of the arrangement of the sections of a magnet.
FIG. 6 shows a schematic of the support means for the core of the Invention.
FIG. 7 shows perspective view of the CERP concept wherein the CERP is connected to a shaft which in turn is connected electrically to the core. The CERP is shown running through the variable resistor and to the lower potential, generally ground.
FIG. 8 shows a view of the CERP connected electrically to the shaft which is in turn placed in electrical communication with the core. FIG. 8 also shows the insulation so that there is no electrical contact between the CERP and the pipe.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is shown a flow pipe 1 which carries the fluid to be treated. Pipe 1 is made of any material which does not interfere with the magnetic flux created from magnets. Pipe 1 can be made of copper, stainless steel, aluminum, nylon, polyvinyl chloride, a conductive polymer and other generally recognized pipe materials, preferably stainless steel or other ferrous material.
The device of FIG. 1 is connected to fluid flow lines by generally recognized plumbing materials. Fluid flows in one end of pipe 1 from a line connected thereto and outside the opposite end of pipe 1. Thus the fluid is treated within the shown pipe 1.
A core member 2 is shown running concentrically within pipe 1. Core 2 is made of any electrically conductive material, preferably a ferrous material such as iron, or a conductive polymer, and preferably Core 2 is stainless steel. Core 2 may include an outer shell made of copper or other substantially non-corrosive material so that core 2 may be protected from corrosion threatened by an aqueous fluid contained within pipe 1. The diameter of core 2 is generally substantially less than the diameter of the pipe as depicted in FIG. 1. The diameter of the core may be 1/50th to 1/10th of that of the pipe. The core may be located in the middle of the cross-section of pipe 1 and may run concentrically within pipe 1.
Core 2 is supported within pipe 1 utilizing support bar 3 and other support bars to be discussed. Exterior to pipe 1 are four separate magnets 4, 5, 6 and 7 arranged equal distant about pipe 1. Each magnet has six separate sections. The magnet section near the pipe where the fluid enters is charged north. The next section is charged south with the next section charged north, next section south, next section north and final or exit section charged south. Each of the four magnets have the sections similarly charged.
Support bar 3 is in electrical contact with core 2. Attached to bar 3 is the novel CERP 8 of the Invention. The CERP 8 is simply an electrically conductive material such as copper, aluminum or iron which can carry electrical charge from the core 2 to a lower electrical potential such as a ground or an electrical conductive structure connected to ground 9. In some applications, the lower potential is a controlled potential so that the process may be modulated. The CERP 8 may be connected to ground 30 as shown in FIG. 7. The CERP can be connected to the core 2, or to any structure in electrical communication with core 2 such as support bar 3 or bolt 10, which is shown exterior to pipe 1.
Shield 11 is exterior to the magnets 4, 5, 6 and 7 and prevents magnetic flux or minimizes escape of magnetic flux from the exterior. Thus magnetic flux is directed towards the pipe and is not lost to the atmosphere. The shield 11 is composed of any material which has a low magnetic reluctance and which can reduce the magnetic field outside the pipe to a minimum. Suitable materials are galvanized sheet metal and the like. Exterior to the shield 11 is an outer housing 12 made of known prior art materials.
FIG. 2 shows a cross-sectional area of the Invention. It can be seen that bolt 10 helps placement of bar 3 within pipe 1 and also acts as the connecting medium for the CERP line 8. A filler material is contained within shield 11 and exterior to pipe 1 and can be composed of any suitable prior art material.
Each magnet may contain a backing strip 14, 15, 16, and 17 at its outer face area to minimize magnetic flux fields flowing towards shield 11. The backing materials may be of ferrous material such as mild steel.
FIGS. 3 and 4 show mounting caps 18 and 19 respectively for placement of the pipe 1 of FIG. 1 onto the system pipe not shown. FIG. 3 shows a hole 20 so that the novel CERP 8 connected to bar 3 or connecting bolt 10 can escape therethrough and be connected to ground. There is shown an opening 21 so that the pipe 1 can be connected therein to the piping of the system exterior to the device of the Invention. Likewise, opening 22 shown in FIG. 4 can be utilized for opposite end connection.
FIG. 5 shows a schematic view of the alternating polarity sections of a typical magnet 6. Shown are magnet sections 6a, 6b, 6c, 6d, 6e and 6f. Referring back to FIG. 1, there are shown four magnets 4, 5, 6, and 7 about pipe 1. There are shown magnet sections a, b, c, d, e, and f, each of magnets 4, 5, 6, and 7. In one embodiment each magnet section a has the same polarity. Accordingly, magnet section 4a has the same polarity as section 5a, 6a and 7a. Also, and as described, the next magnet section 6b has a different polarity. Accordingly, in one embodiment, magnet section 6a is north, section 6b is south, section 6c is north, section 6d is south, section 6e is north and section 6f is south. Likewise, section 7a is north, section 7b is south, section 7c is north, section 7c is south, section 7e is north and section 7f is south. It can be seen that the poles of opposite magnet sections have the same polarity. For example, section 4a has the same polarity as opposite magnetic section 6a. Also, magnet section 5a has the same polarity as opposite magnet section 7a. As stated, in some applications, it is preferable that the magnet sections have a north polarity near the inlet of the pipe where fluid enters. Accordingly, sections 4a, 5a, 6a and 7a would be of a north polarity. In other embodiments it is preferable that the magnet section adjacent the inlet of the pipe be of south polarity, in which case, sections 4a, 5a, 6a, and 7a would be of south polarity.
FIG. 6 shows the core 2 supported within pipe 1 utilizing support bar 3. The core 2 is placed within support 3 utilizing connecting means 34 and a nut 33.
FIG. 7 shows a schematic view of the CERP system. Line 8 is a CERP and can be any electrically conductive wire, such as a copper, ferrous or steel wire or any other electrical means whereunder electricity can flow therethrough. The CERP 8 is shown connected to a shaft 3 in FIG. 7. There is an insulating member 9 placed about the CERP 8, so that there is no electrical contact between the CERP 8 and the pipe 1. Thus, the CERP is in electrical contact with the core 2, without any electrical contact with the pipe. The CERP is then connected to a variable resistor 32. The variable resistor 32 is a standard prior art variable resistor. The CERP 8 is shown connected to ground or to a lower potential such as ground or a pipe. FIG. 7 shows the ground as 30 and a portion of the CERP 8 as line 30, shown from the variable resistor 32 and to ground 30.
FIG. 8 shows a detail front view of the connecting system wherein the CERP is connected to shaft 3, which in turn is electrically and physically connected to the Core 2. The CERP 8 is within an insulating material 9. The CERP 8 surrounds the shaft portion 3 which is bolted by Bolt 10 and Nut 25. There is a piece 9 below the Bolt 25. There is an insulating material 29 so that there is no electrical contact between the Shaft 3 and the Pipe 12. The CERP wired thus surrounds a Shaft 3 so that the CERP 8 is in electrical contact with Core 2.
Other means can be utilized to form an electrical contact with the inner core 2, as is known in the prior art.
OPERATION OF THE INVENTION
The device depicted in FIG. 1 is connected to the fluid flow line which carries the fluid for separation. Fluid for separation may be contained in the system itself or in a separate reservoir or tank. Fluid is pumped within pipe 1. The fluid which exits pipe 1 is then contained within a tank or other storage means.
The particular sizing of pipe 1 and of the magnets and other elements of the Invention can be accomplished readily by knowing the parameters of the system, the volume of materials to be separated and other recognizable features. The type of fluids which are to be treated are of numerous variety such as those disclosed in the above-described patents in prior art. Generally, however, fluids which are the subject of the separation process include those aqueous solutions containing metals and/or hydrocarbons to be treated.
The subject Invention has, in fact, been utilized to separate metals such as chromium, copper, lead and zinc from aqueous solutions to essentially non-detectable levels utilizing the device of the Invention. Additionally, the Invention has been utilized to essentially remove hydrocarbons such as ethyl benzene, toluene and methylene chloride from aqueous solutions. Generally, the fluid flows through the separation piping into a tank where the metals settle below the water and the subject hydrocarbons settle on an upper level above the water.
The foregoing composes the preferred embodiment of the Invention and the Invention is defined by the following claims:
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A device for separation of metals and inorganic or organic fluids from water is provided which is comprised of a pipe containing a core concentric within the pipe; several magnets containing segments of opposite poles arranged exterior to the pipe; and an electrically conductive wire connected electrically to the core and to ground.
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RELATED APPLICATION
This application claims the benefit of the earlier filing date of U.S. Provisional Application No. 61/143,749.
BACKGROUND
Rotator cuff tears are a common source of shoulder pain, especially in athletes or specific occupations. The incidence of rotator cuff damage increases with age. Obesity is also associated with rotator cuff surgery. A host of conditions may be related to eventual surgical intervention including bone spurs, adhesive capsulitis, and tendon degeneration with partial or full tears. Shoulder dislocation and instability caused by trauma may also lead to surgical intervention. Standard of care includes conservative treatment with rehabilitative exercises and injections. In patients who do not respond to conservative care, surgical interventions are frequently undertaken. Although comprehensive epidemiological data is not available on the total number of procedures nationwide or worldwide, just one local Oklahoma City Clinic (HPI data) reported 751 rotator cuff surgical procedures on females between January 2004 and Dec. 31, 2008, or an average of 188 per year. The American Board of Orthopedic Surgeons reports over 25,000 members nationwide. Although the exact number of procedures is not available, it can be estimated to be in the range of 770,000 across 4100 clinics, assuming half of those Board certified specialize in shoulders, and an average practice size of three. At the low end assuming only a third of the Board members participate and assuming practice sizes of five physicians it could be estimated roughly 312,000 procedures are conducted on female patients. Regardless of method (open, mini-open, or arthroscopic) a significant period of partial disability is expected during which the patient is normally undergoing initial range of motion physical therapy. Most patients have a reduced functional range of motion for 4 to 6 months after surgery; however, this duration is patient specific and can be longer depending on factors such as the integrity of the joint prior to surgery, treatment compliance, complications and specifics of the surgical technique.
The primary muscles involved in rotator cuff disability are supraspinatus, infraspinatus, subscapularis and teres minor. These control the rotation of the arm around its long axis. Since it is advised that post surgically the shoulder should not be used with the elbow away from the side for at least 3 months after rotator cuff repair, activities of daily living are problematic on the affected side. (A less common shoulder arthroplasty or complete replacement is performed on arthritis patients (6,700 procedures in 2003 reported by Medicare). Routine tasks can become insurmountably difficult for a woman who becomes physically incapacitated.
People normally take for granted that they are able to be self-sufficient, especially in very personal matters like dressing and undressing herself. When an incapacitating event occurs, such as shoulder injury or amputation, a woman can become traumatized as the pain associated with the incapacitation is compounded by the vulnerability she faces in not being able to carry out simple tasks as before.
This difficult situation is particularly troublesome when it comes to dressing and undressing of brassieres, and is a common inquiry regarding post operative care—one which most physicians are at a loss to answer. These issues do not normally come into play when a woman selects her choice of brassiere (“bra”) undergarments. That is, typically it requires two good hands and arms and a requisite amount of physical dexterity to put a bra on and take it off. In some cases, for example, the closure is located against the woman's back requiring contorting both arms and hands to the mid-back section, or otherwise spinning the clasped bra around her torso and/or lifting the bra over her head. These types of body motions can be impossible or too painful to perform because of a physical incapacity. Also, the weight-bearing straps that typically are trained over the shoulders can be excruciating to get over an incapacitated arm, and can be invasive to the incisions and pain catheters in situations like shoulder surgery, where days or even weeks post surgery, one arm is limp, weak, lacking sufficient dexterity and strength to work straps and lift anything at all. When still under the effects of nerve block for approximately three days post surgery, assistance must be used to even lift the arm as it is numb, dead weight.
What is needed is a bra that enables a woman to carry on with her dignity in personal matters like dressing and undressing herself in the wake of such a physically incapacitating event, especially in light of her attendance at physical therapy sessions and other visits in a public setting. It is to improvements in the art directed to that need that the present embodiments are directed.
SUMMARY
The claimed embodiments generally contemplate an apparatus and associated method for dressing with a brassiere garment with limited mobility.
In some embodiments a brassiere garment is provided having a strap that is operably trained around a user's back and sides, a cup attached at each end of the strap, and an adjustable attachment feature connecting the cups together.
In some embodiments a method is provided for dressing with a brassiere garment, including steps of obtaining a brassiere garment that has a strap that is operably trained around a user's back and sides, a cup attached at each end of the strap, and an adjustable attachment feature connecting the cups together; placing the brassiere garment on a support surface; attaching a support member to one of the cups; folding the brassiere garment over the user while remaining on the support surface; and attaching the other cup to the support member.
In some embodiments a brassiere garment is provided having a strap that is operably trained around a user's back and sides, a cup attached at each end of the strap, and a tab depending from each cup that is operably selectively positionable in relation to a common support member and attachable to the support member via a hook-and-loop type fastener for connecting the cups together.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational depiction of a bra utilized with the optional neck strap that is constructed in accordance with the present embodiments.
FIG. 2 is a rear view of the bra of FIG. 1 with an enlarged detail view of the adjustable rear closure.
FIG. 3 is an enlarged view of the bra of FIG. 1 detailing the adjustable front closure.
FIG. 4 is an enlarged view of the bra of FIG. 1 detailing the clasp that operably connects the neck strap to the bra.
FIG. 5 is an isometric depiction of a neck strap that is constructed in accordance with alternative embodiments.
FIG. 6 is a side view of the bra of FIG. 1 in an operably closed position.
FIG. 7 is a top view of the bra of FIG. 1 depicting initial steps in a method for putting on the bra of FIG. 1 wherein the bra is laid flat, the bra ring is attached to one of the cups, and then that cup is folded over in a closed position such that the folded-over cup encloses the user's left-side breast.
FIG. 8 is top view depicting final steps in the method for putting on the bra of FIG. 1 wherein the other cup is folded over to enclose the user's other breast and attached to the bra ring and tightened. The pre adjusted neck strap provides a desired length, and the neck “loop” is tossed over the head with the unaffected arm using a simple upward motion and connected to the bra 116 .
DETAILED DESCRIPTION
Turning to the FIGS. and first in particular to FIG. 1 which depicts a front elevational view of a bra 100 that is constructed in accordance with the present embodiments. The bra 100 has a left-cup 102 and a right cup 104 that cover and support the user's left and right breasts, respectively. Extending from a distal end of each cup 102 , 104 is a closure tab 106 , 108 that is sized to be insertable through and thereby form a hooking attachment to a bra ring (sometimes referred to as a “front closure member”) 110 .
It will be understood from the description that follows that in some embodiments the user will be satisfied with the support provided only by the bra 100 . Optionally, the user can obtain additional lifting support by using a neck strap 112 . The neck strap 112 is sized to be insertable through and thereby form a hooking attachment to a strap ring 114 . A clasp 116 can operably connect the bra ring 110 to the strap ring 114 .
FIG. 2 is a rear view of the bra 100 of FIG. 1 depicting each of the cups 102 , 104 being connected to respective straps (straps combined referred to as a “torso strap”) 118 , 120 that are separable at distal ends thereof and joined by a rear adjustable fastener 122 to adjust the size of the bra 100 for the user's girth and comfort. In the embodiments of FIG. 2 the rear adjustable fastener 122 , depicted in an enlarged detail view 123 , employs a hook-and-loop type of cloth fastener 124 , such as Velcro® strips, attached to each of the straps 118 , 120 . It will be noted that a sufficient longitudinal length of the cloth fasteners 124 is provided so that the extent to which the straps 118 , 120 overlap in the closed position can be varied in relation to the desired circumference of the bra 100 around the user's torso. The rear adjustable fastener 122 of the present embodiments are not so limited to this construction, such that other types of adjustable fasteners such as but not limited to rows of hooks and clasps, and the like, can likewise be used. The pre surgical adjustability, movement and comfort are key features of the bra 100 provided by the rear adjustable fastener 122 .
FIG. 3 is an enlarged detail view of a front adjustable fastener 126 for attaching the cups 102 , 104 to the bra ring 100 in a manner that adjusts the size of the bra 100 for the user's breast size and comfort. In the embodiments of FIG. 3 the front adjustable fastener 126 employs another cloth fastener 124 attached to the tab 106 and to the cup 102 . Although not depicted, it will be understood that the other tab 108 is adjustably attachable to its respective cup 104 in the same manner. The tab 106 is inserted through the bra ring 110 and then folded over in direction 128 to connect the cloth fastener 124 . It will be noted that a sufficient longitudinal length of the cloth fastener 124 is provided so that the extent to which the tab 106 is inserted into and folded over the bra ring 110 can be varied to selectively determine the size of the cup 102 in relation to the user's breast size.
From the foregoing it is important to note that the rear adjustable fastener 122 and the front adjustable fastener 126 of the present embodiments make it possible for one-size-fits all construction. That is, users of various different girths, breast sizes, and desired lift and comfort levels can all use a commonly manufactured bra 100 because it is readily suited for individual adjustment. These features simplify manufacturing and distribution of the bra 100 , and assist the medical supplier in meeting the patient's needs without the concern of supplying proper size or style. A special order extra extra small or extra extra large customization can be arranged in certain but rare circumstances to accommodate XXS, XXXS, XXL, and XXXL patients.
Again, in some circumstances the user will be satisfied with the lift and support provided entirely by the bra 100 . However, in other circumstances the user will prefer the additional lifting support afforded by the neck strap 112 . Returning to FIG. 1 momentarily, in keeping with the one-size-fits-all advantages of the present embodiments, the neck strap 112 is a discontinuous loop that is selectively attachable at its ends such as by another cloth fastener 124 to form a desired drop above the bra ring 110 . In the embodiments of FIG. 1 the neck strap 112 hookingly engages the strap ring 114 . The clasp 116 hookingly links the bra ring 110 to the strap ring 114 .
FIG. 4 is an enlarged detail view of the clasp 116 that forms a first hook 130 at an upper end thereof for engaging the strap ring 114 . The clasp 116 similarly forms a second hook 132 at a lower end thereof for hookingly engaging the bra ring 110 . Advantageously, by first hooking the first hook 130 to the strap ring 114 , the user can then simply and easily connect the neck strap 112 to the bra 100 by an upward motion of the hook 132 to engage the bra ring 110 . The neck strap, previously set to the correct length prior to surgery, is tossed over the head with the non affected arm, and upward motion to attach the hook 132 is easily accomplished with only one hand, accomplishing the desired solution of the present embodiments. The clasp 116 is held in place by the additional support the neck strap 112 provides, and the attachment adds additional support for larger busted women. The rings 110 , 114 and the clasp 116 in these illustrative embodiments are constructed of a rigid durable material such as a food grade polyethylene or the like, or a metal, in order to minimize the frictional engagements therebetween. Furthermore, the radiused surface of the rings 110 , 114 can be fashioned to minimize the frictional engagement with the items they engage. This type of construction provides the most desirable comfort level to the user, in that the linkage between the neck strap 112 and the bra 100 is extremely fluid in response to the user's body movements. The clasp 116 is hooked to the ring 114 to provide a stable yet flexible attachment.
It will be understood that in alternative equivalent embodiments a less complex and thereby less expensive construction can be provided, such as but not limited to the embodiments depicted by FIG. 5 . The neck strap 112 a in FIG. 5 simply loops through and hookingly engages the bra ring 110 directly, thereby eliminating the need for the strap ring 114 and clasp 116 . The neck strap 112 a depicted in FIG. 5 is constructed of a fixed-size loop, but alternatively it can be an adjustable-size loop as described above. This reduced-cost solution might require a relatively greater patient level of post surgical dexterity to use.
FIG. 6 is a side view of the bra 100 in the operably closed position, that is, with both the rear adjustable fastener 122 and the front adjustable fastener 126 selectively sized and closed. A supporting stay 134 can be sewn into each of the cups 102 , 104 to afford additional support to the user's breasts. Additional support is also provided by the gathers 136 provided by the seam 137 around a supporting stay 139 at the attachment of the cups 102 , 104 to the respective straps 118 , 120 .
FIG. 7 is a top view illustrating initial steps in an illustrative method for a user to put the bra 100 on. The rear adjustable fastener 122 is first sized and connected. Since the bra 100 is being used in rehabilitating from surgery, then the setting for the rear adjustable fastener 122 is preferably done prior to the surgery. The bra ring 110 is connected to one of the closure tabs 106 , 108 at the desired size; in FIG. 2 the bra ring 110 is connected to tab 106 . Preferably, the ring is attached to the cup 102 , 104 associated with the injured side of the user's body.
The bra 100 is then placed on a supportive and substantially flat surface, such as the top of a bed, with the outer surfaces of both cups 102 , 104 facing the flat surface. The user can then recline her back against the bra 100 and fold the cup 102 over to enclose her (in this illustration) left breast. FIG. 8 depicts a continuation of this method after the user has similarly folded over the other cup 104 to enclose her right breast and hooked the tab 108 through the bra ring 110 . The partially incapacitated person is able to put on the bra 100 since sufficient strength is available using the unaffected arm to secure and tighten the fits without any impact on the disabled side, which is hanging limp or nearly immobile from pain medications, pain pump, or too fragile to move due to sutures. The bra 100 allows the woman to dress herself and is adjustable with use of only the non affected arm.
The bra 100 and optional neck strap 112 are preferably made of a fabric providing a desired comfort to the user, such as but not limited to a synthetic material with superior elasticity characteristics such as but not limited to Lycra® or more generally referred to as spandex knit. The chain stitch and nylon thread is employed to facilitate proper stretching of the material. Other features of construction not detailed will be understood to the skilled artisan, such as the type and placement of seams in joining panels of the fabric such as to place the seams away from the user's skin and to prevent direct contact with the stays 134 , 139 .
Referring momentarily to FIGS. 6 and 8 , for example, the seam 137 forming the gathers 136 provides a somewhat expandable end of the cup 102 that is tapered sufficiently to be wide enough to cover the breast comfortably while providing the desired support at the end adjacent the strap 118 . Another seam 141 likewise forms gathers 143 to provide a similarly somewhat expandable end of the cup 102 that is tapered sufficiently to be wide enough to cover the breast comfortably while providing the desired support at the other end adjacent the closure tab 106 .
The described construction of the bra 100 and optional neck strap 112 enables the user to put the bra 100 on according to this illustrative method with only one hand, solving the need for the partially incapacitated person to dress and undress herself and attend required therapies and necessary trips outside the home with sufficient modesty and support. The optional neck strap is sized prior to the surgery using the Velcro tab. The loop can then be tossed over the head with the non affected arm. The clasp is designed ergonomically to be connected with a slight upward motion using the non affected arm. The materials and construction of the clasp may be a single lightweight yet sturdy, injection molded plastic in the final design.
It is to be understood that even though numerous characteristics and advantages of various embodiments of the present invention have been set forth in the foregoing description, together with details of the structure and function of various embodiments of the invention, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present invention to the full extent indicated by the broad general meaning of the terms in which the appended claims express. The particular elements may vary in type or arrangement without departing from the spirit and scope of the present invention. For example, without limitation, although Velcro® type cloth fasteners are depicted in the embodiments disclosed above, the contemplated scope of the invention is not so limited such that other types of fasteners and adjustment mechanisms can readily be substituted and otherwise used in equivalent alternative embodiments.
In addition, although the embodiments described herein are directed to illustrative embodiments for adjustable sizing and attaching the rear adjustable fastener and front adjustable fastener for a bra, it will be appreciated by those skilled in the art that the claimed subject matter is not so limited and various other systems can utilize the present embodiments without departing from the spirit and scope of the claimed invention.
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A brassiere garment and associated method for dressing is provided contemplating a strap that is operably trained around a user's back and sides, a cup attached at each end of the strap, and an adjustable attachment feature connecting the cups together.
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FIELD OF THE INVENTION
This invention relates to a process and composition for simultaneous smoothing, cleaning, and surface protection of metal objects by mass finishing in the presence of a novel type of treating solution.
DESCRIPTION OF RELATED ART
Nowadays, metal workpieces or consumer goods are largely mass-produced by automated industrial processes. The surfaces of such metal parts, which may be made, e.g., of steel, cast iron, copper and its allows, aluminum and its alloys, zinc, magnesium and other metals, generally have to be improved after they are first shaped before they are directly marketed, used as intended, or further processed or assembled.
Metal objects produced by turning, milling, casting or similar processes for treating metals frequently have sharp cut edges or corners or even rough surfaces covered by layers of scale, so that the cut edges and corners have to be trimmed and rounded off and, in many cases, the surface as a whole also has to be smoothed or polished. The quality of surface layers subsequently applied to objects of the type in question depends to a large extent on how well the metal surface has been prepared for the application of such additional refining, protective, and/or decorative layers. For example, the electroplating of metals can proceed satisfactorily only if the electroplating process has been preceded by proper preparation of the surface to be plated. In particular cases, this surface preparation may require cleaning, descaling, and/or grinding of the surface.
Metal workpieces or castings may be shaped, smoothed and finished by a variety of means, including manual mechanical trimming, grinding, rubbing with emery, brushing and polishing, or combined mechanical and chemical finishing process. The purely manual/mechanical finishing of metal parts, particularly small parts produced in large numbers, is no longer economically viable. It is therefore being increasingly replaced by a technique called "mass finishing", which is defined and described in general terms between pages 77 and 98 of Metal Finishing, published by Metals and Plastics Publications, Inc., Hackensack, N.J. in 1985. The non-advertising text and figures of the noted section of Metal Finishing are hereby incorporated herein by reference.
Combined mechanical and chemical finishing may be accomplished in mass finishing by using a chemical composition, usually called "compound" in the art and in this specification, along with the abrasive media and metal objects to be finished. The workpieces are brought into sliding contact with the grinding media, which may be pebble stones, dolomite, quartz, synthetic ceramic or resin bonded corundum, aluminum oxide, silicon carbide or boron carbide of various shapes and, at the same time, are sprayed with usually water-based compositions specially developed for mass finishing. The size and external shape, such as triangles, cylinders, stars, cones, spheres, and the like, and the roughness of the grinding media provide for finishing of the metal surfaces by abrasion and, optionally, polishing. Metal workpieces and/or castings can be descaled, trimmed, ground, smoothed, burnished and polished by mass finishing.
The chemical treatment preparations ("compounds") used for mass finishing are adapted in their composition and concentration to the metal surfaces which are to be finished, but also have to take into account special characteristics of the particular mass finishing process. The principal functions of such treatment compounds are to ensure good cleaning, dispersing, and soil-suspending power, so that oil and grease are emulsified and the grit emanating from the media and the workpieces is completely removed and not deposited onto the workpieces. In addition, the compounds are intended to prevent corrosion of the metal workpieces or castings and also favorably to influence the grinding effect and/or polishing effect during the mass finishing process. To this end, the compounds must not smear the castings during grinding with a greasy layer which would mar the shine produced by polishing of the castings. In addition, compounds of the type in question, through their composition, can affect the grinding effect of the media, thus making it possible first to trim and pre-grind and, after the chemical treatment compound has been changed, to finish and polish the workpieces with the same media.
The compounds are normally prepared in such a way that they may be dispensed in liquid, concentrated or prediluted form by means of automated pumps. Mass finishing compounds normally dissolve in water to produce neutral to mildly alkaline solutions and contain combinations of soil emulsifying and corrosion-inhibiting substances.
A disadvantage of state-of-the-art products, generally developed purely by trial and error, is that a compound of different composition has to be used for each application, i.e. for each metal of the workpieces or castings. This means that the mass finishing process equipment has to be completely changed over or cleaned whenever the workpieces to be treated by mass finishing are changed. Another disadvantage is that satisfactory mass finishing results can only be obtained when the surfaces of the metal workpieces or castings have been carefully cleaned and surface treated before mass finishing. Accordingly, the actual mass finishing process had to be preceded by treatment processes to prepare the metal surfaces in the desired condition. Apart from the fact that these preliminary treatment steps require separate plants and chemicals, the effect of the mass finishing compounds and, hence, the success of the mass finishing process are easily spoiled when the cleaning and treating compositions are carried over into the mass finishing unit. As a result, the mass finishing compounds can only exert their effect to a limited extent.
DESCRIPTION OF THE INVENTION
Except in the operating examples or where otherwise explicitly specified, all numerical quantities in this specification describing amounts or dimensions of materials or reaction conditions are to be understood as if modified by the work "about".
It has now surprisingly been found that it is possible to perform mass finishing in the presence of an appropriate liquid composition and combine the deburring and shaping effects of ordinary mass finishing with cleaning and surface protective effects that are conventionally performed in separate steps. Only one "compound", which has a cleaning and passivating or surface protective effect and also promotes mass finishing, need be used. It is thus possible to avoid the practical disadvantages of a three-step process using three solutions of different composition.
The process embodiments of the present invention are characterized by the fact that the mass finishing is performed while the metal workpieces are in contact with aqueous solutions which have a pH value in the range from 1 to 6 and which contain orthophosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof, one or more carboxylic acids having either two or three carboxyl groups per molecule, such acids being designated hereinafter as "oligocarboxylic" acids and, optionally, one or more surfactants, one or more corrosion inhibitors and other active substances and/or auxiliaries typically present in cleaning, surface protecting, and mass finishing preparations.
The composition embodiments of the present invention contain orthophosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof, one or more oligocarboxylic acids and, optionally, one or more surfactants, one or more corrosion inhibitors and, optionally, other active substances and/or auxiliaries typically present in cleaning, surface protecting and mass finishing compounds and, optionally, water.
The process according to the invention and the compounds used therein for the simultaneous mass finishing, cleaning and passivation or surface protective treatment of metal workpieces may be applied to metal workpieces and/or castings of various different compositions. Thus, workpieces or castings of iron and all its alloys, for example steels of different composition, cast iron, etc., copper and its alloys, for example brass, bronze, etc., aluminum alloys, zinc or magnesium, and other metals or alloys, may be treated in the course of the process. The surprising aspect of the process according to the invention is that not only can the actual mechanical/ chemical surface treatment of mass finishing, which is normally carried out in drums or vibrators, be carried out using these solutions, the step--normally carried out beforehand--of cleaning the metal workpieces or castings and surface protecting the particular metal surface is also carried out using the same solutions and in one and the same process step without any need for additional units or treatment solutions. Thus, the particular metal surface is cleaned, descaled, surface protected, trimmed, ground, smoothed, burnished and polished in one and the same step. According to the invention, this is done by bringing the workpieces into contact with aqueous solutions having a pH value in the range from 1 to 6. Solutions having a pH value in the range from 3.5 to 5 are preferred. The workpieces or castings are brought into contact with the aqueous solutions by immersing or spraying, depending on the unit. In the process according to the invention, the aqueous solutions according to the invention are normally applied by spraying the workpieces or castings with the aqueous solutions in the units (drums, vibrators, etc.), in which the workpieces are moved together with the media, and allowing the aqueous solutions to run through between the workpieces and the media to the bottom of the particular unit. The solutions are in contact with the surfaces of the media and with metallic surfaces in the intervening period. It is preferable, but not necessary, in the practice of this invention to circulate the solutions used, so that they carry the soil and also the metal particles and/or media particles detached during the process out of the treatment zone, are freed from such impurities after issuing from the unit, and are brought back into contact with the workpieces and/or castings.
In the process according to the invention, the workpieces and castings are brought into contact with aqueous solutions which contain phosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof as one of the essential components. Condensed phosphoric acids are understood to be any of those compounds which are formed by the condensation of several phosphate groups onto one another. In one preferred embodiment of the process according to the invention, alkali metal salts and/or ammonium salts or orthophosphoric acid and/or condensed phosphoric acids are used as the phosphate components. Accordingly, suitable alkali metal salts are lithium salts, sodium salts, potassium salts, rubidium salts or cesium salts, of which the potassium salts and, in particular, the sodium salts are preferred by virtue of their ready availability.
Suitable ammonium salts are both those containing an NH 4 + cation and also those ammonium salts which contain one or more organic substituents on the nitrogen atom. Of these organoammonium compounds, those which contain one or more alkyl radicals having a linear or branched chain and 1 to 6 carbon atoms in the alkyl radical are particularly preferred. Of the ammonium salts, the NH 4 + salts are particularly preferred and may be used with advantage as phosphate components in the aqueous solutions used in the process according to the invention.
In one preferred embodiment of the process according to the invention, the workpieces are brought into contact with acidic aqueous solutions containing one or more of the phosphate components mentioned in quantities of 0.2 to 10% by weight. The quantities by weight are based on the prepared in-use solution and indicate the content of specified substance used in such in-use solutions.
The process according to the invention for the simultaneous mass finishing, cleaning and surface protection of metal workpieces is further characterized by the fact that the workpieces or castings are brought into contact with aqueous solutions containing one or more oligocarboxylic acids as another essential component. According to the invention, individual compounds or mixtures or dicarboxylic acids and tricarboxylic acids are preferably used as the oligocarboxylic acids. In another preferred embodiment of the process, the dicarboxylic acid tricarboxylic acids may be substituted by polar groups in the alkylene radical. The polar substituents are, primarily, hydroxy groups. Tartaric acid or citric acid or mixtures of these two carboxylic acids are particularly preferred dicarboxylic acids and tricarboxylic acids for the process according to the invention.
In another preferred embodiment of the process, aqueous solutions containing one or more of the carboxylic acid components mentioned in quantities of 0.01 to 1% by weight are used. As in the case of phosphate components, the quantities by weight are based on the specified substance content of the final in-use solutions.
Another component of the aqueous solutions used in the process according to the invention are, optionally, surfactants. In this case, too, the aqueous solutions may contain one or even more surfactants as surface-active components. It is preferred to use individual compounds or mixtures of solely nonionic surfactants or, instead, combinations of one or more ionic surfactants with one or more anionic surfactants or, alternatively, one or more cationic surfactants. By virtue of their favorable cleaning properties and the fact that they promote the mass finishing process in a particular way, aqueous solutions containing combinations of one or more anionic surfactants with one or more anionic surfactants or, alternatively, with one or more cationic surfactants are particularly preferred for use in the process according to the invention. Combinations containing nonionic and anionic or, alternatively, cationic surfactants in a quantitative ratio of 1:1 to 10:1 may be used with particular advantage. In the process according to the invention, the total quantities of surfactants present in the aqueous solutions used amount to between 0 and 2% by weight and preferably to between 0.005 and 2% by weight. These quantities are also based on the specified substance content in the in-use solution.
In another embodiment of the process, the aqueous treatment solutions optionally contain one or more corrosion inhibitors. The corrosion inhibitors have to be coordinated with the particular constituent metal of the metal workpieces or castings which are to be processed according to the invention. Aqueous solutions in which one or more compounds from the group consisting of alkali metal molybdates, preferably sodium molybdates, benzotriazole, tolyl triazole and benzthiazole are used as corrosion-inhibiting components are preferably used. These corrosion inhibitors which, like the other components, may be used individually or in the form of combinations of several components active in the same manner are present in quantities of 0 to 0.02% by weight and preferably in total quantities of 0.001 to 0.2% by weight. As with the other components, these quantities are also based on the specified substance content in the in-use solution.
The process may be carried out using acidic aqueous solutions which, in addition to the components described generally or in detail above, also contain other typical active substances and/or auxiliaries known per se. Such active substances may be, for example, water hardness stabilizers. They may be used with particular advantage when the compounds used for the process have been prepared with water containing relatively large quantities of hardness salts, particularly alkaline earth metal carbonates. Examples of such water hardness stabilizers are phosphonic acids or derivatives thereof such as, for example, hydroxyethane diphosphonic acid (HEDP) or phosphonobutane tricarboxylic acid (PBTC) or water-soluble salts thereof, and also ethylenediaminetetraacetic acid or water-soluble salts thereof, nitrilotriacetic acid and water-soluble salts thereof, or other compounds known for such purposes from the prior art. They are present in quantities from 0 to 0.2% by weight and, preferably--providing their co-use in desired--in quantities of 0.01 to 0.2% by weight and enable even "hard" water to be used in the process according to the invention.
As described above, aqueous solutions such as these are normally brought into contact with the metal workpieces or castings by dipping or spraying in the process according to the invention, the surfaces of the workpieces being abraded, cleaned, and protected against atmospheric corrosion at one and the same time. This treatment is normally carried out at temperatures in the range from 20° to 60° C., but preferably at room temperature. The treatment times depend to a large extent on the degree of soiling, on the size of the burrs and ridges to be removed, on the hardness, size and shape of the media and also on the properties of the aqueous treatment solutions. In preferred embodiments of the process, the treatment times are between 10 and 60 minutes. Normally, the surface treatment is followed solely by drying. This drying step may be carried out at room temperature by the drum process using typical aids, such as, for example, crushed corn, sawdust, etc., or by means of hot air. In special cases, however, the drying step may be preceded by a rinsing step. This depends largely on the nature of the further treatment of the workpieces or castings treated by the process according to the invention.
The present invention also comprises some of the "compounds" used in the process described above. These compounds contain orthophosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof and one or more oligocarboxylic acids and, optionally, one or more surfactants, one or more corrosion inhibitors and other active substances and/or auxiliaries typically present in cleaning and surface protecting compositions and/or mass finishing compounds. The compounds may either be made in powder form and packed as such, simply being stirred into water at the time and place of use, or alternatively may be made in the form of highly concentrated aqueous solutions and merely diluted at the time of use. The advantage of the first alternative is that only the pure substance need be transported, i.e. water does not have to be unnecessarily transported. The second alternative is of advantage because liquid concentrates can be automatically dispensed at the point of use by means of metering pumps, so that they are convenient to handle for the user. The aqueous solutions marketed in the form of concentrates are homogeneous. Aqueous concentrates normally have a pH value in the range from 1 to 6 due to the components present in them. The pH value is preferably in the range from 3.5 to 5. If, however, the pH value should not lie within this range due to the use of relatively strong alkaline components, it may optionally be adjusted through the addition of non-corrosive acids, preferably for example phosphoric acids, phosphonic acids, phosphono- carboxylic acids or carboxylic acids. However, pH adjustment is normally not necessary. The aqueous in-use solutions are normally used with an active substance content in the range from about 0.2 to about 14% by weight.
The compounds according to the invention for the simultaneous mass finishing, cleaning and surface protection of metal workpieces contain alkali metal salts and/or ammonium salts of orthophosphoric acid and/or condensed phosphoric acids as phosphate components. Preferred phosphate components in the compounds according to the invention are acidic sodium phosphates and/or acidic sodium salts of condensed phosphoric acids. Other essential components of the compounds according to the invention are oligocarboxylic acids. From this group, the compounds may contain either a single compound or a mixture of several compounds, i.e. a mixture of several dicarboxylic acids or a mixture of several tricarboxylic acids or even a mixture of one or more dicarboxylic acids and one or more tricarboxylic acids. Dicarboxylic acids and/or tricarboxylic acids substituted by polar groups are preferably used. From the group of such compounds, tartaric acid and citric acid are particularly preferred as carboxylic acid components.
Surfactants are another, optional component of the compounds according to the invention. They may also be present as individual compounds or in combination with one another. The following combinations are preferred as surfactant components in the compounds according to the invention: either one or more nonionic surfactants may be used as the surfactant components or the compounds may contain combinations of one or more nonionic surfactants with one or more anionic surfactants or, alternatively, also combinations of one or more nonionic surfactants with one or more cationic surfactants. In such combinations of several surfactants of different chemical composition, which have a particularly advantageous effect in the compounds according to the invention and develop an excellent cleaning effect, combinations of nonionic surfactants with anionic or cationic surfactants in a quantitative ratio of 1:1 to 1:10 are particularly preferred.
Many different compounds known per se as surfactants from the prior art may be considered as surfactants for the compounds according to the invention. Thus, suitable nonionic surfactants include condensation products of ethylene oxide and/or propylene oxide with fatty alcohols or fatty amines, i.e. alcohols and/or amines containing 6 to 18 carbon atoms in a linear or branched alkyl radical. Other suitable nonionic surfactants are polyalkylene glycol ethers corresponding to the formula R'--O--[(CH 2 ) m --O] n --R", in which
R' is a linear or branched alkyl radical containing from 8 to 18 carbon atoms,
R" is an alkyl radical containing 4 to 8 carbon atoms,
m is an integer of 2 to 4 and
n is an integer of 7 to 12.
Polyalkylene glycol ethers corresponding to the above general formula are well known as low-foaming nonionic surfactants and, in some cases, even as pronounced foam inhibitors, and are therefore particularly suitable.
Where anionic surfactants are used in the compounds according to the invention, they may be, for example, fatty alcohol ether sulfate and/or fatty alcohol ether sulfonates derived from the fatty alcohols defined above. Other suitable anionic surfactants are fatty acids and water-soluble salts thereof and also naphthalene sulfonic acid and water-soluble salts thereof.
Cationic surfactants which are used in combination with nonionic surfactants in the preferred embodiments of the compounds according to the invention are, typically, ammonium compounds containing one or more alkyl radicals, aryl radicals or aralkyl radicals containing more than 6 carbon atoms. Ammonium compounds such as these typically contain at least one linear alkyl radical containing more than 12 carbon atoms and preferably from 14 to 18 carbon atoms. The anions of such ammonium salts are, typically, anions of non-corrosive acids. Examples of such compounds are lauryl dimethyl benzyl ammonium salts, benzyl trimethyl ammonium salts, trialkyl hydroxyalkyl ammonium salts (such as for example butyl dimethyl-2-hydroxydodecyl ammonium benzoate or bis-(benzyl dimethyl-2-hydroxydodecylammonium)succinate or N-benzyldimethyl-2-hydroxydodecylammonium)benzoate, or cyclic quaternary ammonium compounds, such as imidazolinium salts and derivatives thereof substituted in the 1- and 2-position.
In addition, the compounds according to the invention may optionally contain one or more corrosion inhibitors. The corrosion inhibitors are normally adapted to the particular application envisaged and, hence, are determined by the metal surfaces which are to be cleaned, passivated and subjected to mass finishing. Suitable corrosion inhibitors may also be used in combination with one another, with the advantage that the compounds thus formulated according to the invention may be used for a larger number of applications. For most common metals, one or more preferred corrosion inhibitors may be selected, as is known in the art, from the group consisting of alkali metal molybdates, preferably sodium molybdates, benzotriazole, tolyltriazole, and benzthiazole.
The compounds according to the invention may also contain other active substances and/or auxiliaries known per se for cleaning, surface protecting, and mass finishing compounds. One type of additional active substances in question, which are also used in preferred embodiments of the compounds according to the invention, are water hardness stabilizers. The water hardness stabilizers used may be individual compounds or combinations from the group consisting of phosphonic acid derivatives (such as for example hydroxyethyl diphosphonic acid, phosphonobutane tricarboxylic acid, or water-soluble salts thereof), ethylenediaminetetraacetic acid and salts thereof, and nitrilotriacetic acid and water-soluble salts thereof.
As mentioned in detail above, the compounds according to the invention may be made up as powders, i.e. as 100% active substance, or also as concentrates.
In one preferred embodiment of the invention, the compounds according to the invention are present as powders and have the following composition:
(a) orthophosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof in quantities of 50 to 98% by weight,
(b) one or more oligocarboxylic acid(s) in quantities of 1 to 10% by weight,
(c) optionally one or more surfactant(s) in quantities of 0 to 20% by weight and preferably in quantities of 0.1 to 20% by weight,
(d) optionally one or more corrosion inhibitors in quantities of 0 to 0.5% by weight and preferably in quantities of 0.01 to 0.5% by weight,
(e) optionally other active substances and/or auxiliaries known per se for mass finishing, cleaning and surface protecting compounds in quantities of 0 to 20% by weight and preferably in quantities of 1 to 20% by weight.
In another, equally preferred embodiment of the invention, the compounds according to the invention are present in the form of aqueous concentrates, i.e. in addition to the active substances, such concentrates also contain water which balances the total quantity of all the components to 100% by weight. These aqueous concentrates have the following composition:
(a) orthophosphoric acid and/or condensed phosphoric acids and/or water-soluble salts thereof in quantities of 10 to 50% by weight,
(b) one or more oligocarboxylic acid(s) in quantities of 0.5 to 5% by weight,
(c) optionally one or more surfactant(s) in quantities of 0 to 10% by weight and preferably in quantities of 0.2 to 10% by weight,
(d) optionally one or more corrosion inhibitors in quantities of 0 to 0.1% by weight and preferably in quantities of 0.01 to 0.1% by weight,
(e) optionally other active substances and/or auxiliaries known per se for mass finishing, cleaning and surface protecting compounds in quantities of 0 to 1% by weight and preferably in quantities of 0.05 to 1% by weight, and
(f) the balance water.
Concentrates of the type noted are diluted with more water by the user at the point of use, or the powder-form "compounds" are dissolved in water. As already mentioned, the in-use solutions have an active substance content of from about 0.2 to about 14% by weight. Accordingly, water is added to the total quantities of the components mentioned in detail above in such a quantity that the total quantity of all the components adds up to 100% by weight. pH valves in the range from 1 to 6 and preferably in the range from 3.5 to 5 are typically established for the in-use solutions, depending on the individual components used. Should such pH values not be reached solely by the components mentioned in the in-use solutions according to the invention, other acids may optionally be added. However, those acids should not be corrosive and preferably emanate from the group consisting of phosphoric acids, phosphonic acids, phosphonocarboxylic acids, and carboxylic acids.
The invention is illustrated by the following operating Examples, which do not limit the scope of the invention.
GENERAL PROCEDURE FOR THE OPERATING EXAMPLES
Machined or cast objects of iron, brass, aluminum alloy of the composition AlSi 1 7Cu 4 Mg (Silumin), bronze, copper, a magnesium alloy of the composition MgMn 2 , and zinc were taken directly from production and cleaned, surface-protected, and subjected to mass finishing in a single step in a "Labor-Vibrator" machine sold under the brand "finish" by the German firm Sonnberg. The container of this machine was filled about three-quarters full with metal objects and ceramic media, and about 0.1 liter of the process solutions described below in the Examples was added before beginning vibration under the fixed conditions characteristic of the machine, for the time given in the Examples. After the one-step surface treatment, the workpieces were partially rinsed with tap water (which had a hardness equivalent to a content of about 2.7 mmoles/l of combined calcium and magnesium ions), and dried with crushed corn or hot air (100° C.). The surfaces were then visually evaluated.
EXAMPLE 1
An in-use solution of the following composition in weight percent was used:
98% H 2 O;
0.63% Na 2 H 2 P 2 O 7 ;
1.17% NaH 2 PO 4 ;
0.08% citric acid;
0.06% of an adduct of an average of 12 moles of ethylene oxide (EO) per mole of amine with a mixture of primary amines having the same carbon chains as the acyl groups in natural coconut oil; this adduct mixture is arbitrarily designated subsequently herein as "CA-EO";
0.06% of a mixture of molecules having the general formula R'--O--[(CH 2 ) 2 --O] n --R", in which R" is butyl, R' is a C 12 -C 18 linear alcohol, and the average value of n for the mixture is 9.1; this mixture is arbitrarily designated subsequently herein as "FA-EO-BE".
The metal parts were mass finished for 20 minutes at 25° C. while mixed with this solution, which had a pH value of 3.5. The result of this one-step process showed that degreasing and passivation had been very effective and that the metal burrs stemming from production had been completely removed. The steel parts had an iridescent bluish passivation layer. The surfaces of the non-ferrous metals were all bright and smooth and showed no signs of corrosion or tarnishing. Even after storage for several weeks in an atmosphere of medium relative humidity, no sign of corrosion could be detected on the metal surfaces.
It should again be emphasized at this juncture that the process according to the invention is a one-step process in which the surfaces to be treated are both degreased and deoxidized/passivated and also deburred in a single operation.
EXAMPLE 2
Castings were treated with an aqueous solution of the following composition (pH 3.7) in the same way as described in Example 1:
98.096% H 2 O;
1.40% NaH 2 PO 4 ;
0.108% tartaric acid;
0.06% phosphonobutane tricarboxylic acid;
0.20% naphthalene sulfonic acid;
0.012% of CA-EO;
0.12% of FA-EO-BE
0.004% Na 2 MoO 4 .
The castings were brought into contact (sprayed) with the above aqueous solution for 40 minutes at 25° to 30+ C. while simultaneously being mass finished. The degreasing, surface protecting and deburring effects were excellent. The steel parts had an iridescent bluish passivation layer. Castings of brass and copper had a bright surface and were oxide-free. Alloys of aluminum also has a bright surface.
EXAMPLE 3
Following the procedure of Examples 1 and 2, metal castings were brought into contact during mass finishing with aqueous solutions having the following composition:
94.85% H 2 O;
1.57% Na 2 H 2 P 2 O 7 ;
2.93% NaH 2 PO 4 ;
0.10% citric acid;
0.10% tartaric acid;
0.15% of CA-EO;
0.15% of FA-EO-BE and
0.15% lauryl dimethyl benzyl ammonium chloride.
Both here and in the preceding Examples, the quantities by weight are based on the specified substance content of the particular components in the in-use solution.
The castings or metal surfaces were treated with the above solution for 15 minutes at 20° to 30° C. Complete degreasing or cleaning and very good passivation/deoxidation of the metal surface layer were obtained. In addition, mass finishing in the presence of aqueous solutions such as these led to entirely satisfactory deburring.
The metal workpieces or castings were rinsed with water and then dried with hot air. Thereafter, steel parts showed an iridescent bluish passivation layer with good long-term protection against rust. Castings of brass and copper showed bright, oxide-free surfaces. Castings of aluminum and its alloys remained bright.
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By using an aqueous solution containing a phosphoric acids or phosphate salts together with carboxylic acids containing at least two carboxyl groups per molecule along with conventional mass finishing, a wide variety of metal parts may be simultaneously deburred, cleaned, and provided with a surface with good resistance to corrosion in humid air. The solution used preferably also contains non-ionic surfactant, corrosion inhibitor, and, for use in hard water areas, a water hardness stabilizer.
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BACKGROUND AND SUMMARY
The present invention relates to an arrangement and a method for adapting a cruise control system of a vehicle. The invention further relates to a computer program adapted to perform such a method in a cruise control system when said program is run on a computer, and a computer program product comprising such program code means stored on a computer readable medium. The arrangement is suitable gear vehicles of different kinds which are provided with economy driving settings.
Modern vehicles are often provided with a cruise control system in order to improve the comfort of a driver. Some cruise control system are provided with further functions, such as an adaptive control system that uses distance measuring equipment to monitor the distance to a vehicle in front of the own vehicle, in order to be able to adapt the cruise speed to the speed of the vehicle in front. Such a system will improve the safety of the cruise control system since a minimum distance to the vehicle in front will be maintained. Some systems will also brake the vehicle if the minimum distance is not maintained, or if the distance to the vehicle in front decreases at a certain rate. The cruise control system may be adapted to maintain a set speed by using only the accelerator, or by also using the brakes of the vehicle. This is especially common in heavy vehicles which are equipped with auxiliary brakes, such as engine brakes and retarders. A further function of the cruise control system of the vehicle may be an economy dove setting, in which the regulating parameters of cruise control system are ruled by economy.
The cruise control system has a regulating range in which the actual speed value is maintained. For a system using only the accelerator to maintain the speed, an excessive speed of a few percent may be allowed. Typically, the speed ma in this case vary between e.g. 68 to 72 when the speed is set to 70 km/h. It may be possible to set the maximal allowed excessive speed value for the vehicle. In this way, the system can allow the vehicle to travel at an excessive speed at certain occasions, e.g. when travelling on a slight descent.
When the brake system is also used to maintain the speed of the vehicle, referred to as a brake cruise system, a specified excessive speed can also be allowed for a vehicle rolling down a fairly steep downhill slope. An allowed excessive speed may help to preserve energy by using the momentum of the vehicle. The limit for the allowed excessive speed must of course be set to a value that does not endanger other vehicles.
There are however situations in which the traditional regulating method of the cruise control system does not work in a fuel efficient way. Such situations may e.g. be when the vehicle travels in ascents and descents or when a sudden change in pace is required. In an ascent, a cruise control system of the kind mentioned above will try to maintain a speed of 68 km/h regardless of the steepness of the ascent. This may lead to the vehicle travelling up an ascent with full throttle. In the same way, the speed of the vehicle travelling down a descent is maintained at 72 km/h by engaging the brakes.
There is thus a need for an improved cruise control system that is more energy efficient.
It is desirable to provide an improved cruise control arrangement for a vehicle, where the cruise control operation is adapted to an economy setting. It is also desirable to provide an improved method for adapting the operation of a cruise control system of a vehicle.
In a cruise control arrangement for a vehicle, where the cruise control arrangement is provided with a cruise control speed function, a cruise control brake function and at least one selectable economy level, where the arrangement has a set maximum speed value corresponding to a maximum allowed vehicle speed, a set brake speed value corresponding to a brake cruise speed and a set cruise speed value corresponding to a cruise speed, the problem is solved in that a temporary brake speed value replaces the set brake speed value as the actually used brake speed value when an economy level is selected, where the temporary brake speed value is dependent on the selected economy level.
By this first embodiment of the cruise control arrangement, the arrangement replaces the set brake speed value with a temporary brake speed value depending on a selected economy level. The set brake speed value is kept, and the temporary brake speed value is used as the actual brake speed value as long as the selected economy level is selected. If another economy level is selected, a new temporary brake speed value will be used depending on the selected economy level. If the economy function is switched off, the set brake speed value will be used again as the actual brake speed value. In this embodiment, a cruise control function that is more energy efficient is obtained, in that the allowed speed offset from the set cruise speed is adapted in dependence of the selected economy level. By selecting an economy level, a greater difference between the set cruise speed and the used brake speed is obtained, as compared with no economy level. For a system having several economy levels, the selection of a higher economy level will generate an even greater difference between the set cruise speed and the used brake speed. A greater speed difference between the set cruise speed and the used brake speed will allow the vehicle to preserve more momentum when travelling down a hill, which will save fuel. The set brake speed value is kept as the default brake speed value. The set brake speed value is used together with an offset speed value corresponding to the selected economy level to obtain the temporary brake speed value.
In an advantageous development of the inventive arrangement, the temporary brake speed value is not allowed to be greater than the set maximum speed value. If the sum of the set brake speed value and the offset speed value is equal or larger than the set maximum speed value, the temporary brake speed value is set equal to the set maximum speed value. In this way, it is guaranteed that the maximum speed of the vehicle is held within the predefined limits.
In an advantageous development of the inventive arrangement, the set cruise speed value can also be replaced with a temporary cruise speed value. The temporary cruise speed value is dependent on the selected economy level and the temporary brake speed value. Since the temporary brake speed value gives a larger difference between the used brake speed value and the set cruise speed value, it may be necessary to replace the set cruise speed value with a temporary cruise speed value in order to obtain the desired difference between the used brake speed value and the used cruise speed value. This is the case when the temporary brake speed value is set equal to the set maximum speed value. In this case, the temporary cruise control speed is selected such that the speed interval between the temporary cruise control speed and the set maximum speed value is the same as the speed interval between the set cruise control speed and the sum of the set brake speed value and the offset speed value.
In an advantageous development of the inventive arrangement, the temporary cruise speed value is used as the actual cruise speed value until the economy level is changed to a level where the speed interval between the set maximum speed value and the temporary cruise speed value corresponds to the speed interval between the set cruise speed value and the offset speed value added to the set brake speed value. Further, the set cruise speed value is used as the actual cruise speed value when the speed interval between the set maximum speed value and the set cruise speed value is smaller than the speed interval between the set cruise speed value and the offset speed value added to the set brake speed value. In this way, the original settings of the cruise control systems remains untouched and can be used by the driver when the economy level is switched off without having to re-enter the settings again. This will enhance the safety of the system since the driver is not exposed to any surprises when it comes to the cruise control settings.
In a method for changing the reference brake speed value in a cruise control arrangement for a vehicle comprising a cruise control speed function, a cruise control brake function and at least one selectable economy level, having a set maximum speed value, a set brake speed value and a set cruise speed value, the steps of adding an offset speed value corresponding to a selected economy level to the set brake speed value and using the sun of the offset speed value and the set brake speed value as a temporary brake speed value are comprised.
With the inventive method, an optimized behaviour of the cruise control system of a vehicle can be obtained, in which the cruise control system is adapted to the road characteristics. In this way, the fuel consumption can be lowered compared with a cruise control using nominal set parameters to regulate the operation of the vehicle.
BRIEF DESCRIPTION OF DRAWINGS
The invention will be described in greater detail in the following, with reference to the attached drawings, in which
FIG. 1 shows a schematic view of an arrangement for adapting the operation of a cruise control system, and
FIG. 2 shows a schematic flow chart of an inventive method for adapting the cruise control system of a vehicle.
DETAILED DESCRIPTION
The embodiments of the invention with further developments described in the following are to be regarded only as examples and are in no way to limit the scope of the protection provided by the patent claims. The arrangement is suitable for all kinds of vehicles, but is especially suitable for heavy vehicles such as trucks and busses, having brake cruise control functionality using auxiliary brakes.
FIG. 1 shows a schematic arrangement for adapting the cruise control system of a vehicle depending on a selected economy level. The arrangement 1 comprises a cruise control electronic control unit 4 which may be either a standalone control unit comprising the cruise control system or may be integrated e.g. as a software module in another electronic control unit in the vehicle. The cruise control arrangement further comprises a user interface 2 . The user interface comprises buttons used by a driver to input cruise control parameters and to engage and disengage the cruise control system. The user interface may further comprise display means showing part of or all selected cruise control parameters. In the arrangement, a maximum speed value which is the highest allowed speed value with which the vehicle is allowed to travel can be set. The maximum speed value may be set by the driver or may be preset by the manufacturer and may be governed by legislation in some markets.
The driver can also set or select a cruise speed, which is the reference speed that the vehicle will maintain when the cruise control is engaged. The cruise control system is provided with a preset speed interval around the set cruise speed, e.g. +−1 km/h, in which the cruise speed will be held during cruise control regulation. When the vehicle travels on a substantially even road and the cruise speed is set to 70 km/h, the speed may vary between 69 km/h to 71 km/h.
The driver can further set a brake speed value, which is the speed value that the brake cruise control will maintain when the vehicle is travelling down descents. The brake speed value is normally set as a positive speed offset value that is added to the set cruise speed. If the brake speed offset is set to 4 km/h, the resulting brake speed would in this case be 74 km/h. This speed will be maintained by the auxiliary brakes of the vehicle when the vehicle travels down a descent and where the vehicle will coast faster than the cruise speed. By allowing an excessive speed when travelling down a hill, the travel efficiency can be improved. At the same time, the excessive speed should not be allowed to be too high, such that the vehicle will not be able to stop or such that it will exceed speed limits.
The arrangement further comprises an economy level selector 3 , by which the driver can select one or more economy levels. The economy level selector may be integrated in the user interface 2 or may be separate buttons. The number of economy levels may vary, but a few different levels are preferred. In the example given below, three economy levels will be used. The selected economy level may affect different settings on the vehicle, such as engine parameters and gearbox parameters. For the cruise control arrangement, the selected economy level corresponds to a speed interval between the set cruise speed and the set brake speed, referred to as the cruise-brake speed interval. In this example, the preset speed interval is 1 km/h when the economy function is disengaged, i.e. the cruise speed regulating interval is +−1 km/h. For economy level 1, the speed interval is 3 km/h, for economy level 2, the speed interval is 5 km/h and for economy level 3, the speed interval is 7 km/h. Further, the maximum speed value is preset to 90 km/h, the brake cruise speed offset is set to +2 km/h by the driver which gives a brake cruise speed of 87 km/h and the cruise speed is set by the driver to 85 km/h.
With the economy function disengaged, this gives a cruise control having a regulating interval of +−1 km/h around 85 km/h and a set brake cruise speed of 87 km/h. When the driver selects the first economy level, the cruise-brake speed interval corresponding to the first economy level is 3 km/h, which will give a brake cruise speed of 88 km/h. Thus, a temporary brake speed value of 88 km/h will replace the set brake cruise speed. Thus, when the vehicle travels down a hill, a speed of 88 km/h will be maintained.
By selecting economy level 2, a cruise-brake speed interval of 5 km/h will be selected, which gives a temporary brake speed value of 90 km/h. By selecting economy level 3, the corresponding cruise-brake speed interval is 7 km/h, which would result in a temporary brake speed value of 92 km/h. Since the maximum allowed speed value is preset to 90 km/h, to higher temporary brake speed value cannot be allowed. Instead, the temporary brake speed value is set equal to the maximum speed value such that the temporary brake speed value will still be 90 km/h. In order to obtain the desired economy state, i.e. the cruise-brake speed interval of 7 km/h, the set cruise speed is replaced with a temporary cruise speed such that the cruise-brake speed interval corresponds to the selected economy level. In this case, the temporary cruise speed value used as the actual cruise speed will thus be 83 km/h. In this way, the desired cruise-brake speed interval corresponding to the selected economy level is possible to reach.
The temporary cruise speed will be used until the economy level is changed. Should the economy level be changed back to economy level 2, the temporary brake speed will be set to a value corresponding to the selected economy level. In this case, the temporary brake speed will remain at 90 km/h, since the set cruise speed is 85 km/h and the cruise-brake speed interval corresponding to the selected economy level is 5 km/h. The temporary cruise speed can now be changed back to 65 km/h. If the economy level is changed when the vehicle is travelling with the temporary cruise speed of 83 km/h, this temporary cruise speed will remain until the actual speed of the vehicle corresponds to the set cruise speed, i.e. 85 km/h, which will occur when the vehicle travels down a hill. In this way, there will not be a sudden acceleration of the vehicle when the driver selects another economy level.
If the driver disengages the economy function completely, the cruise control will resume with the set parameters, i.e. the set cruise speed and the set brake speed. If a temporary cruise speed is lower than the set cruise speed, the set cruise speed will be used first when the actual speed of the vehicle corresponds to the set cruise speed or when the cruise control arrangement is disengaged. Since the set brake speed is always lower than the temporary brake speed, the set brake speed can always be used directly.
FIG. 2 shows a schematic flow chart of a method for changing the temporary brake speed value in a cruise control arrangement in a vehicle according to the invention. The arrangement comprises a cruise control speed function, a cruise control brake function and at least one selectable economy level, and the arrangement has a set maximum speed value, a set brake speed value and a set cruise speed value.
In step 100 , an economy level is selected by the driver. In step 110 , an offset speed value corresponding to the selected economy level is added to the set brake speed value.
In step 120 , the sum of the offset speed value corresponding to the selected economy level and the set brake speed value is compared to the set maximum speed value. If the sum is equal to or smaller than the set maximum speed value, the temporary brake speed value is set to the sum of the offset speed value and the set brake speed in step 130 .
If the sum of the offset speed value corresponding to the selected economy level and the set brake speed value is larger than the set maximum speed value, the temporary brake speed value is set to the set maximum speed value in step 140 .
In this case, a temporary cruise speed value will be used as the actual cruise speed in step 150 . The temporary cruise speed value will be selected such that the speed interval between the temporary cruise speed and the set maximum speed is equal to the cruise-brake speed interval. The cruise-brake speed interval is the difference between the set cruise speed and the sum of the offset speed value corresponding to the selected economy level and the set brake speed.
The invention is not to be regarded as being limited to the embodiments described above, a number of additional variants and modifications being possible within the scope of the subsequent patent claims.
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A cruise control arrangement for a vehicle includes a cruise control speed function, a cruise control brake function and at least one selectable economy level, having a set maximum speed value corresponding to a maximum allowed vehicle speed, a set brake speed value corresponding to a brake cruise speed and a set cruise speed value corresponding to a cruise speed, where a temporary brake speed value replaces the set brake speed value as the actually used brake speed value, and where the temporary brake speed value is dependent on the selected economy level. The behavior of the cruise control of a vehicle can be adapted to take account of economy, which makes it possible to optimize the fuel consumption of the vehicle.
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BACKGROUND OF THE INVENTION
In recent years, various air-conditioning systems have been devised for utilization of solar energy. Some of these systems utilize a closed absorption refrigeration cycle with solar collectors providing the heat input for the concentrator portion of the absorption refrigeration system (see U.S. Pat. Nos. 2,030,350 and 2,221,971). Such systems require high operating temperatures, e.g., about 200° F. for the solar current collector and are thus hampered by low heat collecting efficiency. Other systems utilize an open absorption system for dehumidification of the conditioned air and employ solar heat collectors for the part of the concentrator which receives heat in an indirect heat exchange relationship (see U.S. Pat. Nos. 2,257,485 and 4,011,731). These systems utilize conventional refrigeration or solar-powered closed-absorption of rankine-cycle refrigeration for removing sensible heat of the conditioned air.
Still other systems utilize an open absorption system for dehumidification of the conditioned air in which heat pumps or total energy systems provide both concentrator heat input and refrigeration for sensible heat removal (see U.S. Pat. Nos. 3,247,679; 3,401,530; and 3,488,971). None of these systems utilize solar energy for concentrator heat input.
The above-mentioned systems in some cases accomplish heat storage for storage of collected solar energy for use during nocturnal periods on cloudy days but these storage systems typically store energy on a sensible heat basis, i.e., merely by elevating the temperature of the liquid in the reservoir which is usually water or an anti-freeze solution. Other systems do not include energy storage of any type, and cooling loads must be handled by auxiliary equipment during nocturnal periods or on cloudy days.
Hence, a principal object of the invention is to provide a method and apparatus for conditioning air on a year-round basis thereby providing heating or cooling of the air as the season requires while using solar energy as the primary energy source.
Another object is to provide a solar-powered air-conditioning system having the ability to store cooling capability in the form of concentrated aqueous hygroscopic solution to thereby provide a much greater cooling-energy storage potential per unit volume and per unit cost of the energy storage reservoir than has heretofore been available, and to reduce the amount of auxiliary energy required for operation during nocturnal or extended cloudy periods and periods in which the ambient temperature is lower than room temperatures.
It is also an object to provide a system for conditioning air by utilizing a solar collector through which an aqueous hygroscopic liquid circulates and is piped into heat exchange relationship with the air to be conditioned in both the cooling and the heating modes of operation with a view to improving efficiency in the utilization of solar energy and reducing system complexity and cost.
SUMMARY OF THE INVENTION
The present invention resides in an open-cycle absorption air-conditioning apparatus and method of which the essential feature is an ability to store energy in a body of hygroscopic liquid not only by absorbing sensible heat but by absorbing large amounts of heat which cause concentration of the solution and elimination of water. This invention further resides in the use of the concentrated hygroscopic liquid to dehumidify the air to be conditioned to make it possible to achieve substantial adiabatic cooling, and thereafter adiabatically cooling the air through evaporation of water resulting from an injection of a dispersion of water into a current of the air. In short, the concentrated hygroscopic solution is used to dry the air and then the air is cooled adiabatically in an air dispersion of water without the aid of refrigeration equipment but with solar energy as the prime energy source.
The air-conditioning system includes one or more solar collectors for directly heating the aqueous hygroscopic solution connected in circuit relation with a reservoir. An essential part of the system is the solution concentrator which is arranged with respect to the circuit to draw off of at least some of the solution passing from the energy collector toward the reservoir, then forming a finely divided dispersion of the drawn off liquid through which a strong current of ambient air is directed, and collecting the concentrated liquid and returning it to the reservoir or other downstream portion of the circuit. In this manner, the energy content of the liquid in the reservoir not only absorbs sensible heat but acquires substantial water absorption ability through loss of water in the concentrator.
To condition the air, an air-processing apparatus assembly is provided for receiving the air to be conditioned, either cooling or heating it, and forcing it into an air-conditioned space. The intake air of the assembly may be withdrawn from the atmosphere but preferably the air-processing assembly has its intake connected with the air-conditioned space as an air source.
In the cooling mode of operation as practiced during summer, the air to be conditioned is first dehumidified by contact with an air dispersion of the hygroscopic solution. Cooling of the dehumidification chamber is preferably accomplished by using a heat exchanger through which is conducted a coolant, such as cooling-tower water, well water or river water. The relatively dry air passing from dehumidification is then cooled in an adiabatic cooling chamber.
In the heating mode of operation, e.g., during winter, the aqueous solution is passed through the solar energy collector and returned directly to the reservoir without passage through the concentrator. The reservoir acts simply as a thermal storage reservoir for nocturnal periods and cloudy days. Heated solution is pumped from the reservoir through a heating coil in the air-processing assembly by which the air to be conditioned is heated to a desired delivery temperature. The solution is returned from the coil to the reservoir.
DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic diagram of air-conditioning apparatus embodying the invention which has capability as an air-heating system and includes a solar collector, a direct-contact aqueous solution concentrator, a storage reservoir for the aqueous solution, and an air-processing assembly comprising an absorber, a heating coil, and a direct-contact adiabatic cooler and humidifier.
FIG. 2 is a psychrometric chart illustrating a procedure for operating the apparatus of FIG. 1 to affect cooling and humidity control of air.
FIG. 3 is a schematic diagram of a modified air-processing assembly showing alternate means for accomplishing dehumidification of air in the absorber while using an aqueous hygroscopic liquid.
FIG. 4 is a partial schematic diagram showing a modified arrangement of the air-processing assembly in combination with a cooling tower and a cooled water storage reservoir as a cooling means for the absorber.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 illustrates one system in accordance with this invention for utilizing solar energy in the conditioning of air for use in an air-conditioned space 5. For convenience of understanding, the apparatus may be divided into zone A: solar energy collection and storage; zone B: hygroscopic solution concentration; zone C: air dehumidification and cooling (summer operation); zone D: air heating (winter operation); and zone E: adiabatic cooling (summer operation).
The apparatus of zone A comprises a solar collector 6, a reservoir 7, a duct or line 8 connecting the outlet of the reservoir with the inlet end of the sinuous liquid-conducting tube 9 of the collector, a duct or line 10 connecting the outlet end of tube 9 with an inlet 11 of the reservoir. The components just named are arranged in a circuit with which a pump 14 included within the duct 8 near the reservoir outlet may continuously circulate liquid. The circuit as shown further includes a bypass line 15 junctioning with lines 8 and 10 adjacent the collector 6, a three-way control valve 16 located at the junction of lines 8 and 15, and a heater 17 located in the line 10 in adjacent downstream relation with the junction of the lines 15 and 10. Items 15, 16, 17 are useful at times when solar radiation is not sufficient to warrant operation of the collector 6. Accordingly, the air-conditioning apparatus may be powered by an input of energy to the system by the heater 17 with the valve 16 positioned to pass liquid through the bypass line 15 rather than the collector. The liquid circulated in zone A is a hygroscopic solution and may be any of the halide solutions commonly used for reducing the humidity of air. Calcium chloride solution is preferred because of its low cost.
Zone B contains the concentrator 20 by which the concentration of the dissolved material in the liquid 21 of zone A is increased to a sufficient level to maintain the operation of the air dehumidication and adiabatic cooling facilities of zones C and E. The concentrator 20 comprises a housing 21 enclosing a shower device 22, a liquid dispersion-to-air contact chamber 23, a sump 24 and an air pump 25 having its air intake in the atmosphere. Air loaded with moisture taken out of the solution discharged by the shower device 22 is discharged through an opening 26 after passing through a de-mister filter 27. Solution is supplied to the shower device in relatively dilute condition by a line 28 extending to the concentrator from a control valve 29 located in the duct 10. During summer operation, the three-way valve 29 is adjusted to settings which reduce the amount of liquid passing downstream from it through line 10 and increase the amount of liquid passing to the concentrator through line 28. Liquid is returned from the concentrator to the circuit by a line 31 shown joining with line 32 connected directly with the reservoir.
Zones C, D and E relate to portions of the air-processing assembly 35. Zone C contains the absorber portion of the assembly 35 in which dehumidification of a stream of air withdrawn through a duct 36 into an inlet port 37 of the assembly. Zone C is shown including an air fan 38 for pushing the air through the entire assembly. The air flows downstream past a shower device 39 acting to create a fine dispersion from recirculated hygroscopic solution supplied thereto from a sump 42 by way of a pump 43 and a line 44. Concentrated solution is supplied to the sump 42 by way of a line 46 and a valve 47 therein connecting with line 8 of the zone A circuit. Solution is returned to the circuit, e.g., to reservoir 7, through an overflow device 48 and the return line 32. Valve 47 is adjusted to achieve a degree of concentration of solution needed in sump 42 and the shower device 39 to control the rate of dehumidification desired.
The portion of the air-processing assembly 35 in zone E is used simultaneously with the dehumidification apparatus of zone C in summer operation. The degree of dehumidification achieved in zone C determines the potential within the airstream passed on to zone E for adiabatic cooling. Zone E portion of assembly 35 houses a shower device 51 and a sump 52 connected with the shower device by a recirculating pump 53, and a line 54. A fine water dispersion issuing from the device 51 traverses the current of air traversing the adiabatic cooling chamber 55 from a heating chamber 56 of the assembly. The air passes through the outlet port 57 of the assembly and duct 58 for entry into the air-conditioned space 5. Zones C and E are regulated by varying the degree of dehumidification and adiabatic cooling with desired humidification to achieve the temperature and humidity desired in the air discharged to the air-conditioned space.
Zone D is used primarily when zones C and E are inoperative as during the winter time. It may be noted that the current of air to be conditioned flows from zone C portion of the assembly 35 into zone D, i.e., the heating chamber, which contains a heat exchanging coil 64 located downstream from a de-misting filter 65. The coil 64 is connected with a relatively hot portion of the circuit of zone A by a line 66 beginning in a three-way control valve 67 contained in the circuit line 10. Line 66 can thus receive the hotter liquid of the circuit of zone A by being downstream in the circuit from the heater 17 or the discharge end 68 of the collector coil 9. Liquid from the cooler end of the coil 64 is returned through line 69 and line 32 to the reservoir 7.
FIG. 2 shows by way of a psychrometric chart a typical performance of a system according to FIG. 1. Return air from the air-conditioned space 5, point M on the chart, enters the zone C absorber section at 80° F. dry-bulb temperature, 68° F. wet-bulb temperature, and 84 grains per pound absolute humidity. Air leaves zone C, point N on the chart, absorber at 83° F. dry-bulb temperature, 62° F. wet-bulb temperature and 50 grains per pound absolute humidity. The heat lost by the air being cooled from 68° F. to 62° F. wet-bulb temperature is absorbed by the coolant inside a coil 75 of the absorber. The coolant temperature required to obtain this performance is typically 70°-75° F. at the coil coolant inlet manifold. The coolant is supplied from any source represented by reservoir 76. After dehumidification and wet-bulb depression, the air enters the adiabatic humidifier of zone E wherein it is evaporatively cooled to 64° F. dry-bulb temperature, 62° F. wet-bulb temperature, and 80 grains per pound absolute humidity, point P on the chart. This evaporatively-cooled air is supplied to space 5.
FIG. 3 describes an air-processing unit 80 which is modified with respect to the air-processing unit 35 of FIG. 1. In unit 80, the cooling coil 75 of FIG. 1 has been replaced by a contact surface 86 comprising foraminous fibrous or particulate matter and a heat exchanger 87. The hygroscopic liquid from the assembly sump 42a is passed through heat exchanger 87 by pump 43a and cooled therein by the coolant source. The cooled solution is then distributed over the contact surface 86 wherein it dehumidifies and reduces the wet-bulb temperature of the air by direct contact. Essentially, the same system performance can be obtained by using the heat exchanger and contact surface shown in FIG. 3 as by using the cooling coil 75 shown in FIG. 1. In large systems, use of the heat exchanger and contact surface is advantageous in reducing equipment size and cost. Various components of FIG. 3 identified by numerals containing "a" are similar in function to the same respective numerals of FIG. 1 not including "a".
FIG. 4 illustrates one means of supplying cooling water to the heat exchanger 87 of FIG. 3 or the cooling coil 75 of FIG. 1. This cooling system operates in the following way:
Pump 88 operates whenever cooling is called for and/or whenever the temperature sensor 89 indicates that the cooling tower 91 can supply water colder than that in the cooled water storage tank 90. If cooling is called for, valve 92 diverts the flow of cooling water to the heat exchanger 87 of FIG. 3 or the cooling coil 75 of FIG. 1. (1) If cooling is called for, valve 92 diverts the flow of cooling water to the heat exchanger 87 of FIG. 3 or the cooling coils 74 of FIG. 1. (2) If cooling is called for but temperature sensor 89 indicates that the water in the storage tank 90 is colder than can be generated by the cooling tower 91, valve 93 diverts the cooling water past the cooling tower 91 and returns it to storage tank 90. (3) If cooling is called for and the temperature sensor 89 indicates that the water returning from the cooling tower 91 is colder than that available in the storage tank 90, the valve 94 diverts the flow directly to the inlet of pump 88 so as to supply the coldest water possible to the air-processing assembly 35. (4) If cooling is not called for but the temperature sensor 89 indicates that the cooling tower 91 can supply water colder than that in the storage tank 90, valve 92 bypasses the cooling water past the heat exchanger 83 and valve 93 admits the cooling water to the cooling tower. Cooled water passes from the cooling tower 91 and the valve 94 returns the cooled water to the storage tank 90.
The storage tank 90 contains a volume of cooling water sufficient to act as a heat sink for air-processing assembly 35 during periods of the day when the wet-bulb temperature of the outside air is elevated. Conversely, the cooling tower 91 operates during nocturnal periods when the outside air wet-bulb temperature is depressed, to cool all of the water in the storage tank 90.
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An apparatus and a method for air-conditioning by which solar heat is collected and utilized in winter heating and in summer cooling and humidity adjustment. A hygroscopic liquid circulates through a solar heat collector and a reservoir thereof to accumulate sufficient heat to furnish energy for (1) dehumidification, adiabatic cooling of air, and concentrating of the hygroscopic liquid in summertime operation, or alternatively, heating of air in winter time.
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This is a continuation of co-pending application Ser. No. 947,885 filed on Dec. 30, 1986, now U.S. Pat. No. 4,721,437.
BACKGROUND OF THE INVENTION
The present invention relates to an annunciator apparatus which is to an animated telephone apparatus wherein a movable object moves in synchronism with the conversation of one party to a telephone conversation.
Typically, telephone annunciator apparatus record a telephone communication (i.e., the speech of a calling party) on one channel of a recording tape, together with control signals on another channel of the tape recording tape. Subequently, the tape recording tape is played back and a movable object is moved in response to the control signals and the voice signals recorded on the tape recording tape. The structure of such an apparatus is, however, complicated and it is impossible to move the movable object in synchronism with the speech of the calling party. As a result, the movable object does not realistically stimulate conversation between the calling party and a user of the apparatus.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a telephone apparatus wherein a telephone conversation appears to be taking place with a movable object which moves in synchronism with the speech of a calling party.
It is a further object of the present invention to provide a simple and inexpensive telephone apparatus wherein a user appears to converse with a movable object which moves in synchronism with the speech of a calling party.
To achieve the above and other objects, the present invention includes a telephonic means for transmitting and receiving telephone signals; an announcing means for receiving at least a first one of said telephone signals and for generating a voice control signal varying in accordance with the at least one of the telephone signals; and an animation means, having movable elements, for receiving the voice control signal, and for moving the movable element in synchronism with the voiced control signal.
In a preferred embodiment of the present invention, the telephonic means comprises a circuit for receiving telephone signals (e.g., on hook, off hook and speech signals) and placing the apparatus in an active state so as to enable a calling party to converse with a user of the apparatus, and a circuit for transmitting dial signals to enable a user of the apparatus to place a call to another person; the announcing means includes a circuit for enabling a user of the apparatus to place the apparatus in an active state so as to receive and convert speech signals of a calling party into sound. In a preferred embodiment of the present invention the animation means includes an amplifier for generating a motion signal which varies in synchronism with the speech of a calling party, a motor rotating in response to the motion signal, a gear train mechanism which rotates in response to movement of the motor, and linkage elements movably connected to the gear train mechanism so as to selectively move the movable elements in a first direction and in a second direction in accordance with an in synchronism with the speech of the calling party.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a system embodying the present invention;
FIG. 2 illustrates the details of a gear train mechanism employed in the present invention;
FIG. 3 is a block diagram of an embodiment of the present invention;
FIG. 4 is a schematic diagram of a portion of the embodiment illustrated in FIG. 3; and
FIG. 5 is a schematic diagram of the remaining portion of the FIG. 3 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the preferred embodiment of the present invention, like reference numerals identify elements having the same or similar function.
In the subject application, the terms calling party and user of the apparatus of the present invention are used to denote two possible parties to a conversation, regardless of which party initiated the coversation. That is, regardless of whether or not the user of the apparatus initiated the telephone conversation, the person at the other end of the coversation is referred to as the calling party.
FIG. 1 is a schematic diagram of a system embodying the present invention. In FIG. 1 reference numeral 1 identifies a telephone unit or telephonic means which transmits and receives telephone signals, for example on hook, off hook, speech signals and dial (pulse or tone) signals. Reference numeral 2 identifies an operating circuit which operates in response to one of the telephone signals received by the telephone unit. Reference numeral 3 identifies an announcing circuit or means which converts a speech signal received by the telephone unit 1 into sound so that a user of the apparatus can hear the speech of a calling party. Reference numeral 4 identifies a movable object which has movable elements such as eyes 6 and mouth 7. The movable elements move in synchronism with the speech of the calling party, and thus move in synchronism with the sound generated by the announcing circuit.
In operation, telephone signals are applied to a telephone line 5 which is connected to the telephone unit 1. Of the telephone signals, the telephone unit 1 converts speech signals, which correspond to the speech of a calling party, into a voice control signal which is then applied to the operating circuit 2 and to the announcing circuit 3. The operating circuit 2 actuates the movable object 4 in response to the voice control signal, and the announcing circuit produces sound responsive to the voice control signal.
FIG. 1 illustrates the movable object 4 as a teddy bear, but the movable object 4 can be any type of doll, stuffed toy or robot mechanism. The teddy bear or movable object 4 shown in FIG. 1 houses a motor and gear train mechanism such as illustrated in FIG. 2 so that the eyes 6 and mouth 7 move in synchronism with the speech of the calling party. Thus, to the user of the apparatus of the present invention, a conversation appears to be taking place with the teddy bear or movable object 4.
Referring to FIG. 2, each eye 6 comprises an eyeball 6a, and an eyelid 6b which is slidably mounted on the fixed eyeball 6a. Obviously, either one or both of these elements could be moved. The mouth 7 has an upper jaw 7a and a lower jaw 7b. The movable elements, or eyes 6 and mouth 7 in the illustrated embodiment, are moved by a motion sensor 8. The motion section 8 comprises a motor 9; a gear train mechanism 10 and linkage elements 18. The gear train mechanism 10 comprises a first gear 11 fixed to a rotation shaft of the motor 9; a second gear 12 having a larger diameter than the first gear 11 and positioned so as to engage the first gear 11; a third gear 13 rotatable with the second gear 12 and having a smaller diameter than the second gear 12; a fourth gear 14 having a larger diameter than the third gear 13 and positioned so as to engage the third gear 13; a fifth gear 15 having a smaller diameter than the fourth gear and rotatable with the fourth gear; and a sixth gear 16 having sector shape positioned so as to engage the fifth gear 15. The sixth gear 16 pivots about a pivot point 17.
The linkage elements 18 engage the tip portion of the sixth gear 16 as shown in FIG. 2. The linkage elements 18 comprise an oscillating lever 19 pivotably supported by a pivot 20a; a first link 21 connected to the oscillating lever 19; and a second link 22 connecting the first link 21 and the eyelid 6b. The oscillating lever 19 has formed therein elongated openings 23a and 23b. These openings respectively engage pins on the sixth gear 16 and the first link 21. The oscillating lever 19 has formed thereon a pivot which engages a slot 23c of the mouth 7. As the oscillating lever 19 pivots about a pivot point 20a, the upper jaw 7a pivots about a pivot point 20b and the eyelid 6b pivots about pivot point 20c. A limit switch 38 stops motion of the sixth gear 16 at the end of this gear's travel so as to preferably keep the sixth gear 16 engaged with the fifth gear 15.
Referring to FIG. 3, a telephonic unit or means 1 includes a voice processing circuit 23, a keyboard 24, a dial pulse generating circuit 25, a calling circuit 26, a buzzer 27, a rectifier 28 and a hook switch 29. In FIG. 3 and announcing section or means 3 includes the voice processing circuit 23, a microphone 30, amplifier 32 and a speaker 33 which generates sound in response to the output of the amplifier 32. In FIG. 3 the operating circuit 2 includes a gain amplifier 34 driven by the output of the amplifier 32, a motor driving circuit 35 and a motor 9.
FIG. 4 is a schematic diagram of a portion of the embodiment of the operating circuit 3. As illustrated in In FIG. 4 the gain amplifier 34 can include an inverting amplifier 34a, transistor 34b, and the associated circuit components connected as shown in FIG. 4. FIG. 4 also illustrates a waveform shaping circuit 36 including operational amplifiers 36a and 36b, comparator 37, a limit switch 38 (as shown in FIG. 2). A terminal 46 shown in FIG. 4 corresponds to the terminal 46 shown in FIG. 3.
Referring to FIG. 5, reference numeral 44 identifies a telephone line connecting terminal for connection to the telephone line 5 shown in FIG. 1, and numeral 45 denotes a connecting terminal for connection to another telephone line. The hook switch 29 shown in FIG. 5 includes hook switches 29a and 29b; and a rectifier 28 includes a first rectifier 28a and a second rectifier 28b. Reference numeral 25A denotes a dial pulse generating circuit, numeral 39 denotes a transmission signal amplifier for amplifying the signal to be transmitted, and the numeral 40 identifies a network circuit. Reference numeral 41 denotes a transmitting-receiving switching comparator which switches operation of the annunciator apparatus between transmitting and receiving. Reference numeral 42 identifies a receiving signal amplifier which amplifies a telephone signal received at terminal 44, and reference numeral 43 identifies a pulse/tone selection switch, which permits either dial pulses or tones to be applied to the line 5.
The operation of the annunciator apparatus having the above structure is described below. When telephone signals are applied on line 5 to the telephonic unit or means 1, the input signal current is rectified by rectifier 28 (FIG. 5) and then is input to the calling circuit 26 which causes the buzzer 27 to operate. When a user of the apparatus hears the buzzer 27, the user can, for example, speak a predetermined term into the microphone 30. This predetermined speech enables the voice processing circuit 23 to place the apparatus in an active state. By placing the telephone unit in an active state, the hook switch 29 operates hook switches 29a and 29b to connect the telephone line 5 to the calling circuit 26 through the second rectifier 28b. FIG. 5 shows the hook switch 29 positioned to connect the telephone line to the voice processing circuit 23 via the rectifier 28b. With this connection, a signal corresponding to the speech of a calling party received on telephone line 5 can be supplied to the voice processing circuit 23 via signal amplifier circuit 42. The voice processing circuit outputs a voice control signal to the amplifier 32, which then provides a voice control signal to the point 46 shown in FIGS. 3-5. The voice control signal drives the speaker 33 so that the user of the apparatus can hear the speech of the calling party. The voice control signal has drives the operating circuit 2.
Referring to FIGS. 3 and 5, when the user of the apparatus speaks into the microphone 30, the microphone generates a sound signal which is applied to the voice processing circuit 23. This causes the voice processing circuit 23 to transmit the sound signal to the telephone line 5 through the transmission signal amplifier 39. Therefore, when a sound signal is being applied to the voice processing circuit 23 via the microphone 30, this sound signal is not applied to either the speaker 33 or the operating section 2.
In the accouncing circuit 3 shown in FIG. 3, the speaker 33 converts the voice control signal to sound so that the user of the apparatus can hear the calling party. As shown in FIGS. 1 and 3, the voice control signal is also applied to the operating circuit or means 2. Within the operating means 2, the amplifier 34 amplifies and shapes the voice control signal and applies the shaped signal to a motor driving circuit 35, which provides a motion control signal to control the motor 9. The motor 9 provides a rotative motion force for moving the motion mechanism 8 shown in FIG. 2. In the embodiment of the apparatus of the present invention shown in FIGS. 3-5, voice processing circuit 23 can comprise, for example, part number BA6571A manufactured by Rohm Co., dial pulse generating circuit 25 can comprise, for example, part number BU8302A manufactured by Rohm Co., calling circuit 26 can comprise, for example, part number BA656A manufactured by Rohm Co., amplifier 32 can comprise, for example, part number BA546 manufactured by Rohm Co., and the motor driving circuit 35 can comprise, for example, part number LB1630 manufactured by Sanyo Co.
Whenever a voice control signal is supplied by the amplifier 32 to the gain amplifier 34, the motor drive circuit 35 causes the motor 9 to rotate. Referring to FIG. 2, rotation of the motor 9 causes the first gear 11 to rotate, causing the gear train mechanism 10 to rotate. The rotational direction of the motor 29 changes between forward and reverse in accordance with the presence or absence of the voice control signal 46. For example, when the calling party speaks, the voice control signal causes the sixth gear 16 to rotate in the direction of the arrow A1 shown in FIG. 2. This rotation is transmitted to the eyelid 6b through the links 21 and 22 causing the eyelid 6b to close. This motion also causes the upper jaw 7a and the lower 7b of the mouth 7 to open. When the calling party is not speaking, the sixth gear 16 rotates in the direction of an arrow A2 so as to open the eyelid 6a and to close the mouth 7. The above motions continue until the limit switch 38 is operated, causing the motor 9 to stop rotating. Because the voice control signal varys in synchronism with the speech of the calling party, the motions of the motion section 8 shown in FIG. 2 are performed in synchronism with the voice of the calling party. The movable object 4 or teddy bear shown in FIG. 2, therefore, appears to speak the words of the calling party as they are heard by the user of the apparatus from the speaker 33.
Those skilled in the art will recognize many variations of the apparatus of the present invention. The embodiment described above merely illustrates the apparatus of the present invention and is not intended to limit the scope of the present invention to the disclosed apparatus. Instead, the scope of the present invention is defined by the following claims.
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An animated telephone annunicator apparatus provides realistic movements so that a user of the apparatus appears to converse with the apparatus. The apparatus receives telephone signals, and in response to these received signals moves portions of the apparatus in synchronism with the signals. As a result, the apparatus appears to realistically speak the words of a calling party.
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The invention relates to an electrical automatic pattern stitching sewing machine, in which the stitch forming instrumentalties are electrically operated to change the position between the needle and the sewn cloth to form stitches in a pattern. Therefore this invention provides a sewing machine of simple structure producing a stabilized stitch formation.
According to the sewing machine of this invention, the needle mechanism and the feed mechanism are electrically and automatically controlled by stitch control signals memorized in a semi-conductor memory, and the mechanism for controlling and driving the needle bar and the feed mechanism are simplified in structure and operation. As a drive source of such mechanism, at least two reversible electric motors are provided, which are driven by pulse signals to cause the stitch forming instrumentalities to form stitches.
Thus in this invention, a lot of patterns are provided in a limited space of the sewing machine, and the control mechanism of the stitch forming instrumentalities are smoothly and effectively operated, and accurate and stabilized stitches are obtained. Moreover, the operation of the sewing machine is simplified.
Heretofore there have been provided many controlling methods in which a pulse or stepper motor is driven by a signal to control the operations of the stitch forming instrumentalities to determine the stitch co-ordinates. However, in such methods, since the pulse motor directly controls the stitch forming instrumentalities comparatively large output motor is required and accordingly the motor is large sized in volume. Therefore it is difficult to install such a motor in a limited space of the sewing machine, and accordingly a considerable inertia grows in the associated mechanism, and it becomes difficult to determine the exact coordinates. Further, since the stitch control signals to the pulse motor were provided by the dynamic memories such as a mechanical memory, a magnetic tape, a perforated tape, etc., the whole control apparatus of the sewing machine becomes bulky and therefore the weight of the sewing machine becomes heavy.
The present invention has been devised to remove those shortcomings of the prior art.
It is a basic object of the invention to combine a swinging movement of a swinging member in a timed relation to the upper shaft of the sewing machine to the rotation of a pulse motor controlled by electric signals so that complicated patterns or turned over patterns may be easily obtained.
It is another object of the invention to employ a semiconductor memory, and accordingly a small sized pulse motor to reduce the inertia in the associated control mechanisms, so that the exact and stabilized stitch co-ordinates of patterns may be secured.
It is a further object of the invention to reduce abrasions, noises or vibrations of the associated control mechanisms by making small sized the drive source of such mechanisms.
Other features and advantages of the invention and the actual operations thereof will be apparent by the following explanations of the preferable embodiments with reference to the accompanying drawings, in which,
FIG. 1 is a sewing machine according to the present invention,
FIG. 2 is a plan view showing a part of this invention,
FIG. 3 is a vertical cross section taken along the line A--A of FIG. 2,
FIG. 4 is a front elevational view of another part of this invention,
FIG. 5 is a side elevational view taken along the line B--B of FIG. 4,
FIGS. 6-9 show stitches provided by this invention by way of example,
FIG. 10 is a combination of the basic constituents of the stitch control circuits of this invention, and
FIGS. 11A and 11B are block diagrams of the control circuits according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be explained with reference to the accompanying drawings. Regarding a needle bar control mechanism(80) in FIG. 1, reference numeral(1) is the housing of a sewing machine, (2) is an upper shaft, (3)-(39) represent a zigzag amplitude controlling apparatus of a needle bar mechanism. (41)-(62) represent a feed control apparatus which will be explained in FIGS. 4 and 5, in which the output from a fork rod(42) is given to a feed dog(71) in FIG. 1 via a feed adjusting rod(70). A luminous diode(64) and a phototransistor(65) are fixedly mounted on a part of the machine housing in oppositely spaced positions so that a light from the luminous diode is intercepted by a disk(63) which is fixedly mounted on the upper shaft(2) and has a notch of about 180° with respect to a position of a needle bar(40) having a needle at the lower part thereof whereby logical values are predetermined as 0 or 1 in synchronism with each rotation of the upper shaft(2) of the sewing machine to give an output of rectangular waves which are equal time sequence. Another combination of a luminous diode(66) and a photo-transistor(67) so arranged that light from the luminous diode(66) is intercepted by a part, e.g. a swingable part(7) during the movement of about 180° thereof which moves one cycle in two rotations of the upper shaft(2), whereby logical values are 0 or 1 in 1/2 cycle of the case of the combination of the luminous diode(64) and the photo-transistor, to give an output of rectangular wave being equal in the time sequence. (68)(68')(68") are electronic control circuit apparatuses which respectively accomodate the main parts of the control circuits shown in FIGS. 10 and 11. Numeral(69) shows a plurality of pattern selecting switches operated by the machine operator.
Regarding a needle bar jogging control apparatus in FIGS. 2 and 3, a worm(3) fixed to the upper shaft(2) is meshed with a worm wheel(4) which is rotatably mounted on a cam shaft(5) secured to the machine housing(1), and is made integral with a needle bar swinging cam(6) of plastic material, so that this worm(3) drives the needle bar swinging cam(6) at the speed reduced in a half of the rotation speed of the upper shaft(2). A swinging member(7) is swingably mounted on a base plate(30) by means of a shaft(8) and a spacer(9) at the center of the swinging member(7). A groove(7') on the underside of the swinging member(7) at one end part thereof is engaged by the cam(6) which swings the member(7) around the shaft(8). A block element(10) is slidably engaged in an arcuate groove(7") formed in the upper surface of the member(7). The block element(10) and another element(11) are turnably engaged around a pin(12) which is fixedly mounted at the free end(14') of a link(14). A swing amplitude adjusting arm(13) is turnably mounted at its center around a stepped screw(23) which is theaded into the base plate(30) and fastened by a nut(24) with an intermediate bushing(22). The swing amplitude adjusting arm(13) is at its one end formed with a fork(13') to slidably engage the element (11), and is at the other end formed with a segmentary rack(13") to engage a pinion(25) secured to a shaft(26) of a pulse motor(27) which is fixed to the base plate(30) on the underside thereof screws(29). A swing arm(15) shown in FIGS. 1 and 2 is at one end(15') turnably mounted on a pivot(19) on the base plate (30). As shown in FIGS. 1 and 3, a central pivot shaft(19) and a fastening screw(18) connects the other end(15") of the swing arm(13), the other end of the aforementioned link(14) and one end of another link(16), the other end of which is connected by a stepped screw(21) to one end of the swing rod(20), the other end of which is connected to a needle bar swing frame as shown.
In the above mentioned mechanism, control signals from the electronic control circuit apparatuses(68)(68')(68") shown in FIG. 1 are applied to the pulse or stepper motor(27) through the leads(28) from the pulse generating device consisting of the swing member(7), luminous diode(66) and the photo-transistor(67) to determine the needle position co-ordinates when the needle bar(40) is positioned at the vicinity of the upper dead point thereof. The pulse motor(27) is driven by a control signal to turn the swing amplitude adjusting arm(13), and selects a position of the block(10) within the arcuate groove(7") of the swing member(7). On the other hand, the swing member(7) is swingingly moved by the cam(6) to give swinging movements to the needle bar when the needle is above the needle plate. As a result, the swing rod(20) is swung in an amplitude in proportion to the distance of the block element(10) from the swinging center(8) of the swing member(7), and the needle position coordinate of the needle bar mechanism(40) is determined.
FIGS. 6-9 show that various patterns are formed by the relation between the swinging movement of the swing member(7) and the position of the block element(10), where numerals 1, 2, 3, . . . designate the ordered positions of the block element(10), and the corresponding positions of the needle, and (L), (M) and (R) designate the three reference positions of left, center and right of the stitch co-ordinates. FIG. 6 shows that a zigzag pattern is obtained with the movement of the swing member(7) with the condition that a position of the block element(10) is fixed. FIG. 7 shows a pattern obtained by shifting the position of the block element(10) towards the swinging center(8) of the swing member(7) in two complete rotations of the upper shaft(2) (in one complete swinging movement of the swing member(7)). FIGS. 8 and 9 show that more complicated patterns can be obtained in this invention. In FIG. 8, the pulse motor(27) is reversely rotated to locate the block element(10) at a position(1') as a start point of sewing, and thus the swinging movements of the swing member(7) cause the needle to form a pattern which is turned over around the reference needle position(M) to the reference needle position(R). The formation of the pattern in FIG. 9 will be described in relation with the following explanation of the feeding mechanism.
Regarding a feed control mechanism(81) shown in FIGS. 4 and 5, a feeding cam(2) is secured to the upper shaft(41), a fork rod(42) is at the upper forked end(42') engages the feeding cam(41) and is at the lower end(42") connected the rocking rod(70) as shown in FIG. 1. On one side of the fork rod(42), a block element(44) is turnably mounted by means of a pivot(45). A feed adjusting member(43) is turnably mounted on a shaft(48) which is secured in a bushing(46) which is formed with a collar(47) and is fitted into the housing(1). The feed adjusting member(43) is formed with a groove(43') as shown and the block element(44) on the fork rod(42) is slidably fitted into the groove(43'). The segmented member(49) is connected to the feed adjusting member(43) by means of screws(50, 51). The segmented member is formed with a rack at the segmented edge thereof. The rack of the member(49) is meshed with a pinion(52) on a motor shaft(53) of a pulse motor(54) which is secured to a plate(56) by means of screws(57)(58)(59). The plate(56) is secured to the machine housing(1) by means of screws(60,61). The rotation of the feeding cam(41) gives oscillations to the fork rod(42), and the oscillating movement of the fork rod(42), is regulated by the block element(44) which slides in the groove(43') of the feed adjusting member(43) in accordance with the angular position of the groove(43'). The angular position of the groove(43') is changed when a signal from the electronic control circuit apparatuses(68)(68')(68") is applied to the pulse or stepper motor(54) through the leads(55) to drive the same for determining a feed position co-ordinate. Thus, the oscillation of the fork rod(42) is transmitted to the rocking shaft(70) which is operatively connected to the feed dog. Namely by changing and adjusting the inclination of the groove(43'), the feeding amplitude is varied in the forward and rearward directions. With the combination of the needle bar control apparatus and the feed control apparatus, the pattern as shown in FIG. 9 can be obtained.
Regarding a block diagram of the electronic control circuit of the sewing machine of this invention in FIG. 10, a static memory(100) memorizes stitch control signals for effectively operating the pulse motors(27)(54) and address changing signals for changing the addresses of the static memory per rotation of the upper shaft(2) of the sewing machine through a timing buffer. The static memory receives a signal from a manually operated pattern selecting apparatus as a first address, and gives to a needle bar control circuit and a feed control circuit a stitch control signal, which is paired with the first address and designates an initial stitch co-ordinate. The static memory simultaneously gives to a timing buffer an address changing signal for selecting a second stitch coordinate. The timing buffer, upon receiving a signal from a position detector for the swing member(7) including the photo-transistor(67), which is synchronized with the rotation of the upper shaft(2) of the sewing machine, writes the address changing signal from the static memory(100) and gives this signal to the static memory, and holds this signal until it (timing buffer) receives the next synchronized signal. Thus the first address changing signal from the static memory becomes a second address to the static memory. Then the static memory gives to the needle bar control circuit and the feed control circuit a signal which is paired with the address and designates a second stitching co-ordinate. Simultaneously the static memory gives to the timing buffer an address changing signal for selecting a third stitching co-ordinate. Subsequently a new stitching co-ordinate is designated per rotation of the upper shaft(2) of the sewing machine, and a control signal corresponding the stitching co-ordinate is issued from the needle bar control circuit and from the feed control circuit to a needle bar drive circuit(106) and to a feed drive circuit(106') respectively. Thus the static memory issues the stitch control signals in succession. When a final address is issued from the static memory to give the needle bar control circuit and the feed control circuit a signal designating a final stitch co-ordinate, an address changing signal is simultaneously issued from the static memory to the timing buffer to repeatedly select the first stitching co-ordinate, so that a selected pattern is repeatedly sewn.
A clock pulse generating device is set by a signal from the pattern selecting device, and gives the timing buffer a pulse signal which is synchronized with a signal from a swing member position sensor so as to enable the timing buffer to change the address of the static memory in each rotation of the upper shaft(2) of the sewing machine as mentioned. The clock pulse generating device also gives the needle bar control circuit and the feed control circuit a control signal for returning the pulse motors(27,54) to the reset positions in the stitching operation after the pattern has been selected. The needle bar control circuit and the feed control circuit respectively receive pulses in succession from a pulse generator and respectively give a Needle bar drive circuit(106) and a feed drive circuit(106') a signal corresponding a first stitching signal from the static memory. The subsequent stitching signals are issued in such a manner that, as aforementioned, the static memory receives the synchronized signals from the swing member position sensor and is addressed in succession and that simultaneously the needle bar control circuit and the feed control circuit receive the synchronized signals and make the signals from the static memory effective to the needle bar drive circuit and the feed drive circuit respectively. Simultaneously the pulse generator receives the signals from a needle position sensor including the aforementioned luminous diode(64) and the photo-transistor(65) and gives the needle bar control circuit successful pulses for the purpose of driving the pulse motor(27) in one half region of rotation angle 180° of the upper shaft(2) when the needle of the needle bar is located above the needle plate. Simultaneously the pulse generator gives the feed control circuit successive pulses for the purpose of driving the pulse motor(54) in the other half region of rotation angle 180° of the upper shaft(2) so that the stitch control signals to the feed control circuit from the static memory may be effective in a delayed relation (about rotation angle 180° of the upper shaft) to the stitch control signals to the needle bar control circuit.
The needle bar drive circuit(106) receives data from the needle bar control circuit and gives the pulse motor(27) an electric current to drive the same. The feed drive circuit(106') receives data from the feed control circuit and gives the pulse motor(54) an electric current to drive the same. Thus the pulse motors(27,54) control the operations of the needle bar control mechanism(80) and the feed control mechanism(81) respectively.
A pattern turn-over device is provided with a switch which is, when manually pushed, operated to drive the pulse motors(27,54) in the reverse direction, so that the pattern may be made in a form turned over around the center reference needle position(M).
FIGS. 11-A and 11-B show a more detail representation of the block diagram in FIG. 10, in which the pattern selecting device consists substantially of pattern selecting switches(69), a diode matrix(DM) and a latch circuit(L 1 ). When any one of the switches(SW 1 -SW 7 ) is closed, it gives the output terminals (A 1 ,A 2 ,A 3 ) encoded binary numbers and selects one of the seven codes including 000 and excluding 111. The output terminals (A 1 ,A 2 ,A 3 ) are connected to the input terminals of NAND circuit(NAND 1) and are also connected to the input terminals(a 0 )(a 1 )(a 2 ) of a latch circuit(L 1 ). The output terminal of NAND circuit(NAND 1) is connected to the input terminal(IN) of a monostable multivibrator(MM 1). The true side output terminal(Q) is connected to the trigger terminal(C p ) of a latch circuit(L 1 ) and is also connected to the input terminal(IN) of a delay circuit(TD) and to one of the input terminals of AND circuit(AND 1 ). The complement side output terminal(Q) is connected to one of the input terminals of NAND circuit(NAND 2). The true side output terminal(Q) of the delay circuit(TD) is connected to one of the inputs of AND-OR circuit(AND-OR 1 ), which is paired with the other one receiving output(B 0 ) of the latch circuit(L 1 ), and is also connected to the other input terminal of NAND circuit(NAND 2). The complement side input terminal(Q) of the circuit(TD) is connected to another one of inputs of AND-OR circuit(AND-OR 1 ), which is paired with the other one receiving an output(E 5 ) of a latch circuit(L 2 ), and is also connected to the other input terminal of AND circuit(AND 1 ). The output of AND circuit(AND 1 ) is connected to a reset terminal(R) of the latch circuit(L 2 ). The photo-transistor(67) is at its emitter connected to the ground and is at its collector connected to the input terminals(IN) of the monostable multivibrators(MM2)(MM3), and the base thereof receives light from the luminous diode(66) and gives a signal to each of the terminals(IN) in synchronism with the swinging movement of the swing member(7). (Vcc) is a D.C. power source for the control circuit, and (R 3 ) and (R 4 )(R 1 ) and (R 2 ) also are the ordinary control resistors.
The main element of the clock pulse generating device consists of the monostable multivibrators(MM2)(MM3) and D type flip-flop circuit(F/F1). The monostable multivibrator(MM2), at the rise of a signal at the input thereof, and the monostable multivibrator(MM3), at the fall of a signal at the input thereof, respectively give a positive pulse from the output(Q).
The pulse signals are transmitted to the trigger terminal(C p ) of the flip-flop circuit(F/F1) via OR circuit(OR1). The set terminal(S) of this circuit(F/F1) is connected to the true side output terminal(Q) of the monostable multivibrator(MM1). When a signal is given to said terminal(S), it is set, and then when the pulse signal is given to the trigger terminal(C p ), the true side output terminal(Q) is made, at the fall of said signal, a state of the data input terminal(D) which is connected to the ground. The true side output terminal(Q) is connected to one of the input terminals of AND circuit(AND2), and the output terminal of OR circuit(OR1) is connected to the other input terminal of the AND circuit(AND2), and the output terminal of this AND circuit is connected to the input terminal(IN) of the monostable multivibrator(MM4). The monostable multivibrator(MM4) is for changing the pulse width. The true side output terminal(Q) of the monostable multivibrator(MM4) is connected to the reset terminals(R) respectively of D type flip-flop circuits(F/F2)(F/F2') and of the presettable counters(C)(C') and to the set terminals(S) respectively of flip-flop circuit(F/F4)(F/F4'). The complement output terminal(Q) of the flip-flop circuit(F/F1) is connected to one of the input terminals of NAND circuit(NAND), and the output terminal of OR circuit(OR1) is connected to the other input terminal of the NAND circuit. The output terminal of the NAND circuit(NAND3) is connected to one of the input terminals of NAND circuit(NAND4), and the output terminal of NAND circuit(NAND2) is connected to the other input terminal of the NAND circuit(NAND4). The output terminal of NAND circuit(NAND4) is connected to the trigger terminal C p of the latch circuit(L2). The latch circuit(L2) corresponds to the timing buffer circuit shown in FIG. 10, (D 0 )-(D 5 ) composing the address charging signals among the output terminals of the static memory(100) are respectively connected to the input terminals(d0)-(d5) of the latch circuit(L2). When a clock pulse is given to the trigger terminal(C p ) of the latch circuit(L2) the inputs(d0)-(d5) are respectively latched to the terminals(E0)-(E5) at the rise of the clock pulse. These outputs(E0)-(E5) are respectively connected to the address designating terminals(e0)-(e4) of the static memory(100) and the terminal(e5) thereof through AND-OR circuit(AND-OR1). (B1) and (B2) among the output terminals of the latch circuit(L1) are respectively connected to the address designating terminals(e6)(e7) of the static memory(100). These (e0)-(e7) constitute address designating signals of the static memory(100). As shown, the static memory(100) memorizes three sets of signals for one set of address designating signals(e0)-(e7). The terminals(F0)-(F5) constitute the needle bar control signals and the terminals(G0)-(G5) constitute the feed control signals, of which 5 bits(F0)-(F4) are directed to determine the rotations of the pulse motor(27), and are connected to the terminals(f0)-(f4) of the counter(C) respectively. (F5) is a bit for determing the rotating directions of the pulse motor(27), and is connected to the data input terminal(D) of the flip-flop circuit(F/F2). 5 bits(G0)-(G4) of the feed control signals (G0)-(G5) are for determining the rotations of the pulse motor(54) and are respectively connected to the terminals(g0)-(g4) of the counter(C'). (G5) is a bit for determining the rotating directions of the pulse motor(54), and is connected to the data input terminal(D) of the flip-flop circuit(F/F2').
The pulse generator in FIG. 10 is composed substantially of a astable multivibrator(AM), and D type flip-flop circuit(F/F5) in FIG. 11. The astable multivibrator(AM) issues pulse signals in a very short cycle relative to the rotation cycle of the sewing machine. The output terminal of the astable multivibrator(AM) is connected to the trigger terminal(C p ) of the flip-flop circuit(F/F5) and to the input terminals of AND circuits(AND6)(AND7). The photo-transistor(65) is at its emitter connected to the ground and is at its collector connected to the data input terminal(D) of said flip-flop circuit(F/F5), and the base thereof receives the light from the luminous diode(64) in synchronism with the rotation of the upper shaft of the sewing machine, and gives a signal to the terminal(D). The true side output terminal(Q) and the complement side output terminal(Q) of the flip-flop circuit(F/F5) are respectively connected to the other input terminals AND circuits(AND6)(AND7). The output terminal of (AND6) is connected to the trigger terminal(C p ) of D type flip-flop circuit(F/F3) and to one input terminal of AND circuit(AND3). Similarly, the output terminal of (AND7) is connected to the trigger terminal(C p ) of D type flip-flop circuit(F/F3') and to one of the input terminals of AND circuit(AND3').
The needle bar control circuit in FIG. 10 is composed substantially of the flip-flop circuits(F/F2),(F/F3),(F/F4) and counter(C). The feed control circuit is composed substantially of the flip-flop circuits(F/F2'),(F/F3'),(F/F4') and counter(C'). The true side output terminal(Q) of the flip-flop circuit(F/F2) is connected to an input terminal of AND-OR circuit(AND-OR2), which is paired with a terminal connected to the collector of the photo-transistor(67), and the complement output terminal(Q) of the flip-flop circuit(F/F2) is connected to an input terminal of the AND-OR circuit(AND-OR2), which is paired with a terminal connected to the collector of the photo-transistor(67) through an inverter(IN1). The output terminal of the AND-OR circuit is connected to one(NC) of the terminals of a switch(SW8) which is a main element of the pattern turnover apparatus shown in FIG. 10, and is also connected to the other terminal(NO) via an inverter(IN2). A movable element(C) of the switch(SW8) is connected to one input terminal of AND circuit(AND4) and is also connected to one input terminal of AND circuit(AND5) via an inverter(IN3). The true side output terminal of the flip-flop circuit(F/F2') is connected to one of the input terminals of AND circuit(AND4'), and the complement side output terminal(Q) is connected to one of the input terminals of AND circuit(AND5').
In the following description of this invention, the feed control and the needle bar control are substantially the same in structure, and reference will be made only to the needle bar control. The counter(C) is composed of 5 bits(C4)-(C0) with a code 00001 when it is reset, and issue the codes in a predetermined order. The first code to be counted up is determined by the signals at the 5 bits(f4)-(f0) of the input terminals. Each code is counted up at each fall of a signal at the count up terminal(UP), and the count of the codes is terminated when the signals at the output terminals(C4)-(C0) become 11111. The timing at the start of count depends on the rise of a signal at the load terminal(L). The output terminals(C4)-(C0) of the counter(C) are connected to the input terminals of NAND circuit(NAND5). The output terminal of NAND circuit(NAND5) is connected to the data input terminal(D) and to the reset terminal(R) of the flip-flop circuit(F/F3), and to the trigger terminal(C p ) of the flip-flop circuit(F/F4). The true side output terminal(Q) of the flip-flop circuit(F/F3) is connected to the other input terminal of the AND circuit(AND3). The output terminal of the AND circuit(AND3) is connected to the count-up terminal(UP) of the counter(C) and to the other input terminals of AND circuits(AND4)(AND5) respectively. The flip-flop circuit(F/F4) has a data input terminal(D) connected to the ground and has a complement side output terminal(Q) connected to a monostable multivibrator(MM5) and the complement side output terminal(Q) of the monostable multivibrator is connected to one input terminal of NAND circuit(NAND6). The other input terminal of the NAND circuit(NAND6) is connected to the output terminal of NAND circuit(NAND3), and the output terminal of the NAND circuit(NAND6) is connected to the load terminal(L) of the counter(C) and to the trigger terminal(C p ) of the flip-flop circuit(F/F2). The needle bar drive circuit(106) is at its input terminal(F.P) connected to the AND circuit(AND4) to drive the pulse motor(27) in the normal direction. The needle bar drive circuit is at its input terminal(B.P) connected to the output terminal of the AND circuit(AND5) to drive the pulse motor in the inverse direction. The needle bar drive circuit is at its setting terminal(S) connected to the true side output terminal(Q) of the flip-flop circuit(F/F4). The pulse motor(27) is of three phases, and is set at the initiation of the stitching operation. When the terminals(S) and (F.P) of the needle bar drive circuit(106) receive rising signals respectively, the pulse motor(27) is energized at the phase on the side of normal rotation relative to the phase which had been energized at the time of setting. Similarly when the terminals(S) and (B.P) of the needle bar drive circuit receive rising signals respectively, the pulse motor is energized at the phase on the side of the reverse rotation relative to the phase which had been energized at the time of setting. Thus the pulse motor is driven depending upon the counts of the counter(C).
The operation of the control circuit shown in FIG. 11 will be explained. When any one of the pattern selecting switches(Sw1)-(SW7) is closed, the output of the NAND circuit(NAND1) becomes 1, because one of the signals at the encoded outputs(A 1 )(A 2 )(A 3 ) of the diode matrix(DM) becomes 0. Therefore, the monostable multivibrator(MM1) is triggered, and then the signal at the true side(Q) triggers the latch circuit(L 1 ) to latch the signals at the outputs(A 1 )(A 2 )(A 3 ) of the diode matrix(DM) and give these signals to one terminal of the AND-OR circuit(AND-OR1) and to the address designating terminals(e 6 )(e 7 ) of the static memory(100). Since the delay circuit(TD) the AND circuit(AND1) continues to give the output 1 until the delay circuit(TD) gives the output to reset the latch-circuit(L 2 ). Therefore, the outputs(E 0 )-(E 5 ) of the latch circuit(L 2 ) are all rendered 0, and the address designating terminals(e 0 )-(e 4 ) of the static memory(100) are rendered 0 directly, and the terminal(e5) is rendered 0 through the AND-OR circuit(AND-OR). In the meantime, the signals at the output terminals(D 0 )-(D 5 ) responding the signals at the terminals(e 0 )-(e 7 ) are idly changed as will be described.
As the second step, when the delay circuit(TD) gives an output after a certain period of time, the signal at the reset terminal(R) of the latch circuit(L2) becomes null, but as the NAND circuits(NAND2)(NAND3) are rendered 1, the latch circuit(L2) is in a reset condition. On the other hand, the address designating terminal(e5) of the static memory(100) receives a signal from the output(A0) of the diode matrix(DM) via the AND-OR circuit(AND-OR), and gives the signals of the address changing terminals(D0)-(D5), as new input signals, to the address designating terminals(e0)-(e5) of the static memory (100) in the following step.
Namely as the third step, when the operation of the monostable multivibrator(MM1) is completed after a certain period of time, a clock pulse is given to the latch circuit(L2) via NAND circuits(NAND2)(NAND4), and then the latch circuit(L2) latches the signals at the address changing terminals(D0)-(D5) of the second step, and the signals at the terminals(D0)-(D4) are given to the address designating terminals(e0)-(e4) of the static memory(100). However, the next signals of the address changing outputs(D0)-(D5) corresponding to the signals of the address changing terminals(e0)-(e7) are given to the latch circuit(L2), but are not latched until a new clock pulse is given.
As the fourth step, when the operation of the delay circuit(TD) is completed after a certain period of time, the address designating terminal(e5) of the static memory(100) receives a signal of the output(D5) of the static momory(100) via the latch circuit(L2) and AND-OR circuit(AND-OR1) and the signals of the outputs(D0)-(D5) responding to the signals of the address designating terminals(e0)-(e7) are issued. In other words, the signals of the outputs(D0)-(D5) of the second step determine the signals of the outputs(D0)-(D5),(F0)-(F5),(G0)-(G5) of the fourth step.
In the fourth step, the signals of the terminals(F0)-(F5)(G0)-(G5) give the first stitching signals to the subsequent control circuits and at this time the address changing signals at the terminals(D0)-(D5) designate the second addresses. The base of the phototransistor(67) becomes conductive when it receives light from the luminous diode(66) per rotation of the upper shaft of the sewing machine and causes NAND circuit(NAND3) to give a negative pulse, thereby to give a positive pulse to the latch circuit(L2) via NAND circuit(NAND4). Therefore, the signals of said address changing outputs(D0)-(D5) are successively latched to the latch circuit(L2) per rotation of the sewing machine to change and designate the stitches in succession, and the signals of the outputs(F0)-(F5),(G0)-(G5) in the second step designating the addresses in the fourth step become the last stitch control signals. Thus a pattern is repeatedly stiched.
The flip-flop circuit(F/F1) is set by the operator operating the pattern selecting apparatus(69) to render the true side output terminal(Q) 1, and when the sewing machine is rotated in succession, the AND circuit(AND2) issues a positive pulse only once at the rise or fall of the signal of the phototransistor. That is, in the following rotations of the sewing machine, the true side out-put terminal(Q) becomes 0. A pulse from the AND circuit(AND2) causes the flip-flop circuits(F/F2)(F/F2') and the counters(C)(C') to be reset and causes the flip-flop circuits(F/F4)(F/F4') to be set. In this case, if the output of the photo-transistor(67) is 1, and the movable elements(C) of the (SW8) is connected to the terminal(NC), a value 1 is given to one terminal of the AND circuit(AND5).
When the needle of the sewing machine is located above the needle plate at the start of the rotation of the sewing machine, the output of the photo-transistor(65) is 1. During this period of time, pulses are supplied relatively in a short cycle to the trigger terminal(C p ) of the flip-flop circuit(F/F3) from the astable multivibrator(AM) via AND circuit(AND6). Since the output signals at the terminals(C 4 )-(C0) of the counter(C) are rendered 00001 (C0 only is turned to 1 and the others are 0) as it was reset, the data input terminal(D) of the flip-flop circuit(F/F3) receives a value 1, and subsequently the true side output terminal(Q) is rendered 1 at the fall of the signal at the trigger terminal(C p ), and the pulse of the astable multivibrator(AM) is given to the other input terminal of the AND circuit(AND5) through the AND circuit(AND3). The pulse motor(27) is rotated in the reverse direction by the needle bar drive circuit(106) in a speed in accordance to the pulse. Namely the counter(C) counts up at the fall of a signal at the count-up terminal(UP) each time when the AND circuit(AND5) receives the signal from the astable multivibrator(AM). When the output terminals(C 4 )-(C0) become 11111, the value at the NAND circuit(NAND5) becomes 0 to reset the flip-flop circuit(F/F3). In the meantime, the pulse motor(27) is driven in accordance to the count up (30 in this case) of the counter(C) to set the needle bar(40) to a mechanical value, for example, to the reference needle position(L) at the start of stitching operation.
When the value at the NAND circuit(NAND5) becomes 0, the complement side output terminal(Q) of the flip-flop circuit(F/F4) is rendered 1. Therefore the load terminal(L) of the counter(C) receives a signal from the flip-flop circuit(F/F4) through the monostable multivibrator(MM5) and the NAND circuit(NAND6), and then receives the values at the output terminals(F4)-(F0) of the static memory(100). At the same time, the subsequent falling signal is transmitted to the trigger terminal(C p ) of the flip-flop circuit(F/F2), so that a signal from the output terminal(F5) of the static memory(100) may be latched to the flip-flop circuit(F/F2).
Assuming that the codes of (F5)-(F0) of the static memory are determined 111101 by the operation of pattern selecting apparatus(69), the output terminal(C 4 )-(C0) of the counter(C) become 11100, the value at the NAND circuit(NAND5) becomes 1, and output terminal(Q) of the flip-flop circuit(F/F3) is rendered 1 again by the successive pulses from the astable multivibrator(AM). When a pulse is issued from the AND circuit(AND3), the counter(C) counts up with the falling signal at the count-up terminal(UP) and renders the next codes 11111 at the output terminals(C4)-(C0) to reset the flip-flop circuit(F/F3). On the other hand, since the output terminal(Q) of the flip-flop circuit(F/F2) is 1 and the value of the photo-transistor(67) is also 1, the pulse motor(27) is driven by the pulse in the normal direction.
Therefore, the pulse motor(27) moves the needle of the sewing machine to a certain predetermined position (e.g. on the reference needle position L) before the needle penetrates the sewn work on the needle plate, and the first stitch coordinate is determined relative to the reference needle position(L) by a signal of the pattern selecting device(69). This is the same with regard to the feed control. But in this case, the successive pulses from the astable multivibrator(AM) are issued through the AND circuit(AND7) in a phase different 180° of the upper shaft(2) from the case of the needle bar control.
With respect to the stitches following the first one, the falling signals each issued from the NAND circuit(NAND3) per rotation of the upper shaft(2) of the sewing machine enable the latch circuit(L2) to latch the address signals from the static memory(100), and the static memory to issue new stitching codes while the falling signals enable the counter(C) to receive the stitching codes from the static memory.
In order to turn over the patterns such as shown in FIGS. 8 and 9 around the center reference needle position(M) the movable element(C) of the switch(SW8) is shifted to the terminal(NO) from the terminal(NC) so as to transmit the signals of the AND-OR circuit(AND-OR2), which are reversed at the inverter(IN2), to the AND circuits(AND4)(AND5). Therefore, the resetting time point of the pulse motor(27) is determined by the reversed signal from the photo-transistor(67) which is in association with the swing member(7). As the result, the pulse motor(27) is reset to a position in the direction opposite to the position in which it was located before the movable element(C) was switched over, and then it is driven. Thus the patterns, which are sewn with the reference needle position(L) before the movable element(C) is switched over, will be sewn with the reference needle position(R) after the movable element(C) has been switched over.
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The needle-shifting zig-zag unit and the work feeding unit are moved to different positions, when necessary, for successive stitches, to form a stitching pattern. Each unit is powered by the main rotating drive shaft of the sewing machine. However, each unit is provided with a respective stepper motor. Each stepper motor changes the setting of an adjuster in a reciprocating-motion generator driven by the main drive shaft. When one of these adjusters is in a constant setting, its respective reciprocating-motion generator continually generates reciprocating motion of constant corresponding amplitude, for an unlimited time, so long as the drive shaft rotates. The needle-penetration coordinates for the stitching pattern are established by continually changing the amplitude of the reciprocations performed by the two reciprocating-motion generators. A static memory is read out, in synchronism with sewing, to furnish information commanding the stepper motors to move the amplitude adjusters of the reciprocating-motion generators from one amplitude setting to another, very quickly, to in this way establish all the successive needle-penetration coordinates for even complex stitching patterns.
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BACKGROUND/SUMMARY
[0001] Vacuum has long been used in vehicles to operate actuators and other devices. Vacuum has been and continues to be an attractive power source because it may be less expensive and more readily available as compared to other power sources. For example, vacuum may be available from the intake manifold of an internal engine or from a vacuum pump powered by the engine or an electrical power source such as a battery. However, as manufacturers strive to increase engine efficiency, vacuum from the engine intake manifold may be less available from the engine intake manifold since engines are being operated more often at higher intake manifold pressures so as to improve engine operating efficiency. By operating an engine at a higher intake manifold pressure, it may be possible for a small engine to produce the same amount of power as a larger engine. For example, air entering a four cylinder engine can be pressurized so that the four cylinder engine has output power similar to a six cylinder engine. In this way, the smaller engine may be more efficient than the larger engine since it may have less friction and fewer pumping losses than the larger engine. However, when an engine is operated at higher intake manifold pressures, less vacuum may be available to power vacuum operated actuators and devices.
[0002] Of course, vacuum may be also supplied to vacuum operated devices via a vacuum pump. However, vacuum pumps that have a capacity to source sufficient vacuum to operate a vehicle's brake system are often large and heavy. Further, some vacuum pumps require lubricating oil while some vacuum pumps expel oil mist when operated. Thus, vacuum pumps can have limitations that may be undesirable.
[0003] The inventors herein have recognized the above-mentioned disadvantages and have developed a system for providing vacuum for a vehicle, comprising: an ejector; an ejector pump configured to pump only air drawn through a low pressure region of the ejector; and an air conduit, the air conduit housing the ejector and at least a portion of the ejector pump, the air conduit having a sole air inlet and a sole air outlet.
[0004] By placing an ejector or a venturi within an air conduit that has a sole air inlet and a sole air outlet, it may be possible to generate vacuum for actuators and devices even during conditions of high intake manifold pressure. In particular, an ejector pump and/or a venturi pump can be configured to pump air without pump lubricating oil, excepting bearing lubrication which can be placed external to the air conduit so that oil may not enter the air conduit. Further still, since air can be directed from the pump outlet to the pump inlet, the pump may operate at a higher efficiency.
[0005] In addition, by placing the ejector or venturi output at a low pressure, such as along an intake air system, conditions are favorable for producing vacuum. Further, placing the blower that is in communication with an ejector or venturi in a low pressure environment is favorable for reducing blower energy consumption. Ejectors and venturi are devices that are inherently volume flow devices, not mass flow devices, thus lowering the density of the air does not lower the vacuum making potential.
[0006] The present description may provide several advantages. In particular, the approach can selectively provide vacuum based on vacuum consumption. Further, the approach may draw less air into the engine air intake system which bypasses the main air intake filter. Further still, approach may be realized with a light weight ejector or venturi pump. In addition, by using a blower instead of a vacuum pump the expense of sealing the pumping chambers of a vacuum pump are avoided. No conventional air seal is required in the blower configuration.
[0007] The above advantages and other advantages, and features of the present description will be readily apparent from the following Detailed Description when taken alone or in connection with the accompanying drawings.
[0008] It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 shows a schematic depiction of an engine;
[0010] FIGS. 2 show a schematic depiction of an air conduit;
[0011] FIGS. 3-4 show simulated signals of interest during engine operation;
[0012] FIG. 5 shows a high level flowchart of a method for providing vacuum to a vacuum system of a vehicle.
DETAILED DESCRIPTION
[0013] The present description is related to providing vacuum to assists in actuator operation. FIG. 1 shows one example embodiment for providing vacuum to a vehicle vacuum system. FIG. 2 provides one example of an air conduit and ejector for providing vacuum. FIGS. 3 and 4 show simulated signals of interest when providing vacuum with an engine having a selectively operable ejector or venturi vacuum generating system. FIG. 5 shows a method for providing the vacuum and control as illustrated in FIGS. 3-4 .
[0014] Referring to FIG. 1 , internal combustion engine 10 , comprising a plurality of cylinders, one cylinder of which is shown in FIG. 1 , is controlled by electronic engine controller 12 . Engine 10 includes combustion chamber 30 and cylinder walls 32 with piston 36 positioned therein and connected to crankshaft 40 . Combustion chamber 30 is shown communicating with intake manifold 44 and exhaust manifold 48 via respective intake valve 52 and exhaust valve 54 . Each intake and exhaust valve may be operated by an intake cam 51 and an exhaust cam 53 . Alternatively, one or more of the intake and exhaust valves may be operated by an electromechanically controlled valve coil and armature assembly. The position of intake cam 51 may be determined by intake cam sensor 55 . The position of exhaust cam 53 may be determined by exhaust cam sensor 57 .
[0015] Fuel injector 66 is shown positioned to inject fuel directly into cylinder 30 , which is known to those skilled in the art as direct injection. Alternatively, fuel may be injected to an intake port, which is known to those skilled in the art as port injection. Fuel injector 66 delivers liquid fuel in proportion to the pulse width of signal FPW from controller 12 . Fuel is delivered to fuel injector 66 by a fuel system (not shown) including a fuel tank, fuel pump, and fuel rail (not shown). Fuel injector 66 is supplied operating current from driver 68 which responds to controller 12 . In addition, intake manifold 44 is shown communicating with optional electronic throttle 62 which adjusts a position of throttle plate 64 to control air flow from intake boost chamber 46 .
[0016] Compressor 162 draws air from air intake 42 to supply boost chamber 46 . Exhaust gases spin turbine 164 which is coupled to compressor 162 via shaft 161 . Compressor bypass valve 158 may be electrically operated via a signal from controller 12 . Compressor bypass valve 158 allows pressurized air to be circulated back to the compressor inlet to limit boost pressure. Similarly, vacuum operated waste gate actuator 72 allows exhaust gases to bypass turbine 164 so that boost pressure can be controlled under varying operating conditions. Vacuum is supplied to waste gate actuator 72 via vacuum system reservoir 138 . In some examples, vacuum system reservoir 138 may be referred to as a vacuum system reservoir since it can supply vacuum throughout the vacuum system and since brake booster 140 may contain a vacuum reservoir too. Vacuum system reservoir 138 may be supplied vacuum from intake manifold 44 via check valve 63 . Check valve 63 allows air to flow from vacuum system reservoir 138 to intake manifold 44 and substantially prevents air flow from intake manifold 44 to vacuum system reservoir 138 . Vacuum system reservoir 138 may also be supplied vacuum via air conduit 24 . A low pressure region is created via connection through check valve 20 connecting to atmospheric pressure or check valve 21 connecting to intake manifold pressure. Air conduit 24 includes an ejector or a venturi. Ejector check valve 60 allows air to flow from vacuum system reservoir 138 to air conduit 24 and substantially prevents air flow from air conduit 24 to vacuum system reservoir 138 . Ejector or venturi pump 22 is selectively operable and may be comprised of an electrically driven motor. Ejector or venturi pump 22 compresses air within an air conduit 24 supplying air to a converging ejector or venturi nozzle within air conduit 24 . A low pressure region is created in air conduit 24 allowing air to flow from vacuum system reservoir 138 into air conduit 24 . Air exits air conduit 24 and enters the engine air intake system at a location upstream of compressor 162 via check valve 20 . Alternatively, air exits air conduit 24 and enters the engine air intake system at a location downstream of throttle 62 . Check valves 20 and 21 allow air to flow from air conduit 24 to the engine air intake system and substantially prevent air flow from the engine intake system to air conduit 24 . Vacuum system reservoir 138 provides vacuum to brake booster 140 via check valve 65 . Check valve 65 allows air to enter vacuum system reservoir 138 from brake booster 140 and substantially prevents air from entering brake booster 140 from vacuum system reservoir 138 . Vacuum system reservoir 138 may also provide vacuum to other vacuum consumers such as turbocharger waste gate actuators, heating and ventilation actuators, driveline actuators (e.g., four wheel drive actuators), fuel vapor purging systems, engine crankcase ventilation, and fuel system leak testing systems. Check valve 61 limits air flow from vacuum system reservoir 138 to secondary vacuum consumers (e.g., vacuum consumers other than the vehicle braking system). Brake booster 140 may include an internal vacuum reservoir, and it may amplify force provided by foot 152 via brake pedal 150 to master cylinder 148 for applying vehicle brakes (not shown).
[0017] Check valve 63 provides that the reservoir 138 pressure does not exceed the intake manifold pressure. In other words, check valve 63 provides fast pull down of reservoir pressure when a low intake manifold pressure is available. Check valve 60 allows flow when the pressure produced via the ejector within air conduit 24 is lower than the pressure within reservoir 138 .
[0018] Distributorless ignition system 88 provides an ignition spark to combustion chamber 30 via spark plug 92 in response to controller 12 . Universal Exhaust Gas Oxygen (UEGO) sensor 126 is shown coupled to exhaust manifold 48 upstream of catalytic converter 70 . Alternatively, a two-state exhaust gas oxygen sensor may be substituted for UEGO sensor 126 .
[0019] Converter 70 can include multiple catalyst bricks, in one example. In another example, multiple emission control devices, each with multiple bricks, can be used. Converter 70 can be a three-way type catalyst in one example.
[0020] Controller 12 is shown in FIG. 1 as a conventional microcomputer including: microprocessor unit 102 , input/output ports 104 , read-only memory 106 , random access memory 108 , keep alive memory 110 , and a conventional data bus. Controller 12 is shown receiving various signals from sensors coupled to engine 10 , in addition to those signals previously discussed, including: engine coolant temperature (ECT) from temperature sensor 112 coupled to cooling sleeve 114 ; a position sensor 134 coupled to an accelerator pedal 130 for sensing accelerator position adjusted by foot 132 ; a position sensor 154 coupled to brake pedal 150 for sensing brake pedal position; a knock sensor for determining ignition of end gases (not shown); a measurement of engine manifold pressure (MAP) from pressure sensor 121 coupled to intake manifold 44 ; a measurement of boost pressure from pressure sensor 122 coupled to boost chamber 46 ; an engine position sensor from a Hall effect sensor 118 sensing crankshaft 40 position; a measurement of air mass entering the engine from sensor 120 (e.g., a hot wire air flow meter); and a measurement of throttle position from sensor 58 . Barometric pressure may also be sensed (sensor not shown) for processing by controller 12 . In a preferred aspect of the present description, engine position sensor 118 produces a predetermined number of equally spaced pulses every revolution of the crankshaft from which engine speed (RPM) can be determined.
[0021] In some embodiments, the engine may be coupled to an electric motor/battery system in a hybrid vehicle. The hybrid vehicle may have a parallel configuration, series configuration, or variation or combinations thereof. Further, in some embodiments, other engine configurations may be employed, for example a diesel engine.
[0022] During operation, each cylinder within engine 10 typically undergoes a four stroke cycle: the cycle includes the intake stroke, compression stroke, expansion stroke, and exhaust stroke. During the intake stroke, generally, the exhaust valve 54 closes and intake valve 52 opens. Air is introduced into combustion chamber 30 via intake manifold 44 , and piston 36 moves to the bottom of the cylinder so as to increase the volume within combustion chamber 30 . The position at which piston 36 is near the bottom of the cylinder and at the end of its stroke (e.g. when combustion chamber 30 is at its largest volume) is typically referred to by those of skill in the art as bottom dead center (BDC). During the compression stroke, intake valve 52 and exhaust valve 54 are closed. Piston 36 moves toward the cylinder head so as to compress the air within combustion chamber 30 . The point at which piston 36 is at the end of its stroke and closest to the cylinder head (e.g. when combustion chamber 30 is at its smallest volume) is typically referred to by those of skill in the art as top dead center (TDC). In a process hereinafter referred to as injection, fuel is introduced into the combustion chamber. In a process hereinafter referred to as ignition, the injected fuel is ignited by known ignition means such as spark plug 92 , resulting in combustion. During the expansion stroke, the expanding gases push piston 36 back to BDC. Crankshaft 40 converts piston movement into a rotational torque of the rotary shaft. Finally, during the exhaust stroke, the exhaust valve 54 opens to release the combusted air-fuel mixture to exhaust manifold 48 and the piston returns to TDC. Note that the above is described merely as an example, and that intake and exhaust valve opening and/or closing timings may vary, such as to provide positive or negative valve overlap, late intake valve closing, or various other examples.
[0023] Referring now to FIG. 2 , a schematic depiction of an air conduit is shown. In the illustrated example, air may enter air conduit assembly 200 via a sole air inlet 204 . In some examples, a check valve may be placed between air conduit assembly 200 and vacuum system reservoir 138 to substantially prevent air from flowing from air conduit assembly 200 to vacuum system reservoir 138 . In the example of FIG. 2 , an ejector is mechanically coupled to air conduit assembly 200 . Thus, in some examples, the ejector may be included as part of air conduit assembly 200 . The ejector is comprised of suction inlet or sole conduit air inlet 204 , converging nozzle 206 , and diffuser outlet 210 . Alternatively, the ejector may be replaced by a venturi that operates in a similar manner as the ejector. Air is supplied to the converging nozzle 206 via conduits 220 . Air is directed from diffuser outlet 210 by ejector or venturi pump 208 . Ejector or venturi pump 208 is shown being driven via motor 22 . Motor 22 may be electrically, mechanically, or hydraulically driven. In one example, motor 22 has a shaft that enters air conduit assembly 200 via a seal that limits leakage of air from conduit 200 to atmosphere. Of course, if motor 22 is within air conduit assembly 200 , no dynamic seal is necessary. Air may exit air conduit assembly 200 via sole air outlet 212 . Check valve 20 allows air to flow from air conduit to engine 10 when a relief pressure of check valve 20 is overcome via pressure from ejector or venturi pump 208 . In other examples, a plurality of check valves may be positioned at the sole outlet of air conduit assembly 200 so that air may be directed to one or more locations. For example, one check valve may direct air to a location along the air intake of the engine while another check valve directs air to a location in the engine crankcase.
[0024] Thus, ejector or venturi pump circulates air through air conduit assembly 200 by drawing air from the diffuser outlet 210 and directing the air back to the ejector inlet at converging nozzle 206 . The pressurized air accelerates through the nozzle and decreases in pressure. Further, the accelerated air exits the converging nozzle and creates a low pressure region 214 allowing air to flow into air conduit assembly 200 via suction inlet 204 . By circulating air around air conduit 220 , the efficiency of ejector or venturi pump 208 can be increased via recovered energy. As air enters air conduit assembly 200 via suction inlet 204 , the outlet pressure of ejector or venturi pump can increase causing check valve 20 to open and allowing a substantially same amount of air to exit air conduit assembly 200 as is drawn into air conduit assembly 200 via suction inlet 204 . In this way, vacuum is generated via air conduit assembly 200 and does not include inducting additional air beyond air displaced to create vacuum. Further, when sole air outlet 212 is coupled to the engine at a low pressure region (e.g., at the inlet of a turbocharger compressor), the efficiency of ejector or venturi pump 208 can be further increased. This is due to two reasons. First, ejectors produce better vacuum as the discharge pressure is lowered. Second, fans/compressors/blowers consume less energy as the air density decreases. As long as the same volumetric flow is maintained, the vacuum produced is unchanged at this lower density.
[0025] Thus, the systems of FIGS. 1 and 2 , provide for a system for providing vacuum for a vehicle, comprising: an ejector; an ejector pump configured to pump only air drawn through a low pressure region of the ejector; and an air conduit, the air conduit housing the ejector and at least a portion of the ejector pump, the air conduit having a sole air inlet and a sole air outlet. The system includes where the sole air inlet is a suction inlet of the ejector and where the sole air outlet includes at least one check valve positioned to allow air to exit the air conduit and substantially prevent air flow entering into the air conduit. The system also includes where the ejector pump is configured to pump an amount of air out of the sole air outlet that is substantially equivalent to an amount of air drawn through the sole air inlet. In this way, the amount of air drawn from the vacuum system reservoir via the ejector or venturi can reduce the amount of air filtered by the engine as compared to a blower-ejector system that does not circulate the motive fluid (air). In some examples, the system includes where the ejector pump is an electrically motivated pump. The system further includes where the sole air outlet is configured to exhaust air from the air conduit when a relief pressure of the at least one check valve is overcome via a pressure from the ejector pump. The relief valve can substantially limit air flow from the engine intake manifold to the vacuum system reservoir. The system also includes where an inlet to the ejector pump and an outlet of the ejector pump are sealed within the air conduit. The system includes where the air conduit is configured to route air exiting an outlet of the ejector pump to an inlet of the ejector and to route air exiting an outlet of the ejector to an inlet of the ejector pump.
[0026] The systems of FIGS. 1 and 2 also provide for vacuum system for a vehicle, comprising: an ejector or a venturi; an ejector pump or a venturi pump; an air conduit, the air conduit housing the ejector or the venturi and at least a portion of the ejector pump, the air conduit having a sole air inlet and a sole air outlet; and an engine configured to accept air output from the sole air outlet in an intake air passage. The system also includes where the engine is configured to accept air output from the air conduit to a first location in an air intake of the engine downstream of an air inlet throttle. In one example, the system includes where the engine is further configured to accept air from the air conduit at a second location upstream of a compressor input, and where the air inlet throttle is located downstream of a compressor output. By outputting air from the air conduit to the engine, the efficiency of the ejector pump may be increased. In one example, the system further comprises a first check valve and a second check valve, the first check valve configured to limit air flow from an intake manifold of the engine, the second check valve configured to limit air flow from upstream of the compressor input. In this way, the device always exhausts to the lowest available air pressure.
[0027] The system further comprises a vacuum reservoir, the vacuum reservoir configured to supply air to the air conduit. In some examples, the system further comprises a controller, the controller including instructions for selectively operating the ejector pump or the venturi pump in response to a condition of the vacuum reservoir. Thus, operation of the ejector pump may be limited to conditions where operation of the ejector pump is more efficient. The system further comprises instructions for selectively operating the ejector pump or venturi pump responsive to a condition of an intake manifold of the engine. The system further comprises instructions for adjusting the condition of the vacuum reservoir in response to barometric pressure. The system further comprises a controller, the controller including instructions for selectively operating the ejector pump or venturi pump in response to a condition of a brake pedal.
[0028] It should also be noted that the system of FIG. 2 can be applied to fuel vapor purge systems. In particular, the suction inlet 204 of air conduit assembly 200 can be coupled to and in fluidic communication with a fuel vapor storage canister via a conduit and valves. The sole air outlet 212 can be coupled to the engine as shown in FIG. 2 . The ejector pump 208 is operated when an amount of fuel vapors stored in the fuel vapor storage canister exceed a threshold amount. In one example, the air conduit may include a fuel vapor storage medium (e.g., activated charcoal) such that the air conduit acts as a fuel vapor storage device and a vacuum generator. With such a system, the amount of air entering the engine is substantially equivalent to the amount of air entering the air conduit via the fuel vapor storage system. Thus, lower flow rates of higher concentration fuel vapors may be directed to the engine. Consequently, engine air-fuel control may be improved along with fuel economy since the engine may operate with fewer lean or rich air-fuel excursions.
[0029] Referring now to FIGS. 3 and 4 , simulated signals of interest during engine operation are shown. Similar signals may be produced according to the method of FIG. 5 with the system of FIG. 1 . FIG. 3 includes five plots and FIG. 4 includes a single plot. The signals are referenced to vertical markers T 0 -T 11 that represent same times in each plot, and the sequences of FIGS. 3 and 4 occur at the same time and are related. Accordingly, FIG. 4 is explained with FIG. 3 below. It should also be noted that the units between plots may be different. For example, a pressure in the intake manifold may appear at a same level as a vacuum reservoir pressure, however, the two pressures may be substantially different. Thus, the signals in FIGS. 3 and 4 provide directional information rather than absolute data.
[0030] The first plot from the top of FIG. 3 shows an engine torque command versus time. Engine torque increases in the direction of the Y axis arrow. The X axis represents time, and time increases from the left to the right of the plot.
[0031] The second plot from the top of FIG. 3 shows engine speed versus time. Engine speed increases in the direction of the Y axis arrow. The X axis represents time, and time increases from the left to the right of the plot.
[0032] The third plot from the top of FIG. 3 shows engine intake manifold pressure versus time. Engine intake manifold pressure increases in the direction of the Y axis arrow. The X axis represents time, and time increases from the left to the right of the plot. Thus, the intake manifold is at a higher vacuum level when the engine intake manifold pressure is low. FIG. 3 also includes horizontal line 500 that represents atmospheric pressure. Thus, the engine intake manifold holds a positive pressure when engine intake manifold pressure is above line 500 . On the other hand, the engine intake manifold holds a negative pressure or vacuum when the engine intake manifold pressure is below line 500 .
[0033] The fourth plot from the top of FIG. 3 shows secondary vacuum reservoir pressure versus time. Vacuum system reservoir pressure increases in the direction of the Y axis arrow. The X axis represents time, and time increases from the left to the right side of the plot. FIG. 4 also includes two horizontal lines 502 and 504 that represent two threshold vacuum reservoir pressures. Line 504 represents a low pressure or high vacuum threshold whereby it may be desirable to deactivate the ejector or venturi pump. Line 502 represents a vacuum threshold whereby it may be desirable to activate the ejector or venturi pump. Thus, the ejector or venturi pump can be activated at a first pressure and deactivated at a second pressure.
[0034] The fifth plot from the top of FIG. 3 shows brake booster vacuum reservoir pressure versus time. Brake booster vacuum reservoir pressure increases in the direction of the Y axis arrow. The X axis represents time, and time increases from the left to the right side of the plot.
[0035] Referring now to FIG. 4 , the first plot from the top of FIG. 4 shows an ejection or venturi pump command. The pump is commanded on when the signal is near the top of the plot. The pump is commanded off when the signal is near the bottom of the plot. Further, it should be mentioned that the pump may be operated at different speeds to provide different rates and amount of vacuum if desired.
[0036] At time T 0 , the engine torque command is at a middle level as is the engine speed. The engine and vehicle may be cruising during similar conditions. Engine intake manifold pressure is also elevated to a positive pressure. Consequently, the engine intake manifold cannot supply vacuum to the vacuum system reservoir at time T 0 . However, pressure in the vacuum system reservoir is low at time T 0 . Therefore, additional vacuum is not needed at the secondary vacuum reservoir at time T 0 . Further, pressure in the brake booster vacuum reservoir is low at time T 0 so additional vacuum is not needed at time T 0 . Consequently, since there is a desirable level of vacuum in the consumer vacuum reservoir, the ejector or venturi pump is commanded off as indicated by the low level signal at T 0 of FIG. 4 .
[0037] At time T 1 , the engine torque command decreases and engine speed also starts to decrease as less torque is available to keep the engine at an elevated speed. Engine intake manifold pressure also decreases since the engine torque can be provided with less air to meet the engine torque command. Pressure in the brake booster also increases when the brake is applied to slow the vehicle, for example. Since the brake booster pressure increases above the vacuum system reservoir pressure, a pressure difference is created between the brake booster and the vacuum system reservoir that allows air to flow from the vacuum reservoir to the vacuum system reservoir. The pressure in the vacuum system reservoir may lag the pressure in the brake booster vacuum reservoir and the two pressures may during transient conditions since the reservoirs are linked via a conduit. The ejector pump remains off at time T 1 since pressure in the vacuum system reservoir is less than pressure threshold 502 .
[0038] At time T 2 , the engine torque command remains low and the engine speed continues to fall. The intake manifold pressure also has decreased but remains above atmospheric pressure. Pressure in the vacuum system reservoir has reached pressure threshold 502 which causes the controller to activate the ejector or venturi pump as indicated in FIG. 4 . Pressure also continues to increase in the brake booster vacuum reservoir in response to a release of the brakes, for example. Air can enter the brake booster vacuum reservoir during application and release of vehicle brakes. A larger quantity of air may enter the brake booster vacuum reservoir when the brake pedal is released as compared to when the brake pedal is applied since air at atmospheric pressure may be used to assist in the application of vehicle brakes.
[0039] Between time T 2 and T 3 , the engine torque command stays low and the engine speed begins to approach idle speed. In addition, intake manifold pressure continues to decrease and goes from a positive pressure to a negative pressure near time T 3 . Pressure in the vacuum system reservoir peaks in response to air drawn into the vacuum system reservoir from the brake booster vacuum reservoir, and then, pressure starts to decrease in the vacuum system reservoir as air is drawn from the vacuum system reservoir into the ejector or venturi. Consequently, pressure in the brake booster also starts to decrease after peaking when air is drawn from the brake booster vacuum reservoir into the vacuum system reservoir. The ejector or venturi pump remains on between time T 2 and T 3 .
[0040] At time T 3 , the engine torque command is low and the engine speed reaches idle speed. The intake manifold pressure also falls to a pressure less than atmospheric pressure so that air can be drawn into the engine intake manifold when pressure in the engine intake manifold is less than pressure in the vacuum system reservoir. A check valve (e.g., check valves 20 and 21 ) between the engine intake manifold and the vacuum system reservoir substantially prevents air flow from the engine intake manifold to the vacuum system reservoir and the check valve allows air flow from the vacuum system reservoir to the engine intake manifold. Pressure in the vacuum system reservoir decreases quickly after time T 3 at a time when the engine intake manifold pressure is less than vacuum system reservoir pressure. Pressure in the brake booster vacuum reservoir also decreases as air is drawn from the brake booster vacuum reservoir to the vacuum system reservoir. The ejector or venturi pump is deactivated when pressure in the vacuum system reservoir reaches pressure threshold 504 . Thus, near time T 3 , the intake manifold assists the ejector or venturi to remove air from the vacuum system reservoir.
[0041] Between time T 3 and T 4 , the engine torque command is low and the engine is at idle speed. The intake manifold pressure is also below atmospheric pressure. Brake booster vacuum reservoir pressure and vacuum system reservoir pressure briefly increase as the brake pedal is depressed. Air that is released into the brake booster vacuum reservoir is quickly removed as the air flows into the engine intake manifold via the vacuum system reservoir. Shortly before time T 4 , the brake pedal is released and pressure in the brake booster vacuum reservoir and in the vacuum system reservoir increase. However, the pressure rise in the vacuum system reservoir lags the pressure rise in the brake booster vacuum reservoir.
[0042] At time T 4 , the engine torque command increases followed shortly thereafter by an increase in engine speed. Intake manifold pressure is also increased so that the engine air amount can be increased to provide the commanded engine torque. Pressure in the vacuum system reservoir increases to a level above pressure threshold 502 causing the controller to reactivate the ejector or venturi pump as indicated by the high level ejector pump command signal in FIG. 4 . The ejector or venturi begins to draw air from the vacuum system reservoir and pumps it into the engine at a location upstream of a turbocharger so that air enters the engine where pressure in the engine air intake system at a pressure tap is lowest. Pressure in the vacuum system reservoir decreases until it is less than pressure threshold 504 . The ejector or venturi pump is deactivated in response to pressure in the vacuum system less than pressure threshold 504 at time T 5 .
[0043] At time T 6 , the engine torque demand is reduced and the engine speed is also reduced since less engine torque is available to rotate the engine. Intake manifold pressure is also reduced; however, intake manifold pressure remains above atmospheric pressure. The decrease in engine torque and speed may be representative of a vehicle coasting condition. In addition, the brake pedal is applied, but pressure in the vacuum system reservoir remains below pressure threshold 502 . Therefore, the controller does not reactivate the ejector or venturi pump as indicated by the low level pump command at time T 6 of FIG. 4 .
[0044] Just before time T 7 , the brake pedal is released and the engine torque command is increased shortly thereafter. Pressure in the brake booster vacuum reservoir increases above pressure threshold 502 in response to releasing the brake pedal. Consequently, the controller reactivates the ejector or venturi pump. Engine torque and engine speed are also increased after time T 7 to accelerate the vehicle, for example. Intake manifold pressure also increases as engine cylinder air charge is increased to meet the increased engine torque command.
[0045] Pressure in the vacuum system reservoir and the brake booster vacuum reservoir are gradually pumped down by the ejector or venturi until time T 8 where the brake pedal is reapplied and pressure in the brake booster vacuum reservoir increases. As a result, the ejector or venturi pump remains activated. Shortly after time T 8 , engine intake manifold pressure decreases below atmospheric pressure and consequently air is drawn from the vacuum system reservoir into the engine intake manifold. The intake manifold and the ejector or venturi pump combine to draw air from the brake booster vacuum reservoir and the vacuum system reservoir until pressure in the vacuum system reservoir reaches pressure threshold 504 shortly after time T 8 . The ejector or venturi pump is deactivated when pressure in the vacuum system reservoir reaches pressure threshold 504 .
[0046] Shortly before time T 9 , the brake pedal is released and the engine torque demand is increased to accelerate the vehicle, for example. Releasing the brake causes pressure to rise in the brake booster reservoir and in the vacuum system reservoir. Pressure in the vacuum system reservoir increases to a level greater than pressure level threshold 502 . Consequently, the ejector or venturi pump is reactivated and pressure in the vacuum system reservoir and the brake booster vacuum reservoir is lowered as air is drawn into the ejector or venturi.
[0047] At time T 10 , pressure in the vacuum system reservoir reaches pressure threshold 504 and the controller deactivates the ejector or venturi pump in response to the pressure in the vacuum system reservoir. The engine torque and engine speed are at an elevated level as is the intake manifold pressure. As a result, the ejector or venturi pump is the sole device that reduces pressure in the vacuum system reservoir and the brake booster vacuum reservoir.
[0048] Thus, it can be seen from FIGS. 3 and 4 that the ejector or venturi pump can be selectively activated and deactivated in response to a pressure in the vacuum system. Further, in some examples, a timer can be activated and incremented when the ejector or vacuum pump is activated. The control strategy may require that the vacuum pump be activated for a minimum time period to reduce cycling of the vacuum pump. In addition, when the ejector or venturi is configured as is shown in FIG. 2 , the engine inducts only the amount of air removed from the vacuum reservoirs. And, the ejector or venturi pump efficiency may be improved since the ejector or venturi pump is in communication with a lower pressure region of the engine intake system.
[0049] Referring now to FIG. 5 , method 500 is executable as instructions of a controller such as illustrated in FIG. 1 with an ejector illustrated in FIG. 2 . Further, method 500 may provide signals similar to those illustrated in FIGS. 2 and 3 .
[0050] At 502 , method 500 determines engine operating conditions. Engine operating conditions may include but are not limited to engine temperature, brake booster vacuum reservoir pressure, vacuum system reservoir pressure, ambient pressure and temperature, engine speed, engine intake manifold pressure, and engine torque. Method 500 proceeds to 504 after engine operating conditions are determined.
[0051] At 504 , method 500 judges whether or not vacuum system reservoir pressure is greater than a threshold pressure. In some examples, the threshold pressure may be adjusted to account for barometric pressure. For example, if barometric pressure decreases the threshold pressure may be decreased so that a desired pressure differential exists between atmospheric pressure and pressure in the vacuum system reservoir. Consequently, the pressure at which the ejector pump is activated may be adjusted for changes in barometric pressure.
[0052] If vacuum system reservoir pressure is greater than a threshold pressure, method 500 activates a timer, begins to accumulate time, and proceeds to 506 . Otherwise, method 500 moves to 514 . In other examples, method 500 may also require that intake manifold pressure be greater than atmospheric pressure to activate the ejector or venturi pump so that pump operation may be reduced an so that vacuum in the intake manifold provides vacuum to the vacuum system. Thus, method 500 allows pressure to be drawn from the vacuum system reservoir via the intake manifold without activating the ejector or venturi pump when engine intake manifold pressure is low. In addition, method 500 may activate the ejector or venturi pump at a first threshold pressure and deactivate the ejector of venturi pump at a second threshold pressure. As such, the ejector or venturi pump may cycle on and off less often.
[0053] At 506 , method 500 activates the ejector or venturi pump. In one example, the ejector or venturi pump may be electrically motivated. In other examples, the ejector or venturi pump may be mechanically driven and engaged and disengaged via a clutch. Method 500 proceeds to 508 after activating the ejector or venturi pump.
[0054] At 508 , method 500 pumps air from the vacuum system reservoir. In one example, air is pumped from a vacuum system reservoir 138 as shown in FIG. 1 via an air conduit and ejector pump as illustrated in FIG. 2 . Method 500 proceeds to 510 when air is pumped from the vacuum system reservoir.
[0055] At 510 , method 500 re-circulates air through an ejector via a pump as described in FIG. 2 . In particular, air is drawn into an air conduit via a sole air inlet of the ejector. A low pressure region is created in the ejector by compressing and accelerating air through a converging nozzle of the ejector. The air that is drawn into the ejector is expanded as it passes from a suction input to a diffuser outlet. An ejector pump re-circulates at least a portion of the air drawn into the suction inlet to the converging nozzle. Further, the ejector pump re-circulates air that has already passed through the converging inlet nozzle. Method 500 proceeds to 512 after re-circulating at least a portion of air in the ejector.
[0056] At 512 , method 500 pushes air from the vacuum system reservoir to the engine. Since the air conduit of FIG. 2 has only a sole air inlet and a sole air outlet, substantially the same amount of air that is drawn into the air conduit via the air inlet exits the air conduit via a sole air outlet. Air proceeds to the engine air intake system or the engine crankcase and check valves substantially prevent air from flowing from the engine intake system or crankcase to the vacuum system reservoir. Method 500 proceeds to 514 after air begins flowing to the engine.
[0057] At 514 , method 500 judges whether or not vacuum system reservoir pressure is less than a threshold pressure. Further, in some examples, method 500 judges whether or not engine intake manifold pressure is less than atmospheric pressure minus a pressure offset and that the ejector pump has been operating for a predetermined amount of time. If vacuum reservoir pressure is less than a threshold pressure, method 500 proceeds to 516 . Otherwise, method 500 proceeds to exit. It should be noted that in some examples, the threshold pressure may be adjusted to account for barometric pressure. Consequently, the pressure at which the ejector pump is deactivated may be adjusted for changes in barometric pressure. For example, if barometric pressure decreases the pressure at which the ejector pump is deactivated may be increased.
[0058] At 516 , method 500 deactivates the ejector pump. The ejector pump may be deactivated by decoupling mechanical or electrical power sources from the ejector pump. Method 500 proceeds to exit after deactivating the ejector pump.
[0059] Thus, the method of FIG. 5 provides for producing vacuum for a vehicle, comprising: drawing an amount of air from a vacuum reservoir via a low pressure region of an ejector or venturi into an air conduit having a sole air inlet and a sole air outlet; providing at least a portion of the amount of air from the vacuum reservoir to a converting nozzle of the ejector or venturi; and providing an amount of air to an engine via the sole air outlet, the amount of air provided to the engine substantially equivalent to the amount of air drawn from the vacuum reservoir. In one example, the method includes where an ejector pump or venturi pump is selectively operated in response to an operating condition of a vacuum system. The method also includes where operating condition is a pressure of a vacuum reservoir, and where at least a portion of the ejector pump is sealed within the air conduit. Further, the method includes where the amount of air provided to the engine is provided to a first or a second location along an air intake system of the engine depending on a pressure at the first location and a pressure at the second location.
[0060] As will be appreciated by one of ordinary skill in the art, the methods described in FIG. 5 may represent one or more of any number of processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Likewise, the order of processing is not necessarily required to achieve the objects, features, and advantages described herein, but is provided for ease of illustration and description. Although not explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending on the particular strategy being used. In addition, the terms aspirator or venturi may be substituted for ejector since the devices may perform in a similar manner.
[0061] This concludes the description. The reading of it by those skilled in the art would bring to mind many alterations and modifications without departing from the spirit and the scope of the description. For example, single cylinder, I2, I3, I4, I5, V6, V8, V10, V12 and V16 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations could use the present description to advantage.
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A selectively operable vacuum source is disclosed. In one example, vacuum source supplies as much air to an engine as is drawn by the vacuum source from a vacuum reservoir. The approach may provide vacuum to a vehicle vacuum system efficiently and with less weight than other vacuum sources.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the national stage of International Application NO. PCT/ES2012/000275, filed Oct. 31, 2012, and claims priority of European Patent Application No. 11380089.0 filed Oct. 31, 2011, both of which applications are incorporated by reference herein in their entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] This invention relates to devices for applying sealants such as silicones and the like in multiples artifacts or machines such as automobiles, trains, ships and aircrafts, therefore, it is useful in diverse industries such as aviation, automotive, naval, railway, and robotics or similar industries. More particularly, the invention is directed to a nozzle, comprising a bell or hood lower section that is coupled in a non-permanent manner to an injection button with a particular design, which is highly useful in applying silicone and similar sealants on said artefacts and machines.
BACKGROUND OF THE INVENTION
[0003] The manufacturing of machines and other related artefacts or accessories in several industries, such as aviation, automobile, naval, railway, robotics and the like requires processes wherein it is necessary the application of silicones and similar or related sealants to said machines or artefacts, particularly during its manufacture processes. Sealants application requires the use of nozzles in order to apply said sealants to the machines or artefacts from a sealant-container, such as cartridges or injection machines. Thus, the sealant may be applied with a nozzle manually and directly from cartridges filled with sealant, or by an extrusion or manual gun, as those currently available in the market and known in the art. Some of the nozzles known in the art are made of metal and are intended to be reusable; particularly those meant to be used in injections machines, thus they must be cleaned up with solvent or products specifically prepared for such cleaning purpose. Such solvents or cleaning products are hazardous, abrasive and highly irritant to the skin. Furthermore, the design of said nozzles does not allow their use with both manual cartridges and automatic processes using injection machines, nor they have a precision dispersion of the sealant as required in, for instance, sealing operations involving injecting sealants in the chamfers in which rest the heads of rivets and screws or in the walls of orifices, wherein highly precise sealant application is needed and required.
OBJECTS AND SUMMARY OF THE INVENTION
[0004] The above drawbacks and needs are overcome by a nozzle for applying sealants with a bell or hood lower section and an injection button as described herein, which provides several advantageous and novel characteristics for its intended function inherent to its innovative organization and construction, which will be described in detail further below, and which represents a considerable improvement with respect to what is currently known in the market in its field of application.
[0005] One of the main the objective of the invention is to provide a nozzle that once it is connected to a cartridge or injection machine, facilitates the injection of silicone or other sealants in multiple industrial applications. Another objective of the invention is to provide a nozzle having an outlet shaped as a bell or hood in order to facilitate the encapsulation of rivets or screws, particularly applicable in the aeronautical industry, having the innovative characteristic that it also has an injection button coupled to the end section of said bell or hood, said button having a special design with a number of channels and orifices for carrying out sealing operations with greater accuracy, allowing to guide the injection of the sealant around the rivets and nuts. In yet another objective of the invention is to provide a nozzle having a button section that by its particular design substantially improving the encapsulation and providing an optimum sealing of rivets and nuts, and that allows the user to apply sealant operations both manually and by automated sealant injection machines. In still another objective of the instant invention is to provide a nozzle having a bell or hood lower section for sealing rivets and nuts, which may be used in the aviation industry and the automotive, naval, railway and robotics industries.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The foregoing and additional features and characteristics of the embodiments of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawings, which are used herein in a manner of example only, and wherein:
[0007] FIG. 1 shows a diagrammatic representation in perspective view of an example of one preferred embodiment of the nozzle for applying sealants, according to the instant invention, said representation illustrating general outer configuration, and its main parts or elements.
[0008] FIG. 2 shows a cross sectional view along a longitudinal axis of the nozzle according to the invention already shown FIG. 1 .
[0009] FIG. 3 shows a diagrammatic illustration of the plan view of one preferred embodiment the injection button incorporated in the nozzle according to the instant invention.
[0010] FIG. 4 shows a diagrammatic representation of an enlarged view of section 11 on FIG. 2 , wherein the detail of the configuration of the coupling or matching between the bell-shaped tip or lower section of the nozzle and the injection button is illustrated.
[0011] FIG. 5 shows a diagrammatic representation in perspective view of an example of another embodiment of the nozzle for applying sealants, according to the instant invention, said representation illustrating general outer configuration, and its main parts or elements and comprising a button comprising lateral outlets or openings.
[0012] FIG. 6 shows a cross sectional view along a longitudinal axis of the nozzle according to the invention already shown FIG. 5 .
[0013] FIG. 7 shows a diagrammatic illustration of the plan view of a second preferred embodiment of the injection button incorporated in the nozzle according to the instant invention, already illustrated in FIGS. 5 and 6 , wherein such button comprises lateral outlets or openings.
[0014] FIG. 8 shows a diagrammatic representation of an enlarged view of section 31 on FIG. 6 , wherein the details of the configuration of the coupling or matching between the bell-shaped tip or lower section of the nozzle and the injection button of the embodiment illustrated in FIG. 5 are illustrated.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The following detailed description illustrates the invention by way of example and is not limited to the particular limitations presented herein as principles of the invention. This description is directed to enable one skilled in the art to make and use the invention by describing embodiments, adaptations, variations and alternatives of the invention. Potential variations of the limitations herein described are within the scope of the invention. Particularly, the size and shapes of the invention's elements illustrated in the discussion may be varied and still provide embodiments having different sizes or geometric shapes, that are within the scope of the instant invention.
[0016] The instant invention is directed to a nozzle for applying silicones and similar sealants, said nozzle comprising a bell or hood shaped tip and an injection button, which provides several advantageous and novel characteristics for its intended function inherent to its innovative organization and construction, which will be described in detail further below, and which represents a considerable improvement with respect to what is currently known in the market in its field of application.
[0017] A first embodiment of the invention is illustrated in FIG. 1 wherein the nozzle embodiment 10 is illustrated. FIG. 2 illustrates a diagrammatically representation of a cross sectional view of nozzle 10 . The nozzle 10 comprises a main elongated hollow body 12 having a truncated cone shape. Said elongated body 12 comprises a first end 14 and a second end 15 . First end 14 has a wider diameter that second end 15 .
[0018] Physically connected to first end 14 , nozzle 10 comprises connecting hollow round section 16 , which comprises a threaded exterior surface 17 , which allows nozzle 10 to be connected to a silicone or similar sealant cartridge or injection machine. Said threaded section thus allows the coupling of nozzle 10 to most cartridges or machines present in the market, adding versatility in the manner that nozzle 10 is used. Connecting section 16 also comprises protruding ring 18 , which is surrounding the end of said connecting section 16 that is in direct physical contact with said first end 14 of the main elongated body 12 . Protruding ring 18 stops against the cartridge or gun to which nozzle 10 is coupled, as it is the union between the nozzle 10 and the cartridge thus providing or establishing a precision adjustment of nozzle 10 to the sealant container cartridge or injection machine.
[0019] At the second end 15 , nozzle 10 comprises a bell or hood shaped section 19 , physically connected to the second end 15 of said main elongated body 12 . As illustrated in cross section, along a longitudinal axis or line of the nozzle 10 in FIG. 2 , at its peripheral end, bell shaped section 19 has an annular flanged section 21 .
[0020] Bell shaped section 19 is sized to encapsulate rivets or nuts in order to cover them completely with the sealing material and provides a connection element discussed below in detail. Main elongated body 12 , round connecting section 16 and bell shaped section 19 may constitute a single unit, physically connected.
[0021] Connected to the peripheral annular flanged section 21 of the bell-shaped section 19 , nozzle 10 also comprises injection button 22 , which is diagrammatically illustrated in FIG. 3 . It comprises a circular main body 23 and a peripheral groove section 26 around the end of said circular main body 23 . On its front surface, injection button 22 comprises hollow central circular protrusion 27 , which is projected from said main body 23 , and multiple series of radially oriented channels 28 ending in orifices 29 which are distributed around said central circular protrusion 27 .
[0022] As illustrated diagrammatically in FIG. 4 , which illustrates section 11 , the annular flanged section 21 of the bell shaped section 19 cooperatively match with the peripheral groove 26 of injection button 22 , allowing a strong and firm non-permanent connection or coupling of button 22 to the bell shaped section 19 . Once coupled to the bell-shaped section 19 , the button 22 covers the exit or mouth of bell shaped section 19 .
[0000] The whole structure of nozzle 10 is preferably made of plastic, preferably of polypropylene.
[0023] FIGS. 5 to 8 diagrammatically illustrate a second preferred embodiment 30 according to the invention. Embodiment 30 is similar to embodiment 10 since both embodiments comprise a main elongated hollow body 12 having a truncated cone shape; a hollow round and threaded section 16 and a bell or hood shaped section 19 wherein said main parts have the same elements already described previously and wherein the said sections are connected as previously described as illustrated particularly as illustrated in FIGS. 5 and 6 . However, second embodiment 30 comprises injection button 32 in place of injection button 22 . As described previously regarding injection button 22 injection button 32 as illustrated diagrammatically in FIGS. 5 , 6 7 and 8 and particularly in FIG. 7 , comprises a circular main body 23 having a peripheral groove section 26 around the end of said circular main body 23 . On its front surface, injection button 32 comprises hollow central circular protrusion 27 , which is projected from said main body 23 and also comprises multiple series of radially oriented channels 28 ending in orifices 29 which are distributed around said central circular protrusion 27 . Contrary to injection button 22 , nonetheless and as illustrated in FIG. 7 , injection button 32 comprises a series of lateral grooves or openings 34 , located around the lateral sides of said central circular protrusion 27 .
[0024] As in the case of embodiment 10 , and has illustrated diagrammatically in FIG. 8 , which shows the detailed view of section 31 in embodiment 32 , the annular flanged section 21 of the bell shaped section 19 cooperatively match with the peripheral groove 26 of injection button 32 , allowing a strong and firm non-permanent connection or coupling of button 32 to the bell shaped section 19 . Once coupled to the bell-shaped section 19 , the button 32 covers the exit or mouth of bell shaped section 19 .
[0025] In operational terms, the nozzle according to the instant invention may be coupled or connected to most cartridges or machines containing sealant which are present in the market or commercially available by threading connecting hollow round section 16 to the sealant containing cartridge or injection machine. The protruding ring 18 acts as a stopper in the insertion or threading of the cartridge and reinforces the area of greatest pressure, which is the union between the nozzle and the cartridge, allowing the achievement of precision adjustment. The sealant then may enter to the interior of the main hollow elongated conical body 12 via threaded hollow section 16 , which is the sealant inlet point of the nozzle herein described. From the central section of the main hollow elongated body 12 , the sealant is expelled out of the nozzle via the bell or hood shaped section 19 , which acts as the sealant outlet point. The shape of bell shaped section 19 being meant for encapsulating rivets or nuts in order to cover them completely in the sealing material. Once the sealant is expelled from the bell shaped section 19 , it most moves out through injection bottom 22 , which is fitted or coupled in a strong but non-permanent manner to the bell shaped section 19 . Due to said non-permanent coupling, button 22 may be fitted to or remove from bell shaped section 19 at the user's will. The particular design of this button, with channels 28 and orifices 29 , allows executing different precision sealing operations. Specifically, it allows directing the flow of sealing material in two different ways: (1) towards the chamfers in which the rivet heads are adjusted, by means of the series of radially positioned channels 28 , that lead to through orifices 29 located at annular area 27 of the central part of the button or alternatively, and (2) when using injection button 32 , towards the walls of the orifice in which the screws are inserted, by means of lateral outlets 34 provided in an alternative embodiment of the button 32 , which has a hollow central part 27 . In this manner, the plugging of the orifice in which the screw is inserted is prevented, which is important in order to allow its subsequent riveting.
[0026] The sealant applying operations are performed after drilling orifices in the various claddings or parts to be joined, by a riveting that will consequently be fast, clean and uniform, since the appropriate doses of sealant have been applied at the specific points described, as enabled by this system.
[0027] The application of the sealant with the nozzle according to the instant invention may be performed either manually, by cartridges filled with silicone or other sealing materials, or by an extrusion or manual gun, as those currently available in the market. The used of the nozzle according to the invention in applying sealants provides a perfect seal from air and oxidising liquids, which is very important for the pressurisation and lifetime of aircrafts, ships, trains or automobiles.
[0028] Finally, it is worth mentioning that once the aforementioned sealing operations are performed, simply cutting the anterior part of the nozzle with a bell shape, a traditional truncated-cone shaped nozzle is obtained that may be used to apply sealing cords, filler sealant or safety cords that ensure that there is no liquid between two parts joined by rivets and leaving fully sealed the fuel tanks or other elements made from parts joined by rivets. Therefore, the nozzle according to the instant invention disclosed herein provides a device that simplifies the sealing work in both the aesthetic appearance and speed of execution, thus, reducing the sealant application time. As a consequence, the herein disclose nozzle reduce the sealant application time, thus saving time and labour, provides a more economical sealing process and increases the quality of the resulting sealant application simultaneously.
[0029] While the invention has been described in conjunction with some embodiments, it is to be understood that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the forgoing description. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations falling within the spirit and scope of the appended claims.
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A nozzle that includes a connecting section, a main hollow elongated and conical body, a bell shaped section and an injection bottom is described. The design of the connecting section allows it to be connected to injections machines or to a sealant containing cartridges. The injection button is non-permanently connected to the bell shaped section and it has a circular central protrusion, a series of radially oriented channels ending in circularly positioned openings, which facilitates the direction of the expelled sealant. Alternatively, the button may also include lateral grooves at the walls of the central circular protrusion. The particular design of the injection button allows an efficient and highly accuracy distribution of the sealant on the surfaces and selected parts of machines and artifacts wherein the sealant is applied.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is related to provisional patent application No. 60/688,769, filed Jun. 8, 2005 entitled “Obtaining heterostructures with quantum dots by liquid-phase epitaxy for solar cells”, the details of which are hereby incorporated by reference, and the benefit of the earlier Jun. 8, 2005 filing date is claimed in accordance with 35 USC 119(e) (1).
DESCRIPTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a nanotechnology, pulse cooling of substrate (PCS) method enabling formation of III-V compound semiconductor low-dimensional slab and column-like features and also to a method of fabrication of variety of commercially viable optoelectronic and photonic devices based on III-V column materials structures.
[0004] 2. Description of the Related Art
[0005] The method of liquid phase epitaxy (LPE) was developed at 1960 and had been a dominant method for production of semiconductor structures for lasers, power diodes, and photovoltaic devices. LPE had been used for the mass production worldwide until advent of generation of novel semiconductor devices demanding method of growing deep submicron structures with superior control over chemical composition, uniformity and growth rates.
[0006] Nowadays, major methods of [nano] low-dimensional embedded in semiconductor structures growth are Molecular Beam Epitaxy (MBE) and Metal Organic Chemical Vapor Deposition (MOCVD). These methods allow growing low dimensional features [with size less than 0.1 μm] with high degree of control of chemical composition and growth rates. High cost of technological equipment, specific defects in the structures manufactured by MBE and MOCVD technologies stimulate searching of alternative methods of their fabrication, particularly based on crystallization from a liquid phase.
SUMMARY OF THE INVENTION
[0007] The invention is essentially a method for growth of features with size at least in one direction less than 1 μm, for example nano-dimensional layers; two dimensional (2D), and three dimensional (3D) island matrix. Compared to MBE and MOCVD methods, PCS method allow obtaining higher density of islands (˜10 12 cm −2 ), lower defect density and higher growth rates.
[0008] Epitaxial growth of nano dimensional features was realized from III-V and IV column materials low-melting temperature solution-melts in slider-type cassette placed in quartz reactor in the atmosphere of pure hydrogen ( FIG. 1 ).
[0009] In one of the embodiments of the present invention using resistive heater, temperature T 1 in the reactor was maintained within the range of 300-500° C. during growth process. The on-axis as well as off-axis cut GaAs substrates were used for structures with 2D nano-dimensional island matrix growth.
[0010] The main steps of epitaxial growth method of the present invention are as follows:
a) solution-melt and substrate are heated up to the saturation temperature of solution-melt T 1 ; b) the working (growth) surface of the substrate is brought into contact with the solution-melt; c) back surface of the substrate is brought into contact with the heat-absorber (the temperature T p of which is lower than that of the substrate and solution-melt ΔT=T 1 −T p ) that creates the pulse cooling in the range of 0.5-15° C., the duration of the interval is 5×10 −2 −5 s and the speed of growing the fore front of the cooling pulse is in the range of 5×10 3 −0.5×10 3 ° C./s;
[0014] The heat-absorber temperature had been chosen so that an overcooling at crystallization front did not exceeded 5-9° C. to avoid homogeneous nucleation in liquid phase volume. After some time τ the heat-absorber was heated to the temperature T 1 , but during this time there was a cooling at the interface of the substrate and solution-melt, that resulted in crystallization of a dissolved in solution-melt material. The shape of the formed features in particular, low-dimensional layers, 2D and 3D island matrix depends on several factors, for example, stress between substrate and growing feature's material, substrate orientation, and concentration of the material in the solution-melt.
EXAMPLE 1
[0000] The Structure with Nano-Dimensional 2D Island Matrix
[0015] The Scanning Tunnel Microscopy (STM) images of InAs uncapped islands grown on (100) GaAs substrate at T 1 =400° C., ΔT=5° C. and heat-absorber thickness δ=0.3 cm from In solution-melt is presented in FIG. 2 . The observed surface density of islands is ˜10 12 cm −2 . The photoluminescence (PL) spectra of this sample at 77K demonstrate variation in peak position in the 1.24<hv<1.26 eV range, FIG. 3 . Photons with energy of 1.25 eV correspond to photoluminescence from 7.8 nm InAs islands in GaAs. Seven times PL intensity increase is observed when excitation power increases from 5 mW to 20 mW. Further excitation power increase up to 2 W does not significantly effect PL peak position as well as intensity that prove presence of the quantum dots. The PL peak position measured at different spots on the sample was in the 10 meV range what correspond island size variation around 10%.
EXAMPLE 2
[0016] The structure with two populations of nano-dimensional islands grown simultaneously during one cooling pulse
[0017] FIG. 4 presents photoluminescence spectra of two samples. Sample 1 (curve 1) has been grown on (100) GaAs substrate cut 4 degrees off in [110] direction; Sample 2 (curve 2) has been grown on (100) on-axis substrate. Coincidence of long wavelength part of PL spectrum of the samples demonstrates that size distribution of “large” islands is identical for these two samples. At the same time PL spectrum of misoriented sample reveals island size distribution broadened towards smaller sizes featuring split peak. In this case misoriented substrate provided growth front consisting of two steps with different nucleation conditions that resulted in two “independent” populations of InAs islands. Resulting PL spectrum is a superposition of PL from this two populations of InAs islands each having its own Gaussian-like size distribution. The structures containing nano-dimensional islands grown on misoriented substrates can be utilized in photovoltaic devices or diodes due to wider range light absorption or emission; or achieving several specific wavelength light absorption or emission.
[0018] Additional advantages and features of the present invention are described in the following Appendix A, entitled “OBTAINING HETEROSTRUCTURES WITH QUANTOM DOTS BY LIQUID-PHASE EPITAXY FOR SOLAR CELLS”, published August, 2004 (World Renewable Energy Congress), the details of which are hereby incorporated by reference.
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The features with size at least in one direction 1 μm growth method was developed by modifying liquid phase epitaxy. Number of processes was developed where duration and amplitude of the cooling pulse at the substrate interface were chosen in order to form low-dimensional features before system return to the equilibrium condition. This method allows obtaining low-dimensional features with observed quantum effect such as quantum layers, dots and superlattices. The shape of the features strongly depends on substrate orientation, stress and growth conditions.
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TECHNICAL FIELD
The present invention relates to a restraint assembly for a cargo barrier net beam assembly for a cargo barrier net assembly for use in a cargo airplane.
BACKGROUND ART
Apparatus for retaining cargo in cargo carrying airplanes are well known in the art. Currently, the apparatus utilized in almost all cargo carrying airplanes consists of a cargo barrier net. These cargo nets are currently secured inside the airplane by attaching them both to the aircraft fuselage and the aircraft floor to distribute stress to those components when the net is subjected to force, such as cargo striking the net.
The Federal Aviation Authority (FAA) currently requires that cargo barriers, such as cargo nets, be designed to withstand the total weight of the aircraft's cargo multiplied by nine times the force of gravity (9g's). Thus, the attachments between the net and the aircraft floor and fuselage shell must be capable of distributing this relatively large load into the aircraft's basic structure.
Existing attachments of cargo net beam assemblies to the fuselage allow for unrestrained movement of the beam. This movement can cause damage to the fuselage of the airplane, depending upon the force with which the beam strikes the aircraft.
DISCLOSURE OF THE INVENTION
It is an object of the present invention to provide a cargo barrier net assembly that is more durable than prior cargo net installations and is also retrofittable with existing airplanes as applicable.
The cargo barrier net assembly includes a cargo net that is attached to the aircraft floor and the fuselage shell. The cargo net has a plurality of interwoven straps that extend both horizontally and vertically across the cargo hold. A pair of beam assemblies are also included to secure a portion of each side of the cargo net to the fuselage shell. Each beam assembly is generally C-shaped and has a primary portion and a pair of arm portions. Each of the arm portions are secured to the fuselage shell by a pin or the like. The primary portion of the C-shaped beam assembly has cargo net straps attached thereto and is attached to the fuselage shell at existing fittings already secured to the shell. Additional horizontal straps are attached to the fuselage shell above and below the beam assemblies. A plurality of vertical straps of the cargo net also span the area of the fuselage and are attached to the aircraft floor and the aircraft ceiling. The primary portion of the beam assembly is secured to the fuselage by a restraining assembly.
While an embodiment of this invention is illustrated and disclosed, this embodiment should not be construed to limit the claims. It is anticipated that various modifications and alternative designs may be made without departing from the scope of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view from the rear of the aircraft of the fuselage shell of an aircraft with a cargo barrier net secured therein in accordance with the present invention;
FIG. 2 is a perspective view of the C-shaped beam assembly in accordance with the present invention;
FIG. 3 is a side-elevational view of the C-shaped beam assembly of FIG. 2;
FIG. 4 is a perspective view of the restraining assembly to which the C-shaped beam assembly of the present invention is attached;
FIG. 5 is a top plan view of the restraining assembly of FIG. 4;
FIG. 6 is a side view of the restraining assembly of FIG. 4;
FIG. 7 is a front view of the restraining assembly of FIG. 4; and
FIG. 8 is a side view of the restraining assembly in accordance with the present invention when the retaining assembly secures the primary portion of the beam assembly to the fuselage shell.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a cargo net installation 10 in accordance with the present invention. The cargo net installation 10 includes a plurality of horizontal cargo net straps 12 and a plurality of vertical cargo net straps 14. Such straps are known in the art and can be made from any suitable material. The plurality of horizontal cargo net straps 12 substantially extend horizontally across the cargo hold 16 between either side 18, 20 of the fuselage 22. The plurality of vertical cargo net straps 14 substantially extend vertically between the fuselage 22 and the aircraft floor 23. The cargo net installation 10 is located rearward of the cockpit 24 to prevent the pilot and crew from being injured from cargo moving about the cargo hold 16 in the event of a crash. The cargo net straps and the installation thereof can also be of any other suitable construction.
In the embodiment shown, the cargo net installation 10 includes a pair of beam assemblies 26, 28. The beam assemblies 26, 28 are generally C-shaped and are shown in FIGS. 2 and 3. A first beam assembly 26 is located on one side 18 of the fuselage 22, while a second beam assembly 28 is located on the other side 20 of the fuselage 22.
Each of the assemblies 26, 28 have a primary portion 30, 31 and a pair of secondary arm portions 32, 34. The secondary arm portions 32 of the first beam 26 are attached to the one side 18 of the fuselage 22. The secondary arm portions 34 of second beam 28 are attached to the other side 20 of the fuselage 22. Each of the secondary arm portions 32, 34 has a hole 35 formed therethrough for accommodating a pivotable connecting mechanism 37 to pivotably attach the arm portions 32, 34 to the fuselage 22. The mechanism 37 may include a hinged portion attached to the fuselage 22 that has a hole for receiving a pin or other connecting member to secure the arm portions 30, 34, to the respective fuselage side 18, 20. Alternatively, any other conventional way of pivotally attaching the arm portions 32, 34 to the fuselage may be used.
The arm portions 32 of the first beam assembly 26 are positioned such that one arm portion 32 is positioned above an aircraft window (not shown) formed in the side 18 of the fuselage, and such that the other arm portion 32 is positioned below the window. The arm portions 34 of the second restraining bracket are similarly positioned around a window framed in the other side 20 of the fuselage.
As shown, the primary portions 30, 31 of each of the beam assemblies 26, 28 are attached to a plurality of the horizontal net straps 12 at mounts 36 positioned on the beams 26, 28. However, any other suitable method of attachment could be used. The horizontal cargo net straps 12 may be secured to an edge 38 of the primary portion 30 of the first beam assembly 26 and extend across the cargo hold and attach to an edge 40 of the primary portion 31 of the second beam assembly 28.
In one preferred embodiment, four (4) of the horizontal straps 12 are attached at the edges 38, 40 of the respective beams 26, 28. However, more or fewer horizontel straps 12 may be secured to the edges 38, 40 of the assembly 26, 28 depending upon the size and arrangement of the horizontel straps, the vertical spacing between them, and the size of the beam assembly.
As shown in FIG. 8, the primary portions 30, 31 of each of the beam assemblies 26, 28 are secured to the respective side 18, 20 of the fuselage shell 22 by a restraint assembly 42. The restraint assembly 42 includes a connecting bracket 46 and a releasable connecting member 48. The releasable connecting member 48 may be a restraining pin 48 with a detent mechanism 80, which is discussed in more detail below. However, the connecting member may be any other conventional means for securing the brackets during normal use, but releasing the brackets when sufficient force is applied to the cargo net. The fuselage bracket 44 has a first portion 50 that runs generally parallel with the sides 18, 20 of the fuselage 22 and a second portion 52 that runs perpendicular thereto. The fuselage bracket 44 is already present in most cargo airplanes, allowing the present invention to be fitted into current cargo planes without incurring the expense of redesign or additional material.
Turning now to FIGS. 4 through 7, the connecting bracket 46 comprises an outer portion 54 and an inner portion 56. The outer portion 54 has three sections. The first section 58 runs generally parallel with and overlaps the first portion 50 of the fuselage bracket 44. The second section 60 runs generally perpendicular to the first section 58 and extends between the fuselage bracket 44 and the respective beam assemblies 26, 28. The third section 62 extends obliquely upward from the second section 60 at a predetermined angle. The angle varies so long as it allows for release of the beams 26, 28 in accordance with the disclosed invention. The first section 58 lies generally parallel with the first portion 50 of the fuselage bracket 44 to allow the restraining bracket 46 to be secured to the fuselage bracket 44 by a bolt, screw or any other commercially available fastening means through an opening 64 in the first section 58.
The inner portion 56 of the restraining bracket 46 has a first surface 66 that lies generally parallel with the second section 60 of the outer portion 54 such that the inner portion 56 can be secured to the outer portion 54 by securing the first surface 66 to the second section 60 by bolts 68, screws, or any other conventional securing apparatus. A second surface 70 of the inner portion 56 lies generally parallel to both the third section 62 of the outer portion 54 and the primary portion 30, 31 of each of the beam assemblies 26, 28. The second surface 70 of the inner portion 56 is separated a predetermined distance from the third section 62 of the outer portion 54 such that the head 72 of the releasable connecting member 48 is received therebetween.
The head 72 of the releasable connecting member 48 has a diameter which is larger than a hole 74 formed in the third section 62 of the outer portion 54. The diameter of the hole 74 allows the shaft 76 of the releasable connecting member 48 to pass through the hole 74, but retain and secure the head 72 between the third section 62 of the outer portion 54 and the second surface 70 of the inner portion 56. Additionally, the second surface 70 also has an opening to receive a portion of the head 72 of the releasable connecting member 48 for additional stability. The diameter of the opening in the second surface 70 is preferably smaller than the diameter of the hole 74 in the third section 62. The outer and inner portions 54, 56 of the connecting bracket 46 may be made from any suitable material such as sheet metal or the like.
In the embodiment shown, the shaft 76 of the releasable connecting member 48 passes through a hole 51 formed in the primary portion 30, 31 of the beam assemblies 26, 28. The releasable connecting member 48 has a detent 80 formed at one of the shaft 76. The detent 80 retains the beam assemblies 26, 28 in cooperation with the connecting bracket 46 when the cargo net is unstressed. This prevents the beam assemblies 26, 28 from becoming disengaged from the releasable connecting member 48 and thus rotating and banging against the side 18, 20 of the fuselage 22 during normal flight or ground conditions.
In operation, the beam assemblies 26, 28 can rotate between an outboard position adjacent the fuselage shell 22 (FIG. 1), and an inboard position, detached from the releasable connecting member 48, in the direction of a load into the cargo net. When the force from cargo or another item striking the net is large enough, the releasable connecting members 48 are designed to release the beam assemblies 26, 28 allowing them to move into the inboard direction, i.e., in the direction of the force striking the net. This also allows the cargo net to stretch to absorb and distribute the force, to keep the cargo behind the cargo net installation 10 and protect the crew forward of the net from being struck by cargo.
The fuselage preferably has a recess 82 formed therein on both sides 18, 20. The windows are located in each of the recesses 82. Additionally, as shown in the figures, the beam assemblies 26, 28 may be attached to the fuselage 22 in a respective one of the recesses 82. Because the windows are formed in the recesses 82, the cargo net straps cannot be attached directly to the fuselage. Thus, an additional support apparatus is necessary to provide the required strength for the cargo net. As discussed above, the secondary arm portions 32, 34 are positioned such that they fall above and below the window to properly disperse load from the cargo net into the fuselage shell.
While an embodiment of the invention has been illustrated and described, it is not intended that such disclosure illustrate and describe all possible forms of the invention. It is intended that the following claims cover all modifications and alternative designs, and all equivalents, that fall within the spirit and scope of this invention.
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A cargo barrier net installation for a cargo airplane is connected to the floor and fuselage shell of the aircraft. The cargo barrier net installation includes a pair of C-shaped beams that secure the horizontal net straps to the fuselage. The C-shaped beams have a primary portion that is secured to an existing fitting of cargo planes to attempt to eliminate unrestrained movement of the beam assemblies, which movement can cause damage to the aircraft structure.
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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH & DEVELOPMENT
This invention was made with government support under Contract No. N00014-95-C-6024 awarded by the U.S. Government. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
The present invention relates to a method of treating an epoxy resin coated metallic substrate, such as a ship's hull, with an epoxy-silicone-adhesive paint as an intermediate tie-layer to effect the bonding of subsequently applied duplex silicone foul release coatings.
Metallic structures submerged in sea water, such as ship bottoms, are generally infested with organisms, such as barnacles, tube worms, and algae, which can become attached to the surface of these structures causing increased fuel consumption due to increased drag. Routinely, anti-fouling paints are used to treat the surface of these exposed substrates to minimize corrosion. Silicones have been known as effective anti-fouling coatings as early as the 1970's, as shown by U.S. Pat. Nos. 4,025,693, 4,080,190 and 4,227,929.
In Griffith, U.S. Pat. No. 5,449,553, which is incorporated herein by reference, a nontoxic anti-fouling system is described which involves the application of a silicone room temperature vulcanizable (RTV) condensation cure composition, for example, GE RTV 11, as a topcoat, which interfaces with sea water, and which is anchored onto a semi-cured organo-silicon condensation cure RTV bonding layer. An example of a semi-cured RTV condensation cure bonding layer is Silgan J-501 of the Wacker Silicones Corporation of Adrian, Mich., as shown in the aforesaid Griffith, U.S. Pat. No. 5,449,553. The semi-cured RTV condensation cure bonding layer is directly applied, and is in contact with the epoxy treated metallic substrate, such as a ship's hull, and can serve as an anchor for a subsequently applied silicone condensation cure RTV topcoat.
The combination of these condensation cure RTV's has been found to be effective as a duplex non-toxic silicone foul release system when properly secured to a ship's hull. The application of the duplex non-toxic silicone foul release system is preferably made under ambient conditions onto an epoxy-coated metallic substrate, for example a ship's hull, which has been thoroughly cleaned, sand blasted to metallic substrate, and then freshly coated with an epoxy resin.
Experience has shown that even though adhesion between the silicone room temperature vulcanizable (RTV) composition which interfaces with sea water, and the aforementioned silicone-organic bonding layer in the dual silicone foul release system is generally satisfactory, adhesion between the silicone bonding layer and the epoxy coating on the metallic substrate is often unsatisfactory.
A procedure which has been developed to improve adhesion between the silicone-bonding layer and the epoxy resin coating on a metallic substrate, such as a ship's hull, is based on the use of an equal parts mixture of butanol and a curable epoxy resin mixture, referred to sometimes as "epoxy mistcoat". In making the epoxy mistcoat, there is used in combination with butanol, an epoxy resin paint, which may contain Epon 828 resin and an amine curing catalyst for the epoxy resin, such as VERSAMID 140 of the Henkel Coporation of Ambler, Pa. As a result of applying the epoxy mistcoat directly onto the epoxy-coated ship's hull, a binary epoxy layer is formed prior to the application of the duplex non-toxic silicone foul release system. While an improvement in adhesion has been found to occur between the resulting binary epoxy layer, and the subsequently applied silicone-organic bonding layer, considerable environmental concerns have been recognized as a result of butanol emissions. In addition, special mixing procedures, and time restrictions have been found necessary to achieve satisfactory bonding between the epoxy mistcoat and the silicone-organic bonding layer.
Additional techniques are therefore needed to provide an environmentally safe and efficient method to satisfactorily anchor the duplex silicone foul release coating system onto an epoxy-coated ship's hull.
BRIEF SUMMARY OF THE INVENTION
The present invention is based on the discovery that an epoxy-silicone mixture, referred to hereinafter as the "epoxy-silicone-adhesive-paint", can be applied in an environmentally safe manner onto an epoxy-coated metallic substrate, such as a steel or aluminum ship's hull, to form an effective foundation coating to anchor the subsequently applied silicone-bonding layer, which thereafter can be further treated with a condensation cure silicone RTV foul release topcoat to form the duplex silicone foul release system as previously described.
The epoxy-silicone-adhesive-paint, comprises a blend of an epoxy paint, and an effective amount of a silicone adhesion promoter. The silicone adhesion promoter comprises a mixture of a hydrocarbon solvent, for example, mineral spirits, in combination with an RTV silicone condensation cure catalyst system, i.e. a partially condensed organosilicate, a uniformly dispersed, or solubilized metallic catalyst, such as dibutyl tin oxide, and an effective amount of an alkylaminotrialkoxysilane, such as γ-aminopropyltrimethoxysilane.
STATEMENT OF THE INVENTION
There is provided by the present invention, a method of modifying under atmospheric conditions, a metallic substrate coated with a cured epoxy resin to allow the subsequent application thereon of a duplex silicone foul release coating, which comprises the steps of,
(a) applying onto the cured epoxy resin coated metallic substrate, an epoxy-silicone-adhesive paint comprising by weight, (i) 80-85% of an epoxy resin paint, and (ii) 15-20% by weight of a silicone adhesive promoter, comprising a volatile hydrocarbon solvent, a partially condensed organosilicate, a solubilized metallic catalyst, and an aminoalkyltrialkoxysilane, where the aminoalkyltrialkoxysilane is present in the silicone adhesive promoter in an amount which is at least sufficient to impart to the epoxy-silicone-adhesive paint upon cure to at least a tacky state, a degree of adhesion sufficient to satisfactorily anchor a subsequently applied condensation cure RTV, or when allowed to achieve a tack-free state, provide a cohesive failure value in accordance with ASTM D-4541.
There is also provided by the present invention, an epoxy-silicone-adhesive paint comprising an epoxy resin paint, and an effective amount of an aminoalkyltrialkoxysilane based on the weight of epoxy resin. There is also provided by the present invention, the substrate obtained by treating by the method hereinabove.
DETAILED DESCRIPTION OF THE INVENTION
The expression "silicone condensation cure RTV compositions" as used in the present invention, means liquid silicone mixtures, which are often manufactured as "two-part" mixtures. The expression "two-part silicone RTV" as used in the present invention means that liquid silicone mixtures, referred to sometimes as "part one" and "part two", can be converted from the liquid state to the elastomeric, or rubber state, when combined at room temperature.
In part one, there is generally employed a silanol-terminated polydiorganosiloxane, such as a silanol-terminated polydimethylsiloxane along with a filler, for example calcium carbonate. In part two, a curing agent, such as a metallic salt of a carboxylic acid, or metallic compound can be used. While tin oxide, for example, dibutyl tin oxide is preferred, other metallic compounds, such as salts of lead, zirconium, antimony, and manganese, in combination with acid radicals such as acetate, butyrate, octoate have been found effective. These compounds can be used with a partially condensed organosilicate, for example an alkylsilicate, such as an ethylsilicate. A more detailed description can be found in Griffith, U.S. Pat. No. 5,449,553, which is incorporated herein by reference.
In addition to the above described ingredients, the respective parts of the two-part silicone RTV often contain major amounts of organic solvents, such as hydrocarbon solvents, for example mineral spirits, to facilitate application of these paint-like materials.
The epoxy-silicone-adhesive paint is preferably made by thoroughly blending SCM501C, a silicone adhesive of GE Silicones, Waterford, N.Y., with a suitable epoxy resin paint, such as AMERLOCK 400 FD, of the Ameron Co. of Brea, Calif. After the various ingredients have been thoroughly mixed, the resulting mixture can be applied at thicknesses of 4-10 mils, and preferably 6-8 mils, such as by spraying, as a second coat onto the surface of an epoxy-coated steel substrate. Effective bonding of the silicone bonding layer onto the treated epoxy substrate can be achieved after evaporation of volatiles as long as a tacky condition of the epoxy-silicone-adhesive layer is maintained. This feature can allow adequate work time, such as up to 20 hours or more.
While the aminoalkyltrialkoxysilane used in the practice of the invention is preferably γ-aminopropyltrimethoxysilane, other aminoalkyltrialkoxysilanes can be used such as, NH 2 RSi(OR 1 ) 3 , where R is methylene, dimethylene, or C.sub.(4-8) alkylene, and R 1 is C.sub.(2-8) alkyl resin in the epoxy-silicone-adhesive paint.
In order that those skilled in the art will be better able to practice the present invention, the following examples are given by way of illustration, and not by way of limitation. All parts are by weight unless otherwise indicated.
EXAMPLE 1
An epoxy-silicone-adhesive paint is prepared by thoroughly mixing together AMERLOCK 400 FD epoxy resin paint of the Ameron Co. of Brea, Calif., and 15% by weight of a silicone adhesion promoter. The silicone adhesion promoter, SCM501C, is a product of GE Silicones, Waterford, N.Y., and consists essentially of 62% by weight of mineral spirits, 11.3% of partially condensed ethyl silicate, 3.8% of solubilized dibutyl tin oxide, and 22.5% of γ-aminopropyltrimethoxysilane. The resulting epoxy-silicone-adhesive paint is sprayed onto a 6 inch×6 inch epoxy resin coated steel test panel. There is obtained a steel panel having a dual epoxy coating, and a 6-8 mil second coat. The resulting painted panel is allowed to air cure to a tacky state after four hours under ambient conditions.
There is painted onto the dual epoxy-coated steel panel, a silicone-bonding RTV composition, Silgan J-501 of the Wacker Silicones Corporation. A coating is formed after three hours which shows excellent adhesion to the dual epoxy-coated steel panel.
EXAMPLE 2
A epoxy-silicone-adhesive paint is prepared in accordance with example 1, consisting of AMERLOCK 400 FD epoxy resin paint, and 15% by weight of the silicone adhesion promoter. The paint blend is sprayed onto a 6 inch×6 inch steel test panel which is initially coated with a cured epoxy resin paint. There is obtained a steel panel having a dual epoxy coating with a 6-8 mil second coat.
Steel adhesion dollies are imbedded into the surface of the second paint coating on the steel panel surface. After a four-day cure time, the adhesion dollies are pulled using hydraulic adhesion testing equipment. The adhesion measurements are obtained in accordance with ASTM D-4541 for portable adhesion, using HATE MARK 1V test equipment of KTA Company, Pittsburgh, Pa. It is found that cohesive failure occurs in the cured adhesion promoter mixture at 300-325 psi, where cohesive means that a breakdown in the topcoat wall occurs instead of separation between topcoat and tiecoat.
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A method is provided for treating anti-corrosive steel surfaces, such an epoxy-coated ship's hull, in an environmentally improved manner, with an epoxy-silicone-adhesive paint, as a tiecoat, to provide for the subsequent application of silicone foul release coatings.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to plasma processing, and more specifically, to local plasma processing.
[0003] 2. Related Art
[0004] In a typical semiconductor structure fabrication process, the deposition of a film on a wafer can frequently result in the film being thinner on the edge of the wafer than on other parts of the wafer (i.e., under-deposition at wafer edge). In addition, a chemical mechanical polishing (CMP) process performed on the wafer usually has a higher CMP rate at the edge of the wafer than at other parts of the wafer (i.e., over-polish at wafer edge). As a result, integrated circuits formed near the edge of the wafer may be damaged by this nonuniformity.
[0005] Therefore, there is a need for a method (and an apparatus for performing the method) to compensate for the problems of under-deposition and over-polish at the edge of a wafer.
SUMMARY OF THE INVENTION
[0006] The present invention provides a structure processing method, comprising providing an apparatus, wherein the apparatus comprises (i) a chamber, (ii) a plasma device being in and coupled to the chamber, (iii) a shower head being in and coupled to the chamber, and (iv) a chuck being in and coupled to the chamber; placing a substrate on the chuck; using the plasma device to receive a plasma device gas and generate a plasma; directing the plasma at a pre-specified area on the substrate; and using the shower head to receive and distribute a shower head gas in the chamber, wherein the plasma device gas and the shower head gas are selected such that the plasma and the shower head gas when mixed with each other result in a chemical reaction that forms a film at the pre-specified area on the substrate.
[0007] The present invention also provides a structure processing method, comprising providing an apparatus, wherein the apparatus comprises (i) a chamber, (ii) a plasma device being in and coupled to the chamber, and (iii) a chuck being in and coupled to the chamber; placing a substrate on the chuck; using the plasma device to receive a plasma device gas and generate a plasma; and directing the plasma at a pre-specified area on the substrate, wherein the plasma device gas is selected such that particles of the plasma bombard the pre-specified area on the substrate essentially without chemically reacting with materials of the pre-specified area on the substrate.
[0008] The present invention provides a method (and an apparatus for performing the method) to compensate for the problems of under-deposition and over-polish at the edge of a wafer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates an apparatus, in accordance with embodiments of the present invention.
[0010] FIG. 2 illustrates a plasma device of the apparatus of FIG. 1 , in accordance with embodiments of the present invention.
[0011] FIGS. 3-8 illustrate different uses of the apparatus of FIG. 1 , in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] FIG. 1 illustrates an apparatus 100 , in accordance with embodiments of the present invention. In one embodiment, the apparatus 100 comprises a chamber 110 , a chuck 120 , a plasma device 130 , and a shower head 140 .
[0013] The chuck 120 is adapted for holding a wafer 150 for processing. The plasma device (also called plasma jet) 130 is adapted for receiving a plasma device gas and then generating a plasma at atmospheric pressure (i.e., around 1 atm) for processing a pre-specified area of the wafer 150 . The shower head 140 is adapted for receiving and distributing a shower head gas into the chamber 110 .
[0014] FIG. 2 illustrates one embodiment of the plasma device 130 of FIG. 1 , in accordance with embodiments of the present invention. Illustratively, the plasma device 130 comprises (i) a container 210 that also serves as a ground electrode of the plasma device 130 , (ii) a radio frequency electrode 220 , (iii) a gas inlet 230 , and (iv) a nozzle 240 . The plasma device 130 is adapted for receiving the plasma device gas via the gas inlet 230 , creating a plasma inside the container 210 , and outputting the plasma via the nozzle 240 .
[0015] With reference to FIGS. 1 and 2 , in one embodiment, either or both of the plasma device 130 and the chuck 120 are moved with respect to the chamber 110 such that the plasma output by the plasma device 130 via the nozzle 240 is directed at the pre-specified area of the wafer 150 . In addition, the plasma device gas and the shower head gas are selected such that the plasma output by the plasma device 130 and the shower head gas distributed by the shower head 140 when mixed with each other will result in chemical reactions forming a film (not shown) on the pre-specified area of the wafer 150 . After the film is deposited, if another film (not shown) is needed at another pre-specified area of the wafer 150 , the plasma output is re-directed at the another pre-specified area of the wafer 150 .
[0016] In an alternative embodiment, the plasma device gas is selected such that the plasma output by the plasma device 130 contains high ion densities that (i) drive off volatile constituents on the wafer 150 (i.e., drying) or (ii) modify a thin film (not shown) for the purpose of densification, annealing, curing, or cross-linking in the case of polymeric systems on the wafer 150 . For example, in one embodiment, the plasma device gas includes inert gases (e.g., Ar, etc.) or N2 so that the resultant plasma contains radicals that drive off rinsing species from the pre-specified area of the wafer 150 . After the pre-specified area of the wafer 150 is dried off, if another pre-specified area of the wafer 150 needs drying, either or both of the plasma device 130 and the chuck 120 are moved with respect to the chamber 110 such that the plasma output by the plasma device 130 via the nozzle 240 is directed at the another pre-specified area of the wafer 150 . The same plasma device gas (i.e., Ar or N2) can be used to densify, anneal, cure, or cross-link a film on the wafer 150 by heating the film to a high temperature. It should be noted that the plasma device gas is also selected such that the resultant plasma essentially does not chemically react with any material of the wafer 150 .
[0017] In one embodiment, the shower head 140 is omitted if the apparatus 100 of FIG. 1 is to be used to (i) drive off volatile constituents on the wafer 150 (i.e., drying) or (ii) densify, anneal, cure, or cross-link a film on the wafer 150 by heating the film to a high temperature.
[0018] FIGS. 3-8 illustrate different uses of the apparatus 100 of FIG. 1 , in accordance with embodiments of the present invention. More specifically, with reference to FIG. 3 , the apparatus 100 ( FIG. 1 ) is used for depositing a film 320 at a pre-specified location on the wafer 150 . For simplicity, hereafter, only the plasma device 130 instead of the entire apparatus 100 of FIG. 1 is shown in the figures. The positions of the plasma device 130 and/or the chuck 120 with respect to the chamber 110 are such that the nozzle 240 is pointed to the pre-specified location on the wafer 150 . In one embodiment, when the plasma generated by the plasma device 130 exits the plasma device 130 at the nozzle 240 , the plasma is mixed with the shower head gas distributed by the shower head 140 resulting in chemical reactions producing a material that deposits on the pre-specified location on the wafer 150 as the film 320 . The material may also deposit at other areas of the wafer 150 but with negligible amounts.
[0019] FIG. 4 is a table listing some illustrative film materials of the film 320 ( FIG. 3 ) and the corresponding plasma device gas and shower head gas that may be used to create the film 320 ( FIG. 3 ). With reference to both FIGS. 3 and 4 , for instance, assume the film 320 is to comprise silicon dioxide (SiO2). Then, silane (SiH4) may be used as the showerhead gas, and one or more of the group comprising O2, N2O, NO, CO2, and CO may be used as the plasma device gas. For instance, if oxygen (O2) is used as the plasma device gas, then the following chemical reaction occurs outside the nozzle 240 where the oxygen plasma exits the plasma device 130 and is mixed with the showerhead gas: SiH4+O2àSiO2+2H2. As a result, the resultant SiO2 deposits on the pre-specified location on the wafer 150 . In one embodiment, the pressure of the ambient inside the chamber 110 ( FIG. 1 ) is atmospheric (i.e., 1 atm) during the deposition. The flow rate for oxygen (plasma device gas) in the plasma device 130 is in a range of 10-1,000 sccm (Standard Cubic Centimeters per Minute). The flow rate of silane (showerhead gas) is in a range of 10-1,000 sccm. To maintain the chamber 110 ( FIG. 1 ) at atmospheric pressure, a dilutant gas (e.g., oxygen in this example) may be added in the showerhead gas (in addition to silane) at a flow rate in a range of 100-10,000 sccm.
[0020] As another example, assume the film 320 is to comprise tungsten (W). Then, inert gas (e.g., argon) and hydrogen (H2) may be used as the showerhead gas, and WF6 may be used as the plasma device gas. Then, the following chemical reaction occurs outside the nozzle 240 where the plasma exits the plasma device 130 and is mixed with the showerhead gas: WF6+3H2àW+6HF. As a result, the resultant tungsten (W) deposits on the pre-specified location on the wafer 150 .
[0021] With reference to FIG. 3 , in one embodiment, the film 320 is formed at the edge of the wafer 150 so as to compensate for under-deposition and/or over-polish (i.e., over-planarization) at the edge of the wafer 150 . In general, films (not shown) similar to the film 320 may be formed at locations (not necessarily at the wafer edge) of the wafer 150 that are thinner than average so as to compensate for an earlier over-etching and/or a subsequent under-deposition at these locations (over-etching and under-deposition may occur due to pattern/topology nonuniformity). For example, assume a tungsten layer (not shown) deposited on the wafer 150 using a traditional deposition method is thinner at first areas of high device density than at second areas of low device density. Then, the apparatus 100 of FIG. 1 may be used to deposit more tungsten (W) at the first areas where the W layer is thinner so as to compensate for the earlier under-deposition of tungsten there.
[0022] In one embodiment, the plasma device 130 can be stationary (i.e., fixed) with respect to the chamber 110 ( FIG. 1 ) while the wafer 150 is rotated around an axis perpendicular to the wafer 150 . Deposition time is such that the resultant film 320 has a thickness 322 not less than the required minimum thickness. For example, assume that a typical SiO2 film (not shown) deposited on top of the wafer 150 must have a thickness of at least 20 nm, and that the apparatus 100 ( FIG. 1 ) deposits SiO2 at 2 nm/wafer rotation. As a result, the deposition time (in terms of rotations) must be at least: 20 nm/(2nm/rotation)=10 rotations in this example. Assume further that it takes 1 sec for the wafer 150 to make one rotation. Then, the deposition time must be at least: 10 rotations×1 sec/rotation=10 sec.
[0023] FIG. 5 illustrates another use of the apparatus 100 ( FIG. 1 ), in accordance with embodiments of the present invention. More specifically, a chip 505 including a copper wire bond landing pad 510 and a gold wire bond 520 is placed on the chuck 120 of the apparatus 100 ( FIG. 1 ). Then, a SiO2 film 530 is deposited so as to seal off the connection between the copper pad 510 and the gold wire bond 520 . As a result, the connection between the copper pad 510 and the gold wire bond 520 is protected from corrosion. In an alternative embodiment, the film 530 comprises SiN (silicon nitride) instead of SiO2. In yet another alternative embodiment, the film 530 comprises first and second layers (not shown) of SiN and SiO2, respectively, with the first layer of SiN being sandwiched between and in direct physical contact with the copper wire bond landing pad 510 and the second layer of SiO2. Illustratively, the apparatus 100 ( FIG. 1 ) can be used to form the first layer of SiN on the copper wire bond landing pad 510 first, and then form the second layer of SiO2 on the first layer of SiN resulting in the film 530 .
[0024] FIG. 6 illustrates yet another use of the apparatus 100 ( FIG. 1 ), in accordance with embodiments of the present invention. More specifically, the apparatus 100 of FIG. 1 is used to deposit a SiO2 film 620 so as to passivate (seal off) a top surface of a crackstop/through via 610 so as to protect the crackstop/through via 610 from corrosion. The crackstop/through via 610 usually comprises an electrically conducting material (e.g., Al, Cu, and W). Therefore, the SiO2 film 620 helps prevent corrosion of this electrically conducting material. In an alternative embodiment, the film 620 comprises SiN (silicon nitride) instead of SiO2. In yet another alternative embodiment, the film 620 comprises third and fourth layers (not shown) of SiN and SiO2, respectively, with the third layer of SiN being sandwiched between and in direct physical contact with the crackstop/through via 610 and the fourth layer of SiO2. Illustratively, the apparatus 100 ( FIG. 1 ) can be used to form the third layer of SiN on the crackstop/through via 610 first, and then form the fourth layer of SiO2 on the third layer of SiN resulting in the film 620 .
[0025] FIG. 7 illustrates yet another use of the apparatus 100 ( FIG. 1 ), in accordance with embodiments of the present invention. More specifically, the apparatus 100 of FIG. 1 is used to precisely deposit a SiO2 ring 720 on the wafer 150 . Then, a chip 730 is placed on the wafer 150 and inside the ring 730 . In other words, the ring 720 serves as a positioning reference for the placing of the chip 730 . Because the SiO2 ring 720 can be placed on the wafer 150 at a pre-specified location with high precision, the chip 730 can be placed on the wafer 150 at the specified location also with high precision.
[0026] FIG. 8 illustrates yet another use of the apparatus 100 , in accordance with embodiments of the present invention. More specifically, the apparatus 100 of FIG. 1 is used to deposit a ring 820 at a pre-specified location on the wafer 150 . Then, a cooling pad 830 is placed on the ring 820 without being in direct physical contact with the wafer 150 . The cooling pad 830 is adapted for absorbing the heat generated by devices (not shown) formed on the wafer 150 directly beneath the cooling pad 830 . In one embodiment, the ring 820 comprises SiO2.
[0027] In summary, with reference to FIG. 1 , the apparatus 100 may be used to deposit films of different materials at pre-specified locations on the wafer 150 . The apparatus 100 may also be used to (i) drive off volatile constituents on the wafer 150 (i.e., drying) or (ii) modify a thin film (e.g., densification, annealing, curing, or cross-linking of the film) on the wafer 150 .
[0028] In one embodiment, the apparatus 100 has multiple plasma devices (not shown) similar to the plasma device 130 so that (a) multiple films (not shown) similar to the film 320 ( FIG. 3 ) can be simultaneously formed on different pre-specified locations of the wafer 150 , and (b) different pre-specified locations of the wafer 150 can be simultaneously dried by directing the plasma outputs of the multiple plasma devices at the different pre-specified locations of the wafer 150 .
[0029] While particular embodiments of the present invention have been described herein for purposes of illustration, many modifications and changes will become apparent to those skilled in the art. Accordingly, the appended claims are intended to encompass all such modifications and changes as fall within the true spirit and scope of this invention.
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A method and an apparatus for performing the method. The method includes: (a) providing an apparatus, wherein the apparatus comprises (i) a chamber, (ii) a plasma device being in and coupled to the chamber, (iii) a shower head being in and coupled to the chamber, and (iv) a chuck being in and coupled to the chamber; (b) placing the substrate on the chuck; (c) using the plasma device to receive a plasma device gas and generate a plasma; (d) directing the plasma at a pre-specified area on the substrate; and (e) using the shower head to receive and distribute a shower head gas in the chamber, wherein the plasma device gas and the shower head gas are selected such that the plasma and the shower head gas when mixed with each other result in a chemical reaction that forms a film at the pre-specified area on the substrate.
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This invention relates to well casing support systems, and more particularly to systems for suspending casing strings by hangers located in subsea wellheads.
BACKGROUND OF THE INVENTION
Most of the subsea well casing suspension systems currently employed in, or otherwise known to, the petroleum industry comprise a stacked downhole nesting of casing hangers, i.e., each progressively smaller hanger is stacked on, and thus supported by, the top of the previously installed hanger, whereby the total hang load of all the casing strings and their hangers plus the operating pressures in the well to which said strings and hangers are subjected is transferred to the wellhead at a single location near its base. There is a growing need in this industry for casing suspension systems capable of supporting hang loads and operating pressures considerably in excess of those for which the foregoing stacked systems were designed, and lately some higher performance designs have been proposed. However, each of these later designs results in placing all, or almost all, casing hang load and pressure load in a load path connection to a compressive load-carrying, hanger-bearing shoulder at the wellhead base. This stacked arrangement limits the hanger load carrying capability of the entire system, especially where it is exposed to a hydrogen sulfide environment which requires use of lower strength steels.
SUMMARY OF THE INVENTION
Broadly considered, the present invention involves an improved system for suspending well casing in a subsea wellhead, and more specifically a casing suspension system whereby each of a plurality of concentric casing strings and its hanger is directly and totally supported on the wellhead housing, independently of all the other strings and their hangers, by a plurality of expandable load ring slips that are run into the housing in retracted position with, and as a component of, the previous casing's packoff assembly. When the packoff assembly is pressure tested following its installation, the load ring slips expand radially into an annular groove in the inner surface of the housing, and as this expansion occurs the slips rise off the packoff assembly into proper position for supporting the next casing hanger. When this next hanger is lowered into the wellhead housing it precisely positions the load ring slips against the groove prior to imposing the hanger load on them, and in this final position the slips are spaced above, and thus out of contact with, the packoff assembly, resulting in a direct and compressive transfer of the total casing hang load onto the wellhead housing.
Since each casing string is supported by the wellhead housing independently of the other strings, the total load exerted by the casing strings, their hangers, and well test pressure that the suspension system of this invention can support is significantly greater than that supportable by other systems of comparable size. This increase is achieved even when lower strength materials are employed, such as is necessitated by the presence of hydrogen sulfide in the well. The improved load-carrying capability of this new system also facilitates deeper drilling programs to be accomplished offshore from floating drilling rigs.
Further benefits forthcoming from the casing suspension system of this invention include (1) all load ring slips are identical in manufacture and installation, (2) the packoff assemblies which also function as carriers for these slips are identical for all hangers, (3) prior to the installation of each casing hanger any cement or trash (contaminants) can be removed from the load ring slip groove by washout, and (4) the sealing areas for the packoff seal can be mechanically cleaned easily by means of a single running tool. For well completions, tie-back hanger sleeves can be stabbed into each casing hanger, tie-back hangers can be installed, locked and sealed by mechanical functions performed at the drilling deck, and other subsea completion equipment can be installed on the wellhead without requiring modification of design or procedures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary vertical central section through a subsea casing hanger suspension system according to the present invention, showing three concentric casing strings and their hangers installed in a wellhead housing.
FIG. 2 is an enlarged fragmentary view of the uppermost casing hanger and adjacent elements of FIG. 1.
FIG. 3 is a fragmentary vertical central section through a packoff assembly according to the present invention.
FIG. 4 is a view of two adjacent load ring slips and their retainer taken along the line 4--4 of FIG. 3.
FIG. 5 is a view similar to FIG. 4, but showing the load ring slips in their expanded position.
FIG. 6 is a view taken along the line 6--6 of FIG. 3, but with the load ring slips in their expanded position as in FIG. 5.
FIGS. 7-9 are fragmentary sequential operational views of a packoff assembly during its installation in a wellhead housing.
FIG. 10 is a view like FIGS. 7-9, showing the packoff assembly after installation and pressure testing.
FIGS. 11 and 12 are views like FIGS. 7-10, showing the packoff assembly as it is being removed from the wellhead housing.
FIGS. 13-15 are views like FIGS. 4-6, showing another embodiment of load ring slips and their retainers.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, a subsea casing hanger suspension system according to the present invention comprises a casing hanger for each string of casing to be suspended, herein three hangers 20, 22, 24 for suspending three concentric casing strings 26, 28, 30, respectively, a packoff assembly with a plurality of load ring slips for each hanger, herein three assemblies 32, 34, 36 for the hangers 20, 22, 24 respectively, and a wellhead housing 38 in which the casing strings, their hangers and their packoff assemblies are installed. The wellhead housing 38 includes an annular shoulder 40 near its lower end to support the lowermost casing hanger 24, and spaced inner annular grooves 42, 44, 46 for receiving and supporting the load ring slips 48, 50, 52, respectively.
The packoff assemblies 32, 34, 36 are identical, and thus a description of the assembly 34 (seen best in FIGS. 2 and 3) is equally applicable to the assemblies 32, 36. The assembly 34 comprises an upper body 54, a lower body 56 connected to the upper body 54 by threads 58, an expander mandrel 60 surrounding the upper portion of the upper body 54, an axially split lock ring 62 surrounding (FIG. 3) the upper body 54 below the expander mandrel 60, a frusto-conical energizing spring bushing 64 (FIG. 3) surrounding the upper body 54 below the lock ring 62, an anti-rotation ring 66 in and keyed to the upper end of the lower body 56, inner and outer annular packings 68,70 each comprising a compression set seal 72 and a pair of anti-extrusion metal rings 74, and a junk ring 76 secured to the lower end of the lower body 56, as by a plurality of circumferentially spaced cap screws 78 (only one shown), to retain the packings 68, 70 in position. As shown in FIG. 3 the anti-rotation ring 66 is releasably secured to the upper body 54 by a plurality of circumfrentially spaced shear pins 80 (two shown), and the entire packoff assembly 34 is releasably secured to a packoff running tool (not shown) by a shear pin 82 (portion only shown). A snap ring 84 between the expander mandrel 60 and the upper body 54 functions to axially retain the mandrel on the upper body, and a longitudinal key 86 secured to the bore of the mandrel cooperates with a keyway 88 on the opposed surface of the upper body to prevent relative rotation of the mandrel and the upper body while facilitating relative axial movement therebetween.
At the upper end of the expander mandrel 60 is a plurality (preferably six) of arcuate load ring slips 50 arranged end-to-end to form an annular load bearing shoulder for supporting the casing hanger 20 directly and totally on the wellhead housing 38. As seen best in FIGS. 2 and 4-6, the slips 50 are secured to the mandrel 60 by a plurality of circumferentially spaced retainers 90 located between the opposed ends of adjacent slips. The retainers 90 have a somewhat I-shaped configuration in front elevation, and a generally triangular-shaped configuration when viewed in plan. The retainers 90 reside in inverted T-shaped radial slots 92 in the end face of the mandrel 60 and are secured therein by axially-extending retainer cap screws 94, which screws 94 are secured in place by set screws 96.
As seen best in FIGS. 4-6, the opposed ends of adjacent load ring slips, for example 50a, 50b, have angular axial surfaces 98, 100, 102 and 104 and radial surfaces 106 and 108, respectively, that cooperate with adjacent angular surfaces 110, 112, 114 and 116 and radial surface 118, respectively, of the adjacent slip retainer 90 to retain the slips on the expander mandrel 60, while facilitating free radial movement of the slips with respect to the mandrel between their retracted position (FIG. 4) and their expanded position (FIG. 5). The bottom side of each end portion of each of the slips 50a, 50b has an elongated slot 120 into which projects a pin or cap screw 124 that extends upwardly from the top surface of the expander mandrel 60. The slots 120 and the pins 124 cooperate with the retainer 90 and the corresponding slip surfaces 106, 108 to direct radial movement of the slips 50a, 50b between their retracted (FIG. 4) and expanded (FIG. 5) positions, and the limits of such radial movement are defined by the amount of travel permitted by the length of the slots with respect to the diameter of the pin or of the head of the cap screw.
Each of the load ring slips 50 has a multisided configuration when viewed in cross section (FIGS. 1-3), including upper, intermediate and lower inner sloping surfaces 126, 128 and 130, respectively, an upper outer sloping surface 132, an intermediate outer axial toothed surface 134, a lower outer sloping surface 136, and a radial bottom surface 138. The upper and intermediate inner sloping surfaces 126, 128 cooperate with the packoff running tool (not shown) to effect a ramp wedging of the load ring slips outwardly from their retracted position (FIGS. 3 and 4) toward their fully expanded position (FIGS. 2 and 5), and also to provide a support seat for the casing hanger 20 which has correspondingly sloped annular surfaces 140, 142. The lower outer sloping surface 136 of the slips 50 cooperates with the opposed annular lower sloping surface 144 of the wellhead housing groove 44 to effect a rise of the slips off of the top of the packoff assembly, and specifically off of the expander mandrel 60, as the slips are expanded, and also to provide a strong annular seat for directly supporting the slips on, and transferring the compressive load imposed on the slips by the hanger 20 to, the wellhead housing 38. The outer axial toothed surface 134 of the slips 50 engage the axial surface of the groove 44 (FIG. 2) and thus assist in providing a secure support for the hanger 20 on the wellhead housing 38. The upper outer sloping surface 132 of the slips 50 cooperates with the annular upper sloping surface 146 of the wellhead housing groove 44 to cam the slips inwardly toward their retracted position as the packoff assembly 34 is lifted out of the wellhead (FIGS. 11 and 12).
OPERATION/FUNCTION
Installation of First Casing Hanger and Packoff Assembly
The subsea casing hanger suspension system of the present invention is designed for efficient drilling operations with minimum engagement/installation operations from the drilling deck. No thread engagement is required downhole until a tieback or completion operation is required.
The first (largest) casing string 30, including its hanger 24, is lowered into the well until the hanger shoulder 148 lands on the wellhead housing shoulder 40, and the casing 30 is then cemented in place. It should be noted that in this casing hanger suspension system the wellhead housing shoulder 40 is required to support only the casing string 30 and its hanger 24.
The packoff sealing areas of the wellhead housing and the hanger 24, i.e., those areas against which the packoff assembly packings 70, 68, respectively will interface, are cleaned by known methods. The packoff assembly 36 is releasably secured to a running tool (not shown) by a plurality of threaded shear pins 82 (FIG. 3) (one shown) and the assembly run (lowered) on drill pipe (not shown) until it lands on the upper shoulder 150 (FIG. 2) of the hanger 24, thereby placing the packoff assembly lock ring 62 in alignment with its mating annular groove 152 in the wellhead housing 38 (FIGS. 1 and 7). The lock ring 62 remains retracted within the wellhead housing bore until the expander mandrel 60 is forced downward by the running tool. The running tool is then rotated to the right, thereby shearing the pins 82 since the packoff assembly upper body 54 and lower body 56 are held against relative rotation by the anti-rotation ring 66, and the lower body is anti-rotationally keyed at 154 (FIGS. 1 and 2) to the adjacent casing hanger. The running tool then drops, forcing the expander mandrel downward and partially expanding the lock ring 62 into the groove 152, as shown in FIG. 8.
As the running tool rotates it aligns with vertical axial slots (only one shown) 156 in the packoff assembly upper body 54 and drops further, causing the pins 80 to shear and the anti-rotation ring 66 to move downward out of engagement with the upper body 54 (FIG. 8), thereby freeing the upper body to rotate, and fully expanding the lock ring 62 into the groove 152.
Further right-hand rotation of the running tool now also rotates the packoff assembly upper body 54, and as this rotation occurs the threads 58 cause the upper body and the lower body 56 to separate, resulting in a compressive force contained between the lock ring 62 and the casing hanger 24 that actuates the dual packings 68, 70 into a fluid tight seal of the annulus between the hanger and the wellhead housing, as shown in FIG. 9.
Testing the Packoff Assembly
The packings 68, 70 are then tested by closing the blowout preventers and pressuring up through the kill line. This pressure causes the running tool to drop further until it comes to rest on top of the load ring slips 50. As this downward movement, occurs the slips 50 are expanded outwardly and upwardly into their mating wellhead housing groove as shown in FIG. 10. This expansion of the slips 50 is accomplished by a ramp wedging action outward on the slips prior to imposition of the running tool weight on the slips, thereby assuring that the slips are properly in place in their wellhead housing groove before accepting any loading, and thus avoiding placement of loading on the packoff assembly.
If the pressure test is successful, the running tool is removed by release of the test pressure, opening the blowout preventers, applying drill string pressure to the running tool to release it from the packoff assembly, and lifting the tool from the wellhead housing.
If the pressure test is unsuccessful, the packoff assembly is retorqued for retesting, or released for removel. If removal is required, the packoff assembly is released by lifting the expander mandrel 60 with a separate retrieving tool, thereby releasing the lock ring 62 from its wellhead housing groove (FIG. 11). As lifting continues the load ring slips 50 are cammed inwardly from their wellhead housing groove into retracted position (FIG. 12). An annular sleeve (spring-loaded) is forced down over the load, and ring slips and the retracted slips 50 are locked in their retracted position by this sleeve on the retrieving tool for removal from the well without interference.
Installation of Subsequent Casing Hangers
Following completion of the next size drilling program, during which the load ring slips 50 of the packoff assembly 36 have been held in expanded position by a bowl protector, the next casing string 28 and its hanger 22 are lowered into the well until the hanger lands on the expanding slips. All subsequent operations are identical to those described above for each casing string/hanger installation.
EMBODIMENT OF FIGS. 13-15
FIGS. 13-15 illustrate a modified version of the load ring slips and their retainers. In this embodiment the opposite ends of the slips 160 are identical, each end having an angular vertical surface 162, a horizontal surface 164 extending from the vertical surface 162, and a central relieved area 166 in the flange-like extension 168 that cooperates with a pair of vertical pins 170 to limit expansion and retraction of the slip to a selected distance. The pins 170 extend between the modified retainer 172 and holes 174 in the upper end of the packoff assembly expander mandrel 176. When viewed in plan the upper portion of the modified retainer 172 has a truncated pyramid shape (FIGS. 13 and 14) and a somewhat wider upper portion (FIG. 15) than that of the corresponding portion of the retainer 90. In functional aspects, however, the slips 160 and their retainers 172 are the same as their preferred embodiment counterparts.
Although the foregoing description of the apparatus of this invention and the procedure employed in its installation in a subsea well is for a specific casing string program, it should be understood that said apparatus and procedure is applicable to any casing string program required for drilling subsea wells where multiple concentric casing strings are configured on stacked hangers with restricted annulus clearances between casing strings.
Although the best mode contemplated for carrying out the present invention has been herein shown and described, it will be apparent that modification and variation may be made without departing from what is regarded to be the subject matter of the invention.
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A subsea well casing suspension system whereby each of a plurality of concentric casing strings and its hanger is directly and totally supported on the wellhead housing, independently of all the other strings and their hangers, by a plurality of load ring slips that are components of a packoff assembly for an earlier installed casing string. When the packoff assembly is pressure tested following its installation, the load ring slips rise off the assembly and expand into their mating wellhead housing groove wherein they function to transmit the total hang load of the next casing string and hanger directly to that housing.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a divisional application of U.S. patent application Ser. No. 11/181,161, filed on Jul. 14, 2005, which is a continuation of international application PCT/EP2003/002345, filed 7 Mar., 2003, and which designates the U.S. The disclosure of the referenced applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method for spinning and crimping a synthetic multifilament yarn, as well as an apparatus for spinning and crimping a synthetic multifilament yarn.
[0003] In the production of a crimped yarn, a plurality of strandlike filaments are extruded in a first step from a thermoplastic melt by means of a spin unit. After cooling, the filament bundle is combined and subsequently compressed to a yarn plug by means of a crimping device. In this process, the filaments of the filament bundle are deformed in the yarn plug to loops and coils by means of a preferably heated fluid. To realize such a deformation of the filaments, the crimping device includes a stuffer box chamber, in which the conveying medium compresses the filament bundle to the yarn plug. Thus, the desired loops and coils of the individual filaments form, as the filaments impact upon the yarn plug inside the stuffer box chamber.
[0004] To obtain as much as possible a stable crimp, it is preferred to advance the yarn through a heated conveying medium and to heat it at the same time, so that a plastic deformation is able to occur in the individual filaments. To set the crimp, the yarn plug advances through a cooling zone. The cooling zone is formed by a cooling groove preferably on the circumference of a rotating cooling drum. In this arrangement, the length of the cooling zone is defined by the diameter of the cooling drum and by a partial looping on the circumference of the cooling drum. During the cooling, the cooling drum is driven for rotation, so that the circumferential speed of the cooling groove equals the cooling speed of the yarn plug, at which the yarn plug advances through the cooling zone. A method and an apparatus of this type for spinning and crimping a synthetic multifilament yarn are disclosed, for example, in DE 196 13 177 A1.
[0005] According to DE 196 13 177 A1, a most effective and uniform cooling of the yarn plug requires a defined duration of the cooling. Thus, the art proposes to increase the dwelling time in that the yarn plug advances with a partial looping over a second, subsequent cooling drum. With that, however, it is not possible to achieve an uninterrupted, uniform cooling of the yarn plug, since the transition from the first cooling drum to the second cooling drum represents each time an undefined interruption of the cooling process.
[0006] U.S. Pat. No. 5,974,777 discloses a method and an apparatus for cooling a yarn plug, wherein the yarn plug advances with several loopings over the circumference of a cooling drum. While this procedure permits achieving longer dwelling times for cooling the yarn plug even at higher process speeds, it has the disadvantage that the combined yarn plugs interfere with one another on the circumference of the cooling drum, so that, for example, individual filaments of adjacent plugs interlock and lead to undesired filament breaks upon disentanglement of the plugs. In addition, it is necessary to displace the yarn plugs on the cooling drum surface, so that additional shearing forces act upon the plug. Furthermore, such a displacement on the circumference of the cooling drum may cause individual filaments to interlock on the cooling surface.
[0007] It is therefore an object of the invention to further develop a generic type of method and apparatus for spinning and crimping a synthetic multifilament yarn such that after cooling the yarn plug, it is ensured that a stable and high crimp of the yarn is achieved irrespective of the production speed.
SUMMARY OF THE INVENTION
[0008] The invention is based on the discovery that the dwelling time of the yarn plug within the cooling zone or in the cooling groove is the decisive parameter for cooling the yarn plug. Known as further parameters for cooling the yarn plug are the temperature difference between the yarn plug and the cooling medium as well as the volume flow of the cooling medium. However, the influence of these parameters is small in proportion with the duration of the cooling. For example, in tests with a textured yarn of a polyamide PA6 it was possible to find that duplicating the time from 0.25 seconds to 0.5 seconds resulted in an improvement of the crimp of about 10%. A further duplication of the cooling period from 0.5 seconds to 1 second allowed to achieve a further improvement of the crimp of 4%. This asymptotic behavior between dwelling time and crimp applies to all types of polymers. Thus, the length of the cooling zone and the cooling speed of the yarn plug are decisive parameters for the cooling period of the yarn plug. The method of the invention is characterized in that the length of the cooling zone and the cooling speed of the yarn plug are proportionate to each other, so that the yarn plug is cooled in the cooling groove over a period of at least one second. This ensures a substantially complete cooling of the yarn plug, so as to permit attaining a high degree of crimp in the yarn.
[0009] In making further use of the asymptotic behavior between the duration of the cooling and the crimp of the textured yarn, the length of the cooling zone and the cooling speed of the yarn plug are preferably selected such that the yarn plug is cooled on the circumference of the cooling drum over a period of at least two seconds.
[0010] In this process, there basically exist two possibilities of maintaining the ratio of the length of the cooling zone to the cooling speed of the yarn plug, which is decisive for cooling the yarn plug. Thus, a predetermined cooling speed permits varying the length of the cooling zone, or a predetermined length of the cooling zone permits changing the cooling speed of the yarn plug. The cooling length is largely defined by the constructional condition of the cooling groove that is provided for receiving the yarn plug, and is often limited by an allowed space. However, to maintain even in the case of relatively short cooling zones, the decisive ratio of length of the cooling zone to cooling speed of the yarn plug, it is preferred to use the variant of the method, wherein the yarn plug advances before cooling at a yarn advancing speed, and during the cooling at a cooling speed, with the cooling speed being lower than the yarn advancing speed. Thus, more yarn plug material advances to the cooling zone per unit time. Consequently, the greater the difference is between the yarn advancing speed and the cooling speed, the longer the period for cooling the yarn plug.
[0011] With the use of the advantageous further development of the method according to the invention, wherein at the beginning of the cooling zone, the yarn plug is laid in the cooling groove in meander form, preferably in a plurality of superposed layers, it is possible to achieve a uniform filling of the groove and with that a uniform cooling of the yarn plug.
[0012] Preferably, the yarn plug is cooled by a cooling medium flow that penetrates the yarn plug. To this end, it is possible to generate the cooling medium flow by a source of vacuum. To intensify cooling, it also possible to use a source of overpressure to generate an additional cooling medium flow, which is blown, for example, as cooling air, onto the yarn plug.
[0013] The method of the invention is characterized by a clearly increased crimp in the yarn. A carpet produced from such a yarn exhibited a high cover ability without any streak or cloud formation.
[0014] The method of the invention is suited for all polymer types, such as, for example, PA and PP.
[0015] To be able to carry out the method of the invention, the apparatus of the invention has been found particularly suitable, and wherein the width of the cooling groove for receiving and advancing the yarn plug is dimensioned such that the yarn plug is allowed to advance in meander form in a plurality of superposed layers. This allows to ensure an intensive cooling of the yarn plug even at high process speeds, since the yarn advancing speed can be adjusted substantially higher than the cooling speed of the yarn plug.
[0016] To achieve a uniform filling of the cooling groove, a spacing is adjusted between the outlet of the texturing device and the cooling groove, with the width of the cooling groove being at least twice as large as the diameter of the yarn plug.
[0017] Basically, the cooling groove can be provided on a belt-type carrier, or according to an advantageous further development of the invention, on the circumference of a cooling drum. This construction permits controlling the cooling speed for advancing the yarn plug in a simple manner by the drive of the cooling drum.
[0018] Preferably, a source of vacuum is associated to the cooling drum, which permits generating a cooling medium flow that penetrates the yarn plug and the screen-type bottom of the cooling groove.
[0019] For additionally cooling the yarn plug inside the cooling groove, an additional blower with a source of overpressure may be associated to the cooling drum, which permits generating an additional cooling medium flow that is directed into the cooling groove and onto the yarn plug.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following, the method of the invention is described in greater detail by reference to preferred embodiments of the apparatus according to the invention. In the drawing:
[0021] FIG. 1 is a schematic view of a first embodiment of the apparatus according to the invention;
[0022] FIG. 2.1 is a schematic fragmentary side view of the embodiment of FIG. 1 ;
[0023] FIG. 2.2 is a schematic end view of the crimping device and the cooling device as shown in FIG. 2.1 ;
[0024] FIG. 3 is a schematic view of a diagram for illustrating the interdependence of the cooling period of the yarn plug and the crimp of the yarn; and
[0025] FIG. 4 is a schematic view of a further embodiment for cooling the yarn plug.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] FIG. 1 schematically illustrates a first embodiment of an apparatus according to the invention for carrying out the method of the invention. The apparatus comprises a spin unit 1 that connects via a melt supply line 3 to a melt producer, for example, a pump or an extruder (not shown). The spin unit 1 contains a spin head 2 which mounts on its underside at least one spinneret 4 . The spinneret 4 includes a plurality of spin holes, through which a polymer melt supplied to the spin head 2 is extruded under pressure to a plurality of individual filaments 6 . Downstream of the spin unit 1 , a cooling shaft 5 is provided, through which the filaments 6 advance, so that the filaments emerging at approximately the melt temperature are cooled. To this end, the cooling shaft 5 could be connected, for example, to a cross-flow quench system, which blows a cooling air substantially crosswise to the filaments 6 .
[0027] In the outlet region of the cooling shaft 5 , a yarn guide and a yarn lubrication device 8 extend. The yarn lubrication device 8 applies to the filaments 6 a lubricant, so that the filaments 6 combine to a filament bundle 10 . A yarn feed godet unit 9 downstream of the cooling shaft 5 withdraws the filament bundle 10 from the spinneret 4 , and advances it to a subsequent draw godet unit 12 . From the draw godet unit 12 , the filament bundle 10 enters a crimping device 7 . In the crimping device 7 , the previously drawn filament bundle 10 is compressed to a yarn plug 13 .
[0028] Arranged downstream of the crimping device 7 is a cooling device 11 with a moving cooling groove 26 . The cooling groove 26 serves to receive and cool the yarn plug 13 . The construction and operation of the cooling device 11 will be described in greater detail in the following. To disentangle the yarn plug 13 , a withdrawal godet unit 14 withdraws the crimped yarn 15 , and advances it to a takeup unit 16 . In the takeup unit 16 , the crimped yarn 15 is wound to a package 17 .
[0029] The construction and arrangement of the individual units of the embodiment shown in FIG. 1 are exemplary. For example, it is possible to supplement, exchange, or replace the treatment devices and guide elements. To produce a yarn cohesion of the filaments or the crimped filaments, it is possible to arrange an entanglement device 18 upstream and/or downstream of the crimping device.
[0030] The embodiment of the apparatus according to the invention as shown in FIG. 1 is particularly suited for producing carpet yarns. To this end, it is necessary that the crimped yarn have a crimp that is adequate for final processing. Thus, the crimping device 7 and the cooling device 11 downstream thereof represent an important treatment step, which will be described in greater detail in the following.
[0031] FIG. 2.1 illustrates a fragment of the embodiment of FIG. 1 , and is a schematic cross sectional view of the crimping device 7 and the subsequent cooling device 11 . FIG. 2.2 is a schematic end view of the units. Unless specific reference is made to one of the Figures, the following description will apply to both Figures.
[0032] FIGS. 2.1 and 2 . 2 illustrate the crimping device 7 and the cooling device 11 downstream of the crimping device 7 of the embodiment of the apparatus according to the invention as shown in FIG. 1 . The crimping device 7 comprises a nozzle-shaped yarn feed channel 20 . The yarn feed channel 20 essentially consists of two sections, which are separated from each other by a narrowest cross section. In a first section, a short distance upstream of the narrowest cross section, the nozzle holes of an injector 19 extend into the yarn feed channel 20 . The injector 19 connects to a source of fluid (not shown). In the second section, downstream of the narrowest cross section, the yarn feed channel 20 widens and ends in a directly following stuffer box chamber 22 .
[0033] In the inlet region of the stuffer box chamber 22 , the wall of the stuffer box chamber is made air permeable, and arranged inside a pressure relief chamber 21 . Downstream of the pressure relief chamber 21 , the stuffer box chamber 22 continues in the form of a discharge channel 23 having a substantially unchanged cross section. The end of the discharge channel 23 forms a plug outlet 24 .
[0034] The cooling device 11 is constructed as a rotatable cooling drum 25 . The cooling drum 25 is driven at a circumferential speed via a drive shaft 30 by a drive 31 ( FIG. 2.2 ). To receive the yarn plug 13 produced by the crimping device 7 , the cooling drum 25 comprises a cooling groove 26 that extends over its circumference. A bottom 27 of the cooling groove 26 is made air permeable, so that a cooling medium flow that is preferably generated from the outside inward, penetrates and cools the yarn plug 13 advancing in the cooling groove 26 . To this end, a pressure chamber 34 is formed in the interior of the cooling drum 25 , which connects via a suction line 28 to a source of vacuum 29 . With that, the ambient air outside the cooling drum 26 is used as medium for cooling.
[0035] The cooling groove 26 formed on the circumference of the cooling drum 25 has a width B. The width B of the cooling groove 26 is dimensioned in relation to the yarn plug 13 such that the width B is preferably greater than twice the amount of the yarn plug diameter D, i.e., B > 2D.
[0036] Between the plug outlet 24 and the cooling groove 26 , a free spacing A extends to permit an unobstructed deposit of the yarn plug 13 in the cooling groove 26 . During the crimping process, the spacing A remains unchanged.
[0037] In the crimping device 7 , a heated conveying fluid enters the yarn feed channel 20 via the injector 19 . This causes a suction effect to develop at the upper end of the yarn feed channel 20 , which sucks the filament bundle 10 into the crimping device 7 . The conveying fluid advances the filament bundle 10 through the yarn feed channel 20 into the stuffer box chamber 22 . In the stuffer box chamber 22 , the filament bundle 10 compacts to a yarn plug 13 . In so doing, the filament bundle 10 opens up, and the individual filaments come to lie on top of one another in loops and coils. In this process, the formation of the yarn plug 13 is largely defined by the quality of the conveying fluid and by the pressure of the conveying fluid. As conveying fluid it is preferred to use hot air. To decrease the pressure of the conveying fluid, the upper region of the stuffer box chamber 22 is made air permeable in the form of air slots or lamellas, so that the conveying fluid is able to escape into a pressure relief chamber 21 and from there to the outside.
[0038] The yarn plug 13 advances at a defined, adjusted speed v F through the stuffer box chamber 22 to the plug outlet 24 . From there, the yarn plug 13 enters the cooling groove 26 at the yarn advancing speed v F . The cooling groove 26 moves at a cooling speed v K , which is defined by the circumferential speed of the cooling drum 25 . The cooling speed v K is adjusted substantially lower than the yarn advancing speed v F . As a function of the ratio of the yarn advancing speed to the cooling speed, the yarn plug 13 is deposited in the cooling groove 26 in multiple layers and in meander form because of the unobstructed advance. In this connection, the width B of the cooling groove 26 and the ratio of the yarn advancing speed to the cooling speed are adapted to each other such that they allow the yarn plug 13 to fill the cooling groove 26 uniformly.
[0039] The yarn plug 13 advances through the cooling zone on the circumference of the cooling drum 25 . The cooling zone is defined by the degree of the looping of the yarn plug 13 on the cooling drum 25 . In the embodiment of FIG. 2.1 , the yarn plug 13 loops the cooling drum 25 at an angle of 180°. Within the cooling zone, the yarn plug 13 undergoes a cooling by the cooling medium flow that is generated from the outside inward. After cooling, the yarn plug 13 is disentangled at the end of the cooling zone to form the crimped yarn 15 .
[0040] The length of the cooling zone is determined by the diameter of the cooling drum 25 and the degree of looping of the yarn plug 13 on the circumference of the cooling drum 25 . Cooling drums 25 normally have a diameter from 0.3 to 0.6 m. In an example, a cooling drum with a diameter of 400 mm was used. With a looping angle of 180°, this resulted in a length of the cooling zone of about 0.6 m. The yarn advancing speed v F was 90 m/min. The cooling speed v K was adjusted to 20 m/min. This resulted in a cooling time of about 1.8 seconds for cooling the yarn plug. With that, it was ensured that the yarn plug underwent an intensive cooling after advancing through the cooling zone, and that the yarn 15 thus exhibited a stable and high crimp.
[0041] In FIG. 3 , a diagram illustrates the interdependence of time for cooling the yarn plug and the crimp in the produced crimped yarn. The illustrated slope of the curve makes it clear that in the range of less than 1 sec. cooling time, a high dependence exists between the cooling time and the crimp. As the cooling time increases, the curve becomes flatter to approximate asymptotically a limit value of the crimp. This relation between the cooling time and the crimp of the crimped yarn basically applies to all polymer types. In this respect, the method of the invention ensures that at a minimum cooling time of 1 second, preferably 2 seconds, a high degree of crimp is obtained in the produced yarn.
[0042] Tests with an additional cooling of the yarn plug by unheated air further resulted in that the positive effect of cooling with unheated air sets in only at longer dwelling times of about 0.5 seconds. Thus, the method of the invention accomplishes a maximum of crimp stability and crimp irrespective of the way of cooling the yarn plug.
[0043] Preferably, a uniform filling of the cooling groove 26 on the circumference of the cooling drum 25 is achieved. The multilayer deposit of the yarn plug in meander form is adjusted such that no significant gaps form within the cooling groove 26 . This results in a uniform flow resistance and thus in a uniform cooling of the yarn plug. The deposit of the yarn plug can be influenced by additional guide elements. However, the random orientation of the yarn plug in the cooling groove can also be realized in a simple manner by adjusting the spacing A ( FIG. 2.1 ) between the yarn plug outlet and the cooling groove, as well as by the selection of the width B of the cooling groove. The ratio of the yarn advancing speed v F , at which the yarn plug advances before being cooled, to the cooling speed v K , at which the yarn plug advances while being cooled, is in a range from v F /v K =0.1 to 0.4. With that, it is possible to realize even high production speeds of more than 3,000 m/min. (crimping speed) and a long dwelling time.
[0044] FIG. 4 schematically illustrates a modification of the cooling device of the embodiment of FIG. 1 . In this modification, a blower 32 is arranged in spaced relationship with the cooling drum 25 in the region of the cooling groove 26 , and connected to a source of overpressure 33 . The blower 32 has an elongate shape that overlaps at least one section of the cooling zone. A cooling medium flow is generated by the source of overpressure 33 through a plurality of air outlets, and directed to the yarn plug 13 in the cooling groove 26 .
[0045] The construction of both the crimping device 7 and the cooling device 11 is identical with the foregoing embodiment, so that the foregoing description may herewith be incorporated by reference.
[0046] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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A method and an apparatus for spinning and crimping a synthetic multifilament yarn, wherein a filament bundle is spun from a polymer melt and compressed to a yarn plug. The yarn plug is advanced at a cooling speed and cooled within a cooling zone in a moving cooling groove. After cooling, the yarn plug is disentangled to form a crimped yarn, with the latter being wound to a package. The method of the invention also provides for selecting the length of the cooling zone and the cooling speed of the yarn plug such that the yarn plug is cooled in the cooling groove over a period of at least 1 second. To this end, the apparatus of the invention includes a cooling groove, whose width is dimensioned such that the yarn plug can be advanced in meander form in a plurality of superposed layers.
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[0001] The present application is a Continuation-In-Part of U.S. patent application Ser. No. 10/758,000 filed on Jan. 16, 2004, which claims priority to U.S. Provisional Patent Application No. 60/440,622 filed on Jan. 17, 2003, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a torque converter and a system using a torque converter. More specifically, the present invention relates to a torque converter that is capable of multiplying a given torque input based upon compression and decompression of permanent magnetic fields. In addition, the present invention relates to a system that uses a torque converter.
[0004] 2. Discussion of the Related Art
[0005] In general, torque converters make use of mechanical coupling between a generator disk and a flywheel to transmit torque from the flywheel to the generator disk. However, due to frictional forces between the generator disk and the flywheel, some energy provided to the generator disk is converted into frictional energy, i.e., heat, thereby reducing the efficiency of the torque converter. In addition, the frictional forces cause significant mechanical wear on all moving parts of the torque converter.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention is directed to a torque converter that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0007] An object of the present invention is to provide a torque converter having an increased output.
[0008] Another object of the present invention is to provide a system using a torque converter that reduces frictional wear.
[0009] Another object of the present invention is to provide a system using a torque converter that does not generate heat.
[0010] Another object of the present invention is to provide a system using a torque converter than does not have physical contact between a flywheel and a generator disk.
[0011] Another object of the present invention is to provide a system using a torque converter that allows an object to be inserted or reside between a flywheel and a generator disk.
[0012] Additional features and advantages of the invention will be set forth in the description which follows and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0013] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, a torque converter device includes a flywheel rotating about a first axis, the flywheel having a first body portion having a first radius from a circumferential surface and have a first radius of curvature, a first plurality of magnets mounted in the first body portion, each having first ends disposed from the circumferential surface of the first body portion, and each of the first ends of first plurality of magnets having a second radius of curvature similar to the first radius of curvature, a second plurality of magnets mounted in the first body portion, each of the second plurality of magnets being disposed from the circumferential surface of the first body portion, and a generator disk rotatable about a second axis angularly offset with respect to the first axis, the generator disk having a second body portion, and a third plurality of magnets within the second body portion for magnetic coupling with the first and second pluralities of magnets.
[0014] In another aspect, a torque converter device transferring rotational motion from a first body rotatable about first axis to a second body rotatable about and second axis angularly offset with respect to the first axis, the first and second bodies separated by a gap, one of the first and second bodies includes a first plurality of radially mounted magnets, a plurality of backing plates, each disposed adjacent to innermost end portions of the first plurality of magnets, and a magnetic ring disposed apart from each of the backing plates, wherein the backing plates are disposed between an end of the first plurality of radially mounted magnets and the magnetic ring.
[0015] In another aspect, a method of transferring rotational motion from a first body rotatable about a first axis to a second body rotatable about a second axis angularly offset with respect to the first axis includes sequentially compressing magnetic fields of a first plurality of magnets radially mounted in the first body using at least one of a second plurality of magnets mounted in the second body, and decompressing the compressed magnetic fields of the first plurality of magnets as the first body and second body rotate to transfer the rotational motion of the first body to the second body.
[0016] In another aspect, a system for generating electrical power includes a motor, a flywheel rotating about a first axis, the flywheel having a first body portion having a first radius from a circumferential surface and having a first radius of curvature, a first plurality of magnets mounted in the first body portion, each having first ends disposed from the circumferential surface of the first body portion, and each of the first ends of first plurality of magnets having a second radius of curvature similar to the first radius of curvature, a second plurality of magnets mounted in the first body portion, each of the second plurality of magnets being disposed from the circumferential surface of the first body portion, and a generator disk rotatable about a second axis angularly offset with respect to the first axis, the generator disk having a second body portion, and a third plurality of magnets within the second body portion for magnetic coupling to the first and second pluralities of magnets, and at least one electrical generator coupled to the at least one generator disk.
[0017] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. In the drawings:
[0019] FIG. 1A is a layout diagram of an exemplary flywheel according to the present invention;
[0020] FIG. 1B is a side view of an exemplary flywheel according to the present invention;
[0021] FIG. 1C is a side view of an exemplary attachment structure of the flywheel according to the present invention;
[0022] FIG. 2 is a perspective view of an exemplary retaining ring according to the present invention;
[0023] FIG. 3 is an enlarged view of region A of FIG. 1A showing an exemplary placement of driver magnets within a flywheel according to the present invention;
[0024] FIGS. 4A and 4B are views of an exemplary driver magnet according to the present invention;
[0025] FIGS. 5A and 5B are views of another exemplary driver magnet according to the present invention;
[0026] FIGS. 6A and 6B are views of another exemplary driver magnet according to the present invention;
[0027] FIGS. 7A and 7B are views of another exemplary driver magnet according to the present invention;
[0028] FIG. 8A is a layout diagram of an exemplary generator disk according to the present invention;
[0029] FIG. 8B is a side view of an exemplary shaft attachment to a generator disk according to the present invention;
[0030] FIG. 9 is a schematic diagram of exemplary magnetic fields of the flywheel of FIGS. 1A-C according to the present invention;
[0031] FIG. 10 is a schematic diagram of an exemplary initial magnetic compression process of the torque converter according to the present invention;
[0032] FIG. 11A is a schematic diagram of an exemplary magnetic compression process of the torque converter according to the present invention;
[0033] FIG. 11B is a schematic diagram of another exemplary magnetic compression process of the torque converter according to the present invention;
[0034] FIG. 11C is a schematic diagram of another exemplary magnetic compression process of the torque converter according to the present invention;
[0035] FIG. 11D is an enlarged view of region A of FIG. 11A according to the present invention;
[0036] FIG. 11E is another enlarged view of region A of FIG. 11A according to the present invention;
[0037] FIG. 11F is another enlarged view of a region A of FIG. 11A according to the present invention;
[0038] FIG. 12 is a schematic diagram of an exemplary magnetic decompression process of the torque converter according to the present invention;
[0039] FIG. 13 is a schematic diagram of an exemplary magnetic force pattern of the flywheel of FIG. 1 during a magnetic compression process of FIG. 11 according to the present invention;
[0040] FIG. 14 is a layout diagram of another exemplary flywheel according to the present invention;
[0041] FIG. 15 is a layout diagram of another exemplary flywheel according to the present invention;
[0042] FIG. 16 is a layout diagram of another exemplary flywheel according to the present invention;
[0043] FIG. 17 is a schematic diagram of an exemplary system using the torque converter according to the present invention; and
[0044] FIG. 18 is a schematic diagram of another exemplary system using the torque converter according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] Reference will now be made in detail to the illustrated embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0046] FIG. 1A is a layout diagram of an exemplary flywheel according to the present invention. In FIG. 1A , a flywheel 109 may be formed from a cylindrical core of composite material(s), such as nylon, and may be banded along a circumferential edge of the flywheel by a non-magnetic retaining ring 116 , such as non-magnetic stainless steel or phenolic materials. The flywheel 109 may include a plurality of magnets 102 disposed within a plurality of equally spaced first radial grooves 101 of the flywheel 109 , wherein each of the magnets 102 may generate relatively strong magnetic fields. In addition, each of the magnets 102 may have cylindrical shapes and may be backed by a backing plate 203 , such as soft iron or steel, disposed within each of the plurality of first radial grooves 101 in order to extend the polar fields of the magnets 102 closer to a center C of the flywheel 109 .
[0047] In FIG. 1A , the flywheel 109 may also include a plurality of suppressor magnets 108 disposed within a plurality of second radial grooves 107 along a circumferential face of the flywheel 109 . Accordingly, as shown in FIG. 3 , surfaces 110 of the magnets 102 may be spaced from a circumferential surface S of the flywheel 109 by a distance X, and surfaces of the suppressor magnets 108 may be recessed from the circumferential face S of the flywheel 109 by a distance Y.
[0048] In FIG. 1A , each of the plurality of second radial grooves 107 may be disposed between each of the plurality of first grooves 101 . For example, each one of eight suppressor magnets 108 may be disposed within each of eight grooves 107 and each one of eight magnets 102 may be disposed within each of eight grooves 101 . Accordingly, an angular separation β between each of the first radial grooves 101 may be twice an angular separation α between adjacent first and second radial grooves 101 and 107 . Of course, the total number of magnets 102 and 108 and the first and second grooves 101 and 107 , respectively, may be changed. The suppressor magnets 108 in the eight grooves 107 and the magnets 102 in the eight grooves 101 of the flywheel 109 have their north magnetic fields facing toward the circumferential surface S (in FIG. 3 ) of the flywheel 109 and their south magnetic fields facing radial inward toward a center portion C of the flywheel 109 . Alternatively, opposite polar arrangement may be possible such that the suppressor magnets 108 and the magnets 102 may have their south magnetic fields facing toward the circumferential surface S (in FIG. 3 ) of the flywheel 109 and their north magnetic fields facing radial inward toward a center portion C of the flywheel 109 .
[0049] In FIG. 1A , backing plates 203 may be disposed at end portions of the magnets disposed within the plurality of first grooves 101 at the south poles of the magnets 102 in order to form a magnetic field strength along a radial direction toward the circumferential surface S (in FIG. 3 ) of the flywheel 109 . Although not specifically shown, each of the backing plates may be attached to the flywheel 109 using a fastening system, such as retaining pins and/or bolts, or may be retained within the flywheel 109 due to the specific geometry of the magnets 102 within the first grooves 101 . Accordingly, interactions of the magnetic fields of the magnets 102 within the plurality of first grooves 101 and the suppressor magnets 108 disposed within the plurality of second grooves 107 create a magnetic field pattern (MFP), as shown in FIG. 9 , of repeating arcuate shapes, i.e., sinusoidal curve, around the circumferential surface S (in FIG. 3 ) of the flywheel 109 .
[0050] In FIG. 1A , the flywheel 109 may be formed of plastic material(s), such as PVC and Plexiglas. In addition, the flywheel may be formed of molded plastic material(s), and may be formed as single structure. The material or materials used to form the flywheel 109 may include homogeneous materials in order to ensure a uniformly balanced system. In addition to the circular geometry shown in FIG. 1A , other geometries may be used for the flywheel 109 . For example, polygonal and triangular geometries may be used for the flywheel 109 . Accordingly, the number of magnets 102 and the suppressor magnets 108 and placement of the magnets 102 and the suppressor magnets 108 may be adjusted to provide magnetic coupling to a corresponding generator disk 111 (in FIG. 8 ).
[0051] FIG. 1B is a side view of an exemplary flywheel according to the present invention. In FIG. 1B , the flywheel 109 may include first and second body portions 109 a and 109 b. Accordingly, the first and second grooves 101 and 107 may be formed as semicircular grooves 101 a and 107 a in the first and second body portions 109 a and 109 b. In addition, although the first and second grooves 101 and 107 are shown to be circular, other geometries may be provided in order to conform to the geometries of the magnets 102 and the suppressor magnets 108 .
[0052] In FIG. 1A , the total number of the magnets 102 and the suppressor magnets 108 may be adjusted according to an overall diameter of the flywheel 109 . For example, as the diameter of the flywheel 109 increases, the total number of magnets 102 and the suppressor magnets 108 may increase. Conversely, as the diameter of the flywheel 109 decreases, the total number of magnets 102 and the suppressor magnets 108 may decrease. Furthermore, as the diameter of the flywheel 109 increases or decreases, the total number of magnets 102 and the suppressor magnets 108 may increase or decrease, respectively. Alternatively, as the diameter of the flywheel 109 increases or decreases, the total number of magnets 102 and the suppressor magnets 108 may decrease or increase, respectively.
[0053] FIG. 1C is a side view of an exemplary attachment structure of the flywheel according to the present invention. In FIG. 1C , the flywheel 109 includes a fastening system having plurality of spaced fastening members 122 that may be used to attach a major face of the flywheel 109 to a shaft backing plate 120 . Accordingly, a shaft 124 may be fastened to the shaft backing plate 120 using a plurality of support members 126 . In FIG. 1C , the shaft backing plate 120 may be formed having a circular shape having a diameter less than or equal to a diameter of the flywheel 109 . In addition, the shaft 124 may extend through the flywheel 109 and may be coupled to an expanding flywheel 130 . The expanding flywheel 130 may be spaced from the flywheel 109 by a distance X in order to prevent any deteriorating magnetic interference with the magnets 102 and suppressor magnets 108 within the flywheel 109 . The expanding flywheel 130 may include structures (not shown) that would increase an overall diameter D of the expanding flywheel 130 in order to increase the angular inertia of the flywheel 109 . Moreover, the shaft 124 may extend through the expanding flywheel 130 to be supported by a support structure (not shown).
[0054] FIG. 2 is a perspective view of an exemplary retaining ring according to the present invention. In FIG. 1A , the retaining ring 116 of the flywheel 109 may include a single band of stainless steel material, or may include first and second retaining ring portions 116 a and 116 b, and may include attachment tabs 118 a, 118 b, and 118 d that attach to the flywheel 109 via fasteners 118 c. The first retaining ring portion 116 a may have outermost attachment tabs 118 a and innermost tabs 118 b, and the second retaining ring portion 116 b may have outermost attachment tabs 118 d and innermost tabs 118 b. In addition, as shown in FIG. 2 , each of the attachment tabs 118 a, 118 b, and 118 d may include attachment holes 318 for use with a fastener 118 c. Each of the attachment tabs 118 a, 118 b, and 118 d may be positioned within a region between the first and second grooves 101 and 107 . Although not specifically shown, each of the attachment tabs 118 a, 118 b, and 118 d of the first and second retaining ring portions 116 a and 116 b may be formed to include two of the attachment holes 318 for use with two fasteners 118 c.
[0055] As shown in FIG. 1A , the first and second retaining ring portions 116 a and 116 b may cover the entire circumferential surface S (in FIG. 3 ) of the flywheel 109 . Accordingly, the outermost attachment tabs 118 a of the first retaining ring portion 116 a and the outermost attachment tabs 118 d of the second retaining ring portion 116 b may be fastened to the flywheel 109 at adjacent locations to each other. In addition, although each of the first and second retaining ring portions 116 a and 116 b are shown having three innermost attachment tabs 118 b, different pluralities of the innermost attachment tabs 118 b may be used according to the size of the flywheel 109 , the number of magnets 102 and 108 , and other physical features of the flywheel 109 components within the flywheel 109 .
[0056] Although not shown in FIG. 1A , a reinforced tape may be provided along an outer circumference of the retaining ring 116 . Accordingly, the reinforced tape may provide protection from abrasion to the retaining ring 116 .
[0057] FIG. 3 is an enlarged view of region A of FIG. 1A showing an exemplary placement of driver magnets within a flywheel according to the present invention. In FIG. 3 , the surface 110 of the magnet 102 may have a radius of curvature R 1 similar to the radius R 2 of the flywheel 109 . For example, R 1 may be equal to R 2 , or R 1 may be approximately equal to R 2 . In addition, the surface 108 a of the suppressor magnet 108 may have a radius of curvature R 3 similar to the radiuses R 1 and R 2 . However, the surface 108 a of the suppressor magnet 108 may simply have a flat shape.
[0058] FIGS. 4A and 4B are views of an exemplary driver magnet according to the present invention. In FIG. 4A , the magnet 102 may have a first surface 110 having the radius of curvature R 1 that may be similar to the radius R 2 of the flywheel 109 (in FIG. 3 ). In addition, as shown in FIG. 4B , the magnet 102 may include a cylindrical side surface 130 that is constant from a bottom surface 120 of the magnet 102 to the first surface 110 of the magnet 102 .
[0059] FIGS. 5A and 5B are views of another exemplary driver magnet according to the present invention. In FIG. 5A , the magnet 202 may have a first surface 210 having the radius of curvature R 1 that may be similar to the radius R 2 of the flywheel 109 (in FIG. 3 ). In addition, as shown in FIGS. 4A and 4B , the magnet 202 may include a cylindrical side surface 230 that is tapered from a bottom surface 220 of the magnet 202 to the first surface 210 of the magnet 202 . Accordingly, the first grooves 101 of the flywheel 109 may have corresponding sidewalls that conform to the tapered cylindrical side surface 230 of the magnet 202 . In addition, the back plates 203 may also have corresponding tapered cylindrical surfaces as those of the magnet 202 . However, the backing plates may not have tapered cylindrical surfaces as those of the magnet 202 .
[0060] FIGS. 6A and 6B are views of another exemplary driver magnet according to the present invention. In FIG. 6A , the magnet 302 may have a first surface 310 having the radius of curvature R 1 that may be similar to the radius R 2 of the flywheel 109 (in FIG. 3 ). In addition, the magnet 302 may have a shoulder portion 350 that transitions from a neck portion 340 having a first diameter D 1 to a body portion 330 having a second diameter D 2 . Furthermore, as shown in FIGS. 6A and 6B , the body portion 330 of the magnet 302 may having a constant diameter D 2 from a bottom surface 320 of the magnet 202 to the shoulder portion 350 of the magnet 302 . Accordingly, the first grooves 101 of the flywheel 109 may have corresponding portions that conform to the neck, shoulder, and body portions 340 , 350 , and 330 of the magnet 302 .
[0061] FIGS. 7A and 7B are views of another exemplary driver magnet according to the present invention. In FIG. 7A , the magnet 402 may have a first surface 410 having the radius of curvature R 1 that may be similar to the radius R 2 of the flywheel 109 (in FIG. 3 ). In addition, the magnet 402 may have a shoulder portion 450 that transitions from a neck portion 440 having a first diameter D 1 to a body portion 430 having a second diameter D 2 . Furthermore, as shown in FIGS. 7A and 7B , the body portion 430 of the magnet 402 may having a constant diameter D 2 from a bottom surface 420 of the magnet 402 to the shoulder portion 450 of the magnet 402 . Accordingly, the first grooves 101 of the flywheel 109 may have corresponding portions that conform to the neck, shoulder, and body portions 440 , 450 , and 430 of the magnet 402 .
[0062] FIG. 8A is a layout diagram of an exemplary generator disk according to the present invention. In FIG. 8A , a generator disk 111 , preferably made from a nylon or composite nylon disk, may include two rectangular magnets 301 opposing each other along a first common center line CL 1 through a center portion C of the generator disk 111 , wherein each of the rectangular magnets 301 may be disposed along a circumferential portion of the generator disk 111 . In addition, additional rectangular magnets 302 may be provided between the two rectangular magnets 301 , and may be opposing each other along a second common center line CL 2 through a center portion C of the generator disk 111 that is perpendicular to the first common center line CL 1 . Alternatively, the additional rectangular magnets 302 may be replaced with non-magnetic weighted masses in order to prevent an unbalanced generator disk 111 .
[0063] In FIG. 8A , each of the two rectangular magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may have a first length L extending along a direction perpendicular to the first and second common center lines CL 1 and CL 2 , wherein a thickness of the two rectangular magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may be less than the first length L. In addition, each of the two rectangular magnets 301 , as well as each of the additional rectangular magnets 302 , may have a relatively large magnetic strength, wherein surfaces of the two rectangular magnets 301 , as well as each of the additional rectangular magnets 302 , parallel to a major surface of the generator disk 111 may be one of south and north poles. Moreover, either an even-number or odd-number of magnets 301 may be used, and interval spacings between the magnets 301 may be adjusted to attain a desired magnetic configuration of the generator disk 111 .
[0064] FIG. 8B is a side view of an exemplary shaft attachment to a generator disk according to the present invention. In FIGS. 8A and 8B , the generator disk 111 includes a plurality of spaced fastening members 305 that may be used to attach the generator disk 111 to a shaft backing plate 306 . Accordingly, a shaft 307 may be fastened to the shaft backing plate 306 using a plurality of support members 308 . In FIG. 8B , the shaft backing plate 306 may be formed having a circular shape having a diameter less than or equal to a diameter of the generator disk 111 .
[0065] In FIGS. 8A and 8B , the generator disk 111 may be formed of the same, or different materials from the materials used to form the flywheel 109 (in FIG. 1A ). Moreover, the geometry of the generator disk 111 may be circular, as shown in FIG. 8A , or may be different, such polygonal and triangular shapes. In addition, the total number of the magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may be adjusted according to an overall diameter of the flywheel 109 and/or the generator disk 111 . For example, as the diameter of the flywheel 109 and/or the generator disk 111 increases, the total number and size of the magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may increase. Conversely, as the diameter of the flywheel 109 and/or generator disk 111 decreases, the total number and size of the magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may decrease. Furthermore, as the diameter of the flywheel 109 and/or the generator disk 111 increases or decreases, the total number and size of the magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may increase or decrease, respectively. Alternatively, as the diameter of the flywheel 109 and/or the generator disk 111 increases or decreases, the total number and size of the magnets 301 , as well as each of the additional rectangular magnets 302 or the non-magnetic weighted masses, may decrease or increase, respectively.
[0066] FIG. 9 is a schematic diagram of exemplary magnetic fields of the flywheel of FIG. 1 according to the present invention. In FIG. 9 , interactions of the magnetic fields of the magnets 102 and the suppressor magnets 108 create a magnetic field pattern (MFP) of repeating arcuate shapes, i.e., sinusoidal curve, around the circumferential surface S of the flywheel 109 . Accordingly, the backing plates 203 and the suppressor magnets 108 provide for displacement of the south fields of the magnets 102 toward the center C of the flywheel 109 .
[0067] FIG. 10 is a schematic diagram of an exemplary initial magnetic compression process of the torque converter according to the present invention, FIG. 11 is a schematic diagram of an exemplary magnetic compression process of the torque converter according to the present invention, and FIG. 12 is a schematic diagram of an exemplary magnetic decompression process of the torque converter according to the present invention. In each of FIGS. 10 , 11 , and 12 , the schematic view is seen from a rear of the generator disk, i.e., the surface opposite to the surface of the generator disk 111 having the two rectangular magnets 301 , and the flywheel 109 is located behind the generator disk 111 . In addition, the flywheel 109 is rotating in a downward clockwise direction and the generator disk 111 is rotating along a counterclockwise direction, wherein the generator disk 111 may be spaced from the flywheel 109 by a small air gap, such as within a range of about three-eighths of an inch to about 0.050 inches. Alternatively, the small air gap may be determined by specific application. For example, systems requiring a larger configuration of the flywheel and generator disk may require larger or smaller air gaps. Similarly, systems requiring more powerful or less powerful magnets may require air gaps having a specific range of air gaps. Moreover, for purposes of explanation the magnets 102 will now simply be referred to as driver magnets 102 .
[0068] In FIG. 10 , one of the two rectangular magnets 301 disposed on the generator disk 111 begins to enter one of the spaces within a magnetic field pattern (MFP) of the flywheel 109 between two north poles generated by the driver magnets 102 . The driver magnets 102 may be disposed along a circumferential center line of the flywheel 109 , or may be disposed along the circumference of the flywheel 109 in an offset configuration. The gap between the driver magnets 102 in the flywheel 109 is a position in which the MFP where the south pole field is the closest to the circumferential surface S (in FIG. 9 ) of the flywheel 109 .
[0069] In FIG. 10 , as the flywheel 109 rotates along the downward direction, the north pole of one of the two rectangular magnets 301 on the generator disk 111 facing the circumferential surface S (in FIG. 9 ) of the flywheel 109 enters adjacent north magnetic field lines of the driver magnets 102 along a shear plane of the two rectangular magnets 301 and the driver magnets 102 . Accordingly, the shear force required to position one of the two rectangular magnets 301 between the adjacent driver magnets 102 is less than the force required to directly compress the north magnetic field lines of the two rectangular magnets 301 between the adjacent driver magnets 102 . Thus, the energy necessary to position one of the two rectangular magnets 301 between adjacent ones of the driver magnets 102 is relatively low.
[0070] In addition, the specific geometrical interface between the driver and rectangular magnets 102 and 301 provides for a relatively stable repulsive magnetic field. For example, the cylindrical surface 130 (in FIG. 4 ) of the adjacent driver magnets 102 , as well as the cylindrical surfaces of the other exemplary driver magnets 202 , 302 , and 402 in FIGS. 5 , 6 , and 7 , generate specific magnetic fields from the curved surfaces 110 and the bottom surfaces 120 of the driver magnets 102 . In addition, the planar surfaces P (in FIG. 8 ) of the rectangular magnet 301 entering the adjacent magnetic fields of the adjacent driver magnets 102 generate another specific magnetic field. Accordingly, the interaction of the magnetic fields of the driver and rectangular magnets 102 and 301 , and more specifically, the manner in which the magnetic fields of the driver and rectangular magnets 102 and 301 are brought into interaction, i.e., along a magnetic shear plane, create a relatively stable repulsive magnetic field.
[0071] In addition, although the suppressor magnet 108 also provides a repelling force to the driver magnet 102 , the force of repulsion of the suppressor magnet 108 is relatively less than the repulsive force of the rectangular magnet 301 . However, as will be explained with regard to FIG. 12 , the suppressor magnet 108 provides an additional repulsion force when the magnetic fields of the driver and rectangular magnets 102 and 301 are decompressed.
[0072] In FIG. 11A , once the rectangular magnet 301 on the generator disk 111 fully occupies the gap directly between the north poles of two adjacent driver magnets 102 of the flywheel 109 , the weaker north pole (as compared to the north poles of the driver and rectangular magnets 102 and 301 ) of the suppressor magnet 108 on the flywheel 109 is repelled by the presence of the north pole of the rectangular magnet 301 on the generator disk 111 . Thus, both the north and south magnetic fields of the MFP below the outer circumference of the flywheel 109 are compressed, as shown at point A (in FIG. 13 ).
[0073] In FIG. 11A , a centerline CL 3 of the flywheel 109 is aligned with a centerline CL 4 of the magnet 301 of the generator disk 111 during magnetic field compression of the driver magnets 102 , the suppressor magnet 108 , and the magnet 301 of the generator disk 301 . Accordingly, placement of the rotation axis of the flywheel 109 and the rotation axis of the generator disk 111 must be set such that the centerline CL 3 of the flywheel 109 is aligned with the centerline CL 4 of the magnet 301 of the generator disk 111 .
[0074] However, as shown in FIGS. 11B and 11C , placement of the rotation axis of the flywheel 109 and the rotation axis of the generator disk 111 may be set such that the centerline CL 3 of the flywheel 109 may be offset from the centerline CL 4 of the magnet 301 of the generator disk 111 by a distance X. Accordingly, the magnetic field compression of the driver magnets 102 , the suppressor magnet 108 , and the magnet 301 of the generator disk 301 may be altered in order to provide specific repulsion forces between the driver magnets 102 , the suppressor magnet 108 , and the magnet 301 of the generator disk 301 .
[0075] FIG. 11D is an enlarged view of region A of FIG. 11A according to the present invention. In FIG. 11D , a distance X between facing surfaces of the driver magnet 102 (and likewise the other driver magnet 102 adjacent to the opposing end of the magnet 301 of the generator disk 111 ) is set in order to provide specific magnetic field compression of the driver magnets 102 and the magnet 301 of the generator disk 111 . Preferably, the distance X may be set to zero, but may be set to a value to ensure that no torque slip occurs between the flywheel 109 and the generator disk 111 . The torque slip is directly related to the magnetic field compression strength of the driver magnets 102 and the magnet 301 , as well as the magnetic strength and geometries of the driver magnets 102 and the magnet 301 .
[0076] FIG. 11E is another enlarged view of region A of FIG. 11A according to the present invention. In FIG. 11 , the driver magnet 102 may have a cross-sectional geometry that includes a polygonal shape, wherein a side of the polygonal shaped driver magnet 102 may be parallel to a side of the magnet 301 of the generator disk 11 . However, the distance X between facing surfaces of the driver magnet 102 (and likewise the other driver magnet 102 adjacent to the opposing end of the magnet 301 of the generator disk 111 ) is set in order to provide specific magnetic field compression of the driver magnets 102 and the magnet 301 of the generator disk 111 . Preferably, the distance X may be set to zero, but may be set to a value to ensure that no torque slip occurs between the flywheel 109 and the generator disk 111 .
[0077] FIG. 11F is another enlarged view of a region A of FIG. 11A according to the present invention. In FIG. 11F , pairs of driver magnets 102 a and 102 b may be provided in the flywheel 109 . The driver magnets 102 a and 102 b may be provided along centerlines CL 3 A and CL 3 B, respectively, and may be spaced apart from the centerline CL 3 of the flywheel 109 , as well as the aligned centerline CL 4 of the magnet 301 of the generator disk 111 . Accordingly, the magnetic field compression of the pair of driver magnets 102 a and 102 b and the magnet 301 of the generator disk 301 may be altered in order to provide specific repulsion forces between the pair of driver magnets 102 a and 102 b, the suppressor magnet 108 , and the magnet 301 of the generator disk 301 . As with the polygonal shaped geometry of the single driver magnets 102 , in FIG. 11E , the pair of driver magnets 102 a and 102 b may have polygonal shaped geometries. In addition, similar to the distance X, as shown in FIGS. 11D and 11E , distances between facing surfaces of the pair of driver magnets 102 a and 102 b (and likewise the other pair of driver magnets 102 a and 102 b adjacent to the opposing end of the magnet 301 of the generator disk 111 ) is set in order to provide specific magnetic field compression of the pair of driver magnets 102 a and 102 b and the magnet 301 of the generator disk 111 . Preferably, the distance X may be set to zero, but may be set to a value to ensure that no torque slip occurs between the flywheel 109 and the generator disk 111 .
[0078] In FIG. 12 , as the rectangular magnet 301 on the generator disk 111 begins to rotate out of the compressed magnetic field position and away from the flywheel 109 , the north pole of the rectangular magnet 301 is strongly pushed away by the repulsion force of the north pole of the trailing driver magnet 102 on the flywheel 109 and by the magnetic decompression (i.e., spring back) of the previously compressed north and south fields in the MFP along the circumferential surface S (in FIG. 9 ) of the flywheel 109 . The spring back force (i.e., magnetic decompression force) of the north pole in the MFP provides added repulsion to the rectangular magnet 301 of the generator disk 111 as the rectangular magnet 301 moves away from the flywheel 109 .
[0079] Next, another initial magnetic compression process is started, as shown in FIG. 10 , and the cycle of magnetic compression and decompression repeats. Thus, rotational movement of the flywheel 109 and the generator disk 111 continues.
[0080] FIG. 14 is a layout diagram of another exemplary flywheel according to the present invention. In FIG. 14 , a flywheel 209 may include all of the above-described features of the flywheel 109 (in FIGS. 1A-C ), but may include suppressor magnets 208 disposed from the circumferential surface S of the flywheel 209 by a distance X. For example, the distance X may be less that a depth of the first grooves 101 , and may be disposed between adjacent backing plates 203 . Similar to the relative angular displacements α and β of the driver and suppressor magnets 102 and 301 , the relative positioning of the suppressor magnets 208 may be disposed between the driver magnets 102 . Thus, the suppressor magnets 208 may further displace the south magnetic fields of the driver magnets 102 transmitted by the backing plates 203 toward the center C of the flywheel 209 . Moreover, the different exemplary driver magnets of FIGS. 4-7 may be incorporated into the flywheel 209 of FIG. 14 .
[0081] FIG. 15 is a layout diagram of another exemplary flywheel according to the present invention. In FIG. 15 , a flywheel 309 may include all of the above-described features of the flywheel 109 (in FIGS. 1A-C ), but may include suppressor magnets 308 disposed from an end portion of the backing plates 203 by a distance X. In addition, the suppressor magnets 308 may be placed along a centerline of the driver magnets 102 . Thus, the suppressor magnets 208 may further displace the south magnetic fields of the driver magnets 102 transmitted by the backing plates 203 toward the center C of the flywheel 309 . Moreover, the different exemplary driver magnets of FIGS. 4-7 may be incorporated into the flywheel 309 of FIG. 15 .
[0082] FIG. 16 is a layout diagram of another exemplary flywheel according to the present invention. In FIG. 16 , a flywheel 409 may include all of the above-described features of the flywheel 109 (in FIGS. 1A-C ), but may include a suppressor magnet ring 408 concentrically disposed with the center C of the flywheel 409 . Thus, the suppressor magnet ring 408 may further displaces the south magnetic fields of the driver magnets 102 transmitted by the backing plates 203 toward the center C of the flywheel 409 . Moreover, the different exemplary driver magnets of FIGS. 4-7 may be incorporated into the flywheel 409 of FIG. 16 .
[0083] FIG. 17 is a schematic diagram of an exemplary system using the torque converter according to the present invention. In FIG. 17 , a system for generating power using the torque converted configuration of the present invention may include a motor 105 powered by a power source 101 using a variable frequency motor control drive 103 to rotatably drive a shaft 407 coupled to the flywheel 109 , as well as any of the flywheels of FIGS. 1 and 14 - 16 . In addition, the generator disk 111 may be coupled to a drive shaft 113 , wherein rotation of the generator disk 111 will cause rotation of the drive shaft 113 . For example, a longitudinal axis of the drive shaft 113 may be disposed perpendicular to a longitudinal axis of the drive shaft 107 .
[0084] In FIG. 17 , the drive shaft 113 may be coupled to a rotor 119 of an electrical generator comprising a plurality of stators 117 . An exemplary generator is disclosed in U.S. patent application Ser. No. 10/973,825, which is hereby incorporated by reference in its entirety. Specifically, the rotor 119 may include an even number of magnets, and each of the stators 117 may include an odd number of coils, wherein each of the coils includes an amorphous core. The amorphous cores do not produce any heat during operation of the electrical generator. Rotation of the rotor 119 may cause the electrical generator to produce an alternating current output to a variable transformer 121 , and the output of the variable transformer 121 may be provided to a load 123 .
[0085] FIG. 18 is a schematic diagram of another exemplary system using the torque converter according to the present invention. In FIG. 18 , a plurality of the generator disks 111 may be clustered around and driven by a single flywheel 109 , as well as any of the flywheels of FIGS. 1 and 14 - 16 , wherein the generator disks 111 may each be coupled to AC generators similar to the configuration shown in FIG. 17 .
[0086] The present invention may be modified for application to mobile power generation source systems, as drive systems for application in stealth technologies, as an alternative for variable speed direct drive systems, as drive systems for pumps, fans, and HVAC systems. Moreover, the present invention may be modified for application to industrial, commercial, and residential vehicles requiring frictionless, gearless, and/or fluidless transmissions. Furthermore, the present invention may be modified for application in frictionless fluid transmission systems through pipes that require driving of internal impeller systems. Furthermore, the present invention may be modified for application in onboard vehicle battery charging systems, as well as power systems for aircraft, including force transmission systems for aircraft fans and propellers.
[0087] In addition, the present invention may be modified for application in zero or low gravity environments. For example, the present invention may be applied for use as electrical power generations systems for space stations and interplanetary vehicles.
[0088] It will be apparent to those skilled in the art that various modifications and variations can be made in the torque converter and system using the same of the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A torque converter for transferring rotational motion between a first axis and a second axis is provided. The torque converter has a first body rotatable about the first axis; a plurality of first magnets mounted to the first body, each of the first magnets having an inner end portion, the inner end portion being located closer to the first axis than to a peripheral portion of the first body; a plurality of first backing plates, each disposed adjacent to the inner end portion of each of the first magnets; a second body rotatable about the second axis; and a plurality of second magnets mounted to the second body. The second magnets magnetically interact with the first magnets to transfer the rotational motion between the first and second axes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a developer supplying container, and more specifically relates to a developer supplying container used in connection with a developing device or image forming apparatus employing said developing device.
2. Description of the Related Art
Developer supplying containers have been proposed wherein a container accommodating developer is connected to a developing device or image forming apparatus in a state such that a container aperture is downward facing so that the developer accommodated within the container is supplied to a developing device by falling through said aperture.
Japanese Laid-Open Patent Application Nos. SHO53-146639 and HEI3-2881 disclose developer supplying containers which transport the developer accommodated within the container along a spiral channel via the rotation of the cylindrical container provided with a spiral channel, such that said developer is delivered outside the container from an aperture provided at one end of said container. The aforesaid developer supplying containers are advantageous in that there is scant possibility of soiling the interior of the image forming apparatus or the clothing of a user due to overflow of the developer from the aforesaid aperture when installing or removing the container because the container is connected to the image forming apparatus in a horizontal state.
In the aforesaid developer supplying containers, the developer accommodated within the container is gradually supplied to the developing device so as to be depleted in accordance with the consumption of the developer by the image forming apparatus (developing device). When all of the developer accommodated within the container has been supplied to the developing device, the old empty container is removed from the image forming apparatus or the like and replaced by a new container loaded with developer.
Because toner replenishment is accomplished by replacing the container in the previously described methods, it is necessary to replace the container after all the developer accommodated within the container is supplied to the developing device and said container becomes empty so as not to waste developer remaining in the container. Therefore, the time of developer replenishment is actually limited to times when developer within the developer supplying container is completely depleted, which is disadvantageous from a maintenance perspective.
In copying apparatus, for example, service personnel from the manufacturer or dealer periodically visit the user for typical maintenance procedures such as spot inspections, parts replacement, developer replenishment and the like. At such times, the previously described methods are not capable of toner replenishment even when the developer within the developer supplying container is depleted to the extent that there is not sufficient remaining developer to last until the next service visit, thereby necessitating another visit by service personnel at a later date simply to replenish the developer, i.e., replace the container, or the user himself must replace the container. Since the replacement period is limited, developer replenishment cannot be accomplished with operational efficiency and user convenience even though the user performs the replacement.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide a developer supplying container with excellent maintenance characteristics.
A further object of the invention is to provide a developer supplying container which allows complete selectivity as to the timing of developer replenishment.
A still further object of the invention is to provide a developer supplying container which reliably prevents overflow of developer from the container aperture when installing or removing the container.
These and other objects of the present invention are accomplished by a developer supplying container for transporting developer accommodated therein by its rotation, comprising a first aperture provided on a front surface of the container with respect to a direction in which the developer is transported, a second aperture provided at a back surface of the container with respect to said direction corresponding to the position of said first aperture, and a connecting member to detachably connect an another container with the present container in a direction of the rotational axis of the present container.
These and other objects, advantages and features of the invention will become apparent from the following description thereof taken in conjunction with the accompanying drawings which illustrate specific embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following description, like parts are designated by like reference numbers throughout the several drawings.
FIG. 1 is a perspective view of an embodiment of the developer supplying container of the present invention;
FIG. 2 is a longitudinal section view of an embodiment of the developer supplying container;
FIG. 3a is an elevation view of an embodiment of the developer supplying container;
FIG. 3b is a side view of an embodiment of the developer supplying container;
FIG. 3c is a rear view of an embodiment of the developer supplying container;
FIG. 4 is a brief section view illustrating an embodiment of the developer supplying container in a connected state;
FIG. 5 is a conceptual view showing the method for connecting an embodiment of the developer supplying container.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the present invention is described hereinafter with reference to the accompanying drawings.
1) Construction
FIG. 1 is a perspective view showing the exterior of an embodiment of the developer supplying container.
The developer supplying container is a container for accommodating powder developer used by image forming apparatus such as copiers, printers and the like. The container supplies developer accommodated within the container to a developing device via connection to said developing device or main unit of an image forming apparatus (hereinafter, referred to as simply "the container").
In FIG. 1, reference symbol A refers to the developer supplying container which comprises cylindrical section 1, front section 2, and rear section 3. A pair of small protrusions 4 bilaterally positioned so as to coincide with the cylindrical axis are provided near the front end (left side in FIG. 1 labeled front section 2) of the exterior circumference of cylindrical section 1, and a pair of small frames 5 coincident with the positions of small protrusions 4 are provided near the rear end (right side in FIG. 1 labeled rear section 3) (refer to FIG. 3). First aperture 6 is provided on front section 2, and second aperture 7 is provided on rear section 3 (hereinafter respectively referred to as "aperture 6" and "aperture 7").
FIG. 2 is a longitudinal section view of container A.
Spiral protrusions 8 are provided on the interior circumferential surface of cylindrical section 1 facing from the rear end to the front end, and spiral channel 9 is formed between said protrusions 8. Spiral channel 9 starts near the aforesaid aperture 7 and ends near the aforesaid aperture 6.
FIGS. 3a, 3b, and 3c are elevation, side, and rear views, respectively.
Front section 2 comprises three connected surfaces: surfaces 2a and 2c which are perpendicular to the cylindrical axis, and surface 2b which is disposed between surfaces 2a and 2c and forms an obtuse interior angle with surface 2c. The aforesaid aperture 6 is provided at the end of surface 2b. Considering the balance with toner supplying rate and the like, it is preferable to position surface 2a is positioned uppermost.
Rear surface 3 is comprised basically the same construction as front surface 2. That is, rear section 3 comprises three connected surfaces: surfaces 3a and 3c which are perpendicular to the cylindrical axis, and surface 3b which is disposed between surfaces 3a and 3c and forms an obtuse interior angle with surface 3c. The aforesaid aperture 7 is provided at the end of surface 3b.
Surfaces 2a and 3a, surfaces 2b and 3b, surfaces 3c and 3c have similar configurations, and apertures 6 and 7 have similar configurations, and are positioned oppositely across cylindrical section 1. Furthermore, surfaces 2b and 3b are parallel.
The construction of front section 2 and rear section 3 are not restricted to the three-surface construction of the present embodiment insofar as aperture 6 is provided on a surface which forms an obtuse interior angle with a surface perpendicular to the cylindrical axis, and aperture 7 is provided on a surface parallel to the surface on which aperture 6 is provided, and a single surface or two-surface construction may alternatively be used. Furthermore, a four-surface or more construction may also be used.
Container A of the previously described construction when accommodating developer in its interior area, is sealed by seal members (not illustrated) covering apertures 6 and 7.
2) Operation
The container of the present invention employs a plurality of connected containers used as a single container.
FIG. 4 is a brief section view showing the state that two containers are connected.
For the convenience of the following discussion, the far side container (right side in FIG. 4) shall be referred to as container A', and the reference numbers of the various parts of container A' shall be referred to by the corresponding reference number of the various components of container A, i.e., cylindrical section 1' shall correspond to cylindrical section 1, aperture 6' shall correspond to aperture 6 and the like.
Containers A and A' are connected in the direction of the cylindrical axis and conjoined with no spacing between the entire surface of rear section 3 of container A and the entire surface of front section 2' of container A', such that the small protrusion 4' of container A' engages the small frame 5 of container A. At this time, the developers accommodated in containers A and A' are able to move between both containers through apertures 7 and 6'. The seal members covering apertures 7 and 6' are peeled away prior to making the aforesaid connection.
FIG. 5 is a brief conceptual illustration of the connection of the present container to the image forming apparatus.
The connected containers A and A' (hereinafter referred to as "container unit") are connected to the image forming apparatus in a horizontal state with container A at the front. The container unit is connected so as to be freely rotatable with the cylindrical axis as the rotational axis, and is rotated in the arrow "a" direction in FIG. 5 via a drive means such as a motor or the like in linkage with the image forming operation of the image forming apparatus. The connection of the container unit with the image forming apparatus is accomplished by a common method such as that disclosed in Japanese Laid-Open Patent Application No. HEI 3-2881.
When the container unit is rotated, the developer within container A' moves along spiral channel 9' toward the front end of the container. A uniform amount of developer moves toward container A each time aperture 6' moves downward in conjunction with the rotation of the container unit. Similarly, the developer in container A moves along spiral channel 9 and gradually falls from aperture 6 to the developing device (not illustrated) within the image forming apparatus. Thus, the developer within the container unit is completely moved from container A' to container A, and from container A to the developing device in conjunction with the rotation of the container unit, thereby supplying developer to the developing device via aperture 6 of container A.
Since, as described above, the container unit employs a plurality of connected containers, the size of each individual container is necessarily smaller than the size of conventional containers. Although two individual containers are connected in the present embodiment, three or more containers may be connected in accordance with the size of the image forming apparatus to which they are connected.
3) Container replacement
As previously described, the developer within the container unit is gradually depleted from the container on the rear side of the connection. Accordingly, when the developer is replenished, it is not necessary to wait for the developer to be completely depleted from the entire container unit. That is, the developer within container A' moves completely to container A, and when container A' becomes empty said container A' is removed from container A, then developer is replenished by replacing said container A' with a new container loaded with developer.
The removal of container A' is accomplished when the container unit is stopped at a position wherein aperture 6' of container A' is facing upward (the position shown in FIG. 4) so as to prevent overflow of developer from said aperture 6' of container A' and aperture 7 of container A. Although aperture 7 of container A is conversely facing downward at this time, surface 3b on which aperture 7 is provided is set at an angle so as to form an obtuse interior angle with surface 3a which is perpendicular to the cylindrical axis, such that developer does not stay near aperture 7 and does not, therefore, overflow from said aperture 7.
It is convenient to control the previously mentioned drive means to stop the container unit at the aforesaid position when the image forming operation of the image forming apparatus is completed.
Although a spiral cartridge is used as the developer supplying container in the previously described embodiment, other types of cartridges may be used (for example, a cartridge may be used which is connected to a developing device or image forming apparatus with a container aperture facing downward so as to supply developer which falls to said developing device via said aperture).
Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it is to be noted that various changes and modifications will be apparent to those skilled in the art. Therefore, unless otherwise such changes and modifications depart from the scope of the present invention, they should be construed as being included therein.
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A developer supplying container of cylindrical shape which is connectable in a direction of its rotational axis. The container having a developer sending aperture on a base, a developer receiving aperture on the opposite base, and a connecting member to detachably connect the container to a second container having the same construction as the former container. The developer accommodated in the former container is transported to the second container through the developer sending aperture of the former container and a developer receiving aperture of the second container, and supplied to the developing device with the developer accommodated in the second container. When the developer accommodated in the former container is exhausted, only the former container should be replaced.
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