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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to European Patent Application No. 10000685.7, filed Jan. 25, 2010 and PCT/SE2010/051459, filed Dec. 22, 2010.
FIELD OF THE INVENTION
[0002] The invention relates to an object collision warning system for a motor vehicle of the type having a sensing means adapted to sense a surrounding of the motor vehicle and a processing means, said processing means being adapted to detect objects in a surrounding of the motor vehicle by processing a signal provided by said sensing means, to perform an estimation of a collision probability between the vehicle and the detected object, and to output a warning signal in case the collision probability is non-negligible. The invention relates furthermore to a corresponding object collision warning method.
BACKGROUND OF THE INVENTION
[0003] US 2005 0225477 A1 discloses a vehicle collision warning system comprising a road curvature estimation subsystem for estimating the curvature of the roadway using measurements from host vehicle motion sensors, a target state estimation subsystem for estimating the state of a target vehicle on the basis of a radar measurement, and a control subsystem for determining whether or not the host vehicle is at risk of collision with the target, and if so, for determining and effecting corresponding action.
[0004] The goal of a pedestrian warning system is to warn the driver of the vehicle if there is a pedestrian on the road ahead of the vehicle or close to the road and walking towards the road. To be able to warn correctly for the pedestrian the system must know where the pedestrian is and where the road is ahead of the vehicle, which is particularly difficult in curves. For a warning to be meaningful for the driver, the warning must be activated several seconds before the predicted time of collision. However, predicting a curved path of the vehicle based on the vehicle dynamics generally works well at most a few hundred milliseconds ahead.
SUMMARY OF THE INVENTION
[0005] The object of the invention is to provide an object collision warning system and method with an improved prediction performance.
[0006] The invention solves this object with the features of the claims. The invention is based on the assumption that consecutive curves belonging to the same type of road have similar characteristics. Therefore, using stored curve parameters describing previously passed curves allows to predict how the next curve to be passed will behave already at the beginning of the curve, and not only in the middle of the curve as is the case if the vehicle dynamics alone are used to predict the vehicle path. Consequently, a collision risk in particular with an object in a curve can reliably be determined significantly earlier than in the prior art.
[0007] After having passed a curve, curve information describing this curve is preferably determined from measured vehicle motion variables, including but not limited to vehicle yaw as determined from a yaw sensor and/or vehicle speed, and stored preferably in an electronic memory. Curve information suited for describing a curve preferably includes one or more curve variables like curve length, curve radius and/or a prediction reliability.
[0008] Preferably the memory is adapted to store a plurality of information sets describing a plurality of previously passed curves. The use of information from a plurality of previously passed curves may lead to an enhanced quality of the vehicle path prediction in comparison to using information from the last passed curve only. If information from a plurality of previously passed curves is used, the curve information of different curves is preferably weighted in said estimation of the collision probability. In particular, the weight of the curve information is chosen smaller for a curve which has been passed longer ago, since the current curve may be assumed to be most similar to the most lastly passed curves.
[0009] The sensing means preferably is an imaging means adapted to record images from a surrounding of the motor vehicle. However, the invention is not limited to imaging means or vision systems, but is also applicable to non-vision sensing means based for example on lidar, radar or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the following the invention shall be illustrated on the basis of preferred embodiments with reference to the accompanying drawings, wherein:
[0011] FIG. 1 shows in diagrammatic form a safety system for a motor vehicle;
[0012] FIG. 2 shows a schematic diagram explaining the prediction of the forthcoming vehicle path; and
[0013] FIG. 3 shows a schematic diagram explaining the update of parameters used for the calculation of curve information.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The safety/vision system 10 is mounted in a motor vehicle and comprises an imaging means 11 for recording images of a region surrounding the motor vehicle, for example a region in front of the motor vehicle. Preferably the imaging means 11 comprises one or more optical and/or infrared imaging devices 12 a, 12 b, in particular cameras, where infrared covers near IR with wavelengths below 5 microns and/or far IR with wavelengths beyond 5 microns. Preferably the imaging means 11 comprises a plurality of imaging devices 12 a, 12 b in particular forming a stereo imaging means 11 ; alternatively only one imaging device forming a mono imaging means can be used.
[0015] The imaging means 11 is preferably coupled to an image pre-processor 13 adapted to control the capture of images by the imaging means 11 , receive the electrical signal containing the image information from the image sensors 12 a, 12 b, warp pairs of left/right images into alignment and create disparity images, which per se is known in the art. The image pre-processor 13 may be realized by a dedicated hardware circuit. Alternatively the pre-processor 13 , or part of its functions, can be realized in the electronic processing means 14 .
[0016] The pre-processed image data is then provided to an electronic processing means 14 where image and data processing is carried out by corresponding software. In particular, possible objects surrounding the motor vehicle, such as pedestrians, other vehicles, bicyclists or large animals, are identified, which preferably includes classification and verification steps. The position of identified objects in the recorded images is tracked over time. Information relating to an identified object is preferably displayed to the driver on a display means 19 .
[0017] Furthermore, an expected path of the vehicle is calculated on the basis of vehicle dynamics information obtained from vehicle sensors 15 , 16 , and 17 comprising a speed sensor 15 , a yaw sensor 16 and/or a steering angle sensor 17 . When the processing means 14 estimates on the basis of the position of an identified object in the scene and the expected path of the vehicle that there is a non-negligible risk of collision, the processing means 14 outputs a corresponding signal in order to activate or control one or more vehicle safety means 18 in a suitable manner. For example, means 18 could be in the form of a warning adapted to warn the driver is preferably activated. Such a warning may suitably provide optical, acoustical and/or haptical warning signals, which includes displaying an optical warning on the display means 19 . Further safety means 18 may be activated or suitably controlled, for example restraint systems such as occupant airbags or safety belt tensioners; pedestrian airbags, hood lifters and the like; or dynamic vehicle control systems such as brakes.
[0018] The electronic processing means 14 is preferably programmed or programmable and may comprise a microprocessor or micro-controller. Expediently, the electronic processing means 14 has access to an electronic memory means 25 . The image pre-processor 13 , the electronic processing means 14 and the memory means 25 are preferably realized in an on-board electronic control unit (ECU) and may be connected to the imaging means 11 via a separate cable or alternatively via a vehicle data bus. In another embodiment the ECU and a camera of imaging means 12 a, 12 b can be integrated into a single unit. All steps from imaging, image pre-processing, image processing to activation or control of safety means 18 are performed automatically and continuously during driving in real time.
[0019] The determination of an expected path of the vehicle in the processing means 14 is explained in detail using FIG. 2 . The input values 30 are obtained from vehicle dynamics sensors 15 to 17 and may in particular comprise the vehicle speed, yaw rate and steering angle. The input values 30 are continuously updated within fixed time intervals, and input into a Kalman filter 31 providing filtered vehicle parameters 32 , in particular a filtered yaw rate and filtered vehicle speed.
[0020] The filtered vehicle parameters 32 are provided to a change detector 33 which is adapted to detect changes between straight road and curve. Output 34 of the change detector 33 are the last start time of a curve, the last end time of a curve and an indicator indicating whether the vehicle currently is in a curve or on a straight road. From the last start time of a curve, the current vehicle speed and yaw rate, the time when the vehicle has passed half of the curve is estimated in the half time estimator 35 . The start time and end time of the last curve, the half time output by the half time estimator 35 , as well as the speed and yaw rate of the last curve are stored in a memory 36 which may be realized in the electronic memory means 25 shown in FIG. 1 .
[0021] When the vehicle drives through a curve, the expected curve length of the current curve and the expected total curve bending/radius of the current curve can be extracted in corresponding lookup tables 37 , 38 stored in a memory, for example memory means 25 shown in FIG. 1 . In the table 37 values of curve length are stored for the ranges of yaw rate and speed occurring in practice. In the table 38 values of total curve bending are stored for the ranges of yaw rate and speed occurring in practice. The use of tables 37 , 38 is preferred because it is easier to update tables based on new measurements in comparison to updating a corresponding algorithm.
[0022] Based on the information from the curve length table 37 , the curve bending table 38 and the curve half time estimator 35 , final values for the estimated curve length of the current curve and the bending of the current curve are calculated in the curve length and bending estimator 39 . Based on the estimated curve length and curve bending, and information on the last curve stored in the memory 36 , the path of the vehicle is predicted in the vehicle path predictor 40 . The output 41 of the vehicle path predictor 40 may for example be longitudinal position and lateral position of the vehicle at certain forthcoming times. This vehicle path information 41 can be used for reliably estimating the probability of a collision with a detected object in front of the motor vehicle.
[0023] When a curve has ended, the exact curve length and curve bending of this last curve are calculated in the update section 42 . Based on these exact curve values of the lastly passed curve, the update section 42 then calculates new values for the tables 37 , 38 employing a general model of curve progression. As an example, the general model may be based on general construction requirements, such that a curve usually has a start section with a linearly increasing curvature, a middle section of essentially constant curvature and an end section with a linearly decreasing curvature; a certain minimum length of the road in terms of minimum time, for example 3 s, at the speed limit of the road; etc. The new values for the tables 37 , 38 are preferably calculated on the basis of information not only of the ultimately passed curve, but on a plurality of lastly passed curves, where the influence of a curve is preferably weighted with a decreasing weight, for example an exponentially decreasing weight, the longer ago the curve has been passed. The new values for the tables 37 , 38 are then written into the tables 37 , 38 in order to complete the table update.
[0024] FIG. 3 illustrates a general scheme for updating the parameters of a parametric curve describing model used in the calculation of curve information. When a curve is passed, curve describing variables like curve length, curve radius and/or a prediction error are calculated in step 43 using input values 30 describing the dynamics or kinematics of the vehicle, in particular vehicle speed, vehicle yaw and/or steering angle as measured with speed sensor 15 , yaw sensor 16 and/or steering angle sensor 17 ; and on the basis of a parametric curve model describing how to predict a curve from measurement values 30 and variable input parameters 44 . The determined curve variables are used in step 45 to calculate a loss function describing how good the model could predict the lastly passed curve. In step 46 update parameters which better fit the lastly passed curves are calculated based on the loss function, and fed back into the curve variable calculation 43 . Initially, if no updated parameters are yet available, a set of initial parameters 48 are used as input parameters in the curve variable calculation 43 .
[0025] While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification variation, and change without departing from the proper scope and fair meaning of the accompanying claims.
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An object collision warning system for a motor vehicle comprises a sensing means ( 11 ) adapted to sense a surrounding of the motor vehicle and a processing means ( 14 ) adapted to detect objects in a surrounding of the motor vehicle by processing a signal provided by the sensing means ( 11 ), to perform an estimation of a collision probability between the vehicle and the detected object, and to output a corresponding signal in case the collision probability is non-negligible. The processing means ( 14 ) is adapted to determine, after having passed a curve, information describing the passed curve, to store the curve describing information, and to use the curve describing information of at least one previously passed curve for determining the vehicle path in a current curve in the estimation of the collision probability.
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BACKGROUND OF THE INVENTION
(a) Field of the invention
This invention relates to cart brakes, particularly shopping cart brakes. It more particularly relates to an automatic acting brake that is actuated at a particular speed to stop the cart.
(b) Description of the prior art
It is a common problem in modern supermarkets, malls, and discount stores with large parking lots to manage shopping carts. Customers regularly use shopping carts to transport purchased goods from the store to their vehicles. Even though stores provide outdoor racks for return of the shopping carts, some customers don't bother to place the carts in the racks. The result is, because of wind or sloping parking lots, shopping carts all to frequently roll out of control to damage automobiles or inflict injuries on pedestrians in the lot. The result of this is an annual cost to retailers and insurance companies of millions of dollars, not to mention lasting injuries to customers.
Many attempts have been made to provide shopping cart brakes to eliminate this problem, and all have some broad limitations. The first being that the brake is overly complicated to construct and the second being that the brake must be actuated by the customer when it is left in the lot. The sad fact is, is that the customer cannot be relied upon to have the presence of mind to actuate the brake when they abandon the cart in the lot. The first limitation is represented by U.S. Pat. No. 3,652,103 to Higgs. This design requires photoelectric cells, electronic timers and actuators, rechargeable batteries, and actuating device at the store exit. Not only is this approach expensive and complicated to build, but difficult to retrofit to existing carts, and would be a continuous problem to maintain. U.S. Pat. No. 5,042,622 to Smith and Powers, U.S. Pat. No. 5,328,000 to Rutter and Houseman, and U.S. Pat. No. 5,199,534 to Goff are representative of the second type of limitation. That is; they require a deliberate effort on the part of the user to engage and disengage the brake.
A universal disadvantage to all the prior art, is that the brake mechanism is exposed to one degree or the other on the frame of the cart. Since, by their nature, shopping carts are physically abused, a high degree of maintenance would be required for the prior art brake mechanisms. The prior art also is vulnerable to weather conditions, since carts are commonly left outdoors, either in cart racks or singly.
There is still an unmet need for a brake that will automatically actuate without customer action, is economical to produce and install and which can be retrofit to existing shopping cart fleets.
SUMMARY OF THE INVENTION
Accordingly, the object of the present invention is to address and to correct as many of the disadvantages of the current shopping cart brakes as is possible.
The present invention teaches improvements in shopping cart brakes. A shopping cart comprised of a frame with a basket for receiving and holding articles, and a set of wheels is improved by replacing one wheel either in front or in back with a wheel containing a centrifugal braking mechanism. The wheel may be installed during cart manufacture or retrofit to existing carts by removing and replacing a rear nonswiveling wheel or the front swiveling wheel and bracket. The swivel bracket may be adjusted for elevation so that the wheel is in contact with the ground. The brake and wheel assembly is comprised of a standard rubber tire mounted on a rim assembly of roughly the same size as current shopping cart wheels. The brake assembly is comprised of a rotating component with movable weights, which is driven by turning of the wheel. As the rate of wheel rotation increases, the sliding weights are moved against a resisting spring by centrifugal force. At a predetermined cart speed and therefore corresponding rotation and centrifugal force, the weights are in a specific position to move a ratchet shaped gear to engage a similarly shaped ratchet shaped gear on the inside face of the wheel cover. The shape of the ratchets pull and lock the two gears tightly together once they begin to engage. One of the ratchets is connected to the stationary axle by means of a semicircular friction band so that when the ratchet gears are engaged, the wheel is slowed and stopped by action of the friction between the band and axle. The brake may be released by pulling back slightly on the cart to disengage the two ratchet gears, at which point, the movable ratchet gear is pushed back into the starting position by a spring.
It is an object of the present invention to provide a centrifugal automatic shopping cart brake that will automatically engage at a certain speed thus stopping an unattended moving cart before it reaches sufficient speed to cause damage.
It is another object of the present invention to provide a centrifugal automatic shopping cart brake that will automatically engage at a certain speed to prevent customers from operating the cart at an unsafe speed.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that is contained in and is integral with the wheel with no exposed mechanism to be abused or broken.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that is contained in and is integral with the wheel so that the mechanism is protected from the weather.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that can be economically produced with key components of metal and the remainder of suitable plastics.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that does not require a conscious effort by the user to engage the brake.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that is actuated by centrifugal force and that may be adjusted to actuate at various speeds.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that can be readily fit to shopping carts during manufacture without the manufacturer having to modify assembly line procedures.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that can be readily retrofit to existing shopping carts.
It is yet another object of the present invention to provide a centrifugal automatic shopping cart brake that is actuated by a rotating assembly that is driven by the shopping cart wheel and rotates at a different rate than the wheel. This allows the weights and springs of the rotating assembly to be respectively heavier and stronger and so making the brake assembly less affected by movement over rough pavements and ridges or holes.
It is yet another object of the present invention in another embodiment to provide a centrifugal automatic shopping cart brake that is actuated by a movable weight assembly that rotates at the same rate as the shopping cart wheel.
It is yet another object of the present invention in another embodiment to provide a centrifugal automatic shopping cart brake that can be easily removed and replaced for maintenance.
These and other objects of the present invention will become apparent to those skilled in the art from the following detailed description showing the contemplated novel construction, combination, and elements as herein described, and more particularly defined by the appended claims, it being understood that changes in the precise embodiments to the herein disclosed invention are meant to be included as coming within the scope of the claims, except insofar as they may be precluded by the prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the brake-wheel assembly from a generally downward angle.
FIG. 2 is an exploded perspective view of the brake-wheel assembly from a generally upward angle.
FIG. 3 is a detailed exploded perspective view of the rotating weight assembly from a generally downward angle.
FIG. 4 is a detailed exploded perspective view of the rotating weight assembly from a generally downward angle.
FIG. 5 is a detailed exploded perspective view of fixed carrier gear plate and weight assembly drive gear.
FIG. 6 is a detailed perspective view of the tire assembly.
FIG. 7 is a detailed exploded perspective view of the locking ratchet gear with friction band and fluted sleeve with axle from a generally upward angle.
FIG. 8 is a detailed exploded perspective view of the locking ratchet gear with friction band and fluted sleeve with axle from a generally downward angle.
FIG. 9 is a detailed exploded perspective view from a generally upward angle.
FIG. 10 is perspective view of the brake-wheel assembly mounted to a swivel bracket typical in the industry.
FIG. 11 is a section cut according to FIG. 10 with the brake components of the FIG. 1 embodiment in the disengaged positions.
FIG. 12 is a section cut according to FIG. 10 with the brake components of the FIG. 1 embodiment in the engaged positions.
FIG. 13 is an exploded perspective view of an alternate embodiment of the centrifugal shopping cart brake with an alternate locking mechanism from a generally downward angle.
FIG. 14 is an exploded perspective view of an alternate embodiment of the centrifugal shopping cart brake with an alternate locking mechanism from a generally upward angle.
FIG. 15 is a plan view of an alternate embodiment of the centrifugal shopping cart brake with an alternate locking mechanism.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiment of the brake assembly can best be appreciated by referring to FIG. 1 and FIG. 2. A tire assembly 1 is fitted around a cover and rim assembly 2. A rim gear 16 is fitted to the inside face of the rim on cover and rim assembly 2 either by friction fit or with a key to prevent rotation of the rim gear relative to the rim. Also referring to FIG. 3, FIG. 4, and FIG. 5 centrifugal weights 4 are inserted into a weight carrier assembly 3 followed by counterweight springs 13 and a retaining plug 12. A weight recess 17 is aligned with a lug slot 20 in a weight tube 18. The diameter of a weight barrel 16 is sufficient for the centrifugal weight 4 to fit inside of and slide along centrifugal weight carrier tube 18. The speed at which the brake is activated can be adjusted by a screwing plug 12 inward or outward and so either moving the position of the activating feature of the centrifugal weight or by compressing and decompressing the counterweight springs 13 and so changing the resistance of the spring to movement by the centrifugal weights. In addition to the already referenced figures, also refer to FIG. 7, FIG. 8, FIG. 9, and FIG. 11. Placed in order from the inside face of rim cover assembly 2, are a washer 14, a fixed carrier gear plate assembly 9 with a drive gear 11 affixed to a gear axle 24, which is rigidly attached to a gear plate 25. Gear plate assembly 9 is prevented from rotating relative to the stationary axle assembly 8 by virtue of key slots 26 on gear carrier assembly 9 which engage key tabs 31 on stationary axle 8. Centrifugal weight assembly 3 passes over axle assembly 8 through hole 23 and positioned so that an integral gear 21 on the centrifugal weight assembly 3 engages the drive gear 11. Ratchet gear assembly 5 slides over axle assembly 8 so that a gear annular 37 slips inside of a receiver hole 19 in the weight assembly 3. Actuating tabs 38 on the ratchet gear assembly 5 are in position to pass through lug slot 20 and weight recess 17 as the centrifugal weight assembly rotates. A fluted sleeve assembly 8 engages similar flutes 40 in the ratchet gear assembly 5. so that the ratchet gear assembly 5 and the fluted sleeve 8 may not rotate relative to one another. A friction band assembly 7 is fitted over the axle assembly 8 so that a friction band 32 provides a degree of rotational resistance relative to the axle. Tongues 33 more or less vertical to the tangent of the friction band 32 engage slots 35 on the inside face of fluted sleeve assembly 6. The tongue and slot union prevent rotation of fluted sleeve assembly 6 and friction band assembly 7 relative to one another, but allows the friction band assembly to maintain pressure on the axle assembly 8 as material wears away. A spring 15 followed by washer 14 are fitted so that the spring 15 holds the ratchet gear assembly 5 in place until it is acted upon by the actuating tabs 38; A cover assembly 10 is placed so that hole 44 passes over the axle 8 with the ratchet ring 41, integral with inside face 45 in position to engage ratchet gear assembly 5. FIG. 6 illustrates the tire assembly 1 composed of a wearing face 27, side wall 26, and cover recess 28.
The sequence of operation of the brake can be best understood by consideration of all the FIGS. 1 through 12. A Wheel-brake assembly 53 is connected to swivel bracket 48.complete with a conventional swivel and bolt mounting assembly 47 and is shown in FIG. 10. Axle assembly 8 is prevented from rotating relative to a swivel bracket 46, or other chassis mounts. As the cart is pushed the wheel assembly 53 begins to rotate around axle 8. The ring gear 18 imparts rotation to drive gear 11 which is held in position by the gear carrier assembly 9. The rotation is in turn imparted to the centrifugal weight carrier assembly 3 through integral gear ring 21. The gear ratios cause the centrifugal weight carrier to rotate faster than the wheel rotation, thus allowing use of heavier centrifugal weights 4 and heavier counter weight springs 13, making the brake less sensitive to bumping and jolts. During rotation of the wheel, centrifugal force causes centrifugal weights to move outward from the center overcoming the resistant force of the counterweight springs 13. At slower rotational speeds, weight tube 18 and centrifugal weights 4 pass over actuation lugs 38 on ratchet gear assembly 5, by virtue of lug slots 20 and weight recesses 17. As rotational speed increases, the centrifugal weights move outward until the weight recess 17 moves from lug slot 20 and weight barrel 16 fills lug slot 20. On the next rotational pass, the weight barrel 16 contacts the actuation lug 38, forcing ratchet gear assembly 5 toward the ratchet ring 41 integral with the cover assembly 10. The round shape of the weight barrel allows the weight to roll as it passes over the actuation lug, smoothing the action and prolonging part lives. As the teeth of the rotating ratchet ring 41 engage the stationary ratchet gear 5 the slope of the ratchet teeth faces 52 pull and lock the two assemblies together. The ratchet gear assembly 5 is allowed to slide longitudinally along the fluted sleeve assembly 6 which houses the friction band assembly 7 clamped to axle 8. Rotational energy of the wheel assembly 53 is now transferred to ratchet gear assembly 5 and by virtue of the fluted sleeve, to the friction band assembly 7 where the wheel rotational energy is dissipated by frictional force between the axle 8 and the friction band 32. The wheel comes to a gradual stop and is prevented from rotating by the continual engagement of the ratchet ring 41 and the ratchet gear 5 and consequently to the friction band 7 clamping on the axle 8 via the fluted sleeve 6. The ratchet teeth are disengaged by turning the wheel a fraction of a turn in the opposite direction. At this point the centrifugal weights 4 have returned to their at rest position and the spring 15 pushes ratchet gear back along the fluted sleeve 6 to its at rest position. The brake, in the released and locked position are shown in detail in FIG. 11 and FIG. 12.
FIG. 13 and FIG. 14 represent yet another variation of the centrifugal shopping cart brake. Rather than moving interlocking ratchet rings that transfer rotational energy and dissipate it through a friction band, the rotational energy is transferred by weighted centrifugal arms 54. As in the previous embodiment, weight assembly 3 rotates at a faster rate than the wheel. As rotation of the weight assembly increases, centrifugal force causes the centrifugal arms to overcome the resistance of the counter weight springs 13 and move outward away from axle 8. At a predetermined speed, a tang 55 on the centrifugal arm 54 engages the ratchet teeth on ratchet ring 5, transferring rotational energy to the ring and consequently to the friction band 7, which is connected to the ratchet ring 5 as described previously. The friction band dissipates the rotational energy, slowing and stopping the wheel. As before, the shape of the engaging teeth hold the wheel locked, until the cart is pulled backward a fraction of a turn.
FIG. 15 represents yet another embodiment. In this case a centrifugal lever assembly 60 rotates at the same rate as the wheel assembly. Centrifugal force due to rotation causes a weight 61 to force a lever arm 58 to rotate out, about a pin 62, pushing spring pin back against counterweight spring 13, which is held in place by the plug 12 in a spring housing 57. When centrifugal force overcomes the spring resistance, a lever tooth 55 engages the ratchet teeth 56, transferring rotational energy to the ratchet gear and thus to friction band assembly 7, which is connected to the ratchet gear as above by tongues 33.
In all the embodiments, the wheel is brought to gradual stop by means of a friction band engaging the axle of the wheel/brake assembly and then held in a locked position until the cart is pulled backward a fraction of wheel rotation.
It is seen that the present invention addresses and corrects many of the disadvantages of the currently produced shopping cart brakes. It provides a brake that will automatically engage at specific speeds and stop a runaway cart. The brake allows the user to push a cart normally, but will stop the cart at excess speeds. Further it provides a brake that can be fitted to existing carts and fitted to new carts without changes to the manufacturing process. The brake is complete sealed against tampering, weather and abuse so that it represents a minimal maintenance problem, and it can be easily replaced in case of wear or malfunction. The most likely point of wear is the friction band and axle which can be easily replaced to extend unit life.
Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but merely as providing illustrations of some of the presently preferred embodiments of this invention. For example, where two centrifugal weights are shown, one or more may be used. The shape of the weights may vary and the ratio of weight assembly rotation to wheel rotation may be varied by changing gear sizes or adding additional gears to drive the assembly.
While the invention has been particularly shown, described and illustrated in detail with reference to the preferred embodiments and modifications thereof, it should be understood by those skilled in the art that equivalent changes in form and detail may be made therein without departing from the true spirit and scope of the invention as claimed, except as precluded by the prior art.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A shopping cart has a brake added as an improvement. The assembly is completely enclosed within a wheel of the shopping cart and is automatically engaged when a predetermined speed is reached. When the cart is propelled beyond a normal operating speed either by being pushed or when unattended, the brake will engage. The brake is actuated by centrifugal force acting on a mechanism contained within the wheel, consisting of rotating weights and ratchet assemblies that engage to dissipate rotational energy by means of a friction connection to the axle of the wheel. Gears cause the weights to rotate at a faster rate than the wheel, so that heavier weights and counter weight springs may be used, making the brake less susceptible to actuation by jolts when the cart is pushed over uneven surfaces. The brake, being internal to the wheel assembly is protected from the effects of weather and physical abuse.
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FIELD OF THE INVENTION
[0001] The present invention relates to implantable medical devices. More specifically, the present invention relates to subcutaneous cardiac monitoring devices.
BACKGROUND OF THE INVENTION
[0002] Various cardiac events and arrhythmias of the heart are difficult to diagnose based upon sporadic and infrequent monitoring, such as during in-office evaluation. These events, can be of short duration and sudden onset, coming with little or no warning, and may happen very infrequently. Holter monitors are well known for monitoring electrocardiograms for periods of time amounting to days or perhaps a week, but these are bulky and are applied externally to the body and interfere with the patient's normal life, making them impractical for long term use. Further, patient compliance cannot always be guaranteed, and is a common problem in use of the Holter devices Monitoring can be done using implantable pulse generators such as pacemakers and other heart stimulating devices or devices with leads in the heart for capturing physiologic parameters including the ECG. However, the expense and risk from implanting an intracardiac lead and/or a pacemaker with special monitoring functions is something both patients and physicians would prefer to avoid. Such devices, in addition to performing therapeutic operations, may monitor and transmit cardiac electrical signals (e.g., intracardiac electrograms) to an external diagnostic devices typically with leads fixed in the patient's heart, to observe electrical activity of a heart. It is common for implanted cardiac stimulation devices to send intracardiac electrogram signals to a monitoring device, such as an external programmer to allow a user to analyze the interaction between the heart and the implanted device. Often the user can designate that the communication from the implantable device to the programmer include a transmission of codes which signal the occurrence of a cardiac event such as the delivery of a stimulation pulse or a spontaneous cardiac depolarization.
[0003] In addition, there are subcutaneously implantable monitoring devices that collect and record data over a longer period of time, then telemeter some or all of this data to an external device during an interrogation. An example of such a device is the Medtronic Reveal™ implantable loop recorder. The following references related to subcutaneous monitors and are herein incorporated by reference in their entireties: U.S. Pat. No. 5,205,283 to Olson, issued Apr. 27, 1993, entitled “Method and apparatus for tachyarrhythmia detection and treatment,” U.S. Pat. No. 5,233,984 to Thompson, issued Aug. 10, 1993, entitled “Implantable multi-axis position and activity sensor,” U.S. Pat. No. 5,312,446 to Holschbach et al., issued May 17, 1994, entitled “Compressed storage of data in cardiac pacemakers,” U.S. Pat. No. 5,331,966 to Bennett et al., issued Jul. 26, 1994, entitled “Subcutaneous multi-electrode sensing system, method and pacer,” U.S. Pat. No. 5,987,352 to Klein et al., issued Nov. 16, 1999, entitled “Minimally invasive implantable device for monitoring physiologic events,” U.S. Pat. No. 6,230,059 to Duffin, issued May 8, 2001, entitled “Implantable monitor,” U.S. Pat. No. 6,236,882 to Lee et al., issued May 22, 2001, entitled “Noise rejection for monitoring ECG's,” U.S. Pat. No. 6,412,490 to Lee, issued Jul. 2, 2002, entitled “Tool for insertion of implanatable monitoring device and method,” and U.S. Pat. No. 6,317,626 to Warman, issued Nov. 13, 2001, entitled “Method and apparatus for monitoring heart rate.”
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIGS. 1 and 2 are the exterior side view, interior block diagram, respectively of a prior art device.
[0005] FIG. 3 is a block diagram illustrating the main circuit and assembly of a device in accord with a preferred embodiment.
[0006] FIGS. 3A-D are block diagrams of preferred embodiment circuits of the implanted device used for monitoring and storing ECGs.
[0007] FIGS. 4 a , 4 b , and 4 c are exposed front, side, and back views, respectively of a preferred embodiment of the invention.
[0008] FIG. 5 is an illustration of a preferred embodiment of the invention, showing (in dotted line), locations for fin/wing and stubby lead features.
[0009] FIGS. 6 a and 6 b are front and side views of preferred embodiment cross-sections taken from FIG. 5 .
[0010] FIGS. 7A , and 7 B are front, and cross section views of another preferred embodiment of the invention.
[0011] FIG. 8 is a front view of another embodiment of the invention.
[0012] FIG. 9 is a block diagram of the looping memory and its control circuitry in accord with a preferred embodiment of the invention.
[0013] FIG. 10 is a flow chart of the functioning of the recordation of triggered events in a preferred embodiment of the invention.
[0014] FIG. 11 is an illustration of an implantable medical device having a subcutaneously accessible switch.
[0015] FIG. 12 is an illustration of an implantable medical device having a sensor for sensing patient tapping as a communicative input.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0016] With reference to FIG. 1 a device 10 is provided with two suture holes 13 and two spaced apart non-lead or leadless electrodes 12 at one and one-quarter inches distance center to center. The device 10 includes a coating 11 so that the only area of exposure on the body of a pacer can 19 is the exposed area at the electrode 12 a . The other electrode is a metal plug electrode 12 b mounted in a connector block 19 .
[0017] In FIG. 2 the same electrodes 12 supplied signals into the circuitry inside the housing or “can” 18 ( FIG. 1 ) by first entering a analog to digital conversion and amplifier circuit 14 . Data from this circuit 14 was fed to a microcontroller 15 which provided functions of data compression, telemetry control and event capture triggered by patient operation. Telemetry block 16 and RAM memory storage 17 were also provided in this device.
[0018] Referring to FIG. 3 , a circuit model 30 is illustrated in an outline of an implantable device shell 31 . Electrodes 32 a and 32 b bring signal from the body to an input mechanism 38 , here drawn as a differential amplifier for simplicity only, the output of which is fed to a QRS detector 36 and an A/D converter 37 . Both these circuits 36 and 37 supply output to an arrhythmia detector 39 , which in this preferred embodiment supplies the autotrigger signal to the trigger setting circuit 6 . The data output from the analog to Digital converter may be converted, compressed, formatted and marked or reformulated if desired in a circuit 35 before the data is ready for input into the memory 34 . The memory control circuits 8 receives input from the A/D converter, with or without conversion and so forth from circuit 35 , from the auto triggering determination circuit (here seen as the arrhythmia detection circuit) 39 (which may include input directly from the QRS detector if desired) as well as signals from the trigger setter circuit 6 . The trigger setter circuit may also be controlled by a communications unit 5 which operates to receive and decode signals from the outside of the implant 30 that are telemetered or otherwise communicated in by a user. This communications unit 5 will also be able to communicate with the memory controller to request the offloading of memory data for analysis by an outside device. It should contain an antenna a or other transceiver device or circuitry to communicate with an outside device such as device 30 A. A clock or counter circuit 7 reports the time since start or real time to the outside interrogator device 30 A contemporaneously with a data offloading session so that the events recorded in memory 34 may be temporally pinpointed.
[0019] Alternatives to this overall design may be considered, for example by using a microprocessor to accomplish some or all of the functions of circuits 6 , 8 , 39 , and 35
[0020] FIGS. 4 a - c illustrate one configuration of the invention embodied as implantable medical device (IMD) 200 . In this form IMD 200 has an outer titanium shell 40 , in a plastic cap means 44 , which together form the exterior of the device. The cap means 44 may be composed of material similar to those used for pacemaker connector blocks as it is in the case. The two electrodes, 44 and 49 , provide metal surface contacts to the body. Electrode 49 is formed as a whole in a parylene coating over the metal body 40 , of the device. The metal electrode 42 is connected via a feedthrough 43 which is itself electrically connected to the circuit board 41 . Circuit board 41 contains all the electronics required for the device function and is connected to a battery BA for power. An integrated circuit 46 houses circuitry and intelligence required for the function and the memory M is packaged on the other side of the circuit board. In this preferred form, the invention uses a communications circuit 45 having a telemetry antenna both to indicate from outside the body that a read out is requested of the device, and for communicating data out from said device. Programming of the device or mode setting will also use the communications circuit 45 . The communications circuit 45 , in some embodiments, includes an RF transceiver capable of communicating with an external medical device 30 A over ranges from a few to e.g., 20-30 meters. This so-called distance telemetry provides for wireless communication between the IMD 200 and the external medical device 30 A to permit programming or the uplinked transmission of data collected from the IMD 200 . The external medical device 30 A may be a medical device programmer as previously described, a home monitor which is a stand-alone device that provide a communication link between the IMD 200 and a remote device such a central server or a personnel communication device. The personnel communication device also provides a communication link between the IMD 200 and a remote device. For example, the personal communication device could be an analog or digital cellular telephone, a PDA, a pager or any electronic device configured to receive communications from the IMD 200 and access a communication pathway to another device and/or a caregiver.
[0021] In this form also a suture hole 45 is provided through the cap means 44 . Electrode 49 is connected by a conductive connection (not shown in this fig.) to the circuit board. In this embodiment the length “I” is 2⅜″ and “w” is ¾″. These measurements can be varied within the constraints described. Electrode spacing here is about 1¾″, center to center.
[0022] Three or more electrode embodiments are also described with reference to FIGS. 5-8 . A third electrode, like electrode 56 , can be used to optimize signal strength responsive to changes in device position, heart position, or body position. A transistor or other switch means can switch the electrode configuration automatically based on a determination of signal strength or direction from an outside device through the communications circuit. In order to retain the elongated shape yet provide a well spaced orthogonal position, the third electrode can be mounted on a self-positioning (flexible, rigid, or semi-rigid) stubby lead. An additional variation from the most preferred design could provide for a wing or fin-shaped member 57 or more than one wing ( 57 , 56 ) that extend substantially in one plane from the main body of the device. Ideally this would be approximately in the same plane as the other two electrodes ( 53 and 59 ). Unless they are constructed so as to spring from the main body outward after insertion into the intended body area, wings like 57 or 58 will require a larger incision than required for a smooth bodied device. The illustration of the device 50 in FIG. 5 without the dotted line external parts 55 , 57 , 58 , and 60 .
[0023] A single suture hole 54 (or two or more if desired) can be provided in the cap. Additional suture appendages, like ring 60 , having a suture hole 60 a , may additionally be provided for more stability. Additionally, a suture may secure the stubby lead (if present) to the patient's tissue if desired. These suture holding means allow the device to be fixedly held in one orientation in the body of the user, whether intramuscular or strictly subcutaneous. Intramuscular pocket implantation is advantageous in that the device may be protected form the outside world by a layer of muscle, which will provide cosmetic benefits to the patient as well. The exact sites of implant may advantageously be varied from patient to patient for various reasons apparent to the physician. Implant just under the skin now appears to provide the signal most free of skeletal muscle myopotential or body movement signal interference.
[0024] While considering the features of the embodiments illustrated by FIG. 5 , it is well to note the electrode configuration. Here the electrode 53 is a conductive or metal plate compatible with the patient's body that is on one surface of the cap unit 51 , the cap being delineated by dotted line 52 . One can construct the device 50 as a solid container having out of body compatible materials. For examples, titanium or other metal or alloy, coated with compatible insulator but exposed for at electrode areas or fitted with conductive electrodes. This distance should be at least far enough to achieve good signal measurement but not too far so as to make the size of the implant unnecessarily large.
[0025] In the present embodiment the cross-section of the device is an easy-to-insert rounded rectangular or oval shape that also reduce the ability of the device to turn over after implant. FIG. 6A shape 61 and FIG. 6B , shape 62 illustrate this concept while any similarly functional cross-sections may be substituted.
[0026] Additional features are illustrated which can assist in preventing medically unintended movement of the device. In FIG. 7A the electrodes are placed so as to be matched on opposite sides of the rectangular, round, or ovoid shaped device and electrically connected in parallel on opposite sides to retain the same signal in spite of flipping or other movement. (The internal circuitry would operate like the op-amp 75 to produce output 76 from electrodes 71 - 74 as shown to produce this effect.) In surface pacemaker implants, patient populations have been known to play with their implants, often unconsciously and this has been a common enough problem in the pacemaker art to have obtained the name twiddler's syndrome.” These features address this problem. The device of 7 A is seen in cross-section in FIG. 7B .
[0027] Another embodiment employs circumferential electrodes on a cylindrically shaped device. In FIG. 8 this device can be seen to also have a body 69 that is tapered on one end 81 and blunt on the other 82 . The effect again is to provide a constant signal in spite of likely unwanted rotation of the device, because the electrodes each extend around the device circumference. Here the electrode area positions are illustrated for each end, 65 and 68 for end 81 and positions 66 , 67 for end 82 . This approach trades-off the protection from muscle noise of the rectangular outward-facing device.
[0000] In FIG. 3 the inventive system is described as stated above. The external device 30 A is preferably a device that is commonly called a programmer in the pacemaker art, because it's usual function is to communicate with and program implanted devices. Software modifications and modifications to the telemetry system of device 30 A to accommodate communication with and analysis of data from device 30 can be made as required. Such modifications will vary with the programmer type and are within the discretion of the manufacturer and thus will not be illustrated here. Using a programmer will avoid having to have additional devices cluttering the operating room or clinic by creating a separate and distinct external communications device for this invention. The functionality necessary for mere ECG monitoring and event triggering is minimal, so in the preferred embodiments that only monitor some form of ECG or other limited sensory input, a microprocessor can be and is done away with altogether by using particularized functional circuits instead of doing the functions in software.
[0028] In FIG. 3A , a block diagram of an analog to digital conversion circuit for use in this invention is shown. The clock input may advantageously use an output from the clock circuit 7 , input 7 i . The input 38 c is the analog input signal from input circuit 38 , and the converted output is a stream of 8 bit digital data words on line 37 a , sequenced by a timing line 37 b.
[0029] FIG. 3B illustrates the basic parts of circuit 38 , additionally indicating the input of gain set bits which can modify the value of the output of the low noise bipolar amplifier for output at line 38 c , the input to the QRS detector. In this invention QRS detection is done on the analog signal, advantageously saving more complex detection after digital conversion.
[0030] In FIG. 3C QRS detect circuit 36 has a 2nd order bandpass filter with a center frequency preferably in the 20-25 Hz range. It includes a transconductance amp A 1 , summing amp/comparitor A 2 and resistors Rbp 1 - 3 , capacitors Cbp 1 - 4 and selectable resistor R sense connected as shown. R sense is preferably adjusted during manufacture. Additional control is provided for QRS sensitivity at line 36 c , since the gain is delectable for this input.
[0031] A simple arrhythmia detection circuit 39 is included with this preferred embodiment, and illustrated in FIG. 3D . The output from circuit 36 is monitored the preferred embodiment, a high rate can be selected amongst 4 , with two selection bits dedicated to do so at input 9 d and the low and flatline trigger rates each have one bit to turn them on or off provided by inputs 9 d . These inputs designated 9 d preferably come from a register that holds the gain the mode and the rate settings, illustrated as register 9 in FIG. 3 . Such features may be programmable through communication with the implanted device by an external device. Preferred timing for the high rate triggers is 140, 162 and 182 beats per minute, requiring 8 consecutive beats at such a rate to initiate the trigger. Additionally the trigger may be programmed off. The low rate counter/comparitor may be programmable to detect low rates of 40 or 30 bpm, requiring 4 consecutive low rate intervals to trigger. Additionally a flat-line trigger can be set to occur after 3 or 4 and one half seconds of no QRS detection.
[0032] For embodiments that include more sensors and/or electronics, an additional sensor could be added to benefit the patient. One particularly useful would be an activity sensor based on a single or multi-axis accelerometer, which indicates the level of patient activity and his orientation. By checking for output that indicates the occurrence of a VVS (VasoVagal Syncope) episode, (for example, the patient falling from an episode) such an addition offers an improved trigger for events that might otherwise be missed by an arrhythmia detector set up like in FIG. 3D . Such a sensor trigger could replace the circuitry of 3D.
[0033] Additional circuits may be provided to support additional functions if desired, however in order to reduce size and power consumption and extend the life of the device and reduce the intrusion into the body of the wearer, auxiliary circuits should be kept to a minimum. Such additional circuits could support temperature sensing, oxygen sensing, pressure sensing, respiration sensing, and any other kind of sensing that can be demonstrated to have been known for implanted devices. They may each have their own auto triggers based on sensor output, or depend on manual triggers. Additionally, activity sensing or positional sensing devices can provide additional input for recordation and or autotriggerring functions. As new sensors become available they may also be incorporated into these designs.
[0034] One function of the various embodiments of the present invention is the long term ECG monitoring of the subcutaneous (or intramuscular) ECG. The device continuously records and monitors the subcutaneous ECG in an endless loop of memory. In its primary mode the device is triggered to save/retain in memory the last X minutes or seconds of ECG data by the patient subsequent to feeling symptoms of interest (e.g. syncope, palpitations, etc.).
[0035] Additional modes include those with pure autotriggering, which can mirror the patient triggered modes if desired. It should be considered that with autotriggered events, the determination by the device of an event worth recording and the subsequent activation of the trigger by the device itself will be faster than the patient finding his device for activation or otherwise activating the device, so the pre trigger time record can be smaller. In one preferred embodiment the memory is segmented to allow for 14 autotriggers and 3 manual triggers. Further detail regarding modes is described with reference to FIGS. 9 and 10 .
[0036] The patient activated triggering of a preserved form of the recorded ECG signal can be carried out by using a small handheld external device which may be of any number of different forms. A first way is through a handheld battery-powered device which uses a coded radio-frequency telemetered signal through the skin to the device, on the press of a button. Alternatively, a small handheld device having a magnet is used to close a magnetic switch within the implanted device to trigger it by holding the magnet close or patting the area of the body that has the implant a set number of times with the magnet. Other methods for triggering ECG data retention in memory (each of which has it's own advantages for implementation) are to use physical tapping or slapping of the finger or hand on the skin over the device in a particular cadence and/or number of taps. With such methods the disadvantage is that the patient needs to memorize the triggering sequence. Matched voice activation with a known command is possible but the complexity at this time of discerning voice commands precludes such activation for the present time, but could be in future devices using this invention. Another approach is light activation through the skin using a light source and receiver, auditor/sonic activation using a handheld auditory sonic source held over the skin with a microphone receiver in the device. All these methods are patient activated and require patient compliance or cooperation, a feature this device was designed to avoid. Accordingly, in conjunction with one of these patient triggers or alone, an automatic activation or trigger for holding a chunk of memory should be included. This could be activated by automatic recognition of an arrhythmia, a heartbeat too fast or too slow, or for any other condition the device may be set up to find.
[0037] If a patient trigger is used it is advantageous provide feedback to the patient regarding whether the attempt to trigger long term storage of the event was successful. To accomplish this, the implant should telemeter out a signal that indicates it has recognized a valid trigger. (This of course requires additional circuitry and usage of the limited available power supply.) The external triggering device then notifies the patient via the triggering device or through some known alarm mechanism whether they have or have not properly triggered the implanted device. This notification can be one of any combination of a number of feedback methods including: one or two visual sources such LED's, an auditory source such as a beeping speaker in one or two tones, or a tactile source such as a vibration.
[0038] Referring now to FIG. 9 in which a block diagram of a functional model 110 of the controller and memory 111 of an embodiment of a device is illustrated. The memory is generally organized as a continuous loop of, preferably, 8 bit addresses starting at address 0 and looping back around to address 0 through line 124 . By telemetry or hard-wired input during manufacture 120 , a mode selector 121 is set so as to divide the memory 111 into working segments 111 a - d . The address of the start of each of these segments is indicated with lines 112 .
[0039] Since this device is used for recording physiologic data, after the data is compressed, converted, formatted and is in appropriate digital form, it is continually recorded in the memory 111 . The address value at the tip of arrow 122 in the combined memory space 111 d , 111 c is monitored by a program counter register 113 .
[0040] The size of each memory segment set in a given mode limits the amount of data available for each triggered event. In the preferred embodiment, using only one program counter set of registers, the flexibility to accommodate two different trigger lengths can be limited. Alternate forms of memory allocation are available. For example organizing the entire looping memory as one unit and marking Mach trigger would allow more flexibility but increase the overhead. See for example the memory structure in Enigra, U.S. Pat. No. 5,339,824, FIG. 7 , incorporated herein by reference in its entirety.
[0041] To use a single program counter the actual trigger address minus the time (in memory location storage events) required to have already stored the amount of data needed for prevent analysis for that trigger is stored as a value in the trigger location register 116 of FIG. 11 . If a larger time for pre trigger recording is required by a trigger occurring during an already triggered event, (say, a manual trigger follows the occurrence of an auto trigger), the value in the trigger register can be decremented, thus yielding a larger pre trigger time period in the allocated memory segment for this event. A priority system for whether to extend the pre trigger record is simple to implement but again would require additional hardware and is not preferred. In fact the simplest construction ignores any new triggers once a trigger is set until the results of comparing the program counter with the trigger register corresponds to a match in value.
[0042] It is preferred to save more data for a manual triggered event than an auto triggered one because upon recovering from an event the patient has enough time to recover, get their wits about them, and find the triggering device. Manual triggering may therefore be set to record in double or multiple sized segments. FIG. 9 's segments 111 c and d are joined by looping arrow 122 to give effect to this concept.
[0043] Because the memory size is limited a time record or first-in-first-out protocol should be kept on order that the newest triggers record only over the oldest events segments. An additional preferred feature allows for a mode that prevents recording over any triggered event segment. This is preferably implemented by a counter which fills for each segment used and has storage for the set number of looping segments. When it is full recording of new events stops.
[0044] When a trigger is activated and under the control program of the device is allowed, a signal 115 is permitted by some control gate 117 to allow the program counter address to be loaded into a trigger location address register 116 . After loading, each subsequent clock cycle or set of clock cycles depending on the configuration of the device will load the trigger location from 116 into a comparator 118 to compare this location with the program counter address stored in register 113 . When comparator 118 finds that they match, an appropriate output is generated to start the next loop via control circuit 119 . This control circuit 119 will cause the mode selector to point to the next available loop location effectively placing that into the program counter 113 .
[0045] The diagrammatic algorithm 100 to indicate the flow of this information is found in the illustration of FIG. 12 in which an electrode signal 101 is input filtered, converted from analog input to digital values, compressed and formatted if desired in step 102 so as to be in appropriate form to store in a memory location designated by a program counter pointer.
[0046] This data word's form could be containing a value representing input signal compressed at various available ratios, and may be mixed with other information like data provided by another sensor or clock data. The data stored will of course carry information related to the signal taken at the sampling rate. Thus lower sampling rates to save power will adversely affect the usefulness or detail of the data. Whatever its preferred form each data point stored as a word is referred to as a chunk.
[0047] Output form step 102 provides the next chunk of data to the next memory location in step 103 .
[0048] Device checks to see if there is any trigger pending after storing each chunk of data in step 104 . If not, the next chunk of data is stored. If there is, the device preferably checks to see if there is another trigger already set and if so either ignores it or resets the value of the reserved looping memory area (like areas 111 a - d in FIG. 9 ) to accommodate a larger trigger or it ignores the trigger if it is smaller or if it indicates a smaller value needs to be stored. If on the other hand, no trigger is already set, then a new trigger location is recorded in the trigger location memory and then the next memory location is written with the next chunk of data. At step 107 if the trigger location is equal in value to the program counter, the device knows that it has gone through the entire loop reserved by the mode selector for this particular event record and then moves on to the next loop location, step 108 .
[0049] It should be recognized that any of the inventive concepts taught herein may be applied to implantable devices to supplement their other functions, such as a supplemental recording system for a pacemaker, implantable drug pump, et cetera. Further, known enhancements to telemetric communication can be used to automatically activate offloading of data to a device located in the patient's home. Such a device could send its received communications to the attending care giver/physician's office at some convenient time, telephonically or otherwise so as to enable close compliance with prescribed follow-up of patient conditions. This invention is not understood to be limited in scope except by the following claims.
[0050] FIG. 11 illustrates an embodiment of IMD 200 further including a subcutaneously accessible switch 210 . FIG. 12 illustrates an embodiment of the IMD 200 further including a motion sensor, such as an accelerometer 212 disposed within the device. The switch 210 or the accelerometer are provided to permit patient actuation of the IMD 200 while the device is implanted without requiring the use of any external handheld device, such as a programming magnet or RF activator. Thus, patient activation may be achieved by tapping or pressing on the surface of the skin over the implant site. This will either depress the switch 210 or the motion will be detected by the accelerometer, depending upon the embodiment.
[0051] There may be multiple commands for the patient to select from. For example, one command would indicate that the patient is experiencing symptoms and that the IMD 200 is to save the recorded data for some predetermined period of time prior to actuation and following actuation. Another command may be an indication that the symptoms are severe. This would not only cause the IMD 200 to record data, but also to immediately begin to attempt communication with the remote device via the external medical device 30 A. In one embodiment, this entails transmitting the collected data to a remote server for immediate review by a caregiver. Upon review, the caregiver may instruct the patient to take certain actions such as altering a medication regimen or indicating that follow up care should immediately be sought. Alternatively, or in combination, the caregiver identifies this as an emergency situation and summons a medical response to the patient's location.
[0052] Similarly, whether due to the typical symptoms sought to be recorded by the IMD 200 or due to some other situation, the patient may wish to summon emergency care to their location. Thus, the patient activation initiates a communication via communications circuit 45 to the external medical device 30 A which in turn sends a communication to a remote device (e.g., a 911 phone call, an e911 message, or some other automated message) to indicate that the patient is in need of emergency assistance. Thus, the patient having the IMD 200 implanted may respond to an emergency situation and summon help simply by tapping on or otherwise actuating the IMD 200 , without the need for an external patient actuator.
[0053] As described, the IMD 200 is only capable of transmitting to an external medical device 30 A located within a range of, for example 3-30 meters. Thus, the external medical device 30 A, whether in the form of a home monitor or a patient worn or carried device would need to be within range to complete the transmission. This is due to the limited transmission capability of the communication circuit 45 . As technology improves, it may be possible to incorporate the capability of connecting with a longer distance transmission format within communication circuit 45 and thereby obviate the need for the external medical device 30 A.
[0054] In practice, the use of the subcutaneous switch 210 may require the patient to actuate the switch once to indicate symptoms should be recorded; twice to request immediate data transmission; and three times to signal an emergency condition and request a response. Several mechanisms may be utilized to avoid or minimize inadvertent actuation of the switch. For example, the switch may be somewhat recessed so that firm pressure by one or two fingers is required. This would minimize inadvertent actuation due to laying down, crossing ones arms, or other normal physical contact. Alternatively, or in addition, a confirmation actuation may be required. For example, after depressing the switch the desired number of time, the patient may have to wait for a predetermined period of time or for an audible or vibratory response from the IMD 200 and then press the subcutaneous switch 210 yet again to confirm that the actuation was intentional.
[0055] Similarly, use of a sensor 212 , such as an accelerometer, to detect deliberate tapping on the device could employ various patterns. For example, three quick taps would indicate that symptoms are presents; five taps could request immediate transmission; and seven could summon an emergency response. Again, there is a need to balance simplicity and ease of use against inadvertent actuation. Thus, preferably a pattern of taps is required for actuation. Alternatively or in addition, once the IMD 200 recognizes patient actuation via tapping, a secondary input may be requested or required as confirmation. For example, the patient may need to way a predetermined period of time and actuate the device again. Alternatively, the IMD 200 may generate a signal such as an audible tone, recorded message, or vibratory signal. In response the patient may actuate the device to confirm the validity of the input.
[0056] In either embodiment, the IMD 200 will monitor patient parameters, such as the collected ECG data. In the event an emergency response was presumptively requested but the patient failed to confirm the actuation, the IMD 200 may initiate the request for an emergency response based upon the monitored patient parameters. In this manner, the IMD 200 will not require patient confirmation to summon an emergency response when an appropriate medical condition is detected. Similarly, the IMD 200 may initiate the communication to summon an emergency response even in the absence of any patient request if an appropriate medical condition is detected, as the patient may not be able to actuate the device.
[0057] It should be appreciated that other forms of patient actuation are possible that do not require the use of a device separate from the IMD 200 and are included within the scope of the present disclosure. Further, the above described embodiment are only illustrative of type of patient controlled inputs and are not meant to be limiting in either the type of message input nor in the form, format or pattern of the actuation communication.
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An implantable loop recorder (ILR) is subcutaneously implantable to record cardiac data. The ILR includes a patient activation mechanism whereby the patient can input commands to the ILR without using an external device. The patient activation mechanism may be a subcutaneous switch disposed on an outer portion of the ILR or a motion sensor that senses tapping of the device as an input. The patient input will direct the device to store data, telemeter data, or send a message summoning an emergency response. The ILR has distance telemetry capabilities so that a telemetered message is wirelessly transmitted to an external device which then relays the message to a remote location.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/342,998, filed Dec. 21, 2001.
FIELD OF THE INVENTION
This invention relates generally to rotary support tables, and more particularly, to a rotary support table having a slip seal arrangement with improved wear and sealing characteristics.
BACKGROUND OF THE INVENTION
In most conventional oil or gas drilling operations, drilling takes place on a drilling platform, which in turn supports a circular rotary table. The rotary table is designed such that it can be moved in a circular fashion via standard electrical or hydraulic motors. The conventional rotary table has a “kelly” which provides the central opening or bore through which passes the drill string. The kelly itself is supplied with a bushing or “kelly bushing,” which can be interlocked with a bushing on the rotary table or “master bushing” such that the rotary table can drive the kelly and impart the needed rotational force to the drill string to effect drilling. Such well drilling equipment is conventional and well-known in the art.
To add or remove a joint of pipe from the drill string, wedge devices called “slips”, are inserted into the rotary table central opening into a bowl to prevent the drill stem from falling into the well bore. In many conventional drill platforms, placement of the slips is done manually by well personnel. Sometimes the personnel operating the various mechanical devices in proximity to the rotary table are required to remove an entire drill string from the well bore. This is a time consuming process which requires removal of individual lengths of pipe one at a time in order to completely remove the drill string. This removal necessarily requires the personnel to repeatedly disengage the slips or slip assemblies from their operative position of holding the drill string, and back into the operative position when the next section of drill pipe is in position to be removed from the drill string. As a result, at each removal or addition of a length of drill pipe from the drill string, oil well personnel are required to exert a great amount of manual physical labor to remove/replace slips, which is dangerous because of the large forces required, as well as the great amount of weight which is being handled.
To improve the efficiency and safety of the drilling operation, a “power slip” has been developed, which is rotatably retained within a slip bowl to prohibit the slips from vertical movement while the slip bowl rotates with the rotary table about the drill pipe. Such power slip mechanisms include primary components which are arranged in several basic configurations. The main structure is the slip bowl or body which is generally an enlarged support structure having an internal tapered bore. Slip elements are disposed within the bore and when allowed to fall under the force of gravity, wedge radially against the casing so as to prevent the casing from slipping downwardly. The slips and the bowl are configured such that outer surfaces of the slips contact inner surfaces of the slip bowl in sliding friction and can be automatically activated to seize and hold the drill stem when a portion of the drill stem is being added or removed. For example, such power slip arrangements have been shown in U.S. Pat. Nos. 2,570,039; 2,641,816; 2,939,683; 3,210,821; 3,270,389; 3,457,605; 3,961,399; 3,999,260; 4,253,219; and 4,333,209.
Such prior art power slips come in two basic configurations. One in which the power slip is permanently attached to and rotates with the rotary table and one in which the power slip is disconnected from the rotary table when not in use.
Of the first type, U.S. Pat. Nos. 2,641,816 to Liljestrand and 3,961,399 to Boyadjieff are examples. While these power slips do represent an advance over the conventional manually operated slips, most require permanent attachment of a support post or other structure to the rig floor at the side of the rotary table to allow the power slip to be pivoted or raised away from the frill stem. As such, these devices permanently occupy valuable drill floor space despite the fact that during much of the drill time they will not be in use and may interfere with other drilling operations.
However, in most of the early systems of the rotary power slips, a mechanical linkage had to be provided between a stationary fluid cylinder and the rotary power slip housing. In many of the early conventional systems the slip assembly could not be activated at any point in its rotation but required alignment of the stationary fluid cylinder and the rotary housing. As a result the assembly protrudes above the rig floor thus consuming valuable space. The rotary power slips disclosed in U.S. Pat. Nos. 3,999,260 to Stuckey et al. and 4,333,209 to Herst solve this problem by providing expansive seal means on the stationary fluid supply which form a fluid duct with the rotary housing during operation, eliminating the need for a mechanically aligned linkage and reducing or entirely eliminating the need to utilize valuable floor space for the power slip mechanism. However, the expansive seals provided in both of these systems have been found to be prone to leakage and rapid deterioration as a result of rig vibration, affecting the efficacy and alignment of the seal with the rotary housing. In addition, these prior art devices are prone to introducing mud and debris into the seal and pressurizing system, leading to damage of the hydraulic or pressurized air systems.
Accordingly, a need exists to provide improved rotary power slip seals, which have longer wear and more effective seals, and which provide additional protection from mud and debris entering the power slip system.
SUMMARY OF THE INVENTION
Briefly, and in general terms, the present invention is directed to a rotary seal assembly for a rotary support table for use in drilling systems and the like to provide pressurized fluid to a rotary slip assembly disposed within the rotary support table. The rotary seal assembly is designed to be coupled to an existing rotary support table which is used to rotate a drill string, and includes a powered slip that is powered into an engaged position to securely engage a pipe segment, for example, a casing segment. Because the slip assembly is powered into the engaged position by a pressurized fluid system, the rotary portion of the rotary support table must be properly coupled to an external power fluid system using the seal assembly of the present invention.
The rotary support table of the present invention in one illustrative embodiment is directed to a rotary support table and power slip mountable on a rig and including: a rotary housing having a pipe engagement assembly including a central passageway sized for receipt of the pipe segment, the lower pipe engagement assembly including a powered engagement device that is powered to an engaged position to securely and releasably grasp the pipe segment, the lower pipe engagement assembly being in communication with the drive shaft, whereby actuation of the rotary housing assembly causes the lower pipe engagement assembly to rotate. In such an embodiment the lower pipe engagement assembly is powered via an external pressurized fluid power source, which is connected to the rotary housing via the rotary seal assembly of the present invention. The rotary seal assembly including a ribbon of expandable material having an outer surface in fluid communication with a source of pressurized fluid, and an inner surface cooperative with a rotary housing, the rotary seal having a plurality of openings capable of communicating fluid between said outer and inner surfaces, wherein the outer seal surface has a surface area greater than the inner surface such that when the pressurized fluid is conducted to the outer surface of the seal a differential pressure between the outer and inner surfaces is created such that the inner surface of the seal is expanded to engage the rotary housing and form an annular fluid duct providing fluid communication between the pressurized fluid source and the rotary housing. Although any suitable surface difference can be utilized such that a differential pressure is generated between the outer and inner sides of the seal, in one exemplary embodiment the ration is 1:1.02.
In another exemplary embodiment, the rotary seals may be constructed such that the seals further include an outer annular groove formed into the outer seal surface and an inner annular groove formed into the inner seal surface, wherein the plurality of openings are formed between the outer and inner annular grooves, although any shape suitable for forming a fluid tight duct between the seal and the rotary housing may be utilized. Likewise, the seals may be constructed of any material suitable for providing a suitably expandable seal member while providing long-term wear characteristics.
In another exemplary embodiment, the rotary seal system according to the invention includes an interlock control such that the pressurized fluid is prevented from energizing the rotary seal assembly when the rotary housing is rotating.
In yet another exemplary embodiment, the pressurized fluid is constantly pumped through the rotary seal at a pressure sufficient to provide positive fluid flow out of said at least one rotary seal but insufficient to expand said rotary seal to fully sealingly engage the rotary housing such that contaminants are prevented from flowing into the seal assembly and fluid conduits.
Although any suitable number of rotary seals can be utilized in the rotary support table of the current invention, in one exemplary embodiment at least two rotary seals in fluid communication with at least two separate first and second conduits are disposed within the rotary support table. In such an embodiment, one rotary seal is utilized as a slips down seal in fluid communication with a slips down second conduit arranged such that pressurized fluid flowing through the slips down second conduit activates the fluid actuated operator to extend the slip, and the second rotary seal is utilized as a slips up seal in fluid communication with a slips up second conduit arranged such that pressurized fluid flowing through the slips up second conduit activates the fluid actuated operator to retract the slip.
Although a rotary support table having two rotary seals is described above, in another exemplary embodiment, three rotary seals are provided, each in fluid communication with at least three separate first and second conduits, which are disposed within the rotary support table. In such an embodiment, the third rotary seal is utilized as a slips set seal and is arranged such that when the fluid actuated operator has been fully extended or retracted, the pressurized fluid is directed into the slips set second conduit, through the slips set seal to a slips set first conduit arranged in fluid communication with a fluid detector capable of detecting the presence of the pressurized fluid in the slips set first conduit and communicating that presence to an operator.
In still another exemplary embodiment, the rotary seal is arranged in an annular groove formed into the stationary housing. In such an embodiment, the rotary seal may be fixedly mounted in said groove by an o-ring seal.
In still yet another exemplary embodiment, the rotary seal assembly may further include one or more annular wiper seals fixedly mounted in the stationary housing and in cooperative sealing engagement with the rotary housing such that substances are prevented from passing between the wiper seal and the rotary housing. Although any number of wiper seals may be utilized, in one exemplary embodiment, at least two annular wiper seals are utilized and arranged such that the rotary seal lies therebetween.
In still yet another exemplary embodiment, the rotary seal assembly may further include at least one drain conduit arranged adjacent to the rotary seals in fluid communication between a fluid storage tank and the surface of the stationary housing upon which the at least one rotary seal is attached such that any fluid leaking from the rotary seals is recycled back into the pressurized fluid power source system. In such an embodiment, a fluid filter may be arranged between the drain conduit and the storage tank to filter contaminants from the recycled fluid.
In still yet another exemplary embodiment, the rotary support table according to the invention may further include an annular adjustment ring for adjusting the position of the rotary housing in relation to the stationary housing such that the rotary seals fully seal the passage between the fluid conduits within the stationary and rotary housings.
In still yet another exemplary embodiment, the invention includes a method of operating a power slip, wherein the includes utilizing a rotary support table as described in the exemplary embodiments above.
Other features and advantages of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the features of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will become appreciated as the same becomes better understood with reference to the specification, claims and drawings wherein:
FIG. 1 is a perspective view of a rotary support table according to this invention;
FIG. 2 is a cut-away top view of a rotary support table according to this invention;
FIG. 3 is a cut-away side view of a rotary support table according to this invention;
FIG. 4 is a close-up cut-away side view of a rotary support table according to this invention;
FIG. 5 is a cross-sectional side view of a rotary support table according to this invention;
FIG. 6 is a front view of a set of rotary seals according to this invention;
FIG. 7 is cross-sectional sideview of a hydraulic system according to this invention; and
FIG. 8 is an operational schematic of a power slip hydraulic system according to this invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a continuously passively engaged rotary seal for providing fluid communication between a rotary slip bowl and a stationary slip ring.
FIG. 1 depicts an outer perspective view of an exemplary embodiment of the invention including a rotary support table 10 defining a central cylindrical opening or bore 12 . The central bore 12 being arranged such that a pipe or drill string 14 can be suspended therein and turned about a vertical axis 16 in the central bore 12 . The rotary support table 10 further includes an outer stationary housing 18 having a top cover 19 and a rotary slip bowl 20 disposed within the outer stationary housing 18 and arranged coaxially about the vertical axis 16 of the drill string 14 within the central bore 12 . A power slip system (not shown) according to the present invention is disposed within the rotary support table 10 .
FIG. 2 depicts a top view of the rotary support table 10 with the top cover removed. As shown, the rotary support table 10 includes an outer stationary housing 18 defining a cylindrical inner surface 22 . A slip ring 24 is fixedly mounted to the inner surface 22 of the outer housing 18 . The slip bowl 20 is rotatably mounted within the slip ring 24 axially about the central bore 12 such that the slip ring inner surface 26 is adjacent to the slip bowl outer surface 28 creating a seal gap 29 therebetween (shown in FIG. 4 ). In operation, a slip assembly (not shown) is rotatably disposed within the slip bowl 20 . Any suitable slip assembly may be utilized in the slip bowl 20 of the current invention. In most conventional designs the slip assembly includes a plurality of slips having tapered outer walls that are adapted to engage the tapered inner wall 30 of the slip bowl 20 such that the slip assembly is prevented from lateral, but not rotational movement within the slip bowl 20 . Conventionally, each slip carries along its inner surface an engaging insert designed to gripingly engage the drill string to prevent it from falling into the central bore 12 .
With reference to FIG. 2 , any slip bowl 20 suitable for engaging the inner surface 26 of the slip ring 24 and the outer surface of a slip assembly can be utilized with the inventive seals. In one exemplary embodiment the slip bowl 20 , shown in FIG. 2 includes an arc-shaped center section 32 hinged between a pair of arc-shaped side sections 34 and to form a partially enclosed annular body. In such an embodiment, each section is preferably cast from CMS 02 grade 150-135 steel, or more preferably CMS 01 steel, or most preferred CMS 02 grade 135-125 steel, and includes an outer surface, and an upwardly tapered inner surface 30 . The sections are symmetrically disposed about a vertical axis to form a central bore 36 for receiving a slip assembly.
Internally, the slip bowl 20 should be configured to retain a slip assembly from lateral movement while enabling the slip assembly to rotate within the bowl against the frictional contact between the slips and the bowl. In one exemplary embodiment, shown in FIG. 2 , the tapered inner surfaces 30 of the slip bowl 20 are corrugated to form a plurality of grooves 38 that extend into the central bore 12 . The grooves are defined by their tapered contact surfaces which are adapted to engage the outer surfaces of the slip assembly.
Referring to FIG. 2 , the sections 34 of the slip bowl 20 are hinged at opposite ends of the center section 33 about a plurality of hydraulic actuators 40 , which swing the sections of the slip bowl 20 between an “open” position and a “closed” position. In the open position, the side sections 34 are swung “open” to receive the slip assembly within the central bore 12 . In the closed position, the side sections 34 are swung closed to retain the slip assembly within the bowl's central bore 12 . An arc-shaped door may be removably coupled between open ends of the side sections of the slip bowl 20 to retain the side sections 34 in their enclosed “closed” positions and form an enclosed annular body that retains the slip assembly.
Although any conventional slip assembly may be utilized in the current invention, most conventional slip assemblies include a generally annular body formed by a plurality of slips. The slips are generally symmetrically disposed about the vertical axis 16 ( FIG. 1 ) of the bore hole 12 to form an orifice 36 (FIG. 2 ) for receiving the drill string 14 . The slips may be made of any suitable material, but in one exemplary embodiment, the slips are cast from CMS 02 grade 150-135 steel or CMS 01 steel. The slips may be hinged such that the opposite ends of the slip assembly can be brought into abutment by a plurality of hydraulic rams that bias the ends of the slips towards each other. The slip assembly may also include a means coupled to the slip assembly which locks the slips into engagement to “close” the slip assembly or to retain the ends of the slips in abutment and form an enclosed orifice to allow insertion of a drill stem 14 therein.
Any slip design suitable for engaging and holding a drill stem 14 within the central bore 12 may be utilized in the current invention, such as, for example, the Varco BJ® PS 21/30 power slip system. In one conventional design, each slip has an arcuate body shape defined by a radial interior surface and a downwardly tapered exterior surface. In any embodiment, the interior surfaces of the slips must be adapted to receive an insert that extends essentially cylindrically about a central orifice to grip and support a pipe 14 . The inserts may further include teeth for assuring effective gripping engagement with a pipe 14 . For example, the tapered exterior surface of the slips may be corrugated to form a plurality of fingers that outwardly extend from the slip's body. In such an embodiment, the fingers are defined by their tapered contact surfaces which are adapted to engage the inner contact surfaces 30 of the slip bowl 20 . The fingers are configured to retain the slip from lateral movement with the bowl 20 while the bowl 20 rotates about the slips against the sliding friction generated between the contact surface 30 of the bowl 20 . Regardless of the slip design utilized, under normal operating conditions, the slips must be capable of supporting lateral loads of about 300 tons to about 600 tons. Since cold welding between the slips and the bowl 20 is caused in part by the use of similar steels used in casting the slips and the slip bowl 20 , it is desirable that either the slips or the slip bowl 20 is cast from a material dissimilar to steel, namely a material that has little or no tendency to dissolve into the atomic structure of steel (For example). But casting the slips or bowl 20 out of a material other than steel requires specialized hardware and is more expensive to fabricate than steel. Thus, it is desirable to coat the steel slips or the bowl 20 with a dissimilar material along its contact surfaces, such as, for example, copper, a bronze alloy, such as NiAlCu, Tungsten Carbide, Mounting bracket 50 or any other metal in the nickel, aluminum or bronze family.
As shown in FIGS. 4 and 5 , in the exemplary embodiment, the outer surface 28 of the slip bowl 20 is defined by a cylindrical shoulder 44 that outwardly extends from an upper portion of the slip bowl 20 . A reduced diameter outer cylindrical slip ring engaging member 46 is disposed on the shoulder 44 of the slip bowl 20 . The inner surface 22 of the outer housing 18 is also defined by a cylindrical shoulder 48 that outwardly extends from an upper portion of the outer housing 18 . A cylindrical top gap element 50 is adjustably attached to the inner wall 22 of the stationary housing 18 via adjustment screws 52 which allow the cylindrical top element 50 to be moved vertically relative to the slip bowl 20 . The cylindrical top gap element 50 includes a slip bowl engaging groove 54 , which outwardly extends from shoulder 48 of the outer housing 18 such that the outer cylindrical slip ring engaging member 46 of the slip bowl 20 rotatingly engages the adjustable top gap element 50 . The top gap element 50 further includes a slip bowl seal 56 designed to sealingingly engage the outer surface 28 of the slip bowl 20 such that contaminants and debris are prevented from entering the seal gap 29 between the slip ring 24 and the slip bowl 20 . Although one potential means of sealing the gap 29 between the slip bowl 20 and the slip ring 24 is shown in FIG. 4 , and described above, any suitable means of preventing mud, drilling fluids or other debris from entering the seal gap 29 and fouling the slip ring 24 or slip bowl 20 could be utilized with the slip assembly of the current invention.
As shown in FIGS. 6 and 5 , the hydraulic actuators 40 in the rotary slip bowl 20 are connected to a stationary power source external to the outer housing 18 through slip bowl inlets 61 via a rotary slip ring seal assembly 62 arranged cylindrically around the circumference of the inner surface 26 of the slip ring 24 . As shown, the slip ring seal assembly 62 substantially fills the seal gap 29 between the slip ring 24 and the slip bowl 20 . The rotary seal assembly 62 is in turn in fluid communication with a power source via a plurality of external lines 64 disposed within the body of the outer housing 18 . As best shown in FIGS. 4 to 6 , the rotary slip seal assembly 62 , includes a cylindrical annular body with a plurality of sets of hydraulic inlets 66 a , 66 b and 66 c in fluid communication with the outlet of the fluid power supply and outlets 68 a , 68 b , 68 c and 68 d in fluid communication with the filter storage tank inlet of the power supply disposed thereupon. Each set of inlets 66 is arranged within an annular groove 70 . Within each annular groove 70 is received an elastomeric slip ring communication seal 72 a , 72 b , 72 c arranged and designed to sealingly engage a predetermined slip bowl inlet 61 , 61 b and 61 c . In addition to the communication seals 72 , the rotary slip seal assembly 62 further includes a plurality of annular wiper seals 74 a , 74 b and 74 c.
The wiper seals 74 a , 74 b and 74 c are designed to provide a wiping seal with the outer surface 28 of the rotary slip bowl 20 such that the hydraulic communication seals 72 , the inlets 66 and the outlets 68 disposed between the wiper seals 74 are kept free from foreign substances. The wiper seals 74 a , 74 b and 74 c can include any seal design suitable for providing fluid sealing means across the gap between the outer surface 28 of the rotary slip bowl 20 and the inner surface 26 of the slip ring 24 . For example, the wiper seals 74 could include conventional resilient polymer o-ring-type seals which apply a continuous and steady fluid sealing pressure against the outer surface 28 of the slip bowl 20 . Although three wiper seals 74 a , 74 b and 74 c are shown in the exemplary embodiments depicted in FIGS. 4 to 7 , any number of wiper seals 74 may be used such that the area of the slip ring 24 containing the communication seals 66 are kept substantially free of foreign contaminants and fluid within the area bounded by the wiper seals 74 is kept substantially within that area.
One exemplary embodiment of the hydraulic communication seals 72 are shown in detail in FIG. 5 . As shown, the hydraulic communication seals 72 include a ribbon of elastomeric material having inner 76 and outer 78 annular grooves running on opposite sides of a seal wall 80 . The outer edges of each seal 72 are held within the groove 70 of the slip ring 24 and sealed by a groove engaging member 82 , which resiliently engages and attaches the seal 72 within the groove 70 such that fluid applied to the outer surface 78 of the seal 72 is directed through the communication seal inlets 66 and simultaneously prevented from leaking around the edges of the seal 72 . The groove engaging member 82 may include any annular member suitable for sealingly attaching the seals 72 within the grooves 70 . In one embodiment, for example, the engaging member is a conventional elastomeric o-ring designed to fit around the circumference of the slip ring 24 within the annular groove 70 and resiliently press the seal 72 within the groove 70 .
As shown in FIG. 5 , the surface area of the outer annular groove 78 is made smaller than the surface area of the inner 76 annular groove such that when pressurized with hydraulic fluid from the hydraulic power source, a differential pressure is established between the hydraulic fluid on the inner and outer side of the seal wall 80 . This differential pressure creates a differential force on the inner side of the seal wall 80 such that the inner seal surface of the elastomeric hydraulic communication seal 72 is engaged against the outer wall of the slip bowl 28 . When sufficient pressure is exerted on the outer surface of the seal 78 , a fluid sealed passage can be formed between the seal 72 and the outer surface of the slip bowl 28 by the inner annular groove 76 of the seal 72 such that the hydraulic fluid from the power source 60 can flow through the seal inlets 66 into the inner annular groove 76 and then through the slip bowl inlets 61 to activate the hydraulic rams in mechanical communication with a slip assembly. Although any differential size between the inner 76 and outer 78 annular grooves sufficient to create a differential pressure to press the inner surface of the seal 72 against the outer surface of the slip bowl 28 , in one exemplary embodiment the inner seal surface has a surface area of 186 inches 2 and the outer seal surface has a surface area of 190 inches 2 , for a ratio of 0.9. In one exemplary embodiment of the invention, the inner seal surface 76 has dimensions of 3.14×59×1 inches and the outer seal surface 78 has dimensions of 3.14×59×0.5 inches and the inlets 66 include holes having diameters of 0.25 inch. Although specific suitable dimensions for both the seals 72 and the inlet holes 66 are described above, it should be understood that any dimensioned seals and holes may be utilized such that a differential pressure is created from the outside of the seal to the inside such that the inside surface of the seal is suitably sealingly engaged against the outer surface of the slip bowl.
As shown in FIG. 6 , the hydraulic inlets 66 and outlets 68 are arranged around the circumference of the seals 72 within the inner annular grooves 76 such that hydraulic fluid can be evenly distributed within the entire circumference of the inner groove 76 such that an exact alignment of the hydraulic inlets 66 and the slip bowl inlets 61 is not required.
FIGS. 7 and 8 show schematic diagrams of one exemplary embodiment of the hydraulic power supply and control system according to the invention. As shown in FIG. 8 , the hydraulic seal inlets 66 a , 66 b , and 66 c are connected through hydraulic tubing 64 to a series of control valves 84 a , 84 b and 84 c which in turn connect the inlets to a hydraulic power source manifold 86 . Hydraulic seal outlets 68 a , 68 b and 68 c are connected through hydraulic drain lines 88 to the hydraulic power source manifold 86 . The control valves 84 are powered via valve power supply 90 and are hydraulically interlocked via interlock lines 92 to the system pressure of the rotary support table 10 , such that the control valves 84 cannot be opened to pressurize the hydraulic seal inlets 66 during rotation of the slip bowl 20 .
As shown in FIG. 7 , the slip bowl 20 is connected to this external fluid power supply 60 via internal slip bowl conduits 94 disposed within the slip bowl and in fluid communication between the slip bowl inlets 61 and the actuators 40 (shown schematically here).
In one embodiment, as shown in FIG. 8 , the hydraulic system further includes a shuttle valve 96 which connects the hydraulic power source 60 to the slips set control valve 84 b such that the slips set control valve 84 b is activated automatically when either the slips up 84 a or slips down 84 c valves are opened. In this embodiment, the hydraulic power system further includes a pressure sensitive slips set check valve 98 ( FIG. 7 ) disposed within the slip bowl 20 and in fluid communication with all of the slip bowl conduits 94 such that upon full engagement or disengagement of the slips from the drillstem by the actuating rams and the subsequent rise in pressure that results as pressurized fluid continues to build up within the conduits 94 once the actuating ram has completed its travel, the check valve 98 opens allowing pressurized fluid to flow out through the slips set conduit 94 b to a sensor in the slips set control valve 84 b such that a signal indicating the disengagement or engagement of the rams is communicated to the operator. Any hydraulic lines and control valves suitable for containing the pressurized fluid may be utilized in this invention.
During operation, a pressurized fluid, such as, for example air or hydraulic fluid is constantly applied through the power supply to the inlet of each of the control valves 84 . An interlock signal indicative of the rotary table system pressure is also provided to the control valves 84 through the interlock signal lines 92 such that the control valve is incapable of opening during rotation of the rotary slip bowl. Although an engaging pressure is not permitted during rotation because of the interlock, during rotation a constant tank pressure is applied through the lines to the hydraulic seal inlets 66 such that the fluid is constantly flowing out of the seal inlets 66 and against the slip bowl outer surface 28 providing lubrication between the seal 72 and the slip bowl 20 and providing positive flow pressure out of the inlets 66 such that contaminants are not permitted to flow back through the inlets 66 into the hydraulic lines and control valves 84 . Excess fluid is trapped within the rotary seal manifold 62 by wiper seals 74 such that the fluid flows through outlets 68 into drain lines 88 , is filtered and then directed back into the power supply manifold tank 86 .
Referring the FIGS. 7 and 8 , during operation of the rams 40 to engage and hold a drill stem in the central bore of the rotary table for either a load-in or load-out procedure, first the rotation of the slip bowl is stopped by an operator. After stopping, the interlock lines 92 automatically indicate that rotation of the rotary table has stopped to the control valves 84 . Then the operator can activate the slips down control valve 84 c . Pressurized fluid then passes through the slips down control valve 84 c and flows into the outer groove 78 of the slips down hydraulic seal 72 c such that a differential pressure is created between the outer and inner surfaces of the seal wall 80 , thereby energizing the seal 72 c to resiliently expand inwardly toward the slip bowl to engage the outer surface of the slip bowl. The fluid then flows through the plurality of seal inlets 66 c around the circumference of the seal 72 c and into the slip bowl slips down inlets 61 c disposed about the outer circumference of the slip bowl. The fluid then passes through slip bowl slips down conduit 94 c , shown in FIG. 8 , and into the actuating rams such that the actuators push a set of slips inwardly to engage the drillstem 14 .
After the drill stem operation is complete and drilling is to be continued, the operator closes the slips down control valve 84 c and opens the slips up control valve 84 a . Pressurized fluid from the power supply manifold 86 then passes through the slips up lines 64 a to the outer seal groove 78 in the slips up seal 72 a thereby energizing the seal 72 a to press against the outer surface of the slip bowl such that the inner groove 76 of the slips up seal 72 a forms a fluid conduit between the slips up seal inlet 66 a and the slip bowl sips up inlet 61 a . The pressurized fluid then passes through the slip bowl slips up conduit 94 a and into the actuating rams such that the actuating rams are pushed outwardly to disengage the drillstem.
As shown in FIG. 7 , the slips up and slips down lines 64 a and 64 c are connected to the slips set line 64 b via a shuttle valve 96 such that when the pressurized fluid passes through one of the lines the shuttle valve 96 is opened to allow pressurized fluid to also energize the slips set seal 72 b such that the slips set seal 72 b also engages the outer surface of the slip bowl 28 such that a fluid passage is formed between the slip bowl slips set inlet 61 b and the slips set seal inlet 66 b . When the actuating ram has reached its full up or down stroke and the slips are fully set against the drillstem or fully disengaged from the drillstem, the pressure of the fluid inside the slip bowl conduits 94 rises and triggers a slips set check valve 98 , which is in fluid communication with both the slips up and slips down conduits 94 a and 94 c , to open allowing the fluid to move from the slip bowl slips down or up conduits 94 a or 94 c and into the slip bowl slips set conduit 94 b . The fluid passes outward through the slip bowl slips set inlet 61 b , in fluid communication with the slip bowl slips set conduit 94 b and into the slips set seal 72 b . The fluid then passes through the slips set seal inlets 66 b and into the slips set line 64 b such that the fluid interacts with the slips set control valve 84 b signaling that the rams 40 have either been fully engaged or disengaged, and thus that the associated slips are fully engaged or disengaged from the drillstem, i.e., that the slips are in a “set” position. Once the rams 99 are “set” in the up position, or fully disengaged from the drillstem, the operator can once again start rotation of the rotary slip bowl, which in turn will automatically pressurize the interlock line 92 preventing the activation of the control valves 84 to engage the rams 99 .
While several forms of the present invention have been illustrated and described, it will be apparent to those of ordinary skill in the art that various modifications and improvements can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited, except as by the appended claims.
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A rotary seal assembly for a rotary support table for use in drilling systems and the like to provide pressurized fluid to a rotary slip assembly disposed within the rotary support table is provided. The rotary seal assembly is designed to be coupled to an existing rotary support table which is used to rotate a drill string, and includes a powered slip that is powered into an engaged position to securely engage a pipe segment, for example, a casing segment. The rotary seal assembly generally comprises a ribbon of expandable material having an outer surface in fluid communication with a source of pressurized fluid, and an inner surface cooperative with a rotary housing, the rotary seal having a plurality of openings capable of communicating fluid between said outer and inner surfaces, wherein the outer seal surface has a surface area greater than the inner surface such that when the pressurized fluid is conducted to the outer surface of the seal a differential pressure between the outer and inner surfaces is created such that the inner surface of the seal is expanded to engage the rotary housing and form an annular fluid duct providing fluid communication between the pressurized fluid source and the rotary housing. A method of operating a rotary table and powered slip assembly utilizing the rotary slip assembly of the current invention is also provided.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for, and a method of, installing a transmission line such as an optical fibre telecommunications line.
2. Related Art
In the United Kingdom, the telecommunications network includes a trunk network which is substantially completely constituted by optical fibre, and a local access network which is substantially completely constituted by copper pairs. Flexibility in the copper access network is provided at two points en route to the customer; firstly, at street-side cabinets serving up to 600 lines; and secondly, at distribution points serving around 10-15 lines. Eventually, it is expected that the entire network, including the access network, will be constituted by fibre.
The ultimate goal is a fixed, resilient, transparent telecommunications infrastructure for the optical access network, with capacity for all foreseeable service requirements. One way of achieving this would be to create a fully-managed fibre network in the form of a thin, widespread overlay for the whole access topography as this would exploit the existing valuable access network infrastructure. Such a network could be equipped as needs arise, and thereby could result in capital expenditure savings, since the major part of the investment will be the provision of terminal equipment on a `just in time` basis. It should also enable the rapid provision of extra lines to new or existing customers, and flexible provision or reconfiguration of telephony services.
In order to be completely future proof, the network should be single mode optical fibre, with no bandwidth limiting active electronics within the infrastructure. Consequently, only passive optical networks (PONs) which can offer this total transparency and complete freedom for upgrade, should be considered.
The most common passive optical network is the simplex single star, with point-to-point fibre for each transmit and receive path, from the exchange head end (HE) to the customer network terminating equipment (NTE). This network design has been used throughout the world and meets all the access criteria. It involves high fibre count cables, and unique electro-optic provision at HE and NTE for each customer. The resulting inherent cost can only be justified for large business users, who generally also require the security of diverse routing, which increases the cost still further.
The advent of optical splitters and wavelength-flattened devices has enabled the concept of the PON to be taken one step further. These passive components allow the power transmitted from a single transmitter to be distributed amongst several customers, thereby reducing and sharing the capital investment.
The use of splitter based PON architecture thus reduces the cost of fibre deployment in the access network. When compared with point-to-point fibre, savings will result from:
(i) reducing the number of fibres at the exchange and in the network;
(ii) reducing the amount of terminal equipment at the exchange;
(iii) sharing the cost of equipment amongst a number of customers;
(iv) providing a thin, widespread, low cost, fibre infrastructure; and
(v) providing a high degree of flexibility, and allowing `just in-time` equipment and service provision.
Additionally, PON architecture can be tailored to suit the existing infrastructure resources (duct and other civil works).
It will be apparent that upgrading the entire UK access network from copper to fibre will involve a major capital investment program. It is important, therefore, to minimize costs wherever possible. The specifications of our published International patent applications WO95/07475, WO95/07476, WO95/07477. WO95/07478 & WO95/107486 describe a fibre management system which aims to reduce the cost of providing fibre from local exchanges to the network nodes (equivalent to the distribution points of the copper access network) nearest the customers. The specifications of our published International patent applications GB95/00449 and GB95/00450 describe a way of minimizing the cost of getting fibre into a customer's premises via a customer lead in (CLI) provided in an external wall of the premises. The present invention is concerned with minimizing the cost of getting fibre from just outside a customer's premises to the nearest network node.
German,patent number DE3826513 discloses a method for laying a transmission line under the ground alternative to the established method of digging a trench in the ground along the intended route of the line, laying the line into the trench and then backfilling to bury the line. One embodiment of the apparatus has a pneumatically driven tunnelling head whose route is guided by a C-shaped guide attachment mounted on the end of an arm extending radially from the tunnelling head.
Published UK patent application number 2085670 discloses a device for loosening the earth around a previously buried cable. The device has a main body comprising inner and outer cylindrical sections, which are moved alternatively, by hydraulic means, relative to one another, such that the apparatus moves along the previously buried cable with a "shinning" movement. As the apparatus moves along the cable, water is supplied to the apparatus and is ejected through nozzles at the front of the apparatus to loosen the earth around the cable in front of the apparatus.
SUMMARY OF THE INVENTION
The present invention provides a method of installing a transmission line in the ground, the method comprising the steps of forming a tunnel in the ground using a mole constituted by a water-jetting head and piping for supplying pressurized water to the head, and positioning the transmission line in the tunnel, wherein the head is guided along a pre-installed buried elongate member by manually pushing the piping thereby forming the tunnel adjacent to the elongate member.
The pre-installed buried elongate member may be an underground service pipe (water or gas) or cable. Preferably, this member is a telecommunications line such as a twisted copper pair. The method of the invention thus permits the installation of a new telecommunications line using an old telecommunications line as a guide, thereby providing a cost-effective way of installing the new telecommunications line from the curtilage to the CLI.
Advantageously, the transmission line is a ruggedized optical fibre which is rodded into the tunnel after the mole has been withdrawn.
Alternatively, the transmission line is an optical fibre transmission line which is propelled along the tunnel by fluid drag of gaseous medium passed through the tunnel, the optical fibre transmission line being installed in the tunnel after the mole has been withdrawn. In this case, a tubular pathway may be positioned within the tunnel prior to the propelling of the optical fibre transmission line, the optical fibre transmission line being propelled along the tubular pathway by fluid drag of said gaseous medium.
The tubular pathway may be constituted by tubing which is connected to the moie at the head end thereof, the tubing being positioned in the tunnel by subsequently withdrawing the mole from the tunnel.
Preferably, the method further comprises the step of removing the head from the piping of the mole, connecting a second water-jetting head to the piping, attaching the tubing to the second head, and removing the mole from the tunnel.
The invention also provides a cutting head for a water-jetted mole, the cutting head comprising an elongate main body portion formed with a longitudinally-extending bore for supplying pressurized water to a deflection face formed within the main body portion, a guide member fixed to the main body portion in the region of the deflection face, the guide member being sized and shaped for engagement with a buried elongate guide, an axially-extended slot formed in the main body portion on the other side of the deflection face to the bore, the slot being aligned with the bore and extending to the free end of the main body portion thereby defining a passage for producing a first, axially-directed water jet which, in use, cuts a tunnel along the side of the guide, and the deflection face being such as to deflect some of the water supplied along the bore so as to define a second, transversely-directed water jet which, in use, washes over the guide member.
Conveniently, a deflection face is defined by a radial blind bore formed in the main body portion, the radial blind bore intersecting said first-mentioned bore.
Advantageously, the main body portion is provided with an externally-threaded extension portion at that end thereof remote from the axial slot.
Preferably, the guide member is constituted by a guide ring, and one end of the guide ring is fixed to the main body portion, and the other end of the ring is detachably fixed to the main body portion. This facilitates positioning of the guide ring over the buried elongate guide.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described in greater detail, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a perspective view of the cutting head of a guided water-jetted mole constructed in accordance with the invention;
FIG. 2 is an axial cross-section taken through the front portion of the cutting head of FIG. 1;
FIG. 3 is a plan view of the cutting head front portion;
FIG. 4 is a front elevation of the cutting head of FIG. 1; and
FIG. 5 is an axial cross-section taken through the front portion of a modified form of cutting head.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Referring to the drawings, FIG. 1 shows a cutting head H made of stainless steel. The cutting head H has a main body portion 1 and a screw-threaded shank 2. The front end of the main body portion 1 (that is to say that end remote from the shank 2) is shaped to define a tapered nose portion 1a. The main body portion 1 is formed with an axial bore 3 (see FIG. 2) which is contiguous with a bore (not shown) in the shank 2. The bore 3 terminates at a deflection face 4 formed in the main body portion 1 by a cylindrical, radial blind bore 5. An axial slot 6 extends forwardly of the bore 5, terminating at the free end of the tapered nose portion 1a. The main body portion 1 is provided with a flexible guide ring 7 made from a multi-stranded, high tensile steel wire which is surrounded by short tube sections which act as rollers. One end of the guide ring 7 is permanently fixed to the main body portion 1, the other end being detachably fixed to the main body portion by means of a grub screw (not shown). The guide ring 7 is positioned just behind the deflection face 4.
The cutting head H is used with a plurality of stainless steel tubes 8 (one of which is shown in FIG. 1), each of which has an internally-threaded portion at one end and an externally-threaded portion at the other end. The tubes 8 each have a length of2 m, an external diameter of 10 mm and an internal diameter of 6 mm. A first of the tubes 8 can be fixed to the screw-threaded shank 2 of the cutting head H by means of its internally-threaded end portion. Subsequently, further tubes 8 can be added (in a manner described below) by interengagement of adjacent internally-threaded and externally-threaded end portions.
The mole described above can be used to tunnel through the earth to provide a route for the subsequent installation of a telecommunications line such an optical fibre line. In particular, the mole can be used to tunnel from the curtilage of a customer's premises to the customer lead in point provided in the wall of those premises.
In order to guide the mole from the curtilage to the CLI, use is made of any service cable or pipe already buried in the ground. Preferably, where there is an existing telecommunications line (i.e. a copper pair) already buried in the ground, this is used to guide the mole. In this case, the first step of the tunnelling process is to dig a small pit at the curtilage so as to expose the buried telecommunications line (drop cable). The guide ring 7 of the cutting head H is then positioned over the cable by releasing the grub screw, positioning the ring over the cable, and then re-applying the grub screw. A first stainless steel tube 8 is then threaded onto the shank 2 of the cutting head. The free end of the rod 8 is then connected to a Gerni 600 p water lance (not shown) which is supplied with water at a pressure of 2350 psi at a rate of between 17 and 18 litres per minute.
Pressurized water is then supplied to the cutting head H by pressing the trigger of the water lance. Pressurized water is then forced along the bore 3 and against the deflection face 4, resulting in the formation of two separate water jets J1 and J2 (see FIG. 2). The water jet J1 is directed generally along the axial slot 6 towards the tapered nose portion 1a of the cutting head H. This jet J1 is effective to cut a tunnel in the earth in the region of the guiding cable. The other jet J2 is directed upwardly towards the cable and the guide ring 7. This jet J2 forces pressurized water around the cable and the guide ring 7 to prevent earth and stones jamming between the guide ring and the cable, and so preventing the forward movement of the cutting head H. Once the water has been turned on, the operator pushes the tube 8 into the ground. As this occurs, the water jet J1 tunnels into the earth thereby forming a bore adjacent to the guide cable. When the tube 8 has been advanced until the water lance is about to enter the pit, the water is turned off, the lance is unscrewed from the free end of tube 8, and a further tube 8 is threaded onto the first tube 8. The lance is then screwed onto the free end of this second tube 8, the water is turned on again, and the cutting head H is rodded further into the ground by the operator. The procedure is repeated until the cutting head is beneath the customer lead-in point in the wall of the customer's premises. A small pit is then dug at this point to reveal the cutting head H. The cutting head H is then removed from the first tube 8, the tubes 8 are withdrawn from the pit at the curtilage, and a ruggedized optical fibre cable is rodded into the tunnel from either end.
Alternatively, a modified form of cutting head H' (see FIG. 5) is fixed to the internally-threaded portion of the first tube 8 by means of an externally threaded shank 12 formed at one end of a main body portion 11. The main body portion 11 and the shank 12 are formed with a central blind bore (not shown) for feeding water to a number of water jets 13 (only one of which can be seen) formed in the main body portion. An extension 14 is formed on that side of the main body portion 11 remote from the shank 12, the extension being provided with an internally-threaded shank portion 15. In use, a tube clamp (not shown) formed with an externally threaded shank is screwed into the internally-threaded shank portion 15, and a blown fibre tube is fixed in the clamp. This tube is typically made of a polymer such as a high density polythene, and has an outer diameter of 8 mm and an inner diameter of 3.5 mm. The tube is preferably supplied from a coil. Pressurized water is then supplied to the cutting head H' by pressing the trigger of the water lance, and the line of tubes 8 and the cutting head H' are withdrawn from the tunnel by pulling from the pit at the curtilage. As the cutting head H' travels along the tunnel water escaping from the jets 13 is effective to remove any earth or stone which might otherwise impede its passage. When the cutting head H' reaches the pit at the curtilage, the blown fibre tube is removed from its clamp, after which an optical fibre cable can be blown through the tube in the known manner.
In some cases, it may be possible to replace the cutting head H' by a simple threaded member for fixing to the first tube 8 and for threading in a tube clamp.
It will be apparent that the method and apparatus described above could be modified. For example, in order to reduce the amount of effort needed to install the tubes 8, a wetting agent could be added to the water supplied to the lance. A suitable wetting agent, which should be biodegradable in soil, is a Sub-soil Boring Fluid supplied by Enviro Chem.
It would also be possible to install ducting for housing a new transmission line at the same time as the mole cuts the tunnel. For example, lengths of plastics tubing could be pushed over the tubes 8 as the mole is rodded in, the lengths of tubing being glued together, as they are added, using plastics collars.
The method of the invention results in a time-saving of approximately 70% (when compared with standard open trench and back fill methods or those utilizing pneumatic moles) in the upgrade of direct buried telecommunications line customer feeds. This assumes a mixture of grass, flower beds and paving that would be considered a typical front garden. The method requires the digging of only two small pits, one at either end of the feed, and this minimizes re-instatement costs. At the same time, there is minimized disruption to areas that have public access and to the customer's property. Moreover, the method of the invention involves a single man, low skill operation, and so is cheap to carry out.
Although the method of the invention is intended primarily for the replacement of direct, in ground, customer drop cables, scaled versions of the technique could be used to replace any of the other utility lead-ins, for example gas pipes, water pipes, electric cables etc. In addition to the customer premises to curtilage location, scaled versions of the technique could be used for replacement of directly buried cables, ducts and pipes throughout the network infrastructure of all the utilities. In particular, for telecommunications applications, in addition to the customer drop provision, the method of the invention could be used for the replacement and upgrading of distribution cables in frontage "T" topologies, in the replacement of damaged directly buried cable throughout the network, and in the replacement of blocked lead-in ducts.
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A method of installing a transmission line (such as an optical fibre telecommunications line) in the ground includes the steps of forming a tunnel in the ground using a mole constituted by a water-jetting head and piping for supplying pressurized water to the head, and positioning the transmission line in the tunnel. The head is guided along a pre-installed buried elongate member such as a twisted copper pair telecommunications line.
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FIELD OF THE INVENTION
[0001] The invention concerns a positioning device according to the preamble of claim 1 and a system for engagement with vertebrae in a spinal column including such a positioning device.
BACKGROUND OF THE INVENTION
[0002] For patients diagnosed disc degeneration, surgical operations are performed more and more often for released troubles. The most common operation for these patients today is still fusion, where an ossified connection of the vertebrae is obtained. Also metallic connection devices can be used. The movability then ceases between the vertebrae in question but the patient will become free from pain. As the patient becomes more active and movable, the segments above and below the fused region will, however, be subjected to greater strains. The risk of new symptoms from surrounding segments thereby increases.
[0003] As an alternative to fusion, disc implants have been presented. A known disc prosthesis generally consists of two mutually articulated plates that are positioned between two vertebrae instead of the disc. The positioning of a disc implant results in eliminating the disc that causes pain, reinstating the distance between the vertebrae and reinstating movability between them.
[0004] In order to obtain sufficient certainty against a disc implant over time moving in an undesired manner from the intended position between two vertebrae, the two mutually articulated plates of a previously known prosthesis are provided with different kinds of projecting engagement means such as fin-shaped elements, pointed elements, pins and like plural projections for the engagement with the meeting surfaces of the vertebrae.
[0005] The operative method that is used for inserting a disc implant requires positioning of the prosthesis from the abdomen side in order to allow access to the vertebral column from the front. The disc to be replaced is cleared out, whereby the vertebrae are drawn apart with the aid of tension pliers.
[0006] After using possible instruments shaping grooves in the surfaces of vertebrae for the cooperation with possible projecting protrusions for the purpose of achieving a correct position for the disc prosthesis, the latter is now to be positioned.
[0007] According to today's methods, this is achieved by applying the prosthesis on a holder and hammering it in with great force between the vertebrae, guided by the prepared grooves. This step in the operation is very problematic, since the vertebrae tend to be drawn of fall against each other and then it will often be difficult to even bring in the prosthesis between the vertebrae. For this reason the hammering risks to be very violent.
[0008] When the prosthesis is finally positioned, which is verified with X-ray radioscopy, said tension pliers are used in order to again span apart the vertebrae and thereby the disc plates of the prosthesis in order to be able to position a joint detail between these plates. Also this step is troublesome and sometimes laborious.
[0009] When using prostheses that are completely assembled with the joint detail, this second step is not necessary. Such prostheses are, however, thicker and yet more troublesome to position between the vertebrae. Sometimes, unfortunately, damages to the vertebrae will occur during the positioning of the prosthesis. Such damages can be serious and have serious consequences. For that reason, the surgical operation puts great demands on the skill and experience of the surgeon.
[0010] When, finally, everything is place, the operation is terminated and final X-ray is made. Not very seldom it can then be discovered that the disc prosthesis is not correctly positioned in such a way that it is not placed exactly on the middle line or in any other way is not in a proper position. The possibilities of adjusting the position are at this stage almost none.
[0011] Since the disc prosthesis rests on the brittle covering plate of the vertebra, the prosthesis must have maximal size in order to support on a relatively strong peripheral rim of the vertebra. Exact positioning is therefore very essential. Patient having osteoporosis are therefore often disqualified for this type of surgical operation depending on lack of congruence between the parts of the disc prosthesis and the vertebra.
[0012] Incorrect position results in risk of uncontrolled separation and repositioning of the vertebrae.
AIM AND MOST IMPORTANT FEATURES OF THE INVENTION
[0013] It is an aim of the present invention to provide a positioning device of the kind mentioned initially and a system which makes it possible to eliminate or at least reduce the problems of the background art.
[0014] These aims are achieved in a positioning device according to the above through the features of the characterizing portion of claim 1 . The corresponding advantages are obtained in a system device according to claim 18 .
[0015] Hereby it is achieved that when spanning apart of the vertebrae in a spinal column, a prosthesis device, such as for example a disc prosthesis or a vertebral prosthesis, can be correctly positioned with respect to at least one vertebra when vertebrae are spanned apart, so that, when the separation is ended, the prosthesis is indeed in the right position. X-ray radioscopy can be used in connection with adjusting the holder means in order to assist the surgeon during the positioning. The invention is, however, not limited to this method but also other corresponding methods for this are possible to use, such as for example translucence with NMR-camera, magnet camera. Also other fluoroscopy and positioning indication methods can be used.
[0016] When the vertebrae are released against the prosthesis device, through X-ray radioscopy or the like it can be verified that the final position of the prosthesis device also is the desired position. In the event this is not the case, there is a real possibility of repositioning the prosthesis device after a renewed spanning part of the vertebrae also if it is considered to be less likely that this would be necessary if the positioning is made accurately from the beginning.
[0017] After a verified correct positioning, the holding device is released from the prosthesis device, whereafter the used spanning device can be removed permanently. Altogether, the positioning device according to the invention allows essentially more secure and further, more easily handled equipment, which also can be used in a patient-friendly manner with minimized risks of injuries to the patient when it is used.
[0018] By providing two fixing elements outgoing from different engagement positions and which are mutually lockable, satisfactory stability is obtained and positioning security after possibility of adjustment.
[0019] By providing a universal joint, which is lockable/releasable through said locking means, great positioning freedom is provided.
[0020] In particular, it is preferred that the positioning device according to the invention includes distance means in order over connection portions to carry engagement means that are constructed for engagement with two vertebrae at a distance from each other. Hereby the prosthesis device is positioned with respect to these vertebrae, which are preferably located on either side of the operation point.
[0021] In particular, it is preferred that said distance means are arranged such that they are capable of changing the degree of separation of said vertebrae when the engagement means are in engagement therewith. Hereby, in the positioning device, the means for spanning apart the vertebrae are integrated which is a considerable advantage, since the arrangement for spanning apart hereby can be constructed optimally for its use to function as a mechanism for spanning apart and further as the base for the fixing means. Greater freedom when removing the old, damaged disc is also achieved. With previously known technology, the tooling for holding apart the vertebrae comprises an obstacle making it difficult to evacuate the old, damaged disc. This process is time consuming and positioning of a disc implant is more difficult. The integrated aspect of this invention essentially simplifies clearing out of the damaged disc, whereby the entire operation is facilitated and speeded up, resulting in a safer operation. The possibility of spanning apart, which is provided according to this aspect of the invention, makes it possible to freely remove the old disc.
[0022] The positioning of the holding means will thereby be very stable and no further engagement points, besides the ones belonging to the mechanism for spanning apart, that is the distance means, are necessary. The number of operation points in the patient in the form of holes for screws or the like can thereby be limited to a minimum.
[0023] Said distance means preferably include two distance means arranged in parallel carrying the engagement means. The adjustment and handling of the holding means and the prosthesis carried thereon hereby takes place between these parallel arranged distance means. The fixing means are suitably comprised of elongate elements, that are arranged on the distance means and are fixable thereon, which in a common crossing point are lockable, which results in a very stable fixation. The crossing point between these elements is preferably also the starting point for a locking means, which in its locked position fixes the holding means. Preferably the locking means in said locked position also locks the fixing elements in said crossing point.
[0024] By providing the fixing elements with each one slotted portion in their free regions, in the free state, sideways adjustment of the crossing point is allowed with respect to the operation point, which can be desirable for providing an accurate positioning of the prosthesis device in its rotational direction.
[0025] It is previously known to use so called retractors in the kind of surgical operation of the present type in order to hold the soft parts in the abdomen from the operation point. A system according to the invention includes and preferably carries support devices for that purpose. By fastening them to the distance means, they contribute in an optimal manner to hold the abdomen wall pressed down and the operation field free. The clearing out of the old disc is also simplified with these means.
[0026] Corresponding advantages are achieved in a system according to claim 18 and the dependant system claims.
BRIEF DESCRIPTION OF DRAWINGS
[0027] The invention will now be described by way of embodiments and with reference to the annexed drawings, wherein:
[0028] FIG. 1 shows a positioning device according to the invention during the process of introducing an implant in a spinal column, partly in section,
[0029] FIG. 2 shows the positioning device in FIG. 1 in a perspective view,
[0030] FIG. 3 shows the positioning device in FIGS. 1 and 2 in a separate perspective view,
[0031] FIG. 4 shows the positioning device according to the invention with some details removed for the sake of clarity, and
[0032] FIGS. 5 a and b show in different views a holding device for the use with a device according to the invention.
DESCRIPTION OF EMBODIMENTS
[0033] FIG. 1 shows a positioning device 1 in the process of positioning a disc implant 2 between two vertebrae 3 and 3 ′ in a spinal column of a living human being. With 5 are indicated two healthy discs, whereas between the vertebrae 3 and 3 ′ is cleared out all material from a damaged disc to be replaced by said disc implant 2 .
[0034] The disc implant 2 is held by a holding device 6 including a fork-shaped head 10 , which releasably grips around the disc implant 2 and a rod shaped manipulating element 11 which can be manipulated by hand by a surgeon.
[0000] In the embodiment shown in FIG. 1 , the manipulating element 11 is controlled by a fixing means 7 , which in turn is connected to the distance device 8 (only one shown on FIG. 1 ), which in turn over engagement means in the form of screws, (indicated with dash dotted lines, and with numerals 4 and 4 ′), is in engagement with two vertebrae 3 , 3 ′.
[0035] The fixing means 7 includes fixing elements 12 (only one shown in FIG. 1 ) together with a universal joint 9 ′ which is lockable by means of a locking means 9 , wherein the universal joint 9 ′ in a first, free state allows an adjustment movement including rotations and displacements of the holding means 6 and thereby for the disc implant 2 . In a second, locked position, the locking means 9 locks the universal joint 9 ′ and thereby the holding device 6 and thereby the disc implant 2 in a chosen position.
[0036] As is indicated by arrows P 1 -P 6 , essentially total freedom of movement is achieved with the shown embodiment with three linear degrees of freedom P 1 -P 3 and three rotational degrees of freedom P 4 -P 6 for the holding device 6 . It should be noted that freedom of movement in the length direction of the distance device 8 is obtained by displacement of the fixing element 12 relative thereto. Locking of the locking means 9 can suitably be arranged by means of a smaller rotation of the fixing element 12 with respect of the distance device 8 and thereby friction locking of these elements with respect of each other.
[0037] The function of the spanning device of the arrangement is such that the distance device 8 is extendable in the length direction by displacement in such a way that the engagement elements, which thus have been brought to engagement with two vertebrae, because of the extension will cause a change of the degree of separation between these vertebrae 3 and 3 ′ with respect to each other.
[0038] This way the vertebrae can be separated and the space between them be cleared out so that the disc implant 2 without resistance can be inserted between the vertebrae 3 and 3 ′, accurately be positioned by the surgeon supported by simultaneous X-ray radioscopy until an optimal positioning of the disc implant 2 has been reached. Thereafter the holding device 6 is locked and thereby the prosthesis device in the chosen position with the aid of the fixing means 7 , whereafter the distance device 8 is manipulated in such a way that the distance between its outer ends reduces and thereby the vertebrae 3 and 3 ′ come closer to each other until they come into contact against the outer plates of the disc implant 2 . Thereafter a final control is made, by means of X-ray radioscopy or the like, that the disc implant 2 is indeed accurately positioned
[0039] If that should not be the case, the degree of separation is again increased between the vertebrae 3 and 3 ′ and the disc implant 2 is repositioned. When accurate positioning has been reached, the holding device 6 is removed from the disc implant 2 , whereafter the distance device 8 and its engagement means 4 and 4 ′ can be removed from the engagement with the vertebrae.
[0040] In FIG. 2 , the positioning device 1 is represented in a perspective view in about the same position as is shown in FIG. 1 . Hereby is shown that the spanning device belonging to the positioning device 1 includes two sideways separated distance means 8 and 8 ′, which are position such that it between them is a sufficiently great space for introducing a disc implant (not shown in FIG. 2 ), which is carried by a fork head 10 of a holding device 6 .
[0041] From each one of the distance means 8 and 8 ′, extents fixing elements 12 and 12 ′, which are longitudinally displaceable on the respectively means 8 and 8 ′ through sleeve portions 19 . The fixing elements 12 and 12 ′ are united in a crossing point, wherein a locking device 9 engages. The locking device 9 activates and deactivates also a universal joint 9 ′, which carries the manipulating element 11 of the holding device 6 .
[0042] In the fixing means 12 and 12 ′ are arranged longitudinal, elongate through slots 20 and 20 ′, in which a bolt belonging to the locking means 9 can run. This way, in a free state of the locking means, it is possible to displace the locking device and the universal joint 9 ′ in height as well as sideways by side displacement of the locking device and the universal joint with respect to the operation point between the vertebrae 3 and 3 ′.
[0043] Further, the distance devices 8 and 8 ′ are telescopic and thus axially displaceable in order to allow an increased separation of those vertebrae, with which they are in engagement. In the shown example, the distance means 8 and 8 ′ are not in engagement with two adjacent vertebrae, but with a first vertebra 3 ′ and a second vertebra 3 ″, whereas a third vertebra 3 is between these vertebrae. This arrangement allows better space at the place of operation.
[0044] Spanning apart the distance devices are made with a pliers device 18 , which forces apart two telescopic parts 15 ′ and 14 ′ belonging to the distance device 8 ′. For fixing of an obtained separation position, a locking ring 16 ′ is used, which locks against the smaller one of the telescopic parts 15 ′ by means of a locking screw 17 . In practice, the spanning apart of the vertebrae are made through step-wise manipulating of the pliers device 18 on first the one on the distance devices a smaller step, locking thereof, thereafter spanning apart of the second distance device a smaller distance, locking thereof etc. etc.
[0045] In FIG. 3 , the device of FIG. 2 is shown in a different perspective and freed from a spinal column. The distance devices 8 and 8 ′ have at their ends per se known joint devices for cooperation with the engagement means 4 , 4 ′, which are comprised of per se known skeleton screws. By the engagement means being articulately fastened to the distance devices, excess breaking forces onto the vertebra are avoided in connection with spanning-apart the spinal column. The positioning of the screws 4 , 4 ′ are made in those parts of vertebrae that are least porous, and thereby best resist the forces for spanning apart.
[0046] On FIG. 3 are also shown two supporting elements 21 and 21 ′, preferably lockable and slightly curved, which are arranged for cooperation with (not shown) supporting plates for free holding the operation point from body organs in connection with the surgical operation.
[0047] In FIG. 4 are shown essential parts of the positioning according to the invention with some details removed.
[0048] A holding device 6 is shown in FIG. 5 a and b . The holding device 6 includes a fork-shaped head 10 with fork shanks 10 ′ and 10 ″, which from an engagement position, where they with the aid of the engagement means 24 engage with a disc implant, can be brought to a position where the disc implant is released. This is achieved by the normally curved element 23 between the fork shanks 24 , by means of an actuating means 22 in the form of an element inside the rod shape manoeuvring element 11 , is brought to a straightened state, where it presses apart the fork shanks 24 . See interrupted arrows in FIG. 5 b . The actuating means 22 can be manipulated by hand by a surgeon through a press button outermost on the means 22 . The head 10 is preferably made of a plastic material in one piece in such a way that in an unloaded condition, it is in a position for engagement and with a bent element 23 .
[0049] It should be noted that the invention can be modified within the scope of the claims. The shown embodiment with the positioning device thus directly cooperating with a spanning device in the form of distance means is preferred. However, it is not excluded that the positioning device is separate from the spanning device, and in that case it is arranged such that the fixing means are fastened otherwise to one or a plurality of vertebrae. This is, however, not desired, since it means that further operations with holes etc. in the spinal column have to be made. It, however, makes it possible to use another type of spanning device for separating the vertebrae than the one that is described and shown here.
[0050] In order to arrange that a greater space is provided between two distance devices, the attachments of the engagement means can be positioned sideways outwardly, so that the distance devices can be positioned sideways with respect of the axes of the engagement means.
[0051] A modification of the spanning device can have one single distance device, which provides spanning apart instead of two that are shown in the Figures. At the ends, this single distance device can have sideward angled portions for cooperation at different positions after their lengths with typically each two engagement means that are engaged with the vertebrae so that the spanning device will have a shallow U-shaped construction with the distance device as web and the sideward angled portions as the shanks of the U. In this case positioning, as an example, may need to be arranged on the one hand on the only distance device, on the other hand on a fixed point on a vertebra.
[0052] The arrangement between the distance device (devices) and the engagements means can be different, for example, the arrangement with three independent joints for allowing movements: 1: in a plane parallel with the axis of the distance device, 2: in a plane at right angle to the axis of the distance device, 3: in a plane at right angle against the axis of the engagement means (screw). Independent locking of these joints results in possibility of changing the angles of the screws, also under load, which gives greater possibilities of influencing the positions and the parallelism of the vertebrae.
[0053] The fixing means can in that and other cases be constructed otherwise, thus include portions for cooperation directly with a vertebra. Also other kinds of arrangements for locking the holding means can be envisaged, for example with a locking device arranged at the fastening point of the fixing means on the spanning device or on the vertebra itself. It is also possible to have other types of locking and a plurality of separate locks for movements in different directions instead of the integrated lock shown in the Figures. The distance devices can be manipulated otherwise, for example by screwing, with a notched rod with possibly spring loaded locking device, or with a leaver mechanism.
[0054] In a simply handled modification, the distance device is manoeuvred with the aid of an adjustment cable, such as a “Bowden cable”, which can have its fastenings on engagement portions on mutually movable parts of a distance device in a manner which is per se obvious for the person skilled in the art. This way spanning apart of two vertebrae is initiated from a distance from the area of spanning apart, which is an advantages, since it enhances control and accessibility. Also other arrangements such as with pawl and rack and corresponding, actuating means with hydraulics or with pneumatics can be used for spanning apart.
[0055] It shall be noted that it is not excluded that other prostheses are positioned with a device according to the invention, for example vertebra prostheses.
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A positioning device ( 1 ) for placing a prosthesis device ( 2 ) in a spinal column of a living mammal, including at least one holding device ( 6 ) for cooperation with the prosthesis device and for guiding thereof during positioning, wherein it includes fixing means ( 7 ) for fixation with respect to at least one vertebra ( 3,3 ′), and said fixing means includes locking means ( 9 ), which in a first, free state, allows adjustment movement of said holding means ( 6 ) and thereby of the prosthesis device ( 2 ), and in a second, locked state, fixes said holding device ( 6 ) and thereby the prosthesis device ( 2 ) in a selected position. The invention also concerns a system.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of provisional patent application Ser. No. 62/125,595 filed on Feb. 4, 2015 by the present inventor.
FEDERALLY SPONSORED RESEARCH
[0002] No
SEQUENCE LISTING OR PROGRAM
[0003] No
BACKGROUND
[0004] This invention relates to a Hybrid High Integrity Pressure Protection System (H-HIPPS) for severo services, the hybrid system includes a quick isolation subsystem between an overpressure zone and a normal pressure zone and a quick releasing subsystem between the overpressure zone and a lower pressure zone with quadruple redundancies for 30 year service without repair, more particularly, the hybrid system has a novel valve and a novel pilot, each with two independent plugs with metal to metal seal (buckling seal) B ring assemblies and a novel (attachable) A seal ring assembly to block or release over pressurize fluids without actuators for protecting the pipelines or the pressures vessels from surge pressure at the highest level of a system reliability, the quick releasing subsystem has novel hybrid and redundant pressure relief mechanisms, redundant pressure sensing mechanisms and secondary pressure surges depressor, cavitations and erosion suppression and detect mechanisms, while quick isolation subsystem has redundant closures members and cavitations reducer can be used for a control valve or pressure regulator with the best both static and dynamic performances, in most cases, two valves are used, one for isolating fluids, one for regulating the fluids.
[0005] When pipelines or pumping stations or piping terminals, pressurized fluids plants are in services, many times, the operations like open and closing, pumping and metering can cause water hammer and pressure surge, the pressure surge in pipelines or plant can cause many problems as following; (a) Axial temporal and permanent separation of flange joints (b) Pipe fatigue at weld joints (c) Longitudinal pipe splits (d) Severe damage to piping and piping supports (e) Severe damage to elbow (f) Pipe leak (g) High cost for constant repair (h) inaccurate metering due to leaks in supply stations (i) environmental pollution.
[0006] There are two solutions for the problem (1) to block the overpressure fluid zone into a normal pressure zone or (2) to release the overpressure fluid into a low pressure zone, the conventional quick blocking subsystems like HIPPS based on API 170 is equipped with two shut off valves, two actuators and pressure transmitters and a feedback control system, but this subsystem at this point is just a combination of conventional parts like valves, actuators and pressure sensors and controller at a lower system reliability and is constructed under overpressure class at least three time in overpressure fluid zone even for a short period time and waste lot of materials and capacity in normal pressure conditions, so far there is no single valve or actuator, which are developed for the high integrity system, while the conventional quick releasing subsystem is constructed as overpressure safety device under U.S. Department of Transportation, Pipeline Safety Regulations, Hazardous Liquids Part 195, paragraph 195.428, the subsystem includes the pressure surge relief valve s like plug axial pressure surge relief valves, those valves are widely used in the pipeline protection from pressure surge and constructed with main three functions sensing, tracking and releasing, the plug axial pressure surge relief valves have two types, a gas loaded and a pilot operated configurations, the gas loaded pressure surge relief system has a fast response time about 250 millisecond, but it is equipped with external energy resources like pressurized bottle nitrogen, pressure regulator, check valve, tubing, insolated plenum bottle and control boxes, the subsystem not only increase cost and reduce a system reliability and sensible to temperature swing, but also has high operation cost to remain the set pressure with high cavitation and erosion, while the pilot relief system is operated by internal fluid energy with a compact pilot, but the pilot has a remote pressure sensing function and slow response time about two second or more and is less tolerated with dirty fluid and unreliable, every pressure releasing causes 10 to 30% pressure or energy loss and with high cavitation and erosion, in short the both type subsystems have no redundant system and cannot provide a good seal at low temperature, or high temperature and have high blow down pressure up to 30% and waste significant fluid energy and need constant seal goods replacements.
[0007] So the flow control industry has long sought means of improving the performance of the pressure protection valve and systems valve, improving the seal, creating a robust hybrid, enabling the valve to handle various flows under multiple extreme conditions.
[0008] In conclusion, insofar as I am aware, no such a system is formerly developed with fully metal to metal seal, hybrid highly reliable pressure protection system, easy manufacturing at low cost, they can be used for blocking and releasing overpressure fluids in sever service.
SUMMARY
[0009] This invention provides a simple, robust, reliable and versatile hybrid pressure protection system for severe services or under extreme conditions. This hybrid pressure protection system not only release overpressure fluid into lower pressure zone but also block overpressure fluid into normal pressures zone, and greatly reduce total isolation time, increase reliability with four redundancies, the subsystem has a valve and a pilot, the valve has two pockets respectively to receive two plug assemblies, each plug assembly works as an independent valve, the pilot has two vertical bores respectively receive two pilot plug assemblies, each pilot plug assembly works as an independent pilot to control each closures assembly in the valve, each plug assembly has a metal B ring assembly for sustaining seals and Wiper slurry fluid or fluids with solid particles fast closing impact forces without damage, metal B ring assembly is based on buckling theory, the deformation of metal seal is away below yield strength of the material, the A ring with attachable function play a key role in the system for preventing pipe leak even under temporal separation of axial flange joint due to water hammer and keep the leakage between 0-50 ppm or under high thermal change and high pressure, the redundancy feature is applied for the valve and the pilot, those include two plug valves, two pressure sensing devices, two pressure relief paths, two pressure protection methods, reach the highest level of system reliability over all prior arts or existing products the system comprises three type system with a normal open, normal closed and the combination.
[0010] This subsystem can be used for normal closed, normal open and between positions with small modifications, with a blind flange attached on the body, the subsystem has one inlet and one outlet for on-off or throttling applications, the pilot can be used for two pressure regulators with sensing port connected to outlet port.
[0011] The erosion/cavitation reducing assembly is other feature for the system to reduce cavitation and erosion level, it comprises a pair of trims and a rotor assembly, the trim assembly comprise a pair of fins each fin is defined by a front surface, area of fin and gaps between each fin, the trim has step bore with pin hole with one pin installed between the elbow and the flange, the rotor assembly has a rotor, the rotor has three blades, one of the blade with a slot, so the rotator will generate a unbalanced rotation as the fluid pass, in turn the unbalanced rotation will create a designed vibration, and the vibrations feature will change as the erosion process developed, the gaps between the elbow wall and the blades will increase, the erosion can be monitored, detected and predicted through the vibration data, while one of the blade with magnetic material, so the rotation can be monitored detected by a magnetic sensor or instrument, so those two data can be verified with high accuracy, those devices are very useful and critical for subsea and underground pipeline or remote area, where human accesses are impossible or difficult.
[0012] Finally the plug can be modified with a trim for handling cavitations and erosion application, the dynamic trim is installed in the outlet plug, the trim will not restrict the flow capacity as plug move between open and closed positions, in the most cases, the cavitation and erosion happen at small opening, as the plug has the conical front surface with multiple cylindrical rings to gradually restrict the open flow but with multiple holes to release the flow, such a arrange prevents the pressure drop below a fluid vapor pressure, so cavitations can be reduced or avoided, the front plate of the plug can be made with different materials from the base ring and be easily replaced.
[0013] Accordingly, besides objects and advantages of the present invention described in the above patent, several objects and advantages of the present invention are:
(a) To provide high redundant pressure protection system, such a system has the highest system reliability for serve services or extreme conditions. (b) To provide a pressure sensing device with a fast response time and releasing time, so such a system can protect a pipeline or critical vessel for severe service and has long life and high reliability. (c) To provide a metal to metal seal with ability to sustain high closing impact force for extreme conditions: fast closing, high pressure, cryogenic or high temperature or fire-safe applications. Such a seal ring can keep good static and dynamic seals with low leakage between 0-50 ppm. (d) To provide a seal with an attachable feature under extreme conditions: high pressure, cryogenic or high temperature or fire-safe applications. Such a seal ring can keep good seals with low leakage between 0-50 ppm under axial temporal separation of flange joints. (e) To provide a reliable pilot for controlling a valve in a pressure protection system, so the pilot can provide fast response time, reliable performance has and buildup-proof seal and mechanisms and long life for severe service. (f) To provide a device with functions to reduce erosion and cavitation as well as to monitor, detect and predict the process of erosion and cavitation, so the system has an ability to prevent fluid leak and predict efficiently the repair damage or replacements at good timing before the accidents happen. (g) To provide a highly efficient movable trim in a choked flow, so such a trim has a compact, simple structure to reduce the cavitations and erosions without high pressure drops. (j) To provide a highly efficient trim to reduce the cavitations without reducing the flow capacity, so such a trim can handle slurry fluid or fluid with solid particles or dissipate fluid energy under high pressure like damping valve used in water dam. (k) To provide a pressure protection system without external actuation, stem, so such a valve can avoid the actuation failure, a stem leak. (l) To provide a pressure protection system with solid/liquid interaction mechanisms to reduce the blocking time and releasing time, so the system can reduce the damage of pressure surge to minimum and cost of the system. (m) To provide fully metal to metal coal pressure protection system, so the system last 25 to 50 year service and fire safety service, the maintain period would increase at least five year period and reduce the operation cost and increase reliability. (n) To provide heat reservoir mechanism, so the system can use less pressurized gas and reduce operation cost and increase reliability.
[0026] Still further objects and advantages will become apparent from study of the following description and the accompanying drawings.
DRAWINGS
Drawing Figures
[0027] FIG. 1 is an exploded, tripe cut view of a pressure protection subsystem constructed in accordance with this invention.
[0028] FIG. 2 is an exploded, quarter cut view of a pilot of FIG. 1 .
[0029] FIG. 3 is a front view of valve of FIG. 1
[0030] FIG. 4 is a cross sectional view of valve of FIG. 2 along line A-A.
[0031] FIG. 5 is a cross sectional views of valve of FIG. 2 along line B-B.
[0032] FIG. 6 is a cross sectional view of valve of FIG. 4 along line C-C.
[0033] FIG. 7 is an “E” detail view of the valve of FIG. 5 .
[0034] FIG. 8 is a “D” detail view of in the valve of FIG. 5 .
[0035] FIG. 9 is a “F” detail view of in the valve of FIG. 5 .
[0036] FIG. 10 is a front view of pilot of FIG. 2 .
[0037] FIG. 11 is an ISO view of pilot of FIG. 10
[0038] FIG. 12 is a cross sectional view of pilot of FIG. 10 along line A-A.
[0039] FIG. 13 is a cross sectional view of pilot of FIG. 10 along line B-B.
[0040] FIG. 14 is an “E” detail view of pilot of FIG. 12
[0041] FIG. 15 is a “F” and “G” detail views of pilot of FIG. 13
[0042] FIG. 16 is a front view of subsystem of FIG. 1
[0043] FIG. 17 is a cross sectional view of pilot of FIG. 16 along line J-J.
[0044] FIG. 18 is a cross sectional view of pilot of FIG. 16 along line K-K.
[0045] FIG. 19 is a cross sectional view of valve of FIG. 16 along line G-G
[0046] FIG. 20 is a “T” detail view of valve of FIG. 19
[0047] FIG. 21 is a “M” detail view of valve of FIG. 19
[0048] FIG. 22 is a “P” detail view of valve of FIG. 19
[0049] FIG. 23 is a “L” detail view of valve of FIG. 19
[0050] FIG. 24 is a side view of an alternative subsystem of FIG. 1
[0051] FIG. 25 is a cross sectional view of valve of FIG. 24 along line A-A.
[0052] FIG. 26 is a cross sectional view of pilot of FIG. 24 along line G-G.
[0053] FIG. 27 is a side view of an alternative subsystem of FIG. 1
[0054] FIG. 28 is a cross sectional view of valve of FIG. 27 along line B-B.
[0055] FIG. 29 is a cross sectional view of valve of FIG. 27 along line F-F.
[0056] FIG. 30 is a “K” detail view of valve of FIG. 25
[0057] FIG. 31 is a front view of an alternative subsystem of FIG. 1
[0058] FIG. 32 is a cross sectional view of valve of FIG. 31 along line K-K.
[0059] FIG. 33 is a cross sectional view of valve of FIG. 32 along line L-L.
[0060] FIG. 34 is a cross sectional view of pilot of FIG. 31 along line R-R.
[0061] FIG. 35 is a cross sectional view of pilot of FIG. 31 along line P-P.
[0062] FIG. 36 is a front view of an alternative subsystem of FIG. 1
[0063] FIG. 37 is a cross sectional view of valve of FIG. 36 along line A-A.
[0064] FIG. 38 is a cross sectional view of valve of FIG. 37 along line H-H.
[0065] FIG. 39 is a cross sectional view of valve of FIG. 36 along line C-C.
[0066] FIG. 40 is a “J” detail view of valve of FIG. 39 .
[0067] FIG. 41 is a cross sectional view of valve of FIG. 3G along line D-D.
[0068] FIG. 42 is a front view of an alternative subsystem of FIG. 1
[0069] FIG. 43 is a cross sectional view of valve of FIG. 42 along line B-B.
[0070] FIG. 44 is a cross sectional view of valve of FIG. 43 along line D-D.
[0071] FIG. 45 is a cross sectional view of pilot of FIG. 42 along line A-A.
[0072] FIG. 46 is a cross sectional view of pilot of FIG. 42 along line F-F.
[0073] FIG. 47 is a front view of an alternative pilot of FIG. 42
[0074] FIG. 48 is a cross sectional view of valve of FIG. 47 along line G-G.
[0075] FIG. 49 is a cross sectional view of valve of FIG. 47 along line H-H.
[0076] FIG. 50 is a ISO view of a pressure protection system constructed in accordance with this invention.
[0077] FIG. 51 is a front view of the system of FIG. 50
[0078] FIG. 52 is a cross sectional view of the system of FIG. 51 along line A-A.
[0079] FIG. 53 is a cross sectional view of the system of FIG. 51 along line B-B.
[0080] FIG. 54 is a “H” detail view of gate valve of FIG. 53 .
[0081] FIG. 55 is a “E” detail view of gate valve of FIG. 52 .
[0082] FIG. 56 is a “F” detail view of gate valve of FIG. 52 .
[0083] FIG. 57 is a “L” detail view of gate valve of FIG. 52 .
REFERENCE NUMBER IN DRAWING
[0084] 10 Pressure protection system
[0085] 20 Pressure relief valve
[0086] Normal Closed
[0087] 20 a Gas/liquid Pilot
[0088] 20 b Gas/Gas pilot
[0089] 20 c Liquid/liquid Pilot
[0090] 40 elbow assembly
[0091] 41 elbow
[0092] 42 step bore
[0093] 43 boss
[0094] 44 rotor hole
[0095] 45 trim assembly
[0096] 46 fin
[0097] 47 step
[0098] 48 gap
[0099] 60 pipe line
[0100] 61 elbow bore
[0101] 100 Valve a, b, c, d, e, f,
[0102] 101 body
[0103] 102 Inlet a, b
[0104] 103 Outlet,c
[0105] 104 Internal housing
[0106] 105 housing bore
[0107] 106 ID
[0108] 107 rib
[0109] 108 front surface
[0110] 109 seat pocket shoulder
[0111] 110 seat pocket
[0112] 111 groove bore with W teeth
[0113] 112 groove
[0114] 113 pocket port
[0115] 114 release port
[0116] 115 pocket hole
[0117] 116 cavity
[0118] 117 pocket
[0119] 118 seal shoulder
[0120] 119 OD forming step bore
[0121] 120 OD lock bore
[0122] 121 Seat pocket
[0123] 122 position groove
[0124] 123 side flange
[0125] 124 seat groove
[0126] 125 ID forming step bore
[0127] 126 Boss with W teeth
[0128] 127 snap ring groove
[0129] 128 seat
[0130] 129 ID lock bore
[0131] 130 plug assembly
[0132] 131 conical front plate
[0133] 132 OD
[0134] 133 step OD
[0135] 134 nose hole
[0136] 135 seat
[0137] 136 groove
[0138] 137 step
[0139] 138 joint hole
[0140] 139 cage
[0141] 140 base ring
[0142] 141 Front ID
[0143] 142 groove
[0144] 143 Step OD
[0145] 144 OD surface
[0146] 145 OD shoulder
[0147] 146 seat lock Hole
[0148] 147 bearing hole
[0149] 148 holder
[0150] 149 bottom slots
[0151] 150 B-ring assembly a,b,c,d,e
[0152] 151 engaged ring
[0153] 152 Internal surface
[0154] 153 External surface
[0155] 154 C shape groove
[0156] 155 C shape bump
[0157] 156 Front end
[0158] 157 Back end
[0159] 158 multiple cylindrical rings
[0160] 159 holes
[0161] 161 Support ring
[0162] 162 Internal surface
[0163] 163 External surface
[0164] 164 C shape groove
[0165] 165 C shape bump
[0166] 166 Front end
[0167] 167 Back end
[0168] 168 trim assembly
[0169] 169 screw hole
[0170] 170 snap ring
[0171] fastener (setscrew or spring
[0172] 171 pin)
[0173] 172 seat
[0174] 173 needle
[0175] 174 gland
[0176] 175 needle valve
[0177] 176 rupture disc
[0178] 177 ball bearing assembly
[0179] 178 ball
[0180] 179 spring
[0181] 180 sensing valve
[0182] 181 groove
[0183] 182 middle wall
[0184] 183 volume substitute box
[0185] 184 solid head
[0186] 185 hollow head
[0187] 186 conical nose
[0188] 187 radial hole
[0189] 188 link hole
[0190] 189 screen
[0191] 190 unformed A ring
[0192] 273 hole
[0193] 274 top cover assembly
[0194] 280 clamp
[0195] 281 C shape lock ring
[0196] 282 position leg
[0197] 283 screw hole
[0198] 284 shear seal assembly
[0199] 191 OD
[0200] 192 ID
[0201] 193 Formed A ring
[0202] 194 W teeth groove
[0203] 194 ′ Mated W teeth groove
[0204] 195 adapter flange
[0205] 196 spring
[0206] 197 seal plug
[0207] 198 boss
[0208] 199 back plate
[0209] 20 Pressure block valve
[0210] Normal Open/between
[0211] 20 d Gas/liquid Pilot
[0212] 20 e Liquid/liquid Pilot
[0213] 20 f Liquid/liquid Pilot
[0214] 49 front surface
[0215] 50 pin hole
[0216] 51 pin
[0217] 52 elbow rotor assembly
[0218] 53 rotor
[0219] 54 shaft
[0220] 55 blade
[0221] 56 slot
[0222] 57 screw
[0223] 58 washer
[0224] 59 cover
[0225] 200 Pilot a,b,c,d,e,f,g
[0226] 201 body
[0227] 202 main passageway
[0228] 203 link passageway
[0229] 204 plug bore
[0230] 205 plug step bore
[0231] 206 seat bore
[0232] 207 seat step bore
[0233] 208 sense port
[0234] 209 top groove
[0235] 210 top step
[0236] 211 bottom groove
[0237] 212 top surface
[0238] 213 pocket port
[0239] 214 release port
[0240] 215 bottom surface
[0241] 216 plug cover
[0242] 217 hole
[0243] 218 spring gland
[0244] 219 adjustable screw
[0245] 220 top cover
[0246] 221 top hole
[0247] 222 groove
[0248] 223 screw hole
[0249] 224 snap ring
[0250] 225 fixed ring
[0251] 226 screw hole
[0252] 227 setscrew
[0253] 228 OD surface
[0254] 229 hole
[0255] 230 plug assembly
[0256] 231 plug
[0257] 232 front side
[0258] 233 back side
[0259] 234 front side OD
[0260] 235 back side OD
[0261] 236 front side step
[0262] 237 front side shoulder
[0263] 238 back side step
[0264] 239 back side shoulder
[0265] 240 seal bore
[0266] 241 spring
[0267] 242 front seal
[0268] 243 hole
[0269] 244 seal surface
[0270] 245 corner seal surface
[0271] 246 back seal
[0272] 247 hole
[0273] 248 seal surface
[0274] 249 corner seal surface
[0275] 250 B-ring assembly,a,b,c,
[0276] 251 engaged ring
[0277] 252 Internal surface
[0278] 253 External surface
[0279] 254 C shape groove
[0280] 255 C shape bump
[0281] 256 Front end
[0282] 257 Back end
[0283]
258
[0284] 259 notch
[0285] 260 seat cover
[0286] 261 front piston
[0287] 262 back plate
[0288] 263 front surface
[0289] 264 groove
[0290] 265 inlet port
[0291] 266 radial hole
[0292] 267 link hole
[0293] 268 main hole
[0294] 269 link slot
[0295] 270 base seal
[0296] 271 front surface
[0297] 272 back surface
DESCRIPTION
[0298] FIGS. 1-57 illustrate a pressure protection system 10 and subsystem 20 constructed in accordance with the present invention, the pressure protection subsystem 20 has six models 20 a, 20 b , 20 c, 20 d, 20 e, 20 f with six types of valves 100 a, 100 b, 100 c , 100 d, 100 e, 100 f and seven types of pilots 200 a, 200 b, 200 c, 200 d , 200 e, 200 f, 200 g.
[0299] Referring FIGS. 1-23,50 , the subsystem 20 a has a valve 100 a and a pilot 200 a , the valve 100 a comprises a body 101 a and two side flanges 123 a , 123 a ′ connected with the body 101 a on the right and left sides with two inlets 102 a , 102 a ′, the body 101 a has an internal housing 104 a connected with the body 101 a by three ribs 107 a , 107 a ′, and 107 a ″, three ribs 107 a , 107 a ′, 107 a ″ are respectively expended to three extrenal bosses 198 a, 198 a ′ and 198 a ″, two plug assemblies 130 a, 130 are respectively movably positioned in the internal housing 104 a in an opposite direction between closed and open positions, the normal positions of the plug assemblies 130 a and 130 a ′ are in the closed position, the valve 100 a has two pockets 117 a, 117 a ′, pocket 117 a is defined by a middle wall 182 a and the plug assemblies 130 a and internal housing 104 a , pocket 117 a ′ is defined by the middle wall 182 a and the plug assemblies 130 a and internal housing 104 a , the pocket 117 a, 117 a ′ are respectively connected to two pocket ports 113 a , 113 a ′ into pocket holes 115 a , 115 a ′ through the ribs 107 a , 107 a, 107 a ″, the valve 100 a has a cavity passageway 116 a between the internal housing 104 a and the body 101 a , between the body 101 a and side flange 123 a , between the body 101 a and side flange 123 a ′, the cavity 116 a is expended to an outlet 103 a, an inlet 102 a is sealed out from the cavity 116 a by B ring assembly 150 d , an inlet 102 a ′ is sealed out from the cavity 116 a by B ring assembly 150 c , the cavity 116 a is connected to release port 114 a, a pressure sensing valve 180 a is provided for sensing a pressure of pocket 117 a , a rupture disc 176 a with a needle valve 176 a is provided for pressure safety protection in case of overpressure fluid not releasing at presetting max pressure limit and for sealing after rupture disc 176 a is ruptured, the pilot 200 a has two pocket ports 213 a, 213 a ′ and a release ports 214 a, two pocket ports 213 a, 213 a ′, release ports 214 a are respectively connected to the pocket ports 113 a , 113 a ′ and release port 114 a on the valve body 101 a , and for control movements of the plug assemblies 130 a , 130 a ′, the pilot 200 a functions as two independent three-ways/two position valves and has two plug assemblies 230 a , 230 a ′ to move between the two positions.
[0300] Referring FIGS. 1-6 , Body 101 includes the outlet 103 connected to the cavity 116 a and connected with an adapted flange 195 a to a fluid tank (not shown), the internal housing 104 a has two grooves 112 a , 112 a ′ in the right and left sides, the body 101 a also the pocket hole 115 a through the rib 107 a to a boss 198 a ′ and the pocket hole 115 a ′ through the rib 107 a ′ to the boss 198 a ′, the pressure sensing valve 180 a has a cylindrical seat ring 172 a with an edge engaged with a conical needle 173 a in a pocket hole 115 a for open and closed operations, a holder 148 a has four slots 149 a at a bottom for supporting the seat 172 a and releasing overpressure from the pocket 115 a to cavity 116 a, the needle 173 a is biased by a gland 174 a and spring 179 a for sensing a fluid pressure in pocket 117 a , the rupture disc 176 a and a needle valve 175 a are installed with the holder 148 a ′ in pocket hole 115 a ′, a holder 148 a ′ has four slots 149 a ′ at a bottom for supporting the rupture disc 176 a and releasing overpressure from the pocket 115 a ′ to cavity 116 a, the needle valve 175 a is used for sealing off the pocket 116 a ′ after rapture disc 176 a is raptured, the body 102 a has a lock groove 181 a.
[0301] Plug assembly 130 a ′ is disposed in a left side of valve with functions of a gas pressure control, immediate sensing, tracking and has a solid head 184 a and a front plate 131 a and a base ring 140 a , the sealed pocket 117 a ′ is formed by the plug assembly 130 a ′, the middle wall 182 a and the internal housing 104 a , the volume substitute box 183 a constructed with the middle wall 182 a is used for reducing the pocket 117 a ′ volume and the temperature effect and as a heat reservoir filled with liquids for averaging today and night time temperatures and reducing gas consumption.
[0302] Referring FIGS. 6-7 , plug assembly 130 a is disposed in a right side of valve with functions of a liquid pressure control and immediate sensing, tracking and has a hollow head 185 a and a front plate 131 a and a base ring 140 a , the pocket 117 a is formed by the plug assembly 130 a, the middle wall 182 a and the internal housing 104 a , the head 185 a has a conical front 186 a and three radial holes 187 a extended to an axial hole 188 a for communicating and creating a pressure difference between a fluid in the inlet 102 and a fluid in the pocket 117 a, a screen 189 a is placed outside head 185 a for slurry fluid applications, the head 185 a has two functions (1) when the pressure sensing valve 180 a starts to open and release into pocket hole 115 a , the pressure in the pocket 117 a start to drop and through hole 188 a as well, head 185 will increase the pressure drop even bigger (2) when the pressure difference between the pocket 117 a and inlet 102 become so big, the pressurized fluids in inlet 102 a is to push the plug assembly 130 a inwardly with full piston effect and full front area of the front plate 131 a , because of no front open holes in the head 185 a and front plate 240 a , the fluid in the pocket 117 a would pour out through two ways (a) pocket hole 115 a and (b) head radial holes 187 a, the relief streams of fluid through the head 185 a release radially and to help the main fluids in inlet 102 a even faster to release into the cavity 116 a as the plug assembly 130 a moves away from the closed position, the full piston effect creates the faster pressure relief than any existing pressure relief mechanism in comparison with the conventional relief valve with reduced piston areas due to open axial holes, the front plate 131 a has a conical surface and a step bore 133 a and four radial fastener holes 138 a on the back side, the base ring 140 a has four bearing holes 147 a equally spanned on an outside diameter surface 144 a respectively to receive four ball bearing assemblies 177 for supporting and balancing the plug assembly 130 a and reducing moving frictions of the plug assembly 130 a, the ball bearing assembly 177 has a ball 178 biased by spring 179 , the ball bearing assembly 177 is positioned over the groove 112 a for stabilizing the plug assembly 130 a at full open position for normal open applications and reducing speed of the plug assembly 130 a and preventing secondary pressure surge as the plug assembly 130 a is too fast to be closed for normal closed applications.
[0303] Referring FIG. 6-8 , a B ring (after Bump and Buckling) assembly 150 a for providing dynamic seals under buckling condition between the cavity 116 a and base ring 140 a ′ is positioned In the left side of the body 101 a , the B ring assembly 150 a is disposed in a seat pocket 110 a of Internal housing 104 a and has an engaged ring 151 a and a support ring 161 a , the engaged ring 151 a has an inside diameter surface 152 a , an outside diameter surface 153 a, a conical front end 156 a and a conical back end 157 a , the support ring 161 has an inside diameter surface 162 a , an outside diameter surface 163 a, a conical front end 166 a and a conical back end 167 a , the engaged ring 151 a inserted into ring 161 a with a fit is rolled together for creating a C shape groove 154 a , a C shape bump 155 a on the engaged ring 151 a and a C shape groove 164 a , a C shape bump 165 a on the support ring 161 a, two sets of B ring assemblies 150 a in series are disposed in seat pocket 110 a , the C bump 155 a is engaged with the surface 144 a ′ for creating initial contact seal force at a presetting pressure on a surface 144 a ′ of base ring 140 a ′, the B ring 151 a with front end 156 a and 161 a with front end 166 a are engaged with a conical pocket shoulder 109 a for providing supports and seals, the outside diameter surface 163 a of support ring 161 a is engaged with the seat pocket 110 a for seals, the C groove 164 a is engaged with a snap ring 170 a , four fasteners 171 a are respectively fastener holes in the holes 169 a to push the snap ring 170 a and B ring 150 a for creating a buckling condition at the C shape bump 155 a between front end 156 a and the C shape groove 154 a and a buckling condition at the C shape bump 165 a between front end 166 a and the C shape groove 164 a for increasing further contact seal force, between the C shape bump 155 a and the surface 144 a ′ at a working seal pressure.
[0304] Referring FIGS. 6-9 , plug assembly 130 a and a B ring assembly 150 b are provided with dynamic seals between the cavity 116 a and the base ring 140 a, B ring assembly 150 b has an engaged ring 151 b and a support ring 161 b , the engaged ring 151 b has an inside diameter surface 152 b , an outside diameter surface 153 b, a conical front end 156 b and a flat back end 157 b , the support ring 161 b has an inside diameter surface 162 b, an outside diameter surface 163 b, a conical front end 166 b and a flat back end 167 b , ring 161 b inserted into ring 151 b is rolled together for creating a C shape groove 154 b , a C shape bump 155 b on ring 151 b and a C shape groove 164 b , a C shape bump 165 b on the ring 161 b , the C shape bump 155 b is engaged with the surface 105 a for an initial seal contract force between the internal housing 104 a and a base ring 140 a , the engaged ring 151 b with the front end 156 b against a conical pocket shoulder 145 a for supporting and creating an initial seal contact force between the C shape bump and the surface 105 a at a presetting seal pressure, support ring 161 b is engaged with the seat pocket 145 a for seals, the inside diameter surface 162 b of ring 161 b is engaged with a conical surface of 143 a for seals, fasteners 171 b (setscrews or pins) are inserted in the hole 144 a to push the ring 161 b and create a buckling condition at the C shape bump 155 b between front end 156 b and the C shape bump 154 b for increasing further contact seal force between the C shape bump 155 b and the surface 105 a at a working seal pressure.
[0305] Referring FIGS. 2, 12, 13 , the pilot 200 a is a dual three-way/two position valve, pilot 200 a has a cylindrical body 201 a , a pair of plug assemblies 230 a , 230 a ′ and a pair of seat covers 260 a, 260 a ′ and a pair of base seals 270 a, 270 a ′, a pair of plug covers 216 a , 216 a ′ and a top cover assembly 274 a and clamp 280 a , the body 201 a has two vertical plug bores 204 a, 204 a ′ from a top surface 212 a , bores 204 a, 204 a ′ respectively have step bores 205 a, 205 a ′ and to receive plug assemblies 230 a, 230 a ′, the body 201 a has two horizontal seat bores 206 a , 206 a ′, seat bores 206 a, 206 a ′ are respectively expended to the bores 207 a, 207 a ) and respectively to receive seat covers 260 a, 260 a ′, the body 201 a has two main passageways 202 a , 202 a ′ and two link passageways 203 a, 203 a ′ from a bottom surface 215 a , two main passageways 202 a, 202 a ′ are respectively expended to pocket ports 213 a, 213 a ′ and seat bores 206 a, 206 a ′, seat covers 260 a, 260 a ′ respectively are positioned in seat bores 206 a, 206 a ′ and have front pistons 261 a, 261 a ′ and back plates 262 a , 262 a ′, front pistons 261 a, 261 a ′ respectively have inlet ports 265 a, 265 a ′ expended to main holes 268 a, 268 a ′, the pistons 261 a , 261 a ′ respectively have seal surfaces 263 a, 263 a ′ and link holes 267 a , 267 a ′ expended to radial hole 266 a, 266 a ′, front pistons 261 a , 261 a ′ respectively have grooves 264 a, 264 a ′ connected to the radial holes 266 a, 266 a ′, plug assemblies 230 a, 230 a ′ are respectively positioned in the plug bores 204 a , 204 a ′ and plug step bores 205 a , 205 a ′ and are biased by springs 241 a, 241 a ′ and spring glands 218 a, 218 a ′, the plug bores 204 a , 204 a ′ are respectively covered by plug covers 216 a, 216 a , plug covers 216 a, 216 a ′ respectively have holes 217 a, 217 a′ , top cover assembly 274 a has a top cover 220 a , fixed ring 225 a , snap ring 224 a and eight setscrew 227 a , top cover 220 a placed on plug covers 216 a, 216 a ′ has bores 221 a, 221 a ′ respectively to aligned with holes 217 a , 217 a ′ and a groove 222 a and eight threaded holes 223 a equally located on an outside diameter surface 228 a of the top cover 220 a and expended to the groove 222 a , the body 201 a has a step 210 a with a cyclical groove 209 a , the snap ring 224 a is placed between the groove of 222 a and groove 209 a , each of four setscrew 227 a is threaded in each of four holes 223 s in the top cover 223 a to press the snap ring 224 a into the groove 209 a of the body 201 a , a fixed ring 225 a is placed on the top cover 220 a to prevent the setscrew 227 a from falling out and has four holes 229 a respectively aligned up with four holes 223 s without the setscrew 223 to block the setscrew 227 a, each of four setscrew 227 a is respectively threaded through holes 229 a into thread holes 223 a for securing a joint between fixed ring 225 a and the top cover 220 a, each of base seals 270 a , 270 a ′ has one of holes 273 a, 273 a ′, one of front seal surfaces 271 a, 271 a ′, one of back seal surfaces 272 a , 272 a ′, the plug assemblies 230 a, 230 a ′ respectively have plugs 231 a , 231 a ′ and shear seal assemblies 284 a , 284 a ′, shear seal assemblies 284 a, 284 a ′ respectively have front seal plates 242 a , 242 a ′, B rings 250 a, 250 a ′ and back seal plates 246 a, 246 a ′, shear seal assemblies 284 a , 284 a ′ respectively are disposed in seal radial bores 240 a , 240 a ′ and are against surfaces 264 a , 264 a ′ and surfaces 248 a, 248 a ′ for seals, the clamp 280 a has a lock ring 281 a and leg 282 a with two sections, the clamp 280 a is placed between groove 211 a on pilot 200 a and a groove 181 a on the valve 200 a for securing a joint, leg 282 a has a fit with groove 181 a, if the joint is permanent, the inference fit will be used, if the joint is a semi-permanent joint or for high vibration applications, the transitional fit will be used, the joint method replaces the conventional long through screw joint with benefit of redundancy of joint, less machining and high structure integrity, because of the clamp structure, the clamp 280 a still has flexibility like long screw, bolts (not shown) are used for securing the joint between valve 100 a and pilot 200 a.
[0306] Pilot 200 a has the pocket port 213 a, release port 214 a respectively connected to the pocket port 113 a and release port 114 a on the valve 100 a for the liquid pressure control pressure track and pressure sensing, a distance sensing fluid from the upstream overpressure zone about 10 to 20 times diameter pipe away is connected to port 208 a , a pressure fluid from the upstream fluid zone is connected to the inlet port 265 a , the inlet port 265 a is connected to main passageway 202 a through holes 268 a, 243 a , 247 a , and B ring 250 a of seat assembly 284 a , plug assembly 230 a disposed in the plug bore 202 a , the plug assembly 230 a is biased by spring 241 a at a lower position as a pressure in the sensing port 208 a is lower than a presetting pressure, a pocket port 213 a is connected with main passageway 202 a.
[0307] Pilot 200 a has the blocked release port 214 a, the pocket port 213 a ′ is connected to port 114 a on the valve 100 a for the gas pressure control, pressure track and pressure sensing, a regulated gas is connected to hole 217 a ′ for a presetting pressure against a pressure in the sensing port 208 a ′, the regulated gas in hole 217 a ′ is connected to main passageway 202 a ′ through passageway 203 a ′, groove 264 a ′ and holes 266 a ′, 267 a ′, 247 a ′ 243 a ′, main passageway 202 a ′ is connected to port 213 a ′, the inlet port 265 a ′ is as a release port, as the plug assembly 230 a is biased by spring 241 a ′ and the regulated gas is at a lower position, as a pressure in the sensing port 208 a is lower than a presetting pressure due to force of spring 214 a and a difference area between plug bore 204 a ′ and plug step bore 205 a ′, a pocket port 213 a is connected with main passageway 202 a.
[0308] Referring FIGS. 14 to 15 , Plug assembly 230 a is assembled with shear seal assembly 284 a , the shear seal assembly 284 a has the front seat 242 a, back seat 246 a and B ring 250 a, front seat 242 a has a flat seal surface 244 a and an edge seal fillet 245 a , back seat 246 a has an edge seal fillet 249 a and a flat seal surface 248 a, B ring 250 a has an engaged ring 251 a, the engaged ring 251 a has an inside diameter surface 252 b , an outside diameter surface 253 a, a conical front end 256 a and a conical back end 257 a ring 251 a is rolled for creating C shape groove 254 b , a C shape bump 255 b, the C shape bump 255 a is engaged with the surface 240 a with a non-inference fit, B ring 250 a is placed between front seat 242 a and back seat 246 a for creating buckling condition at the C shape bump 255 a under compression between front seat 242 a and back seat 246 a, the front end 256 a is engaged with the corner 249 a for seals between B ring 250 a and back seat 246 a, while the back end 257 a is engaged with the corner 245 a for seals between B ring 250 a and front seat 242 a . Plug assembly 230 a has a plug 231 a ′ and B ring 250 b , the plug 231 a ′ has a step bore 236 a ′ expended to a shoulder 236 a ′, B ring 250 b has an engaged ring 251 b, the engaged ring 251 b has an inside diameter surface 252 b , an outside diameter surface 253 b, a conical front end 256 b and a “L” back end 257 b , ring 251 b is rolled for creating a C shape groove 254 b , a C shape bump 255 b , the engaged ring 251 b placed in step bore 236 a ′ has the front end 256 b against shoulder 236 a ′ for supporting and creating an initial seal contact force between the C shape bump 255 b and the surface 204 a ′ at a presetting seal pressure, a lock ring 258 b with a slot placed in step 236 a with a press fit is forced to push ring 251 b for creating a buckling condition at a C shape groove 254 b and C shape bump 255 b for increasing further contact seal force between the C shape bump 255 b and the surface 204 a ′ at a working seal pressure, the slot can be broken for replacement of new B ring 250 b, an engaged ring 250 C is the same as 250 b.
[0309] Referring FIGS. 16,17,18,19 , the plug assembly 230 a in pilot 200 a move up due to the increased pressure in sensing port 208 a , the pocket port 213 a is connected to release port 214 a through main passageway 202 a ′, shear seal assembly 284 a, hole 267 a and passageway 203 a , the plug assembly 130 a moves away from a closed position, the plug assembly 230 a ′ in pilot 200 a moves up due to the pressure in sensing port 208 a ′ increase over a presetting pressure, the pocket port 213 a ′ is connected to release port 265 a ′ through main passageway 202 a ′, shear seal assembly 284 a ′, hole 268 a ′, the gas pressure from pocket port 213 a ′ is increased over the limit by at least 10% due to temperature change not working pressure change, especially in summer between the day and night time, this pressure release method only release the hottest portion of gas from the pocket 117 a ′, while the conventional method is to release the gas outside the valve and between the valve and a gas storage so those gases which are not hot hut high pressure in the gas storage are released, the conventional method wastes 30% of regulated, pressurized gas in comparison with this method.
[0310] Referring FIGS. 20 , the plug assembly 130 a has a front plate 131 a , a base ring 140 a and four fasteners 171 a , the front plate 131 a has a step bore 133 a and four holes 138 a , base ring 140 a has a groove 142 a and a conical bore 141 a engaged with the mating step bore 133 a of front plate 131 a , four fastener 117 a (setscrews or pins) are respectively inserted in the holes 138 a into the groove 142 a for securing a repairable joint between the front plate 131 a and base ring 140 a , four fastener 117 a (spring pins) can be used for securing a permanent join between the front plate 131 a and base ring 140 a.
[0311] Referring FIG. 21 , plug assembly 130 a ′ and B ring assembly 150 c are provided with seals between the side flange 123 a ′ and front plate 131 a ′ in the left side of the body 101 a , the side flange 123 a ′ has a snap ring groove 127 a ′ with four fastener 171 a , the B ring assembly 150 c is disposed in a seat pocket 121 a ′ of side flange 123 a ′ and has an engaged ring 151 c and a support ring 161 c the engaged ring 151 c has an inside diameter surface 152 c, an outside diameter surface 153 c , a conical front end 156 c and a “L” back end 157 c , the support ring 161 c has an inside diameter surface 162 c , an outside diameter surface 163 c , a conical front end 166 c and a flat back end 167 c , ring 151 c inserted into ring 161 c with a fit is rolled together for creating a C shape groove 154 c , a C shape Bump 155 c on engaged ring 151 c and a C shape groove 164 c , a C shape bump 165 c on the support ring 161 c the C shape bump 155 c has a clearance fit with seat 135 a ′, when the plug assembly 130 a ′ is approached to the seat 135 a ′, support ring 161 c with a longer front end 166 c first is engaged with a conical pocket shoulder 137 a ′ for absorbing closing impact forces and creating a buckling condition to force C shape bump 155 c to move outward for providing seals between front end 166 c and shoulder 137 a ′, then the engaged ring 151 c with front end 156 c is engaged with conical pocket shoulder 137 a ′ for absorbing closing impact forces and creating a buckling condition to force C shape bump 155 to engaged with seat 135 a ′ at a presetting working pressure, the outside diameter surface 163 c of support ring 161 a is engaged with the seat pocket 110 a for seals, a snap ring 170 a is placed in the groove 127 a ′, four fasteners 171 a are to push the snap ring 170 a to engaged with the C shape groove 164 c of ring 161 c for securing a joint between the B ring 150 c and seat pocket 121 a′.
[0312] Referring FIG. 22 , plug assembly 130 a and a B ring assembly 150 d are provided with seals between the side flange 123 a and the front plate 131 a, B ring assembly 150 d has an engaged ring 151 d and a support ring 161 d , the engaged ring 151 d has an inside diameter surface 152 d , an outside diameter surface 153 d , a conical front end 156 d and a “L” back end 157 d , the support ring 161 d has an inside diameter surface 162 d, an outside diameter surface 163 d, a conical front end 166 d and a flat back end 167 d , support ring 161 d inserted into engaged ring 151 d is rolled together for creating a C shape groove 154 c , a C shape bump 155 d on engaged ring 151 d and a C shape groove 164 d , a C shape bump 165 d on the support ring 161 d , the C shape bump 155 d has a clearance fit with seat 118 a, when the plug assembly 130 a is approached to the seat 118 a, support ring 161 d with a longer front end 166 d is engaged first with a conical pocket shoulder 128 a for absorbing closing impact forces and creating a buckling condition to force C shape bump 155 d to move outward for providing seal between front end 166 d and shoulder 128 a , then the engaged ring 151 d with front end 156 d is engaged with conical pocket shoulder 128 a for absorbing closing impact forces and creating a bucking condition to force C shape bump 155 d to engaged with seat 118 a at a presetting working pressure, the outside diameter surface 153 d of ring 151 d is engaged with a step of front plate 131 a , the “L” back end 157 d is locked in step 137 a for securing a joint between the ring 150 c and plug assembly 130 a.
[0313] Referring to FIG. 23 , a formed A ring 193 a is placed between body 101 a and side flange 123 a. the body 101 a has W shape teeth 111 a with an angle between 75 to 105 degree in a lock conical bore 120 a and an outside diameter forming step bore 119 a , the side flange 123 a has a mating boss 126 a with mated W teeth and a conical lock bore 129 a and inside diameter forming step bore 125 a , a unformed 190 a has an outside diameter 192 a placed in the forming step bore 119 a and an inside diameter surface 192 a placed in the inside diameter forming step bore 125 a , after body 101 and said flange 123 a are compressed, the unformed 190 a becomes A formed ring 193 a with W shape, the inside diameter surface 192 a is attached to lock bore 129 a and the outside diameter 191 a is attached to lock bore 120 a , there are other two unformed A rings 190 a ′ and 190 a ′, A ring 190 a ′ has only inside diameter 192 a ′ attached to lock bore 129 a , A ring 190 a ″ has only outside diameter 191 a ″ attached to lock bore 120 a, the attached A ring 190 a is provided with robust seal solution even when the subsystem under water hammer and temporal axial flange separation, so far there is no attachable seal ring in use to solve the operation problem.
[0314] Referring to FIGS. 24-30 , the subsystem 20 b based on subsystem 20 a comprises valve 100 b and pilot 200 b , the valve 100 b has two plug assemblies 130 b , 103 b for two gas pressure controls, two pressure tracking and two pressure relief, the subsystem 20 c based on subsystem 20 a comprises valve 100 c and pilot 200 c , a valve 100 c based on valve 100 a comprises two plug assemblies 130 c , 103 c for two liquid pressure control, two pressure tracking and two pressure relief, B ring 150 e is placed in grooves 194 b and 194 b ′, each groove 194 b, 194 b have respectively bottom fillets and corners chamber, B ring 150 e has an engaged ring 151 e, the engaged ring 151 e has an inside diameter surface 152 e , an outside diameter surface 153 e, a conical front end 156 e and a conical back end 157 e , ring 151 e is rolled for creating a C shape groove 154 e , a C shape bump 155 e, the C shape bump 155 e is engaged with the chamfers both grooves 194 b , 194 b ′, the both ends 157 e, 156 e are respectively engaged with two chamfers of grooves 194 b , 194 b ′ under a buckling condition.
[0315] Referring to FIGS. 31 to 35 , the subsystem 20 d based on subsystem 20 a has a valve 100 d and pilot 200 d , the valve 200 d comprises two plug assemblies 130 d, 103 d ′ for blocking off, the valve 100 d has one inlet 102 d and one outlet 103 d and a blind flange 195 d , two release ports 114 d , 114 d ′ are blocked, the pocket ports 113 d , 113 d are open and respectively connected to pocket ports 213 d and 213 d ′ on the pilot 200 d for gas or liquid pressure controls, the plug assembly 130 d ′ is located on a side of an inlet 102 d and sealed off by a head 184 d ′ and biased by a spring 196 d ′ at a normal open position, the plug assembly 130 d is located on a side of an outlet 102 d and sealed off by a head 184 d at a normal open position, the head 184 d is connected with a back plate 199 d in a spring cage 139 d , the spring cage 139 d holds spring 199 d for pushing plug assemble 130 d inwardly and is trend to open, the cage 139 d is secured with the middle wall 182 d with bolts (not shown), pilot 200 d has pocket ports 213 d, 213 d ′ and release port 214 d , release ports 114 d , 114 d ′ are blocked, the pocket ports 213 d , 213 d ′ are open and respectively connected to pocket ports 113 d , 113 d on the valve 100 d, the sensing fluid comes into ports 208 d , 208 d ′ and against the plug assembly 230 d and 203 d ′, the fluid in the pockets 117 d, 117 d ′ are respectively connected respectively to ports 202 d, 202 d ′ through ports 213 d , 213 d ′, when a fluid pressure rises in the ports of 208 d or 208 d ′, the plug assembly 230 d will move up and connect port 268 d to 202 d , port 268 d is connected actuation fluid (not shown), the plug assembly 230 d ′ will move up and connect port 268 d ′ to 202 d ′, then the plug assembly 130 d and 130 d ′ in valve 100 d will move to closed positions.
[0316] Referring to FIGS. 36-41 , a subsystem 20 e based on subsystem 20 d comprise a valve 100 e and pilot 200 e , valve 100 e comprises two plug assemblies 130 e, 103 e ′ for pressure regulation applications, two release ports 114 e , 114 e ′ are open and respectively connected with release ports 214 e and 214 e ′ on pilot 200 e , the pocket ports 113 e , 113 e are open and respectively connected with pocket ports 213 e and 213 e ′ on the pilot 200 e , the plug assembly 130 e ′ is located on a side of an inlet 102 e, the plug assembly 130 e ′ is located on a side of an outlet 102 e , pilot 200 e has pocket ports 213 e, 213 e ′ and release ports 214 e, 214 e ′, release ports 214 e , 214 de ′ are open and respectively connected to pocket ports 114 ed , 114 e ′ on the valve 100 e, the pocket ports 213 e, 213 e ′ are open and respectively connected with pocket ports 113 e , 113 e on the valve 100 e, sensing fluids come into ports 208 e , 208 e ′ and against the plug assemblies 230 e and 230 e ′, the pockets 117 e, 117 e ′ are respectively connected to ports 202 e, 202 e ′, the plug assembly 230 e ′ is disposed in plug bore 204 e with a spring 241 e ′, a pressurized fluid is constantly connected to ports 267 e ′ and 268 e by a slot 269 e for regulating the pressurized fluid at a smaller step but more frequency, seat cover 260 e ′ has a slot 269 e ′ for communication between hole 268 e ′ and 267 e ′, the slot 269 e ′ is constructed by three profiles, flat, comical and spherical, while the plug assembly 230 e without a slot is disposed in plug bore 204 e with a spring 241 e , a pressurized fluid is constantly connected to ports 268 e , 268 e ′, ports 267 e is connected to passageway 203 e to release, so plug assembly 230 e ′ acts as a control valve but moves fast with small changes, while plug assembly 230 e acts as an on-off valve and move slow with large changes such a combination create the best dynamic and static performances with fast response but stable output fluid, no single pressure regulator can have such performance, plug assembly 130 e ′ has a conical front plate 131 e ′ on the outlet 103 e , the conical front plate 131 e ′ has a dynamic trim 168 e the trim 168 e has multiple coaxial cylindrical rings 158 e ′ with multiple horizontal holes 159 e ′ for controlling a relief fluid pressure drop above a vapor pressure and preventing cavitation, such a dynamic trim 168 e not only control cavitation very effectively at small opening where the most cavitations happen, but also open the fluid area when the plug assembly 130 e ′ at an open position and does not reduce the flow capacity unlike conventional static trim, the trim can be constructed as welding part or as an integral part with the front plate 131 e.
[0317] Referring to FIGS. 42-46 , a subsystem 20 f based on subsystem 20 e comprises a valve 100 f and pilot 200 f , the valve 100 f comprises two plug assemblies 130 f, 130 f′ for pressure regulation applications, the two release ports 114 f , 114 f′ are blocked, the pocket ports 113 f , 113 f are open and respectively connected with pocket ports 213 f and 213 f ′ of pilot 200 f , the pocket ports 213 d, 213 d ′ are open and respectively connected with pocket ports 113 f , 113 f ′ on the main valve 100 f, fluids in sensing ports 208 f , 208 f′ are respectively connected to ports 213 g , 213 g ′ and are against the plug assembly 230 f and 230 f ′, the pockets 117 f, 117 f are respectively connected respectively with ports 202 f, 202 f ′ through the pocket ports 113 f , 113 f , the plug assembly 230 f is disposed in plug bore 204 f with a strong spring 241 f, a pressurized fluid is constantly connected to port 268 f by a slot 269 e for regulating the pressurized fluid at a larger step but less frequency, the slot 269 e ′ is constructed by three profiles, flat, comical and spherical, while the plug assembly 208 e is disposed in plug bore 234 e ′ with a weak spring 241 f for regulating the pressurized fluid at a smaller step but high frequency, such a combination creates the best dynamic and static performances with fast response but stable output fluid, no single pressure regulator can have such performances.
[0318] Referring to FIGS. 47-49 , a pilot 200 g based on 200 f has two plug assemblies 230 g, 230 g ′, both pocket ports 213 dg , 213 g ′ and release ports 214 g , 214 g ′ are open and for receiving and releasing fluids as an independent pilot, both pocket ports 213 g , 213 g ′ are respectively connected to sensing ports 208 g , 208 g ′, the valve 200 g acts as two pressure regulators, a pressurized fluid through 265 g and 268 g port is connected to port 243 g at a low pressure, when a fluid pressure in port 213 g increases, the plug assembly 230 g will move up, the port 243 g will connected to 267 g to release the overpressure fluid, when a fluid pressure in port 213 g decreases, the plug assembly 230 g will move down, the port 243 g will connected to 268 g to receive the pressurized fluid and increases the fluid pressure In port 213 g , because of the slots 269 e , the pressure change is seamless and stable for precision control applications.
[0319] FIGS. 50-57 illustrate a hybrid pressure protection system 10 constructed in accordance with the present invention, the system 10 includes one of subsystems 20 e for isolating over-pressurized fluid at a normal open position, one of subsystems 20 a, 20 b, 20 c for releasing over-pressurized fluid at a normal closed position and subsystem 20 f , 20 g for both applications and a pipe 60 and two elbow assemblies 40 for connections from an over pressurized fluid to the pressure protection subsystems 20 , the elbow assembly 40 has elbow 41 , a rotor assembly 52 and a pair of trims 45 , 45 ′ and a pair of pins 51 , the elbow 41 has two step bores 42 on each of ends of elbow 41 and a boss 43 with rotor bore 44 on an outward side of a middle of the elbow 41 at 45 degree section, each step bore 42 has a pin hole 50 , trims 45 has three fins, 46 , 46 a, 46 b with two gaps 47 , 47 a and three surfaces 46 , 46 a and 46 b defined by one of prolife a conical and spherical surface, the trim 45 has a step 47 with a hole 50 a engaged with the bore 42 for reducing turbulent fluid and erosion in the outward wall of elbow 41 to average the fluid pressure gradient in the elbow 41 when the system 10 start to release an over-pressurized fluid, the pin 51 is inserted through hole 50 and hole 50 a for securing the trim 45 with the elbow 41 . Trim 45 ′ has fins, 46 ′, 46 a ′, 46 b ′ and step 47 ′, the rotor assembly 52 is disposed in bore 61 for mixing a high speed fluid stream in the outward wall of the elbow 41 and a slow speed fluid stream in an inward wall of the elbow 41 and reducing the erosion on the outward wall of elbow 41 , The rotor assembly 52 has a rotor 53 , the rotor 54 has three blade 55 , 55 ′, 55 ″, blade 55 has a slot 56 , so when a fluid passes the elbow 41 and force the rotor 53 to rotate, the unbalanced rotor 53 will generate a unbalanced rotation and a designed vibration, as the erosions on the elbow 41 and rotor 54 progress, so does the vibration features, so the level of erosion can be detected and monitored and predicted by a vibration sensor, one of blade 55 , 55 ′ 55 ′ are made out of a magnetic material, so an unbalanced rotation can be detected and monitored by a magnetic sensor, those two data will enhance the reliability of the data and accuracy of the predication of erosion and timing of replacement, they can be used undersea and underground pipelines.
CONCLUSIONS
[0320] The present invention provides a long sought solution—an inherent high integrity pressure protection system instead of a combination of conventional low integrity pressure protection devices, the solution is (1) actuator-less, without external actuators, the valve has no actuator joint failure, no additional pipe leak, piston leak and joint leak, no piston sticking, no unbalanced force, no force or energy loss on frication or motion conversion (2) stem-less, the valve has no stem leak issue, no joint broken and no installation issue, especially in subsea, the installation between the valve and actuator are very difficult (3) both blocking overpressure fluid into normal pressure zone and releasing overpressure fluid into low pressure zone, greatly reducing total shut off time or impact time, risk of water hamper damage or pressure surge in normal pressure zone, rather than the old response time, which is meaningless (4) by nature, the plug valve has the least volume replacement over all valves with a travel about ¼ of diameter, in blocking side, the back plug assembly is much faster to close than other conventional valves due to less fluid resistance with the same moving direction, secondly a combination of the immediate sensing and releasing and a distant sensing and releasing, for the first time, pilot load liquid pressure control with the pressure sensing valve, pocket pressure drop effect and full area piston effect can match with gas loaded pressure control in term of full relief time (4) redundancy, inherent redundancy include (a) the left and right plug assemblies in the valve (b) the left and right plug assemblies in the pilot (c) external and Internal actuation energies (d) gas and pilot loaded controls (e) immediate sensing and a distinct sensing (f) destructive and nondestructive pressure protection methods
[0321] The present invention discloses other breakthrough achievement—A Metal B ring, the metal B ring comprises the engaged ring and support ring for both static and dynamic seals applications, for the first time, metal seal for high speech impact seal because when the plug moves at speech of 00 ft./s to a closed position, most metal seal will deform and cause leaks, so no metal seal can survive at the speed 80 ft./s even with high flexible spring metal, the B ring is based on pipe buckling mechanism, which most engineers in the field would avoid, but here B ring can survive because of the buckling condition, the seal compression stress stays away below the yield strength of the materials, moreover B ring has the seals in both axial and radial seal areas and more support points to reduce stress value than any other seal rings, other is critical element for the invention is the rolling process, the rolling process not only creates the C shape groove and bump, but also strengthen material of the B ring by 30% due to the surface hardening, the joint between the engaged ring and the support ring under the buckling absorb the most of impact force without damage as a spring and heat dissipation through contact frictions, even the 316 stainless steel can be used for most applications, moreover the multiple B rings can be installed in a series, in short first B ring assembly also has capacities for axial and radial seals, no other all existing sealing device can provide, second it breaks the temperature limit from −250 to 1500 F, third it provides a dynamic seal under high temperature and high pressure, fourth it will last from 5 to 30 years without any replacement under high temperature, while non-metal seal material will deteriorate or age under sever service, so the applications with B ring will be quick pipe joint seals, subsea flow control systems for 25 years life time or, nuclear power plant for 60 years life time, or jet engines control valve or check valve with quick closed impact for millions cycles without replacement or failure.
[0322] The dual plugs in pilot is a heart of this invention if the two plugs in the valve act as the muscle, first the fully metal shear seal assembly is designed to shear off any buildup from dirty fluids between the seat cover and shear seal assembly during operation, second the B ring provides constant seals and spring force to push out the front and back seat against the seat cover and base seal for providing dynamic seals, instead of rubber O-rings and washer spring, second the novel porting structures with the axial port connected to release port through radial hole and a groove on one part of seat cover greatly reduce risk of leak and port block and part machining, third the slot between the through side port and axial port, greatly increase the function of the pilot for various applications, the slot includes multiple profiles, a flat, conical and spherical profiles, the most significant improvement is both plugs assembles not only work independently as two redundancies but act in a manner of synergy as a pressure regulator to produce both high dynamic performance—a fast response as pressure changes and static performances, stable pressure holding as pressure has no change with combinations of various springs and various slots, which no single regulator in any prior art can produces.
[0323] The full piston effect is a novel solution to the pilot operated system major problems—a slow response and inability to handle dirt fluids, the full piston effect is based on an optimal sold/liquid interaction mechanism on the plug with the combination of the direct sensing and the remote sensing, and the combination of direct release and indirect release, the full piston effect not only greatly increases the release speed of overpressure fluid, but also enhances sensibility for overpressure, sensing reliability and dirty fluid handling abilities with the shear seal assembly and the plug head screen.
[0324] The anti-cavitation plug trim in this invention provides a simple and effective way to reduce the cavitation without reducing the fluid capacity, the plug is constructed with multiple cylindrical rings on a conical front surface, each hole pass two layers of ring, so the fluid will pass the holes and change angle and move out along with the cylindrical ring, since the plug is movable, the flow condition can change any time unlike most fixed trim, it also can be used for water damping on dams or river or energy dissipating cone valve and terminal fluid control.
[0325] The elbow erosion control assembly is another innovation here, it provides a system solution not in in the prior arts, first the assembly provide a pair of fixed trim with multiple fins in the inlet and outlet of the elbow, the fastest fluid steam than ⅓ cross sectional area along with the outward wall of the elbow will divert to a middle stream and the slowest flow stream about ⅔ cross sectional area along with the inward wall of the elbow, second it provides a rotor assembly as dynamic trim to protect the outward wall of the elbow for dissipating some of energy of the faster fluid stream, and mix it with rest of streams, finally, the most important element is to monitor, detect and predict the erosion process, the rotor will create a designed, signature vibration profiles with an unbalanced blade as well as has one blade with a magnetic material Instead of avoiding vibrations, the unbalanced rotor not only create unbalanced rotation and vibration, but also a magnetic rotation signal, so both data will create critical data in regarding of erosion of the elbow as well as fluid conditions and are verifiable for a point of analysis, this device is very critical and useful tool for the pipelines underground, subsea or remote areas, where human access are difficult or impossible.
[0326] The A ring as an attachable ring between a pair of mated W shape teeth is other feature in this invention, the feature of seal attachablility is so critical for most flange connection in pumping or compression station, the pipeline, nuclear power or chemical plants, any sudden closing of pipeline valve or pump shutoff, vibrations or earthquakes would create water hammer or cause axial temporal or permanent separations of flange joints, the sudden separations generate million volatile gas or poison fluid leak every year around the world, so far there is no solution for axial temporal separation of flange joints, A ring is a simple but effective solution, it either can be attached to the outside diameter of A ring or the inside diameter of A ring, or both the inside diameter and outside diameter of A ring, the materials can be soft metal or polymer materials or composite materials or metal with polymer coating.
[0327] The volume substitute box is a great improvement in this gas loaded application, this not only reduces portion of pressurized fluid sensible to temperature swing effect, greatly improved the pressure sensing reliability due to gas temperature change reduction and gas consumptions, but also works as a heat reservoir filled with liquids or heat storable materials or fluids in the pipelines for averaging daytime and night time temperatures differences.
[0328] Although the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustration of some of the presently preferred embodiments of this invention.
[0329] Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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This invention relates to a Hybrid High Integrity Pressure Protection System (H-HIPPS) for severe services, the hybrid system includes a quick isolation subsystem between an overpressure zone and a normal pressure zone and a quick releasing subsystem between the overpressure zone and a lower pressure zone with quadruple redundancies for 30 year service without repair more particularly, the hybrid system has a novel valve and a novel pilot each with two independent plugs with metal to metal seal—(buckling seal) B ring assemblies and a novel (attachable)) A seal ring assembly to block or release over pressurize fluids without actuators for protecting the pipelines or the pressures vessels from surge pressure at the highest level of a system reliability with a fast block off time, redundant sensing valves, redundant releasing methods, redundant pressure protections, and cavitations and erosion suppressor.
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PRIOR RELATED APPLICATIONS
This application is a continuation of U.S. Ser. No. 12/584,685, now U.S. Pat. No. 8,476,343, which claims priority to U.S. Provisional Patent Application Ser. No. 61/192,172, filed Sep. 16, 2008 and U.S. Provisional Patent Application Ser. No. 61/201,340, filed Dec. 9, 2008 and are hereby formally incorporated herein in their entireties by reference thereto.
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention deals with the field of moldable solid materials such as putties and similar soft solid materials which are commonly used as toys or playthings by children which can be molded by hand or otherwise into various shapes and designs. The class of putty material to which the present invention pertains is the class of solid materials that can flow to at least some extent, that is, materials which can some type of a rigid form or to three-dimensional rigid structure to adhere onto to provide a somewhat rigid framework such that the material forms a layer thereover in a decorative manner. The material can also be formed independently into shapes without a separate rigid frameworks in certain applications. This type of putty material has a limited flowable characteristic such that it can be manipulated and kneaded by hand in an amusing and playful manner, preferably by children. Manual manipulation will also tend to heat the material to make it more pliable or flowable. The putty material can be stretched into sheets and can be rolled into longitudinally extending strings of material. The material is can be colored by the application of translucent ink or by using conventional markers in order to create various visual effects. Glitter can be added to the putty for creating pleasing aesthetic effects.
Description of the Prior Art
Many examples of putty or paste are shown in the prior art which are designed for manual manipulation for fun and enjoyment or other purposes such as shown in U.S. Pat. No. 3,061,572 patented Oct. 30, 1962 to M. Packer on a “Polyvinyl, Acetate And A Mixture Of A Compatible And Incompatible Plasticizer And Method Of Preparation”; and U.S. Pat. No. 4,094,694 patented Jun. 13, 1978 to W. J. Long and assigned to United States Gypsum Company on a “Water-Resistant Gypsum Composition And Products, And Process Of Making Same”; and U.S. Pat. No. 4,131,581 patented Dec. 26, 1978 to J. N. Coker and assigned to E. I. Du Pont de Nemours and Company on “Adhesive Compositions Consisting Essentially Of A Vinyl Alcohol Polymer, A Crystalline Solvent And A Viscosity Reducing Diluent”; and U.S. Pat. No. 4,956,404 patented Sep. 11, 1990 to J. Pelzig on a “Plastic Composition For Toys, Novelty Items And Arts And Crafts”; and U.S. Pat. No. 5,006,586 patented Apr. 9, 1991 to D. Touji et al and assigned to Sumitomo Rubber Industries, Limited on a “Heat Reserve Material”; and U.S. Pat. No. 5,395,873 patented Mar. 7, 1995 to H. Mizoule on a “Toy Paste Based In Polyvinyl Alcohol”; and U.S. Pat. No. 5,916,949 patented Jun. 29, 1999 to W. H. Shapero et al and assigned to Mattel, Inc. on “Moldable Compositions And Method Of Making The Same”; and U.S. Pat. No. 6,348,534 patented Feb. 19, 2002 to M. Bianco on a “Gel Toy”; and U.S. Pat. No. 6,680,359 patented Jan. 20, 2004 to C. J. Schoenheider on a “Moldable Composition”; and U.S. Pat. No. 6,713,624 patented Mar. 30, 2004 to L. E. Doane, Jr. and assigned to Hasbro, Inc. on a “Starch-Based Modeling Compound”; and U.S. Pat. No. 6,767,938 patented Jul. 27, 2004 to A. Cordova and assigned to Mattel, Inc. on a “Modeling Dough And A Surface Active Drying Agent Coating Composition For Same”; and U.S. Pat. No. 6,864,346 patented Mar. 8, 2005 to C J. Schoenheider on “Moldable Compositions”; and also German Patent No. 2935019 dated March 1981; and Japanese Patent No. 0027905 dated August 1973; and Japanese Patent 0041748 dated April 1976; and 51-125446 dated November 1976; and Japanese Patent 0047034 dated April 1977; and Japanese Patent 0154411 dated December 1979; and Japanese Patent 55-052086 dated April 1980; and Japanese Patent 0034148 dated February 1982; and Japanese Patent 0059940 dated April 1982; and Japanese Patent 59-036278 dated February 1984; and Japanese Patent 2172060 dated July 1987; and Japanese Patent 3072544 dated April 1988.
OBJECTS OF THE INVENTION
It is an object of the composition for a putty material of the present invention to have critical levels of physical elasticity to allow the material to be capable of being stretched without snapping to form sheets or panels by manual manipulation.
It is an object of the composition for putty material of the present invention to be capable of mixture with glitter or other particulate metallic components of various sizes and configurations to create pleasing physical appearances.
It is an object of the composition for putty material of the present invention to be mixable with various pigments for providing different colorations to the material for aesthetic purposes.
It is an object of the composition for putty material of the present invention to be capable of being formed into three dimensional forms which can then have coloration applied to the exterior surface thereof to create pleasing visual appearances.
It is an object of the composition for putty material of the present invention to be capable of adhering onto three dimensional forms and extending thereover to at least partially assume the shape of the form and then have coloration applied to the exterior surface thereof, such as by a conventional marker or with translucent ink to present a unique and pleasing visual effect which can be varied as desired by the user.
It is an object of the composition for putty material of the present invention to be capable of being formed into three dimensional forms which can then have coloration applied to the exterior surface thereof by contacting of the writing nib of a conventional marker thereunto such that the pigment of the marker will be absorbed into the exterior surface of the putty material to present a unique visual effect which is particularly pleasing when the putty is clear and can include a white glitter component mixed therewith.
It is an object of the composition for putty material of the present invention to be easily manipulated by hand without feeling sticky to the touch of the user and without forming any residue on the hands of the user.
It is an object of the composition for putty material of the present invention to easily stretch into panel shapes or curtain forms without pulling or snapping apart.
It is an object of the composition for putty material of the present invention to be capable of having air injected into small portions of material such that the materials expands outwardly generally equally to form air filled bubbles of various sizes formed of the putty material.
It is an object of the composition for putty material of the present invention to be capable of being stretched and spun to form long lengths of cylindrically shaped materials such as experienced during the ancient practice of noodle-making.
It is an object of the composition for putty material of the present invention to be capable of being wrapped around plastic forms and surfaces and other three-dimensional sculptures to make artistic designs thereover.
It is an object of the composition for putty material of the present invention to be engageable with three-dimensional mesh forms for making window art or other decorative three-dimensional items after being urged through the openings defined in the mesh.
It is an object of the composition for putty material of the present invention to be capable of being warmed to greater than room temperature by holding thereof within the hand of a person manipulating the material to provide added flexibility or flowability thereof.
It is an object of the composition for putty material of the present invention to be capable of being formed into three dimensional forms which can then have coloration applied to the exterior surface thereof by a conventional marker such that the pigment of the marker itself will be absorbed into the surface of the putty material wherein various colors can be used to present different overall artistic visual appearances.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A children's activities kit for forming a moldable putty composition that includes the following components:
(a) an aqueous alcohol borax solution comprising water and an alcohol, wherein the weight ratio of the alcohol to water in the solution is in the range of 1:7 to 1:3;
(b) xanthan gum; and
(c) a colorant.
A method for providing a children's activities kit and for forming a moldable putty from the kit that includes the following steps:
(i) providing the following components in a kit;
(a) an aqueous alcohol borax solution comprising water and an alcohol, wherein the weight ratio of the alcohol to water in the solution is in the range of 1:7 to 1:3;
(b) xanthan gum in an amount of 2% to less than 5% by weight;
(c) a colorant; and
(ii) combining the kit components (a), (b) and (c) to form the moldable putty composition wherein the xanthan gum is 2% to less than 5% by weight.
The unique composition of matter which forms the flowable putty material is a very critical aspect of the present invention. A preferred formulation for this composition of matter usable in accordance with the present invention is shown in the below chart.
Percentage By Weight
Water
67.7%
Polyvinyl Alcohol
13.1%
Propanediol
10.8%
Borax
00.8%
Preservative*
00.5%
Xanthan Gum
2.00%
Glitter
5.00%
Naringin
0.10%
*The preferred preservative is 1-[1,3-bis(hydroxymethyl)-2,5-dioxo-imidazolidin-4-yl]-1,3-bis(hydroxymet-hyl)urea
The percentages by weight set forth in the chart above and the components of the composition detailed therein are only approximate and other compositions will work as long as they are generally in the same ratios with similar components. Most particularly, the ratio of borax to polyvinyl alcohol is preferred to be in the range of between 1:12 to 1:22. The use of borax in this very small percentage relative to the polyvinyl alcohol is an important advantage of the formulation of the present invention because it allows the putty material to stretch and flow with significantly enhanced characteristics.
This formulation of this invention also allows the putty material to be very flexible even when somewhat dry or under low conditions of humidity and will prevent cracking. The putty material of this formulation is particularly useful included within toy activity kits that can be used to make jewelry, window art, play sets, activity kits and many other creative related items. Also this formulation maintains the important characteristics thereof when mixed with higher concentrations of glitter which is very useful for the purpose of allowing children to provide unique items made with the more decorative putty material which contains an attractive glitter component, particularly white glitter.
This putty material having this general formulation is particularly useful for play since it can be stretched as needed into long cylindrical columns or in panels and can be used also to inflate while forming bubbles. It can sometimes snap and/or pop if stretched beyond the capability of the material and it also can also be used to bounce to a limited extent similar to bouncing a ball.
The putty composition shown above is particularly useful for forming a flowable putty material which is not sticky to when touched or manipulation by hand but is still capable of stretching significantly into panels or long cylindrical sections without unwanted snapping or disengagement. The elasticity characteristics of the putty material are important because it needs to be capable of stretching in various modes to be capable of many different manners of manipulation such as above described.
Various types of glitter can be used with the material of the present invention and, in particular, the smaller sizes of glitter can be used to form a final putty material which has a pearlescent or pearl-like glitter appearance. Larger sized glitter can be used if a larger metal flake or a chunky appearance is desired. Different sizes can be used with different colors for achieving different appearances and effects as desired.
The material made in accordance with the above-described formulation is particularly usable for hand manipulation or kneading and has been formulated such that when manipulated by hand, no residue is left upon the surface of the fingers or hands. When placed into the hand, the material will become slightly heated above ambient temperature due to the heat from the user's body and this added heat can enhance the flowable characteristics thereof. The putty material normally feels cool and wet to the touch and these characteristics will vary somewhat dependent upon the amount of humidity in the air and the resulting variation in the total moisture content in the putty material itself.
One of the important characteristics of the putty material using the composition set forth herein is in the capability of spreading the material wide and then stretching it out to form large panels or curtains or sheets which are somewhat translucent and yet suspend the glitter therewithin for a very decorative and appealing visual effect particularly when looking at or through the sheets of material.
When the putty material is stretched or pulled apart it sometimes separates by snapping which is initially undesirable but will always ultimately occur if a significant amount of stretching is performed beyond the designed capabilities of the material. When the material becomes rigid because a significant portion of the moisture within the material has been lost then the material will snap more easily.
One of the unique manners of use of the present invention is to place one end of a small straw into the center of a small piece of material and blow through the straw which will cause the putty material to expand into a bubble filled with air.
It is also possible to stretch the putty material into long cylindrical pieces wherein the weight of the material itself is sufficient to cause it to gently fall downwardly and then spin it horizontally in a motion similar to the commonly known ancient Chinese practice used for the purposes of forming paste noodles. For this purpose it is important that the correct elasticity or moisture content of the material be maintained in order to maintain the shape of the long cylindrical piece of toy paste as it is spun into the shape of a noodle.
Another important aspect of usage of the composition of matter of the flowable putty material of the present invention is in the capability of manually forming the material into many different physical sizes and shapes. The material is significantly flowable due to the particular characteristics of the specific composition of the toy putty set forth herein and, for this reason, will sometimes be difficult to use in such a manner as to hold shape by itself. However, when formed over somewhat rigid three-dimensional items such as a form or the like, a shape can be more easily maintained. For example, a plastic horse can have sections of thin flowable glitter lava material molded in thin layers across the horse in such a manner as to achieve a three-dimensional artistic effect over the rigid form. Plastic bugs or plastic horses or any somewhat rigid three-dimensional form, commonly made of mesh plastic or metal or other similar material, can be used for this purpose.
Another manner of maintaining the shape of this flowable putty material is to use somewhat flat two-dimensional forms which have a plurality of interstices therein to allow the material to flow through these apertures to form flat primarily two-dimensional designs or constructions by allowing the material of the glitter lava to be secured to the form extending through the apertures defined therein. Normally the forms are made of a flat mesh or screen material and the flowable molding material of the present invention is positioned in engagement with the apertures defined in the form, preferably extending therethrough to some extent, for the purpose of defining unique items such as pieces of window hanging art or other generally flat articles.
One of the more unique aspects of the composition of matter of the present invention is the possible use thereof as a substrate for coloration such as by using markers or by applying translucent ink onto the three dimensional items designed and formed therewith. Coloration can be performed in many different ways. One of the manners of coloration makes use of conventional writing instrument marking pens. The dyes used in such markers or marking pens as commonly available mass marketed at the current time have been found to be capable of easily marking the exterior surface of the putty composition of the present invention. Thus, when a three dimensional article is formed it can then be easily colored with such markers which are available in many various colors. The dye from the markers is easily applied onto the exterior of the three dimensional items formed with the composition of matter of the putty of the present invention. Thus, an article can be conveniently colored with markers similar to conventional coloring upon three dimensional substrates. This manner of decorating the three dimensional items formed using the improved putty composition of the present invention yields particularly unique artistic effects when used with clear putty containing glitter, especially white colored glitter. Marker dye or transparent ink has the capability to color the exterior surface of the putty to the many various colors available in such markers being mass marketed today as stationary supplies.
While particular embodiments of this invention have been described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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A putty material primarily used as a toy which is solid and capable of flowing for forming, preferably by manual manipulation, onto various pleasing shapes. This putty material is used primarily by children as an amusement device. The putty material is formed from a homogeneous mixture of primarily water, polyvinyl alcohol, gum, polyethylene terephthalate (PET) and a small amount of borax wherein the ratio by weight of borax to polyvinyl alcohol is preferably in the range of between 1:12 to 1:22. The toy modeling composition can be formed opaque or translucent and can be dyed, particularly when clear, to create various overall artistic effects, and glitter can be applied on the paste to create unusual aesthetic effects, particularly when using white glitter. Coloration can be applied to the materials with translucent ink or with a marker.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the masonry field, especially to the art of laying up forms in which concrete footings are poured. Forms for concrete footings are usually made of dimensional lumber or heavy plywood panels, or may even be manufactured aluminum panels. Where these lengths of lumber or panels are laid up end to end, they must be joined together in a fixed relationship, so that the concrete will not blow out the joint in the forms.
[0002] A typical method of joining form boards in end to end relationship is to nail a splice board over the joint. While this method can result in a satisfactory joint, it is an inefficient method in that wood must be cut to length and applied over the joint with sufficient nails to secure the splice. When such a splice is removed, as the forms are taken up, the forms are often damaged and cannot be reused.
[0003] Another method of joining forms at corner joints is to nail through the face of one form board into the end of the other. Nailing into an end grain of a form board results in a weak joint. Again, the form boards are often destroyed when the forms are removed from the cured concrete.
[0004] Some attempts have been made to provide a form connector for joining concrete form boards. Most of these devices are complex in structure, complicated to use, and expensive to manufacture. One such connector is shown in U.S. Pat. No. 4,320,888 to Oury. Oury shows a connector in the form of a plate with slots therein, where the slots slide over studs preformed into the form surface. The connector can be configured to connect two forms end-to-end, or in a corner relationship. A drawback of this connector is that the form boards must be preconfigured with the studs that the connector must engage. This limits its use to forms specifically made for this connector.
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a connector for connecting forms for concrete footings. A first embodiment provides a connector that joins two form boards in end to end abutting relationship. Another embodiment provides a connector for form boards in overlapping relationship. A third and fourth embodiment of the present invention provides a connector that connects form boards at a corner joint, both inside and outside.
[0006] The connector of the present invention consists of a stamped, sheet metal bracket which sits over the top edge of the form boards spanning the joint therebetween. The bracket can extend downwardly over the inside face and outside face of the form boards, and is secured in place with a number of double headed nails. The connector of the present invention is simple and easy to use, is inexpensive to produce, and is effective in joining form boards in rigid relationship. Also, the present form connector does not cause damage to the form boards when in use or when being removed, and can be used over again. Further, the present connector can be used with dimensional lumber form boards. No specially made form boards are needed for use with this connector.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The invention will be further described in connection with the accompanying drawings, in which:
[0008] FIG. 1 is a perspective view of a first embodiment of the invention, connecting two forms in end-to-end abutting relationship;
[0009] FIG. 2 is a perspective view of a second embodiment of the invention, connecting two forms in overlapping relationship;
[0010] FIG. 3 is a perspective view of a third embodiment, used for making a connection at an inside corner of two forms;
[0011] FIG. 4 is a perspective view of a fourth embodiment, used for making a connection at an outside corner of two forms;
[0012] FIG. 5 shows the connector of FIG. 3 in use connecting two form boards at an inside corner; and
[0013] FIG. 6 shows the connector of FIG. 4 in use connecting two form boards at an outside corner.
DETAILED DESCRIPTION
[0014] FIG. 1 shows a first embodiment of the form connector 1 in use connecting two form boards 7 and 8 in an end-to-end abutting relationship. Form connector 1 consists of a sheet metal body having an outside portion 2 , a top portion 3 , and an inside portion 4 . Form connector 1 sits atop the joint between two form boards 7 and 8 , spanning the joint therebetween. Outside portion 2 extends downwardly from the top of the form boards and extends over a portion of the outsides of the form boards. Top portion 3 is connected to the outside portion 2 and extends across the upper surface of the form boards, also spanning the joint therebetween. Connected to the top portion 3 is an inside portion 4 , which extends downwardly from top portion 3 and extends over a part of the inside surface of the form boards 7 and 8 . Nail holes 5 are strategically placed on the outer portion 2 and top portion 3 allowing for double headed nails 6 to pass therethrough, securing the connector 1 to the form boards 7 and 8 . Double headed nails 6 are used to allow quick and easy removal of the nails, connector and form boards after the concrete is cured. Preferably, two vertically spaced nail holes 5 are placed on the part of outside portion 2 extending over the outside of form board 7 , and two vertically spaced nail holes 5 are placed on the part of outside portion 2 extending over the outside of form board 8 . Nails 6 will pass through these nail holes 5 , fixedly securing the form connector 1 to the form boards 7 and 8 , thereby securing form boards 7 and 8 in an end-to-end fixed relationship. Nail holes 5 can also be placed in the top portion 3 , with one hole 5 being placed on each side of top portion 3 , allowing a single nail to be placed in the top of each of boards 7 and 8 . FIG. 1 shows the outer portion 2 having an opening 30 therein. This opening 30 allows the installer of the connector to clearly see the joint between form boards 7 and 8 so that the connector can be quickly and properly aligned during installation, allowing for maximum strength of the connection. The connector could also be made without this opening 30 . To use the connector, form boards 7 and 8 are laid up into the desired position, with the ends in tight abutting relationship. Connector 1 is then placed over the top edge of form boards 7 and 8 , with the joint therebetween placed in the center of opening 30 . Double headed nails 6 are then nailed through openings 5 in the top portion and into the top edge of the form boards, to either side of the joint. Nails 6 can also be placed through openings 5 in the outer portion of the connector and into the outer surface of the form boards. It is to be understood that more or less nails can be placed through connector 1 , as is needed to secure a strong connection between form boards 7 and 8 .
[0015] FIG. 2 shows another embodiment of the form connector. In this embodiment, form connector 9 is used in connecting two form boards 7 and 8 in overlapping relationship. Form connector 9 has outside portion 11 , top portion 10 and inside portion 12 . Portions 11 , 10 and 12 lie in relationship to form boards 7 and 8 in the same way as portions 2 , 3 , and 4 of FIG. 1 , respectively. Outer portion 11 has a screw 13 threadably engaged therein, and passing therethrough to a plate 15 . Plate 15 is located inside the outer portion 11 , between outer portion 11 and form board 8 . Screw 13 has a T-handle 14 on its outer end to allow a user of the connector to tighten the screw placing a force on plate 15 and thereby securing the connector 9 to the form boards 7 and 8 . In use, connector 9 is placed over the overlapping form boards 7 and 8 , with the outer portion 11 placed over the exterior of the form board 8 and the inner portion 12 placed over the interior of form board 7 . Inner portion 12 engages the interior of form board 7 , while plate 15 engages the exterior of form board 8 . When screw 13 is tightened by turning T-handle 14 , the connector fixedly engages form boards 7 and 8 in overlapping relationship. As shown in FIG. 2 , more than one connector 9 may be used at each joint to increase the strength of the overlapping joint.
[0016] FIGS. 3 and 4 show form connectors for making connections of form boards at inside corners and outside corners, respectively. FIG. 3 shows connector 16 , which is used for connecting two form boards at an inside corner. Connector 16 has a top portion 19 that extends over the upper edge of a form board, and inside portion 17 that extends downwardly over the inside face of the form board. Connector 16 is formed at a right angle to match the right angle between the form boards that make the inside corner. Connector 16 has nail holes 5 extending through the top portion 19 . Preferably, two nail holes 5 are provided in each part of the top portion 19 . FIG. 4 shows a similar connector 20 , but made to a connection to form boards at an outside corner. Connector 20 has top portion 21 that extends over the upper edge of a form board, and an outside portion 22 that extends downwardly over the outside face of the form board. Connector 20 is also formed at a right angle to match the right angle between the form boards that make the outside corner. Similar to connector 16 , connector 20 also is provided with nail holes 5 in the top portion 21 .
[0017] FIGS. 5 and 6 show connectors 16 and 20 in use, respectively. In FIG. 5 , connector 16 is shown spanning the inside corner joint between form boards 27 and 28 . Double headed nails 6 pass through nail holes 5 in the top portion 19 and into the top edge of form boards 27 and 28 , thereby securing the form boards together at an inside corner, right angle relationship. In FIG. 6 , connector 20 is shown spanning the outside corner joint between form boards 37 and 38 . Double headed nails 6 pass through nail holes 5 in the top portion 21 and into the top edge of form boards 37 and 38 , thereby securing the form boards together at an outside corner, right angle relationship.
[0018] While the connectors have been described as being formed from stamped sheet metal, it is to be understood that the connectors could be made of other materials such as molded plastics, or forged metals such as steel or bronze.
[0019] While the preferred embodiments of the invention has been illustrated and described, it will be apparent that various changes can be made in the disclosed embodiments without departing from the scope or spirit of the invention, as set forth in the following claims.
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A stamped, sheet metal, form connector connects two concrete form boards together in end-to-end abutting relationship in one embodiment. In another embodiment, the connector connects two form boards in overlapping relationship. In a third and fourth embodiment, the connector connects two form boards at an inside and outside corner, respectively. Double headed nails fasten the connector to the form boards, allowing for easy removal without damage to the forms. The connector is inexpensive to manufacture, and is simple and convenient to use.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. § 119(e) from U.S. provisional application Ser. No. 60/225,748, entitled “Long Latency Interface Protocol,” filed Aug. 17, 2000, the contents of which are incorporated by reference herein, U.S. provisional application Ser. No. 60/236,180, entitled “Simplified Long Latency Interface Protocol,” filed Sep. 29, 2000, the contents of which are incorporated by reference herein, and U.S. provisional application Ser. No. 60/249,287, entitled “Simplified Long Latency Interface Protocol,” filed Nov. 17, 2000, the contents of which are incorporated by reference herein.
This application is related to commonly-assigned copending application Ser. No. 09/661,912, entitled “High Latency Interface Between Hardware Components,” filed Sep. 14, 2000, the contents of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a versatile, latency-independent interface between hardware components, such as between a read/write (R/W) channel or read channel (RDC) and a hard disk controller (HDC). Such an interface is flexible enough to support high read and write latencies of greater than one sector, a split sector format, and a second sector mark.
2. Description of the Related Art
As is shown in FIG. 1 , a typical disk drive system includes a hard disk controller (HDC) 12 that interfaces with a R/W channel or RDC 14 which is in communication with a disk 16 . Data transfer between HDC 12 and the R/W channel is synchronized by read gate (RGATE) and write gate (WGATE) control signals. In a read operation, R/W channel 14 processes an incoming analog signal from disk 16 and transfers the data to HDC 12 . In a write operation, data is transferred from HDC 12 to the R/W channel to be written to the disk. Latency refers to the time or byte delay that data remains in the R/W channel. Some disk drive systems have latencies of about 20 bytes which, depending on the particular system, amounts to a time delay of between about 800 ns and 5 ms.
Technology such as iterative turbo coding, which is being introduced into modern disk drive systems, requires more processing before the data is available, which, in turn, requires R/W channels or RDCs with higher latencies. One problem is that the interface used in the shorter latency systems is not capable of supporting the higher latencies. Accordingly, a new interface is needed that supports higher latency R/W channel or RDC designs.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, a latency-independent interface between first and second hardware components is provided comprising, a serial control data circuit that transmits a serial control data signal and a data circuit that transmits or receives data under the control of the serial data gate signal. The serial control data signal comprises information as to whether the data is one of split and non-split.
According to a second aspect of the present invention, a latency-independent interface between first and second hardware components, comprising a serial control data circuit that transmits a serial control data signal, a data circuit that transmits or receives data under the control of the serial control data signal, and a sync mark transceiver that transmits or receives sync mark information. During a write operation a first assertion by the first hardware component of the sync mark information indicates a start of sync mark insertion and a second assertion by the first hardware component of the sync mark information indicates a start of writing of padding data, and during a read operation by the second hardware component information that a sync mark was detected.
According to a third aspect of the present invention, a latency-independent interface between first and second hardware components, comprises a serial control data circuit that transmits a serial control data signal, a data circuit that transmits or receives data under the control of the serial data gate signal, and a ready transceiver that transmits or receives a ready signal. During a write operation the ready signal indicates the second hardware component is ready to receive data from the first hard component; and during a read operation the ready signal indicates the first hardware component is ready to receive data from the second hard.
According to a third aspect of the present invention, a method of transmitting and receiving signals between first and second hardware components comprises the steps of transmitting a serial control data signal, and transmitting or receiving data under the control of the serial control data signal. The serial control data signal comprises information as to whether the data is one of split and non-split.
According to a fourth aspect of the present invention, computer program for transmitting and receiving signals between first and second hardware components, comprises the steps of receiving a serial control data signal and transmitting or receiving data under the control of the serial control data signal. The serial control data signal comprises information as to whether the data is one of split and non-split.
Other objects and attainments together with a fuller understanding of the invention will become apparent and appreciated by referring to the following description and claims taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings wherein like reference symbols refer to like parts.
FIG. 1 is a block diagram of a conventional RDC/HDC interface;
FIG. 2 is a block diagram of an interface between two hardware components, such as an HDC and an RDC or R/W channel, in accordance with a first embodiment of the invention;
FIG. 3 is a timing diagram of a read operation with a long instruction in accordance with the first embodiment of the present invention;
FIG. 4 is a timing diagram of a read operation a read operation with a Short Instruction in accordance with the first embodiment of the present invention;
FIG. 5 is a timing diagram of a write operation of an SCD serial transfer occurring right after a DATA_VALID assertion in accordance with the first embodiment of the present invention;
FIG. 6 is a timing diagram of a write operation for a single codeword per sector without split in accordance with the first embodiment of the present invention;
FIG. 7 is a timing diagram for a write operation for a single codeword per sector with split assertion in accordance with the first embodiment of the present invention;
FIG. 8 is a timing diagram for a write operation for multiple codewords per sector without split in accordance with the first embodiment of the present invention;
FIG. 9 is a timing diagram for a write operation for multiple codewords per sector with multiple splits in accordance with the first embodiment of the present invention;
FIG. 10 is a timing diagram for a read operation for a single codeword per sector without split in accordance with the first embodiment of the present invention;
FIG. 11 is a timing diagram for a read operation for a single codeword per sector with split in accordance with the first embodiment of the present invention;
FIG. 12 is a timing diagram for a read operation for multiple codewords per sector without split in accordance with the first embodiment of the present invention;
FIG. 13 is a timing diagram for a read operation for multiple codewords per sector with multiple splits. R/W channel 24 operates similarly as in the single codeword per sector with split case in accordance with the first embodiment of the present invention;
FIG. 14 is a block diagram of an interface between two hardware components, such as an HDC and an RDC or R/W channel, in accordance with a second embodiment of the invention;
FIG. 15 is a timing diagram for a single codeword per sector without a split for a write operation, in accordance with the second embodiment of the invention;
FIG. 16 is a timing diagram for single codeword per sector with split for a write operation, in accordance with the second embodiment of the invention;
FIG. 17 is a timing diagram for multiple codewords per sector without split for a write operation, in accordance with the second embodiment of the invention;
FIG. 18 is a timing diagram for multiple codewords per sector with multiple splits for a write operation, in accordance with the second embodiment of the invention;
FIG. 19 is a timing diagram for a single codeword per sector without split for a read operation, in accordance with the second embodiment of the invention;
FIG. 20 is a timing diagram for a single codeword per sector with split for a read operation, in accordance with the second embodiment of the invention;
FIG. 21 is a timing diagram for multiple codewords per sector without split for a read operation, in accordance with the second embodiment of the invention;
FIG. 22 is a timing diagram for multiple codewords per sector with multiple splits for a read operation, in accordance with the second embodiment of the invention;
FIG. 23 is a schematic diagram of a data format without a split, in accordance with the second embodiment of the invention;
FIG. 24 is a schematic diagram of a data format with a split, in accordance with the second embodiment of the invention;
FIG. 25 is a block diagram of an interface between two hardware components, such as an HDC and an RDC or R/W channel, in accordance with a third embodiment of the invention;
FIG. 26 is a timing diagram for a single codeword per sector without a split for a write operation, in accordance with the third embodiment of the invention;
FIG. 27 is a timing diagram for single codeword per sector with split for a write operation, in accordance with the third embodiment of the invention;
FIG. 28 is a timing diagram for multiple codewords per sector without split for a write operation, in accordance with the third embodiment of the invention;
FIG. 29 is a timing diagram for multiple codewords per sector with multiple splits for a write operation, in accordance with the third embodiment of the invention;
FIG. 30 is a timing diagram for multiple codewords per sector with multiple splits for a write operation, in accordance with the third embodiment of the invention;
FIG. 31 is a timing diagram for a single codeword per sector with split for a read operation, in accordance with the third embodiment of the invention;
FIG. 32 is a timing diagram for multiple codewords per sector without split for a read operation, in accordance with the third embodiment of the invention;
FIG. 33 is a timing diagram for multiple codewords per sector with multiple splits for a read operation, in accordance with the second embodiment of the invention;
FIG. 34 is a block diagram of an interface between two hardware components, such as an HDC and an RDC or R/W channel, in accordance with a fourth embodiment of the invention;
FIG. 35 is a timing diagram for a single codeword per sector for a write operation, in accordance with the fourth embodiment of the invention;
FIG. 36 is a timing diagram for multiple codewords per sector for a write operation, in accordance with the fourth embodiment of the invention;
FIG. 37 is a timing diagram for a single codeword per sector for a read operation, in accordance with the fourth embodiment of the invention; and
FIG. 38 is a timing diagram for multiple codewords per sector for a read operation, in accordance with the fourth embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Referring to FIG. 2 , a block diagram of an interface 20 between a first hardware component 22 and a second hardware component 24 , in accordance with a first embodiment of the present invention, is illustrated. In a preferred embodiment, first hardware component 22 is a hard disk controller (HDC) and second hardware component 14 is a read/write (R/W) channel or read channel (R/W channel 24 ), although the invention is not so limited. Rather, interface 20 of the present invention may be employed in connection with other suitable functional hardware components between which data is transferred.
In accordance with the invention, interface 20 employs a new signaling protocol, which decouples the timing of the conventional read, and writes gate control signals by replacing them with a single RWGATE signal. Additionally, five more signals are added in the preferred embodiment. A description of these signals is described below. The interface supports the following features:
multiple sectors of read and write delay;
multiple codewords per sector;
multiple splits per sector;
multiple codeword sizes per sector;
expandable serial interface (SCD pin—Serial Control Data); and
data recovery between 1 st sync mark and 2 nd sync mark.
In the illustrated embodiment, the interface 20 of the present invention employs a read clock signal (RCLK), sourced from R/W channel 24 and output during read operations, and a write clock signal (WCLK) sourced from HDC 22 and output during write operations. A R/W signal, sourced from HDC 22 , is provided in which a “1” indicates a read operation and a “0” indicates write operation. Of course, as will be appreciated by one of ordinary skill in the art, other bit configurations may be utilized for the R/W signal. Alternatively, this signal may be replaced by programming an internal register. A BUF_FULL signal, source from the R/W channel 24 indicates an internal buffer from R/W channel 24 is almost full. More specifically, once the BUF_FULL signal goes high, only 8 more bytes of data can be transferred. During a write operation if BUF_FULL goes high, HDC 22 either asserts a RWGATE signal to flush out the data from the internal buffer or HDC 22 resets R/W channel 24 . Otherwise R/W channel 24 will continue to wait.
During a read operation, BUF_FULL goes high only when HDC 22 is not ready for data transfer and RWGATE stays high. HDC 22 will then need to either assert a HDC_RDY signal or to reset R/W channel 24 .
A DATA_VALID signal can be source from either HDC 22 or R/W channel 24 . During a write operation, DATA_VALID is sourced from HDC 24 and indicates the 9-bit NRZ data bus is valid when it goes high. Therefore, R/W channel 24 can latch the NRZ data from the bus correctly at the rising edge of WCLK. During a read operation, Data_Valid is sourced from R/W channel 24 and indicates the 9-bit NRZ data bus is valid when it high. Therefore, HDC can latch the data from the bus correctly at the rising edge of RCLK.
A RDY signal comprises a RC_RDY during the write operation and a HDC_RDY, during the read operation. RC_RDY signal is source by R/W channel 24 goes high when R/W channel 24 is ready for HDC 22 to assert RWGATE. HDC_RDY signal is sourced by HDC 22 and goes high when HDC 22 is ready for R/W channel 24 to assert DATA_VALID. The RWGATE signal is source by HDC 22 . When R/W is set for the read operation (or =1) RWGATE=RGATE, and when R/W is set for the write operation (or =0) RWGATE=WGATE.
The Serial Control Data Transfer utilizes the SCD pin to transfer important control information from HDC 22 to R/W channel 24 for both read and write operations. Each serial transfer contains one START bit followed by 10 bits of control data and one END bit. If the END bit goes low at the end of a transfer, it indicates the completion of the transfer. Otherwise, another 10 bits of control data and one END bit are expected. Therefore, HDC 22 can transfer for unlimited number of times 10-bit control data to the R/W channel 24 as long as every END bit is “1”. This facility provides flexibility and allows for expandable and additional feature sets for any future development.
For a write operation, the START bit gated with DATA_VALID is used to indicate the beginning of a transfer. Similarly for a read operation, the START bit gated with RWGATE is used to indicate the beginning of a transfer. However, the data on SCD pin has slightly different definition during Read and Write operations. Detailed description of the SCD pin can be found in Table 1 below.
SCD Functional Description
TABLE 1
SCD Pin Function Descriptions
Bit
Definition
Description
Start Bit
“1” means start a transfer. Once started the R/W channel 24
looks for End bit to stop.
Instruction
Only available in read operation.
Bit
“1” means long instruction and “0” means short instruction.
Split Bit
Only available in Write Operation.
“1” means split and “0” means non-split
Mode Bit
During Read Operation, it indicates sector types as following:
[1:0]
00 = non-split
01 = first-split
10 = continue-split
11 = last-split
During Write Operation: Not used or Reserved
Reserve
Reserved.
Bit[2:0]
Counter
During Read Operation:
[13:0]
If Instruction Bit = 1, Counter[13:0] is the read counter value
which indicates the number of bytes expected to be read
during current RWGATE.
If Instruction Bit = 0, Counter[7:0] is the read counter value
which indicates the number of bytes expected to be read
during current RWGATE.
During Write Operation:
14-bit write counter value to indicate the total number of bytes
to write for one sector.
Code-
10-bit codeword size used for the current sector. In the
word —
presence of multiple codeword sizes, Codeword_Size can be
Size[9:0]
sent to the R/W channel 24 one by one.
Interface 20 also comprises an RCLK signal sourced by R/W channel 24 having a constant width of 8 times R/W channel 24 clock and an WCLK signal sourced by HDC 22 having the same clock frequency as RCLK but at a different phase.
A SM_ST or a SM_DET signal is also provided. During the write operation, SM_ST is asserted by HDC 22 twice for each RWGATE. The first assertion indicates the start of Sync Mark insertion. The second assertion indicates the start of Write padding data.
Therefore, HDC 22 can freely control the lengths of Sync Field and Write padding data. At the same time, R/W channel 24 knows the number of data bytes written by counting the number of WCLK's between the two SM_ST assertions. Since iterative encoding adds 28 bytes per codeword, HDC 22 need to add 28 times the number of words per sector bytes into the total write padding length.
During the read operation, SM_DET is asserted by R/W channel 24 to indicate that the Sync Mark is found after RWGATE is asserted. The NRZ[8:0] signal is source by either HDC 22 or R/W channel 24 . During the write operate NRX[8:0] is source by HDC 22 as an input to R/W channel 24 . NRZ[8] is the parity bit and NRZ[7:0] is the user data including data permuted by ECC (error correcting code) and/or RLL (run length limited coding). HDC 22 functions to ensure user data is in 8-bit form. If the last user data in a string is less than 8 bits, HDC 22 pads the last string so that it is 8 bits. During the read operation NRZ[8:0] is sourced by R/W channel 24 . NRZ[8] is a multi-purpose bit and NRZ[7:0] is the user data, which is read back.
Interface 20 may contain a RDONE or a WDONE signal. During the write operation, WDONE indicates one RWGATE write completion, and during the read operation, RDONE indicates one RWGATE read completion.
Each of HDC 22 and the R/W channel 24 include appropriate circuitry for transmitting and receiving the various signals, data and mode selection information between the two hardware components. For example, HDC 22 includes a R/W transmit circuit 60 that transmits the R/W signal to R/W receiver circuit 32 on R/W channel 24 , a data valid transceiver circuit 64 that transmits the DATA_VALID signal to and receives the DATA_VALID signal from a data valid transceiver circuit 36 on R/W channel 24 . A ready transceiver 66 is provided in HDC 22 to transmit HDC_RDY signal to and receive RC_RDY signal from a ready transceiver circuit 38 on R/W channel 24 . HDC 22 also comprises a RWGATE transmit circuit 68 which transmits the RWGATE signal to RWGATE receive circuit 40 of R/W channel 24 . HDC 22 also includes a write clock transmit circuit 74 to transmit the WCLK signal to write clock receive circuit 46 on R/W channel 24 . HDC 22 comprises a SM transceiver 76 , which transmits the SM_DET or SM_ST signal to and receives the SM_DET or SM_ST signal from the SM transceiver 48 on R/W channel 24 . HDC 22 and R/W channel 24 comprise respective NRZ transceivers 78 and 50 , respectively, for exchanging NRZ data and serial transceivers 82 and 54 respectively for exchanging serial data. R/W channel 24 comprises a buffer full transmit circuit 34 to transmit the BUF_FULL signal to a buffer full receive circuit 62 on HDC 22 , a receive clock transmit circuit 44 to transmit RCLK signal to a receive clock receive circuit 72 on HDC 22 . R/W channel 24 comprises done transmit circuit 52 to transmit the RDONE or WRITE done signal to done receive circuit 80 .
Signal and data transmitting, receiving and transceiving circuits are generally known, and based on the teachings provided herein, one skilled in the art would be able to construct and implement transmitting and receiving circuits to carry out the specific signaling protocol described herein.
FIG. 3 is a timing diagram of a read operation with a long instruction in accordance with the first embodiment of the present invention. The SCD transfer occurs during the read operation right after RWGATE is asserted. As shown therein, in the SCD signal, the first or START bit, goes from low to high indicating the start of a transfer. The next bit is an Instruction Bit. In FIG. 3 , it is set to “1” to indicate a long instruction. The next 2 bits, Mode Bit[1:0], indicate sector type of this RWGATE. It can be non-split, first-split, continue-split or last-split sector. The next 3 bits are reserved. The last 4 bits for this 10-bit SCD data are the most significant bits (MSBits) of a 14-bit read counter. The least significant (LSBits) 10 bits are provided in the next 10-bit SCD data transfer.
At the end of the 10-bit SCD data transfer, an END bit is appended to indicate the continuation or termination of the transfer. In the example of FIG. 3 , the END bit is set to “1”, indicating that there will be a continuation of data transfer in the next SCD data. In the example illustrated herein, the LSBits 10 bits are provided in the next 10-bit SCD data.
The next 10-bit SCD data contains the LSBits of the read counter. In this example the End bit is set to “1” to indicate another 10-bit SCD data transfer. The next (or third) 10-bit SCD data contains the codeword size information. The End bit is set to “0” to indicate the end of the SCD data transfer.
FIG. 4 illustrates a timing diagram of a read operation with a Short Instruction in accordance with the first embodiment of the present invention. For this operation, the first bit, START Bit, goes from low to high indicating the start of a transfer. As shown therein, the first bit of the 10-bit SCD data is Instruction Bit which is set to “0” indicating a short instruction. The next 2 bits, Mode Bit[1:0], indicate sector type of this RWGATE. It can be non-split, first-split, continue-split or last-split sector. The next 7 bits are the value of the 7-bit read counter. For a read operation expected to read the data less than 127 bytes it is advantageous to use the Short Instruction.
FIG. 5 illustrates a timing diagram of a write operation of an SCD serial transfer occurring right after a DATA_VALID assertion in accordance with the first embodiment of the present invention. In this write operation, the first bit (START Bit) goes from low to high indicating the start of a transfer. The first bit of the following 10-bit SCD data is Split Sector Bit, which is set to “1” indicating a split sector. The next 5 bits are reserved. The last 4 bits for this 10-bit SCD data are the MSBits of a 14-bit write counter. At the end of the current 10-bit SCD data transfer, an END bit is set to “1”, and is appended to indicate the continuation of the transfer. In this example, the least significant 10 bits of the 14 bit write counter are sent in the next 10-bit SCD data transfer. The End bit of “1” is asserted to indicate another 10-bit SCD data transfer. The 10-bit SCD data is the codeword size information. For this 10-bit SCD data the End bit of “0” is asserted to indicate the end of the SCD data transfer.
FIG. 6 is a timing diagram of a write operation for a single codeword per sector without split, in accordance with the first embodiment of the present invention. As shown therein, a write operation of 1 codeword per sector without split is performed. The sector control information is sent through the SCD pin at the beginning of the DATA_VALID signal. HDC 22 sends the sector type, total number of user data bytes and the codeword size information for this sector to R/W channel 24 .
After R/W channel 24 finishes the iterative encoding, CH_RDY is asserted by R/W channel 24 to indicate that it is ready to transfer the encoded data. Then HDC 22 asserts RWGATE, and thereafter HDC 22 asserts the first SM_ST to indicate the start of Sync Mark and the second one to indicate the start of Write padding data operation. As a result of this interface, HDC 22 can freely control the lengths of the Sync Field and the Write padding data for each RWGATE asserted during a write operation.
FIG. 7 is a timing diagram for a write operation for a single codeword per sector with split assertion in accordance with the first embodiment of the present invention. In FIG. 7 , a write operation of 1 codeword per sector with 1 split is performed. First, the entire codeword of user data is transferred to R/W channel 24 . HDC 22 uses DATA_VALID to qualify the NRZ data bus. At the beginning of DATA_VALID assertion, HDC 22 transfers sector control data information to R/W channel 24 via SCD pin. In order to track the completion of one user data sector transfer, R/W channel 24 counts between each pair of SM_ST during each RWGATE and adds all the counts up to the expected number of bytes to be transferred.
FIG. 8 illustrates a timing diagram for a write operation for multiple codewords per sector without split, in accordance with the first embodiment of the present invention. The write operation shown in FIG. 8 is the same as the one codeword per sector case except CH_RDY is set to “1” with a latency of 10 bytes per additional codeword. Once RWGATE is asserted by HDC 22 after CH_RDY goes high, R/W channel 24 must write out the data in a non-stop manner. As a result, R/W channel 24 requires a longer latency and larger buffer to handle the multiple codewords per sector case. In addition, HDC should continuously transfer data to R/W channel in order to avoid buffer underflow. If buffer underflow happens, the write operation may fail.
FIG. 9 illustrates a timing diagram for a write operation for multiple codewords per sector with multiple splits, in accordance with the first embodiment of the present invention. This write operation is the same as the write operation of the one codeword per sector with one split case except the first CH_RDY comes later due to the requirement of R/W channel 24 relating to buffer underflow.
FIG. 10 illustrates a timing diagram for a read operation for a single codeword per sector without split, in accordance with the first embodiment of the present invention. At the beginning of each RWGATE assertion, sector control information such as sector type, read counter value and codeword size are sent by HDC 22 via SCD pin. After R/W channel 24 finishes decoding and HDC_RDY is set to “1”, R/W channel 24 starts to send the user data to HDC 22 via NRZ data bus along with DATA_VALID which is set to “1”.
FIG. 11 illustrates a timing diagram for a read operation for a single codeword per sector with split in accordance with the first embodiment of the present invention. In FIG. 11 , consecutive read operations of 1 codeword per sector with split are performed. At the beginning of each RWGATE assertion, sector control information such as sector type, read counter value and codeword size are sent by HDC 22 via SCD pin. After collecting the first-split and the last-split sectors, R/W channel 24 merges the two split sectors and then transfers the decoded data to HDC 22 via NRZ data bus.
FIG. 12 illustrates a timing diagram for a read operation for multiple codewords per sector without split, in accordance with the first embodiment of the present invention. HDC 22 uses SCD pin to send the sector control information to R/W channel 24 . As soon as R/W channel 24 finishes decoding one codeword, R/W channel 24 asserts DATA_VALID and transfers the user data to HDC 22 via NRZ data bus. If HDC_RDY is not set to “1” for a long period of time after RWGATE assertion, R/W channel 24 buffer may overflow.
FIG. 13 illustrates a timing diagram for a read operation for multiple codewords per sector with multiple splits. R/W channel 24 operates similarly as in the single codeword per sector with split case in accordance with the first embodiment of the present invention. HDC 22 sends the sector control data information via SCD pin at the beginning of each RWGATE. In this read operation, the first codeword is being split into the first two RWGATE's. After R/W channel 24 collects the first completed codeword and completes iterative decoding, it starts sending the decoded user data to HDC 22 along with DATA_VALID which is set to “1” provided that HDC_RDY is set to “1”. However, if the gap between the split sector is too far apart, R/W channel 24 buffer may underflow. If underflow happens, R/W channel 24 deasserts DATA_VALID although HDC_RDY is still set to “1”. On the other hand, if HDC_RDY is set to “0” and RWGATE is continuously asserted, R/W channel 24 may overflow and force BUF_FULL to “1”.
Second Embodiment
FIG. 14 illustrates a second embodiment of the present invention. The second embodiment is similar to the first embodiment with the following differences, the second embodiment does not have the SCD signal and associated circuitry, the second embodiment has an additional one RCLK cycle drop on RWGATE during a read operation. Moreover, in the second embodiment there is an insertion of an SF_HEADER signal by HDC 22 ′ before each user data stream or split data stream, and an insertion of an END_SECTOR signal by HDC 22 ′ at the end of each data stream. In the second embodiment there is a restriction of codeword size modifications through a regular 3-bit serial interface. A more detailed discussion is provided hereinbelow.
Each of HDC 22 ′ and the R/W channel 24 ′ include appropriate circuitry for transmitting and receiving the various signals, data and mode selection information between the two hardware components. For example, HDC 22 ′ includes a R/W transmit circuit 60 ′ that transmits the R/W signal to R/W receiver circuit 32 ′ on R/W channel 24 ′, a data valid transceiver circuit 64 ′ that transmits the DATA_VALID signal to and receives the DATA_VALID signal from a data valid transceiver circuit 36 ′ on R/W channel 24 ′. A ready transceiver 66 ′ is provided in HDC 22 ′ to transmit HDC_RDY signal to and receive RC_RDY signal from a ready transceiver circuit 38 ′ on R/W channel 24 ′. HDC 22 ′ also comprises a RWGATE transmit circuit 68 ′ which transmits the RWGATE signal to RWGATE receive circuit 40 ′ of R/W channel 24 ′. HDC 22 ′ also includes a write clock transmit circuit 74 ′ to transmit the WCLK signal to write clock receive circuit 46 ′ on R/W channel 24 ′. HDC 22 ′ comprises a SM transceiver 76 ′ which transmits the SM_DET or SM_ST signal to and receives the SM_DET or SM_ST signal from the SM transceiver 48 ′ on R/W channel 24 ′. HDC 22 ′ and R/W channel 24 ′ comprise respective NRZ transceivers 78 ‘and 50 ’, respectively, for exchanging NRZ data and serial transceivers 82 ′ and 54 ′ respectively for exchanging serial data. R/W channel 24 ′ comprises a buffer full transmit circuit 34 ′ to transmit the BUF_FULL signal to a buffer full receive circuit 62 ′ on HDC 22 ′, a receive clock transmit circuit 44 ′ to transmit RCLK signal to a receive clock receive circuit 72 ′ on HDC 22 ′.
As noted above, signal and data transmitting, receiving and transceiving circuits are generally known, and based on the teachings provided herein, one skilled in the art would be able to construct and implement transmitting and receiving circuits to carry out the specific signaling protocol described herein.
The interface 20 ′ of the second embodiment provides for multiple-sector read and write delays; one codeword size per drive (preferred but not limited to); multiple splits per sector; maximum one split per codeword; and data recovery between first sync mark and second sync mark. The second embodiment is similar to the first embodiment except that there is no SCD signal and more functionality is provided by the RWGATE signal. In terms of pin count, second embodiment requires one fewer pins than first embodiment. In comparison to the conventional interface between an HDC and an R/W channel, the second embodiment has additional 3 pins to make the data transfer operations occur stepwise as explained below.
During a write operation, HDC 22 ′ transfers a block of user data to the R/W channel 24 ′ through the 9-bit NRZ data bus for encoding before it asserts the RWGATE signal. HDC 22 ′ waits for the R/W channel 24 ′ to signal the end of the encoding process and then it asserts the RWGATE signal to flush out the data inside the R/W channel buffer.
During a read operation, HDC 22 ′ asserts the RWGATE signal first to allow the R/W channel 24 ′ to read data for iterative decoding. After the R/W channel 24 ′ completes the decoding process and HDC_RDY is set to one, the R/W channel 24 ′ transfers the user data to HDC 22 ′″ through the 9-bit NRZ data bus.
The four additional signals for this two-step process during the read and write operations are R/W_, BUF_FULL, DATA_VALID, and HDC_RDY/RC_RDY. A detailed description of these pins is listed in the Table 2 below.
Signal
Type
Description
RW
Input to
0: = Write operation.
R/W
1: = Read operation.
channel
Alternatively, this signal can be replaced by internal
24′
register programming through the regular 3-bit
Serial Interface.
BUF —
Output
Indicates channel internal buffer is almost full. Once
FULL
from
it goes high, only 8 more bytes of data can be
R/W
transferred. During a write operation, if BUF —
channel
FULL goes high, HDC 22′ either asserts the
24′
RWGATE to flush out the data inside the R/W
channel 24′ buffer or resets the R/W channel 24′.
Otherwise, the R/W channel 24′ will continue to
wait. During a read operation, BUF_FULL goes
high only when HDC 22′ is not ready for data
transfer and RWGATE stays high. HDC 22′ will
either assert HDC_RDY signal or reset the R/W
channel 24′.
DATA —
bi-
During a write operation, DATA_VALID is an
VALID
direc-
input signal to R/W channel 24′ and DATA —
tional
VALID indicates the 9-bit NRZ data bus is valid
when DATA_VALID goes high. Therefore, R/W
channel 24′ can latch the data from the bus correctly
at the rising edge of WCLK. During a read
operation, DATA_VALID is an output signal and
DATA_VALID indicates the 9-bit NRZ data bus is
valid when it goes high. Therefore, HDC 22′ can
latch the data from the bus correctly at the rising
edge of RCLK.
RC_RDY
bi-
During a write operation, RC_RDY is an output
or HDC —
direc-
from R/W channel 24′. RC_RDY goes high when
RDY
tional
the R/W channel 24′ is ready for HDC 22′ to assert
RWGATE. During a read operation, HDC_RDY is
an input signal to R/W channel 24′. HDC_RDY
goes high when HDC 22′ is ready for the R/W
channel 24′ to assert DATA_VALID.
RWGATE
Input to
RW = 0, RWGATE = WGATE
R/W
channel
RW = 1, RWGATE = RGATE
24′
For a read operation, the codeword size is
previously programmed into a R/W channel 24′
internal control register through the regular 3-bit
serial interface. HDC 22′ asserts RWGATE as a
normal RGATE. HDC 22′ starts counting RCLK
cycles when it detects the SM_DET. When HDC
22″′ counter value is equal to the number of
expected read bytes (written in HDC 22″′ table),
one RCLK cycle is dropped on the RWGATE. The
number of RCLK cycles between the SM_DET
pulse and the one RCLK cycle drop of RWGATE is
used to determine the read byte length expected
from this RWGATE. At this point, HDC 22′ sends
the byte length to R/W channel 24′.
RCLK
Output
Constant width equal to 8 times the R/W channel
from
24′ bit clock.
R/W
channel
24′
WCLK
Input to
Same clock frequency as RCLK but different phase.
R/W
channel
24′
SM_DET
Output
During a read operation, SM_DET is asserted by
from
the R/W channel 24′ to indicate that Sync Mark is
R/W
found after RWGATE is asserted.
channel
24′
NRZ[8:0]
bi-
During a write operation, NRZ [8:0] are inputs to
direc-
R/W channel 24′. NRZ [8] is the parity bit and NRZ
tional
[7:0] is either the SF_HEADER or the user data
(including permuted ECC/RLL). The number of
00hex in the SF_HEADER determines the actual
length of the sync field written into the disk after
RWGATE is asserted. Sync Mark is auto-inserted
after the sync field during the assertion of
RWGATE for write operation. The format of SF —
HEADER is {FF,FF,FF,FF,00,00, . . . ,00,00,FF,
FF,FF,FF}. At the end of each data stream per
sector, HDC 22′ inserts the END_SECTOR pattern
to indicate the end of the data stream for this sector.
The format of the END_SECTOR is {EF,EF,00,00,
00,00,EF,EF}. HDC 22′ ensures that the user data is
in an 8-bit format. If the last user data is less than 8
bits, HDC 22′ pads the data up to 8 bits. During a
read operation, NRZ [8:0] are output from R/W
channel 24′. NRZ [8] is a multi-purpose bit and
NRZ [7:0] is the read-back user data.
Control Data Transfer
Since the second embodiment does not have the SCD signal, HDC 22 ′ does not transfer various control information (codeword size, read/write length counter and split sector size) on the fly. Each time HDC 22 ′ wants to use a different codeword size for each read and write operation, HDC 22 ′ must set up the internal registers of R/W channel 24 ′ apriori through the regular 3-bit serial interface. This would normally slow down read and write operations, however in order to avoid this problem, it is assume the second embodiment will use one codeword size per drive application. The codeword size is provided at power up from HDC 22 ′ to the registers of R/W channel 24 ′ through the regular 3-bit serial interface. The following sections discuss read/write length counter and split sector size information during write and read operations.
Write Operation Control Data Transfer
Additionally referring to FIGS. 23 and 24 , for a write operation, the DATA_VALID is used as a qualifying signal for the NRZ[8:0] bus. For each data stream, HDC 24 ′ sends an SF_HEADER before each user data stream. In the case of a split inside the user data stream, HDC 24 ′ also sends another SF_HEADER in front of each split. Each SF_HEADER consists of 4 bytes FF, followed by N bytes of 00 and then 4 bytes of FF where N has a value of 4 to 32. N is used to indicate the total number of sync fields written to the disk for each RWGATE. The number of bytes received between the SF_HEADER and the END_SECTOR is the total number of bytes expected to write to the disk for a given RWGATE (See FIG. 23 ). Each END_SECTOR is equal to {EF,EF,00,00,00,00,EF,EF}. R/W channel 24 ′ has an internal parser. 84 ′ (see FIG. 14 ) for SF_HEADER, user data and the END_SECTOR. This enables the channel to extract write length counter and sector size information.
In the case of a split sector, write length counter and split sector size can be extracted if HDC 22 ′″ provides the data format, as shown in FIG. 24 .
Read Operation Control Data Transfer
For a read operation, HDC 22 ′ asserts RWGATE as a normal RGATE. HDC 22 ′ starts counting RCLK cycles when R/W channel 24 ′ detects the SM_DET. When HDC 22 ′ counter value is equal to the number of expected read bytes (written in HDC 22 ′ table), one RCLK cycle is dropped on the RWGATE. The number of RCLK cycles between the SM_DET pulse and the one RCLK cycle drop of RWGATE is used to determine the read byte length expected from this RWGATE. At this point, HDC 22 ′ sends the byte length to the R/W channel 24 ′, as explained in detail herein below.
FIG. 15 is a timing diagram of a write operation of a single codeword per sector without a split. The R/W channel 24 ′ receives the sector control information from the data stream which is parsed internally, as discussed in above. When the DATA_VALID signal is asserted, the data stream on the NRZ bus is qualified. As mentioned previously, the codeword size information for this sector is obtained from the internal R/W channel registers, which were previously programmed, such as, during initialization or power up.
After R/W channel 24 ′ finishes the iterative encoding, CH_RDY is asserted by R/W channel 24 ′ to indicate readiness to transfer the encoded data. Then HDC 22 ′ asserts RWGATE. The R/W channel 24 ′ first sends out the Sync Field pattern and then the Sync Mark pattern. The length of the Sync Field pattern is obtained from internal registers after the data stream passes through parser 84 ′. At the end of RWGATE drop, one to four bytes of Write pad data is sent to the preamp (not shown).
FIG. 16 is a timing diagram of a write operation of a single codeword per sector with 1 split. Firstly, the entire codeword of user data is transferred to R/W channel 24 ′. HDC 22 ′ uses DATA_VALID to qualify the NRZ data bus. After DATA_VALID assertion, R/W channel 24 ′ obtains various sector control data through parser 84 ′.
FIG. 17 is a timing diagram of a write operation having multiple codewords per sector without any splits. This write operation is the same as the write operation for a single codeword per sector case except CH_RDY is set to ‘1’ having a latency of 10 bytes per additional codeword. Once RWGATE is asserted by HDC 22 ′ after CH_RDY goes high, R/W channel 24 ′ writes out the data continuously. Therefore, the R/W channel 24 ′ has a longer latency and larger buffer to handle the multiple-codeword-per-sector case. In addition, HDC 22 ′ continuously transfers data to the R/W channel 24 ′ in order to avoid buffer underflow. If buffer underflow occurs, the write operation may fail.
FIG. 18 is a timing diagram of a write operation having multiple codewords per sector with multiple splits. This write operation is the same as the write operation for a single codeword per sector with one split case except the first CH_RDY comes later due to the R/W channel's buffer underflow requirement.
FIG. 19 is a timing diagram of consecutive operations of a single codeword per sector without a split. The codeword size was previously programmed into a R/W channel's internal control register through the 3-bit serial interface. HDC 22 ′ asserts RWGATE as a normal RGATE. HDC 22 ′ starts counting RCLK cycles when HDC 22 ′ detects the SM_DET. When HDC 22 ′″ counter value is equal to the number of expected read bytes (written in HDC 22 ′″ table), one RCLK cycle is dropped on the RWGATE. The number of RCLK cycles between the SM_DET pulse and the one RCLK cycle drop of RWGATE is used to determine the read byte length expected from this RWGATE. At this point, HDC 22 ′ sends the byte length to R/W channel 24 ′.
After R/W channel 24 ′ completes decoding and HDC_RDY is set to ‘1’, R/W channel 24 ′ starts to send the user data to HDC 22 ′″ via the NRZ data bus. DATA_VALID must also be asserted.
FIG. 20 is a timing diagram of consecutive operations of a single codeword per sector with a split. After collecting the first-split and the last-split sectors, R/W channel 24 ′ merges the two split sectors and then transfers the decoded data to HDC 22 ′ via the NRZ data bus.
FIG. 21 is a timing diagram of a read operation of multiple codewords per sector without a split. The codeword size was previously programmed into a R/W channel internal control register through the 3-bit serial interface. HDC 22 ′ asserts RWGATE as a normal RGATE. HDC 22 ′ starts counting RCLK cycles when HDC 22 ′ detects the SM_DET. When HDC 22 ′″ counter value is equal to the number of expected read bytes (written in HDC 22 ′″ table), one RCLK cycle is dropped on the RWGATE. The number of RCLK cycles between the SM_DET pulse and the one RCLK cycle drop of RWGATE is used to determine the read byte length expected from this RWGATE. At this point, HDC 22 ′ sends the byte length to R/W channel 24 ′.
As soon as the R/W channel 24 ′ completes decoding one codeword, R/W channel 24 ′ asserts DATA_VALID and transfers the user data to HDC 22 ′ via the NRZ data bus. If HDC_RDY is not set to ‘1’ after a fixed time RWGATE is not asserted and the R/W channel buffer will continue to read the data from the media. Consequently, the R/W channel buffer may experience overflow.
FIG. 22 is a timing diagram of a read operation of multiple codewords per sector with multiple splits. In this read operation, the first codeword is divided into two RWGATEs. After R/W channel 24 ′ collects the first completed codeword and completes iterative decoding, R/W channel 24 ′. starts sending the decoded user data to HDC 22 ′. The DATA_VALID is set to ‘1’ and HDC_RDY is set to ‘1’. However, if the gap between the split sector is too large, the R/W channel buffer may underflow. If underflow occurs, R/W channel 24 ′ drops DATA_VALID even if HDC_RDY is still set to ‘1’. On the other hand, if HDC_RDY is set to ‘0’ and RWGATE is continuously asserted, R/W channel 24 ′ may overflow and force BUF_FULL to ‘1’.
Third Embodiment
FIG. 25 illustrates a third embodiment of the present invention. The third embodiment is similar to the first embodiment with the following differences, the third embodiment does not have the SCD signal and associated circuitry, the third embodiment does not have a CH_RDY/HDC_RDY pin and associated circuitry, the third embodiment has fault condition handling, the third embodiment has the option to use a register to set the sync field size. In the third embodiment RCLK is not required to equal 8 times the channel clock, the third embodiment provides for the use of the register to set the write padding data length. The third embodiment does not require the passing of the write length counter information, and third embodiment provides for indirect passing of the read length counter information by RWGATE and the third embodiment provides for restriction of codeword size modifications through a standard 3-bit serial interface. A more detailed discussion is provided hereinbelow.
Referring again to FIG. 25 , each of HDC 22 ″ and the R/W channel 24 ″ includes appropriate circuitry for transmitting and receiving the various signals, data and mode selection information between the two hardware components. For example, HDC 22 ″ includes a R/W transmit circuit 60 ″ that transmits the R/W signal to R/W receiver circuit 32 ″ on R/W channel 24 ″, a data valid transceiver circuit 64 ″ that transmits the DATA_VALID signal to and receives the DATA_VALID signal from a data valid transceiver circuit 36 ″ on R/W channel 24 ″. A read reset transceiver 164 is provided in HDC 22 ″ to transmit the RD_RST signal to and receive the WRT_FAULT signal from a write fault transceiver circuit 138 on R/W channel 24 ′. HDC 22 ″ also comprises a RWGATE transmit circuit 68 ″ which transmits the RWGATE signal to RWGATE receive circuit 40 ″ of R/W channel 24 ′. HDC 22 ″ also includes a write clock transmit circuit 74 ″ to transmit the WCLK signal to write clock receive circuit 46 ″ on R/W channel 24 ″. HDC 22 ″ comprises a SM_DET transceiver 76 ″ which transmits the SM_DET signal to and receives the SF_ST signal from the SF_ST transceiver 48 ″ on R/W channel 24 ″. HDC 22 ″ and R/W channel 24 ″ comprise respective NRZ transceivers 78 ″ and 50 ″, respectively, for exchanging NRZ data and serial transceivers 82 ″ and 54 ″ respectively for exchanging serial data. R/W channel 24 ″ comprises a receive clock transmit circuit 44 ″ to transmit RCLK signal to a receive clock receive circuit 72 ″ on HDC 22 ′.
As noted above, signal and data transmitting, receiving and transceiving circuits are generally known, and based on the teachings provided herein, one skilled in the art would be able to construct and implement transmitting and receiving circuits to carry out the specific signaling protocol described herein.
The interface 20 ″ of the third embodiment provides for multiple-sector read and write delays; one codeword size per drive (preferred but not limited to); multiple splits per sector; maximum one split per codeword; and data recovery between first sync mark and third sync mark.
During a write operation, HDC 22 ′″ first transfers a block of user data to the Read Channel (RC) through the 9-bit NRZ data bus for encoding. The 9-bit NRZ data is qualified with the DATA_VALID signal throughout the transfer. When the DATA_VALID signal is set to 1, the 9-bit NRZ data is considered to be valid data, ready for R/W CHANNEL 24 ′″ to latch into its working buffer. HDC 22 ′″ then waits for a fixed delay prior before asserting RWGATE (which can occur any time after the fixed delay) to flush out the encoded data inside R/W channel 24 ′″ buffer. The fixed delay, which is calculated from the assertion of the DATA_VALID signal, is required for R/W channel 24 ′″ to finish encoding one codeword.
During a read operation, HDC 22 ″ asserts RWGATE to allow R/W channel 24 ″ to read data for iterative decoding. As soon as one codeword is completely decoded, R/W channel 24 ″ transfers the decoded data through the 9-bit NRZ data bus to HDC 24 ″. The 9-bit NRZ data is qualified with the DATA_VALID signal throughout the transfer. When the DATA_VALID signal is set to 1, the 9-bit NRZ data is considered to be valid, ready for HDC 24 ″ to latch in.
The third embodiment comprises the following three signals for a two-step process during read and write operations:
R/W_;
DATA_VALID; and
WRT_FAULT/RD_RST
Since the RGATE and WGATE signals are combined into one RWGATE signal, only two pins are effectively added. A detailed description of these signals is provided in Table 3 below.
TABLE 3
Signal
Type
Description
RW
Input to R/W
0: = Write operation.
channel 24″
1: = Read operation.
This signal may be replaced by internal register programming through the standard 3-bit
serial interface.
DATA —
Bi-
During a write operation, DATA_VALID is an input signal and indicates that the 9-bit NRZ
VALID
directional
data bus is valid when it goes high. Therefore, R/W channel 24″ can latch the valid data from
the bus at the rising edge of WCLK
During a read operation, DATA_VALID is an output signal and indicates the 9-bit NRZ data
bus is valid when it goes high. Therefore, HDC 22″′ can latch the valid data from the bus at
the rising edge of RCLK.
WRT —
Bi-
During a write operation, WRT_FAULT is asserted from R/W channel 24″′ to HDC if there is
FAULT or
directional
an overflow on the internal data buffer, in which case HDC 22″′ must redo the write
RD_RST
operation for the previous sector.
During a read operation, RD_RST is asserted from HDC 22″′ to R/W channel 24″′ under the
following conditions:
As soon as R/W channel 24″′ completes decoding one codeword, it sends the user data to
HDC 22″′ without any knowledge of HDC 22″′ status. If HDC 22″′ is not ready to accept
the user data, HDC 22″′ should issue an RD_RST (minimum of five RCLK cycles) to
R/W channel 24″′ and redo the read operation.
If HDC 22″′ receives more or less data than it expected, it issues an RD_RST (minimum
of five RCLK cycles) to R/W channel 24″′ and redo the read operation.
RWGATE
Input to R/W
RW = 0, RWGATE = WGATE
channel 24″
RW = 1, RWGATE = RGATE
For a read operation, the codeword size is previously programmed into R/W channel 24″′
internal control register through the standard 3-bit serial interface. HDC 22″ asserts
RWGATE as a normal RGATE. HDC 22″ starts counting RCLK cycles when it detects
SM_DET. When HDC 22″′ counter value is equal to the number of expected read bytes
(which is stored in HDC 22″′ table), RWGATE is deasserted. The number of RCLK cycles
between the SM_DET pulse and the deassertion of RWGATE is used to determine the read
byte length expected from this RWGATE. At this point, HDC 22″′ indirectly sends the byte
length to R/W channel 24″.
RCLK
Output from
Most of the time, this is equal to 8 × channel clock. During the assertion of RWGATE, a
R/W channel
dynamic clock insertion occurs after the sync mark is found for a read operation. During a
24″
write operation, a dynamic clock insertion occurs after sending out the sync mark pattern to
the preamp.
WCLK
Input to R/W
Same clock frequency as RCLK, but different phase.
channel 24″
SM_ST
Bi-
During a write operation, if the USE_SM_ST bit is set to 1, SM_ST is used to indicate the
or
directional
start of the insertion of a sync mark. Otherwise, the insertion of a sync mark is controlled by
SM_DET
an internal register.
During a read operation SM_DET is asserted by R/W channel 24″ to indicate that a sync
mark was found after RWGATE was asserted.
NRZ[8:0]
Bi-
During a write operation, NRZ [8:0] are used as inputs. NRZ [8] is the parity bit, and NRZ
directional
[7:0] is the user data (including permuted ECC/RLL). HDC 22′ is also responsible for
ensuring that the user data is in an 8-bit format. If the last user data is less than 8 bits, it
should be padded up to 8 bits.
During a read operation, NRZ [8:0] are used as outputs. NRZ [8] is a multi-purpose bit, and
NRZ [7:0] is the user data.
Since the third embodiment does not utilize an SCD pin, as in the first embodiment, HDC 22 ″ does not transfer various control information (codeword size, read/write length counter, and split sector size) on the fly. Each time HDC 22 ″ wants to use a different codeword size for each read and write operation, HDC 22 ″ must set up R/W channel 24 ′″ internal registers ahead of time through the standard 3-bit serial interface.
In traditional arrangement read and write operations would normally slow down. However, in accordance with the third embodiment one codeword size per drive application is used to avoid this problem. The codeword size is provided at power-up from HDC 22 ″ to R/W channel 24 ″ registers through the standard 3-bit serial interface.
Fault Condition
The third embodiment requires two steps for each read and write operation.
During a write operation, a block of user data from HDC 22 ″ is transferred to R/W channel 24 ″ for encoding. HDC 22 ″ then asserts RWGATE to flush out the encoded data from R/W channel 24 ″. During a read operation, HDC 22 ″ asserts RWGATE to read in a block of encoded data into R/W channel 24 ″.
After R/W channel 24 ″ completes the iterative decoding process, the block of user data is transferred back to HDC 22 ″. In this mode R/W channel 24 ″ is in a slave mode relative to HDC 22 ″. If HDC 22 ″ fails to follow the proper two-step process for each read and write operation, a fault condition could occur in R/W channel 24 ″.
The following describes the fault handling for each read and write operation.
Write Fault Handling
One Codeword per Sector
The two-step process for a write operation is as follows:
One codeword size of user data is transferred from HDC 22 ″ to R/W channel 24 ″ for encoding.
HDC 22 ″ asserts RWGATE to flush out encoded data from R/W channel 24 ″.
Under abnormal conditions, if HDC 22 ′″ transfers another single codeword size of user data prior to asserting RWGATE to flush out the previous encoded data, a fault condition occurs. R/W channel 24 ′″ either asserts the WRT_FAULT signal or replaces the current working buffer data with the new user data. The response of R/W channel 24 ″ depends on the register bit setting. If WRT_FAULT is asserted, HDC 22 ″ is responsible for resetting RC 24 ″ through the standard 3-bit serial interface and the write operation performed again. If R/W channel 24 ″ replaces the new encoded data with the current encoded data, HDC 22 ″ can resume step 2 to flush out the encoded data inside RC 24 ″ working buffer.
Multiple Codewords per Sector
The two-step process for a write operation is as follows:
Transfer one codeword size of user data from HDC 22 ″ to R/W channel 24 ″ for encoding.
HDC 22 ″ asserts RWGATE to flush out encoded data from R/W channel 24 ″.
Under abnormal conditions, if HDC 22 ″ does not assert RWGATE for a prolonged period of time, an overflow occurs (because the working buffer is only a limited size). When an overflow occurs in the working buffer for a write operation, R/W channel 24 ″ asserts WRT_FAULT. If WRT_FAULT is asserted HDC 22 ″ is responsible for resetting R/W channel 24 ″ through the standard 3-bit serial interface and the write operation is performed again.
Read Fault Handling
One or Multiple Codewords per Sector
The two-step process for a read operation is as follows:
HDC 22 ″ asserts RWGATE to read in a block of encoded data into R/W channel 24 ″.
User data block is transferred back to HDC 22 ″ after R/W channel 24 ″ completes iterative decoding process.
Since R/W channel 24 ″ has no knowledge of whether HDC 22 ″ is ready to accept decoded data, HDC 22 ″ asserts the RD_RST signal (for a minimum of five RCLK cycles) to reset R/W channel 24 ″ and retry the read operation sequence for the previous sector.
Single Codeword per Sector without Split
In FIG. 26 , a write operation of one codeword per sector without a split is performed. When the DATA_VALID signal is asserted, the data stream on the NRZ bus is qualified. The codeword size information for this sector is obtained from internal R/W channel registers, which are programmed, for example, at the beginning of a power-up.
After R/W channel 24 ″ completes the iterative encoding (it waits for a fixed delay period), HDC 22 ″ asserts RWGATE. R/W channel 24 ″ first sends out the sync field pattern, then the sync mark pattern. The length of the sync field pattern is obtained from internal registers or by detecting the assertion of SM_ST. At the end of the RWGATE drop, one to four bytes of write pad data is sent to the preamp. The gap between two consecutive DATA_VALID signals are larger than the sum of the Sync Field Size (SF), the Sync Mark Size (SM) and the Padding Data Size (PM).
Single Codeword per Sector with Split
In FIG. 27 , a write operation of one codeword per sector with one split is performed. First, the entire codeword of user data must be transferred to R/W channel 24 ″ for encoding. When the DATA_VALID signal is asserted, the data stream on the NRZ bus is qualified. The codeword size information for this sector is obtained from internal R/W channel registers, which are programmed at the beginning of a power-up.
After R/W channel 24 ″ completes the iterative encoding (it waits for a fixed delay period), HDC 22 ″ asserts RWGATE. R/W channel 24 ″ first sends out the sync field pattern, then the sync mark pattern. The length of the sync field pattern is obtained from internal registers or by detecting the assertion of SM_ST. At the end of the deassertion of RWGATE, one to four bytes of write pad data is sent to the preamp. Since RWGATE is asserted twice for one codeword, the gap between two consecutive DATA_VALID pulses must be larger than 2(SF+SM+PF).
Multiple Codewords per Sector without Split
FIG. 28 illustrates a write operation of multiple codewords per sector without splits being performed. Because a clock insertion is ongoing after a sync mark is inserted there is no difference between one codeword per sector without split and multiple codewords per sector without split. The fixed delay is substantially identical for both cases.
Multiple Codewords per Sector with Multiple Splits
In FIG. 29 , a write operation of multiple codewords per sector with multiple splits is performed. It is similar to one codeword per sector with one split except that the minimum gap between two consecutive DATA_VALID pulses is equal to NUMBER_OF_SPLIT×(SF+SM+PM). The WRT_FAULT signal is asserted by R/W channel 24 ″ if the working buffer overflows, which can occur when the gap between successive RWGATEs exceeds the amount that R/W channel 24 ′″ buffer can accept.
Single Codeword per Sector without Split
FIG. 30 shows consecutive read operations of a single codeword per sector without a split being performed. The codeword size was previously programmed into an internal R/W channel control register through the standard 3-bit serial interface. HDC 22 ″ asserts RWGATE as a normal RGATE. HDC 22 ″ starts counting RCLK cycles when it detects SM_DET. When HDC 22 ′″ counter value equals the number of expected read bytes (as stored in HDC 22 ′″ table), RWGATE is deasserted. The number of RCLK cycles between the SM_DET pulse and the deassertion of RWGATE is used to determine the read byte length expected from this RWGATE. At this point, HDC 22 ′″ indirectly sends the byte length to R/W channel 24 ″. After R/W channel 24 ″ completes decoding, R/W channel 24 ″ starts to send the user data to HDC 22 ″ via the NRZ data bus.
Single Codeword per Sector with Split
In FIG. 31 , consecutive read operations of one codeword per sector with a split are performed. After collecting the first- and last-split sectors, R/W channel 24 ″ merges the two split sectors and transfers the decoded data to HDC 22 ″ via the NRZ data bus.
Multiple Codewords per Sector without Split
FIG. 32 illustrates a read operation of multiple codewords per sector without a split being performed. The codeword size was previously programmed into an internal R/W channel control register through the standard 3-bit serial interface. HDC 22 ″ asserts. RWGATE as a normal RGATE. HDC 22 ″ starts counting RCLK cycles when it detects SM_DET. When HDC 22 ′″ counter value equals the number of expected read bytes (as stored in HDC 22 ′″ table), RWGATE is then deasserted. The number of RCLK cycles between the SM_DET pulse and the deassertion of RWGATE is used to determine the read byte length expected from this RWGATE. At this point, HDC 22 ″ indirectly sends the byte length to R/W channel 24 ″. As soon as R/W channel 24 ″ completes decoding one codeword, it asserts DATA_VALID and transfers the user data to HDC 22 ′″ via the NRZ data bus.
Multiple Codewords per Sector with Multiple Splits
In FIG. 33 , a read operation with multiple codewords per sector with multiple splits is performed. In this case, the first codeword is divided into two RWGATEs. After R/W channel 24 ″ collects the first completed codeword and completes iterative decoding, it begins sending the decoded user data to HDC 22 ″ and the DATA_VALID must be set to 1.
Fourth Embodiment
FIG. 34 is illustrative of the fourth embodiment which is a subset of the first embodiment and provides for multiple-sector read and write delays, one codeword size per drive (preferred but not limited), multiple splits per sector, maximum one split per codeword, data recovery between first sync mark and second sync mark, fault handling, and synchronize read and write operation.
Referring again to FIG. 34 , each of HDC 22 ′″ and the R/W channel 24 ′″ includes appropriate circuitry for transmitting and receiving the various signals, data and mode selection information between the two hardware components. For example, HDC 22 ′″ includes a R/W transmit circuit 60 ′″ that transmits the R/W signal to R/W receiver circuit 32 ′″ on R/W channel 24 ′″, a data valid transceiver circuit 64 ′″ that transmits the DATA_VALID signal to and receives the DATA_VALID signal from a data valid transceiver circuit 36 ′″ on R/W channel 24 ′″. A DATA_FAULT receiver 164 ′″ is provided in HDC 22 ′″ to receive the DATA_FAULT signal to from DATA_FAULT transmit circuit 138 ′″ on R/W channel 24 ′″. HDC 22 ′″ also comprises a RWGATE transmit circuit 68 ′″ which transmits the RWGATE signal to RWGATE receive circuit 40 ′″ of R/W channel 24 ′″. HDC 22 ′″ also includes a write clock transmit circuit 74 ′″ to transmit the WCLK signal to write clock receive circuit 46 ′″ on R/W channel 24 ′″. HDC 22 ′″ comprises a SM_DET receiver 76 ′″ which receives the SM_DET signal from the SM_DET transmitter 48 ′″ on R/W channel 24 ′″. HDC 22 ′″ and R/W channel 24 ′″ comprise respective NRZ transceivers 78 ′″ and 50 ′″, respectively, for exchanging NRZ data and serial transceivers 82 ′″ and 54 ′″ respectively for exchanging serial data. R/W channel 24 ′″ comprises a receive clock transmit circuit 44 ′″ to transmit RCLK signal to a receive clock receive circuit 72 ′″ on HDC 22 ′″. HDC 22 ′″ includes a data valid transceiver circuit 64 ′″ that transmits a parity signal to and receives the parity signal from a parity transceiver circuit 36 ′″ on R/W channel 24 ′″. R/W channel 24 ′″ comprises a EXT_WGATE transmitter 384 ′″ to generate the EXT_WGATE to control a preamplifier (not shown). When EXT_WGATE is asserted the preamplifier is set to write data onto the media, when deasserted data can be read from the media.
A detailed description of these signals is provided in Table 4 below.
TABLE 4
R/W channel 24″′ Signal Definition
Signal
Type
Description
R/W —
Input to R/W
0: = Write operation.
channel 24″′
1: = Read operation.
Alternatively, this signal can be replaced by internal register programming through the
standard 3-bit serial interface.
DATA —
Bi-
During a write operation, DATA_VALID is an input signal to R/W channel 24″′ and it
VALID
directional
indicates the 8-bit NRZ data bus is valid when it is asserted. Therefore, R/W channel 24″ can
latch the data from the bus correctly at the rising edge of WCLK. When DATA_VALID is de-
asserted, R/W channel 24″′ can latch one more data from the NRZ data bus correctly.
During a read operation, DATA_VALID is an output signal from R/W channel 24″′ and it
indicates the 8-bit NRZ data bus is valid when it is asserted. Therefore, HDC 22″′ can latch
the data from the bus correctly at the rising edge of RCLK. When DATA_VALID is de-
asserted, HDC 22″′ can latch one more data from the NRZ data bus correctly.
DATA —
Output from
DATA_FAULT is an output signal from R/W channel 24″′ that is used to indicate an
FAULT
R/W channel
abnormal transaction happen between HDC 22″′ and R/W channel 24″′. When
24″′
DATA_FAULT is asserted by R/W channel 24″′, HDC 22″′ reads the DATA_FAULT_REG
through the 3-bit regular serial register to find out what cause the fault. After reading the
DATA_FAULT_REG, the DATA_FAULT_REG will automatic clear itself and the
DATA_FAULT is de-asserted.
List of fault conditions:
(1) R/W channel Encoder buffer overflow
(2) R/W channel Encoder buffer underfiow
(3) Boundary codeword check fail for DATA_VALID during Write operation
(4) Boundary codeword check fail for RWGATE during Write operation
(5) Boundary codeword check fail for RWGATE during Read operation
(6) Boundary codeword check fail during merger the split sector in Read operation
(7) Parity Error
RWGATE
Input to R/W
RWGATE is always synchronized with WCLK. The total number of WCLKS elapsed during
channel 24″′
the assertion of RWGATE is equal to total number of bytes of data expected to be written or
read during this assertion of RWGATE. During a write operation, the RWGATE is asserted
as a conventional WGATE except the duration of this assertion is only equal to the actual
data length in terms of WCLK During the read operation, the RWGATE is asserted as a
conventional RGATE except the duration of this assertion is only equal to the actual data
length in terms of WCLK.
RCLK
Output from
Most of the time, RCLK is either 8 × channel clock or 10 × channel clock (i.e. 888888810).
R/W channel
24″′
During write operations, another level of dynamic clock insertion occurs after sending out
the sync mark pattern to the preamp.
During a read operation, another level of dynamic clock insertion occurs after the sync mark
is found for a read operation.
WCLK
Input to R/W
Same clock frequency as RCLK, but different phase.
channel 24″′
SM_DET
Bi-
During a read operation, one SM_DET is asserted by R/W channel 24″′ to indicate that a
directional
sync mark 1 was found after RWGATE was asserted.
During a read operation, two SM_DET is asserted by R/W channel 24″′ to indicate that a
sync mark 2 was found after RWGATE was asserted.
NRZ[7:0]
Bi-
During a write operation, NRZ [7:0] is the user data (either including permuted ECC/RLL or
directional
not) which is synchronized with WCLK.
During a read operation, NRZ [7:0] are used as outputs from R/W channel 24″′. NRZ [8] is a
multi-purpose bit, and NRZ [7:0] is the user data and it is synchronize with RCLK.
PARITY
Bi-
Parity is used as multiple function signal, one of the functions is used as parity which is
directional
generated from the NRZ[7:0] bus. During a Write operation, it is synchronized with WCLK
During a Read operation, it is synchronized with RCLK
EXT —
Output from
During the Write operation, EXT_WGATE is generated from R/W channel 24″′. Since the
WGATE
R/W channel
length of Sync Filed, Sync Mark and the padding data is pre-programmed., R/W channel 24″′
24″′
generates the EXT_WGATE from appropriately extending the RWGATE.
In accordance with the fourth embodiment, read and write operations are performed in a synchronized manner as follows.
The following is the sequence of a write operation. Firstly, HDC 22 ′″ asserts the R/W_signal to 0. HDC 22 ′″ then waits for a first predetermined time, referred to as “Fixed Delay 1 ”, and HDC 22 ′″ then asserts DATA_VALID to “1”. User data is valid on the 8-bit NRZ bus, and is latched at the rising edge of WCLK by R/W channel 24 ′″. When HDC 22 ′″ HDC 22 ′″ de-asserts DATA_VALID; one additional user data is valid on the 8-bit NRZ bus, which is latched at the rising edge of WCLK by R/W channel 24 ′″. R/W channel 24 ′″ checks the codeword boundary. If the total size of user data received by R/W channel 24 ′″ is different from the pre-programmed codeword size, R/W channel 24 ′″ asserts DATA_FAULT. Once DATA_FAULT is asserted, it can be cleared by reading the DATA_FAULT_REG through the 3-bit serial interface. After HDC 22 ′″ de-asserts DATA_VALID, HDC 22 ′″ waits for a second predetermined time, referred to as “Fixed Delay 2 ”. (i.e. a block of encoded data is stored in a working SRAM buffer of R/W channel 24 ′″)
HDC 22 ′″ positions the head over the desired track of the media. RWGATE is asserted by HDC 24 ′″, and R/W channel 24 ″ asserts the EXT_WGATE. R/W channel 24 ′″ counts the total number of WCLKs elapsed from this RWGATE to determine the total number of user data expected to be written onto the media for this write operation. In combination with the pre-programmed information of sync field (PLO), sync mark, code table and padding data, R/W channel 24 ′″ can exactly determine how to extend the EXT_WGATE. Right after the RWGATE is asserted, DATA_VALID is asserted by HDC 22 ′″. While R/W channel 24 ′″ latches the new user data at the rising edge of WLCK, R/W channel 24 ′″ provides the encoded data to the media.
After the completion of the EXT_WGATE, a new block of encoded data is stored into the buffer of R/W channel 24 ′″ and the previous stored encoded data has already been written into the media. For next write operation, HDC 22 ′″ only needs position the head on the desired media and continue from there. If HDC 22 ′″ changes from a write operation to a read operation and back to a write operation, HDC needs to start from the beginning.
The following is the sequence of a read operation.
HDC 22 ′″ assets R/W_to “1”, and HDC 22 ′″ waits for “Fixed Delay 1 ”. HDC 24 ′″ then positions the head over the desirable track. RWGATE is asserted from HDC 22 ′″, and R/W channel immediately asserts an internal RGATE. R/W channel 24 ′″ counts the total number WCLKs elapsed from this RWGATE to determine the total number of user data expected to read from the media for this read operation. RGATE is an extended version of RWGATE. In combination with the pre-programmed information of sync field, sync mark, code table and padding data, R/W channel 24 ′″ can determine how to extend the RGATE.
As soon as one codeword is completely decoded by R/W channel 24 ′″, DATA_VALID is asserted by R/W channel 24 ′″. The decoded data is sent to the 8-bit NRZ bus for HDC 22 ′″ to latch in at the rising edge of RCLK. After the de-assertion of DATA_VALID by R/W channel 24 ′″, HDC 22 ′″ latches one more decoded data on the 8-bit NRZ bus. Each time R/W channel 24 ′″ transfers only one codeword of data through the 8-bit NRZ bus. Therefore, HDC 22 ′″ checks the boundary condition every time it receives data from R/W channel 24 ′″. For another read operation, HDC 22 ′″ only needs start from the positioning the head step described above. Only when HDC 22 ′″ performs a read operation follow by a write operation and back to another read operation, HDC 22 ″ must start from the beginning.
Control Data Transfer
As compared to the first embodiment, the fourth embodiment does not have the SCD pin. As such, HDC 22 ′″ can not transfer various control information (codeword size, read/write length counter, and split sector size) on the fly. In the fourth embodiment, each time HDC 22 ′″ wants to use a different codeword size for each read and write operation, HDC 22 ′″ must set up the R/W channel internal registers in advance through the standard 3-bit serial interface.
This would normally slow down read and write operations. However, it is preferred that the fourth embodiment use one codeword size per drive application to avoid any such degraded performance. The codeword size is preferably provided at power-up from HDC 22 ′″ to the R/W channel registers through the standard 3-bit serial interface.
Fault Condition
The fourth embodiment requires two steps for each read and write operation. During a write operation, a block of user data from HDC 22 ′″ is transferred to R/W channel 24 ′″ for encoding, and HDC 22 ′″ then asserts RWGATE to flush out the encoded data from R/W channel 24 ′″. During a read operation, HDC 22 ′″ asserts RWGATE to read in a block of encoded data into R/W channel 24 ′″.
After R/W channel 24 ′″ completes the iterative decoding process, the block of user data is transferred back to HDC 22 ′″. R/W channel 24 ′″ is actually working in slave mode relative to HDC 22 ′″. If HDC 22 ′″ fails to follow the proper two-step process for each read and write operation, a fault condition could occur in R/W channel 24 ′″.
The following describes the fault handling for the read and write operations.
Write Fault Handling
One Codeword per Sector
The two-step process for a write operation is as follows:
Transfer one codeword size of user data from HDC 22 ′″ to R/W channel 24 ′″ for encoding, and HDC 22 ′″ asserts RWGATE to flush out encoded data from R/W channel 24 ′″.
If HDC 22 ′″ transfers another single codeword size of user data without asserting RWGATE to flush out the previous encoded data. It may causes the working buffer overflow, and R/W channel 24 ′″ asserts the DATA_FAULT signal.
If HDC 22 ′″ asserts the RWGATE without prior transferring any codewords to R/W channel 24 ′″ for encoding, it may cause a working buffer underflow. As a result, R/W channel 24 ′″ asserts the DATA_FAULT signal.
If DATA_FAULT is asserted, HDC 22 ′″ may read the DATA_FAULT_REG through the standard 3-bit serial interface to determine what is the cause of the DATA_FAULT. Once HDC 22 ′″ reads the DATA_FAULT_REG, the DATA_FAULT is automatically reset.
Multiple Codewords per Sector
The two-step process for a write operation is as follows:
One codeword size of user data is transferred from HDC 22 ′″ to R/W channel 24 ′″ for encoding, and HDC 22 ″ asserts RWGATE to flush out encoded data from R/W channel 24 ′″. If HDC 22 ′″ does not assert RWGATE for a prolonged period, an overflow may occur (because the working buffer has only a limited size). When an overflow occurs in the working buffer for a write operation, R/W channel 24 ′″ asserts DATA_FAULT. If DATA_FAULT is asserted, HDC 22 ′″ may read the DATA_FAULT_REG through the standard 3-bit serial interface to determine the cause or the DATA_FAULT. Once HDC 22 ′″ reads the DATA_FAULT_REG, the DATA_FAULT is automatically reset.
Boundary Condition Check
Each time when HDC 22 ′ asserts the DATA_VALID signal. The length of DATA_VALID is equal to codeword size −1 byte. If R/W channel 24 ′″ does not latch the correct number of bytes, DATA_FAULT is asserted.
Additionally, if the length of RWGATE does not end in the codeword boundary for non-split case, DATA_FAULT is asserted. In the case of a split sector, if the two consecutive combinations of RWGATE does not meet the codeword boundary condition. DATA_FAULT is asserted.
If DATA_FAULT is asserted, HDC 22 ′″ may read the DATA_FAULT_REG through the standard 3-bit serial interface to determine the cause of the DATA_FAULT. Once HDC 22 ′″ reads the DATA_FAULT_REG, the DATA_FAULT is automatically reset.
Read Fault Handling
One or Multiple Codewords per Sector
The two-step process for a read operation is as follows:
HDC 22 ′″ asserts RWGATE to read in a block of encoded data into R/W channel 24 ′″ and user data block is transferred to HDC 22 ′″ after R/W channel 24 ′″ completes iterative decoding process.
Each time R/W channel 24 ′″ sends the user data to HDC 22 ′″ in terms of one codeword size. HDC 22 ′″ checks the boundary condition for each transfer. If any error is found, HDC 22 ′″ can retry the read operation again or reset R/W channel 24 ′″ with the RW_signal.
One or Multiple Codewords per Sector with Split
During the merger of split sections of a read operation, R/W channel 24 ′″ counts the total amount of combined data. If the result is not met the boundary condition requirement, a DATA_FAULT signal is asserted.
If DATA_FAULT is asserted, HDC 22 ′″ may read the DATA_FAULT_REG through the standard 3-bit serial interface to determine the cause of the DATA_FAULT. Once HDC 22 ′″ reads the DATA_FAULT_REG, the DATA_FAULT is automatically reset.
Write Operation
Single Codeword per Sector Write Operation
FIG. 35 is a timing diagram of a single codeword per sector write operation. A write operation of one codeword per sector is performed when R/W_is set to “0” from “1” by HDC 22 ′″ which is an indication to start a write operation. After waiting for a “fixed delay 1 ” as shown in FIG. 35 , HDC 22 ′″ asserts the DATA_VALID and sends the user data “A” onto the 8-bit NRZ bus. R/W channel 24 ′″ latches each byte of user data “A” over the 8-bit NRZ bus at the rising edge of WCLK. The length of DATA_VALID should equal to (codeword size −1)*WCLK. After HDC 22 ′″ de-asserts DATA_VALID, R/W channel 24 ′″ can latch the last byte of valid data “A” from the 8-bit NRZ bus. Then a boundary codeword condition check is performed by R/W channel 24 ′″. If the total number of user data latched by R/W channel 24 ′″ is not equal to the pre-programmed codeword size, an error is found, and DATA_FAULT signal will be asserted by R/W channel 24 ′″. Otherwise, HDC 22 ′″ completes the transmission of the whole user data “A” to R/W channel 24 ′″ for encoding. The encoded data “A” is stored inside the working buffer of R/W channel 24 ′″.
After waiting for a “fixed delay 2 ”, HDC 22 ′″ positions the head over the desirable track. HDC 22 ′″ asserts the RWGATE to flush out the encoded data “A” inside the working buffer of R/W channel 24 ′″. Immediately following the assertion of RWGATE, HDC 22 ′″ asserts the DATA_VALID and transmits the user data “B” via the 8-bit NRZ bus. R/W channel 24 ′″ (1) latches each byte of user data “B” over the 8-bit NRZ bus at the rising edge of WCLK, (2) flushes out the encoded data “A” from its working buffer, and (3) asserts the EXT_WGATE concurrently. R/W channel 24 ′″ will automatically insert the PLO, Sync Mark and Padding data during the write operation for each sector. The length of the RWGATE only indicates the total number of data to be written into media for this Write operation. R/W channel 24 ′″ counts the total number of WCLKs elapsed for this RWGATE to determine how much data is written onto the media. Therefore, the length of EXT_WGATE must longer than the DATA_VALID. Before finishing writing the encoded data “A” to the media, a new encoded data “B” is stored inside the working buffer. R/W channel performs the boundary codeword condition check for data “B”. Every time when HDC 22 ′″ finishes transferring one codeword of data to R/W channel 24 ′″, a boundary codeword is performed from R/W channel 24 ′″.
When HDC 22 ′″ flushes out the encoded data inside R/W channel 24 ′″, it also sends the next user data for R/W channel 24 ′″ to be encoded. As long as HDC 22 ′″ follows this sequence, R/W channel 24 ′″ can perform back to back synchronized write operations.
In case HDC 22 ′″ switches from a write operation to a read operation, HDC 22 ′″ must flush out the pre-encoded data stored inside R/W channel 24 ′″ working buffer. When HDC 22 ′″ switches back from a read operation to a write operation, HDC 22 ′″ pre-sends one codeword data to R/W channel 24 ′″ first before performing the synchronized write operation as describe above.
FIG. 35 is a timing diagram of a write operation with a split sector. In this example, the user data “C” is split into two portions, namely data “C 1 ” and data “C 2 ”. Since the whole user data “C” is already pre-send to R/W channel 24 ′″ for encoding. When HDC 22 ′″ asserts the RWGATE that has the length less than one codeword size, R/W channel 24 ′″ automatically switches to split sector mode. In the preferred embodiment R/W channel 24 ′″ permits only allow one split per codeword. The number of user data written for the “C 1 ” is determine by the number of WCLKs elapsed under the current RWGATE, and it is used to flush out the encoded data “C 1 ” portion. The number of user data written for the “C 2 ” is determine by the number of WCLKs elapsed under the next RWGATE, and is used to flush out the encoded data “C 2 ” portion. If the total length of these 2 RWGATEs is not equal to the codeword size, an error condition has occurred, and DATA_FAULT will be asserted by R/W channel 24 ′″.
Multiple Codewords per Sector Write Operation
FIG. 36 illustrates a timing diagram of a write operation having multiple codewords. In such a write operation, R/W_is set to “0” from “1” by HDC 22 ′″ which indicates a start of the write operation. After waiting for a “fixed delay 1 ” as shown in FIG. 36 , HDC 22 ′″ asserts the DATA_VALID and puts the valid user data “A 1 ” onto the 8-bit NRZ bus. R/W channel 24 ′″ latches each byte of user data “A 1 ” over the 8-bit NRZ bus at the rising edge of WCLK. The length of DATA_VALID is equal to (codeword size −1)*WCLK. After HDC 22 ′″ de-asserts the DATA_VALID, R/W channel 24 ′″ latches the last byte of valid data “A” from the 8-bit NRZ bus. Then a boundary codeword condition check is performed by R/W channel 24 ′″. If the total number of user data latched by R/W channel 24 ′″ is not equal to the pre-programmed codeword size, an error condition is determined, and a DATA_FAULT signal will be asserted. Otherwise, HDC 22 ′″ completes the transmission of the remaining data “A 1 ” to R/W channel 24 ′″ for encoding. The encoded data “A 1 ” is stored inside the working buffer of R/W channel 24 ′″.
After waiting for a “fixed delay 2 ”, HDC 22 ″ positions the head over the desirable track. HDC 22 ′″ asserts the RWGATE to flush out the encoded data “A 1 ” inside the working buffer of R/W channel 24 ′″. Immediately following the assertion of RWGATE, HDC 24 ′″ asserts the DATA_VALID and moves the valid user data “A 2 ” onto the 8-bit NRZ bus. R/W channel 24 ′″ (1) latches each byte of user data “A 2 ” over the 8-bit NRZ bus at the rising edge of WCLK, (2) flushes out the encoded data “A 1 ” from its working buffer, and (3) asserts the EXT_WGATE concurrently. R/W channel 24 ′″ will automatically insert the Sync Field (PLO), Sync Mark and Padding data during the Write operation for each sector. The length of the RWGATE indicates the total number of data to be written onto media for this write operation. R/W channel 24 ′″ counts the total number of WCLKs elapsed for this RWGATE to determine how much data is written onto the media. Therefore, the length of EXT_WGATE must longer than the DATA_VALID. Before finishing writing the encoded data “A 1 ” to the media, the next encoded data “A 2 ” is stored inside the working buffer. R/W channel 24 ′″ performs the boundary codeword condition check for data “A 2 ”. Since the RWGATE is still asserted by HDC 22 ′″ more than one codeword is being transmitted, and R/W channel 24 ′″ automatically switches to the multi-codeword mode. The encoded data “A 2 ” will continue to flush out right after the encoded data “A 1 ”. In FIG. 36 , 4 codewords per sector is shown. Before finishing the writing of the encoded “A 2 ” to the media, a new encoded data “A 3 ” is stored inside the working buffer. The encoded data “A 3 ” will continue to follow the encoded data “A 2 ” to be written onto the media. Every time when HDC 22 ′″ finishes, one codeword of data is transferred to R/W channel 24 ′″. The process repeats until the last encode data “A 4 ” is finally sent to the media. At this point, R/W channel 24 ′″ still has one encoded codeword data “B 1 ” stored in its working buffer.
Since every time HDC 22 ′″ flushes out the encoded data inside R/W channel 24 ′″ the next user data for R/W channel 24 ′″ is also sent to be encoded. As long as HDC 22 ′″ follows this sequence, R/W channel 24 ′″ can perform back to back synchronized write operations for multiple codewords per sector. In case HDC 22 ′″ switches from a write operation to a read operations, HDC 22 ′″ preferably flushes out the pre-encoded data stored inside the working buffer R/W channel 24 ′″. When HDC 22 ′″ switches back from a read operation to a write operation, HDC 22 ′″ preferably pre-sends one codeword data to R/W channel 24 ′″ first before performing the synchronized write operation as described above.
FIG. 36 also illustrates a split sector. The user data “B 1 ,B 2 ,B 3 ,B 4 ” is split into data “B 1 ,B 2 ,B 3 / 2 ” and data “B 3 / 2 ,B 4 ”. R/W channel 24 ′″ performs the write operation for data “B 1 ”, “B 2 ” similarly as above description. Since the whole user data “B 3 ” is already pre-sent to R/W channel 24 ′″ for encoding, when HDC 22 ′″ asserts the RWGATE, which has the length less than 3 codeword size, R/W channel 24 ′″ auto-switches to split sector mode. In the preferred embodiment, R/W channel 24 ′″ only allows one split per codeword. The number of user data written for the “B 1 ,B 2 ,B 3 / 2 ” is determined by the number of WCLKs elapsed under this RWGATE, and is used to flush out the encoded data corresponding to the “B 1 ,B 2 ,B 3 / 2 ” portion. The number of user data written for the “B 3 / 2 ,B 4 ” is determine by the number of WCLKs elapsed under the next RWGATE, and is used to flush out the encoded data “B 3 / 2 ,B 4 ” portion. If total combined length of these 2 RWGATE is not equal to 4 codeword size, an error has occurred, and a DATA_FAULT signal will be asserted by R/W channel 24 ′″.
Read Operation
Single Codeword per Sector Read Operation
FIG. 37 illustrates a timing diagram of a single codeword per sector read operation. A read operation of a single codeword per sector is performed when R/W_is set to “1” from “0” by HDC 22 ′″ that is indicate to start a read operation. After waiting for a “fixed delay 1 ” as shown in FIG. 37 , HDC 22 ′″ positions the head over the desirable track and asserts the RWGATE for data “A”. The total number of WCLKs elapsed under this RWGATE is equal to total number user data expected from this read operation. As soon as R/W channel 24 ′″ detects the assertion of RWGATE, R/W channel 24 ′″ asserts the internal RGATE. RGATE is an extended version of RWGATE for a read operation. Since the Sync Field (PLO), Sync Mark and Padding data are pre-programmed into the registers of R/W channel 24 ′″, R/W channel 24 ′″ can easy to extend the RGATE from RWGATE. As soon as iterative decoding is completed for data “A”, R/W channel 24 ′″ asserts DATA_VALID and sends the decoded data “A” back to HDC 22 ′″. HDC 22 ′″ then latches each byte of data “A” at the rising edge of RCLK. The number of WCLKs under each DATA_VALID is equal to codeword size −1. After the de-assertion of DATA_VALID, HDC 22 ″ latches the last valid byte of decoded data “A”. If the total number of bytes latched by HDC 22 ′″ for each DATA_VALID is not equal to codeword size, an error has occurred. HDC 22 ′″ handles the abnormal condition, by for example, retrying the read operation.
For a split sector read operation, HDC 22 ″ asserts the RWGATE twice to read the split sectors, as shown on FIG. 37 . After HDC 22 ′″ positions the head over the desirable track and asserts the first RWGATE for data “E 1 ”. The total number of WCLKs elapsed for this RWGATE is equal to the number of bytes expected to be read for this read operation. If the WCLKs under this RWGATE is less than one codeword size, R/W channel 24 ′″ automatically switches to the split sector mode. R/W channel 24 ′″ will wait for the next RWGATE to be asserted for data “E 2 ”. In the preferred embodiment, only one split per codeword is allowed. After combining the data during these RWGATEs, R/W channel 24 ′″ will continue to perform the iterative decoding. When the decoding has been completed, the whole decoded codeword data “E” is sent to HDC 22 ′″ through the 8-bit NRZ bus. In case the total combination of data “E 1 ” and “E 2 ” does not equal to codeword size boundary, a DATA_FAULT will be asserted by R/W channel 24 ′″. After completion of the iterative. decoding, R/W channel 24 ′″ automatically sends the decoded data to HDC 22 ′″. Of course, HDC 22 ′″ must have an appropriately sized buffer before assertion of RWGATE.
Multiple Codewords per Sector Read Operation
FIG. 38 illustrates a read operation having multiple codewords per. In this read operation, R/W_is set to “1” from “0” by HDC 22 ′″ which indicates a start of a read operation. After waiting for a “fixed delay 1 ” as shown in FIG. 38 , HDC 22 ′″ positions the head over a desirable track and asserts the RWGATE for data “A 1 ,A 2 ,A 3 ,A 4 ”. The total number of WCLKs elapsed under this RWGATE is equal to the total number of user data expected from this read operation. As soon as R/W channel 24 ′″ detects the assertion of this RWGATE, R/W channel 24 ′″ asserts the internal RGATE, which is an extended version of RWGATE for the read operation. Since the Sync Field (PLO), Sync Mark and Padding data are pre-programmed into R/W channel 24 ′″ registers, R/W channel 24 ′″ can easy extend the RGATE from the RWGATE. As soon as iterative decoding has completed for data “A 1 ”, R/W channel 24 ′″ asserts DATA_VALID and sends the decoded data “A 1 ” to HDC 22 ′″. HDC 22 ′″ latches each byte of data “A 1 ” at the rising edge of RCLK. The number of WCLKs under each DATA_VALID is equal to codeword size −1. After the de-assertion of DATA_VALID, HDC 22 ′″ latches the last byte of decoded data “A 1 ”. If the total number of bytes latched by HDC 22 ′″ for each DATA_VALID is not equal to codeword size, an error has occurred. HDC 22 ′″ request a retry of this read operation in response to this error condition. Since the length of RWGATE is longer than one codeword size, R/W channel 24 ′″ automatically switches into the multi-codeword mode. The data “A 1 ,A 2 ,A 3 ,A 4 ” is decoded in a pipeline style. In other words, the decoded data “A 2 ” follow the decoded data “A 1 ”. Since the length of DATA_VALID is always codeword size −1, it allows HDC 22 ′″ to check the boundary condition for each data “A 1 ”, “A 2 ”, “A 3 ”, and “A 4 ”.
In case of split sector read operation, HDC 22 ′″ asserts the RWGATE twice to read the split sectors as shown on FIG. 38 . After HDC 22 ′″ positions the head over the desirable track and asserts the first RWGATE for data “C 1 ,C 2 ,C 3 / 2 ”, the total number of WCLKs elapsed for this RWGATE is equal to the number of bytes expected to be read for this read operation. After counting the total number of WCLKs under this RWGATE which is not in codeword size boundary and it is greater than one codeword size, R/W channel 24 ′″ automatically switches into the split sector mode. As soon as one codeword is completely decoded, R/W channel 24 ′″ will assert the DATA_VALID and sends the decoded data to HDC 22 ′″. Since the data “C 1 ,C 2 ,C 3 / 2 ” is processed in a pipelined manner by R/W channel 24 ′″, data “C 1 ,C 2 ” is sent to HDC 22 ′″ first. For the data “C 3 / 2 ”, R/W channel 24 ′″ will wait for the next RWGATE before decoding the “C 3 / 2 ”. Once the next RWGATE is asserted for data “C 3 / 2 ,C 4 ”, the data “C 3 ” is decoded. As soon as R/W channel 24 ′″ finishes the decoding process for data “C 3 ”, R/W channel 24 ′″ asserts the DATA_VALID and sends the data “C 3 ” to HDC 22 ′″. The data “C 4 ” is decoded as described above.
R/W channel 24 ′″ can perform back to back read operations. As soon as R/W channel 24 ′″ finishes decoding one codeword under the split sector read case, the decoded data is automatically sent to HDC 22 ′″. HDC 22 ′″ insures that it can receive the data before asserting the RWGATE.
The interface signaling protocol of the present invention may be controlled by a processor operating in accordance with a program of instructions, which may be in the form of software. Alternatively, the program of instructions may be implemented with discrete logic components, application specific integrated circuits (ASICs), digital signal processors, or the like. Based on the teachings herein, one skilled in the art would be able to implement an appropriate instruction program in either software or hardware for carrying out the interface signaling protocol of the present invention.
While embodiments of the invention have been described, it will be apparent to those skilled in the art in light of the foregoing description that many further alternatives, modifications and variations are possible. The invention described herein is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the appended claims.
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A system includes a read/write channel and a hard disk controller. The hard disk controller includes a latency-independent interface that communicates with the read/write channel. A serial control data circuit transmits a serial control data signal including serial control data, wherein the serial control data signal has a variable number m of words, wherein each of said m words comprises n bits, and wherein at least one of said n bits of each of said m words includes information indicating whether a subsequent word of said serial control data signal will follow. A data circuit that transmits or receives data under the control of the serial control data signal.
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BACKGROUND OF THE INVENTION
The invention relates to a padlock in particular to a padlock for securing and monitoring a switch of an industrial plant. The invention further relates to a set of padlocks, to a padlock housing and to a method of retrofitting a padlock.
A particular area of application of a padlock is in the field of occupational safety. There is the risk in connection with the servicing of industrial plants, for example, of a production machine, that the industrial plant deactivated for the purpose of service work is activated again by accident while the servicing work is still continuing. A substantial danger for the service engineer can result from this. It is therefore customary that the service engineer moves a switch associated with the industrial plant to an OFF position for the duration of the service work and secures it in this position, i.e. the switch is directly blocked or access to the switch is blocked. The named switch is typically an energy supply switch, for example a main electrical switch of a control device or of an energy supply device of the industrial plant (e.g. power switchbox). Alternatively to this, the named switch can, for example, be a valve of a liquid line or of a gas line.
In order to effectively avoid an accidental activation of the industrial plant by another person, each service engineer hangs a padlock on the named switch or on a blocking device associated with the switch before starting his work and locks said padlock. The switch is hereby secured in its OFF position, i.e. the switch cannot be moved accidentally back into an ON position by another person. When the service engineer has ended his work, he unlocks his padlock again and releases it from the switch. Each service engineer usually has his own individual padlock (or a plurality of his own individual padlocks) associated with him.
This procedure is also called locking out. The padlock used is accordingly called a lockout lock. The document U.S. Pat. No. 5,449,867 shows such a securing of an electric rocker switch by means of a padlock. It is known from the document U.S. Pat. No. 3,171,908 to secure the position of a rotary switch by means of a padlock.
So that a plurality of service engineers can block and release the switch again independently of one another, a plurality of receivers (e.g. eyelets) can be provided at the switch for hanging a plurality of lockout locks. This is known from the document U.S. Pat. No. 6,388,213, for example. If only a single receiver for a lockout lock is provided, a securing claw can be used which is hung into the respective eyelet of the switch or of the associated blocking device and which in turn has a plurality of hang-in eyelets for a respective padlock. Only when the last padlock has been removed from the securing claw, the securing claw can be removed from the switch so that it can again be brought into the ON position. Such a securing claw for use at an electric switchbox is known, for example, from documents U.S. Pat. Nos. 6,396,008, 5,365,757 and 3,667,259.
It is known in connection with such a securing of a switch of an industrial plant to equip the lockout lock having a lock body used with a housing of plastic, with a shackle being displaceably held at the lock body and with a lock cylinder being arranged in the lock body. The lock cylinder can selectively be brought from an open position into a locked position to lock the shackle to the lock body after the shackle has, for example, been hung into an eyelet of the switch. By forming the lock housing from plastic, a particularly light padlock results which is of advantage in the use as a lockout lock since the service engineers occasionally carry a plurality of lockout locks simultaneously. A housing of plastic can also contribute to a desired electrical insulation. By the use of a plastic housing, there is furthermore a particularly simple possibility of color marking the padlock. Such a lockout lock having a housing of plastic is known, for example, from documents U.S. Pat. Nos. 7,278,283 and 5,755,121.
Depending on the specific application or use, a customer may desire different designs of the lockout lock. It may for example be necessary to have a relatively long lock housing so that identity pictures or photos can be applied to the lock housing and/or warning messages can be printed on the lock housing in multiple languages. Such a modification of the exterior of the lockout lock should, however, not necessarily affect its interior (i.e. the lock body, particularly the locking mechanism including for example a lock cylinder, an associated key and displaceable locking members). It is also desirable that such a change of the design may be carried out fast and easily by a locksmith or a service unit. The known padlocks, however, require an enormous investment in inventory to meet the market's expectations for fast delivery of special versions, due to the numerous possibly required versions (e.g. color, size, shackle engagement length, cylinder configuration).
SUMMARY OF THE INVENTION
It is an object of the invention to provide a padlock which enables a reliable securing of a switch of an industrial plant with a simple design, and which allows for an easy and fast change of the exterior of the padlock.
Particularly, it is an object of the invention to provide a padlock which has a relatively long housing and which can be produced by retrofitting a standard size padlock. It is another object of the invention to provide a padlock which minimizes the necessary inventory investment.
This object is satisfied by a padlock having
a lock body defining first and second passages therein; a shackle having first and second shanks linearly displaceable in the first and second passages between a locked position and a released position, the first shank being withdrawn from the first passage and the second shank being retained in the second passage in the released position; a housing having a lock body reception space and a head space; the housing comprising a reception groove at an outside thereof extending along the head space adjoining the first passage; and the first shank at least partly overlapping the housing and being pivotable into and out of the reception groove about the second shank in the released position.
Such a padlock has a modular design which allows not only to exchange the lock body (including the locking mechanism) if necessary, but also the housing. Particularly, instead of a standard size housing of relatively short length a long housing may be used which for example has bilingual warning messages printed on its exterior. The padlock can be easily and quickly assembled from an existing padlock having a standard size housing and shackle by exchanging the housing and shackle, while optionally keeping the lock body if desired. As such, if a customer requires a padlock (particularly a lockout lock) having a relatively long housing, a locksmith or a service unit may simply provide an off-the-shelf or existing standard lock body with the housing according to the invention and an associated shackle. The padlock according to the invention and particularly its housing therefore in conjunction with standard size padlocks create a modular padlock system which allows an easy and fast modification of the padlock exterior design.
The housing including the reception groove can be manufactured very cheaply, particularly when the housing is made of plastic. For example, the housing can be made in an injection molding process. The associated shackle must be of corresponding length but can be of simple design. If an electrical insulation is desired for the use as a lockout lock, the shackle can be made of plastic, or the shackle can be made of a metal or a metal alloy having a plastic cover on the parts protruding from the housing during use.
As such, the invention minimizes the inventory investment and at the same time facilitates faster delivery of desired padlock configurations.
Moreover, by providing the housing with said reception groove a padlock is created which can only be opened by pivoting the padlock about the second shank in one direction. This also prevents the padlock from unnecessarily engaging plant parts when the lock is opened, since it cannot open about a full angle of 360° as is the case for prior art padlocks.
The padlock in accordance with the invention will be explained in the following only by way of example with reference to the drawings and by means of the dependent claims.
The invention further relates to a set of padlocks which comprise a first padlock, which is of prior art design, i.e. having a relatively short housing without a reception groove, and a second padlock having the herein described features.
The invention further relates to a padlock housing comprising:
a lock body reception space for receiving a lock body and a head space; and a reception groove at an outside of the housing extending along the head space for receiving a shank of a shackle of the padlock.
The invention further relates to a method of retrofitting a padlock, the padlock comprising a lock body defining first and second passages therein, a first shackle having first and second shanks linearly displaceable in the first and second passages between a locked position and a released position, and a first housing having a lock body reception space. The method comprises the steps of:
removing the first housing and the first shackle from the lock body; and mounting a second shackle and a second housing to the lock body;
wherein the second shackle is longer than the first shackle along an axis of the first passage; and wherein the second housing is longer than the first housing along the axis of the first passage, the second housing comprising a lock body reception space for receiving the lock body and a head space, and further comprising a reception groove at an outside of the second housing, wherein the reception groove extends along the head space and adjoins the first passage of the lock body.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
FIG. 1 is a cross-sectional view through the center of a padlock from the front in accordance with the invention;
FIG. 2 is a perspective rear view of the padlock; and
FIG. 3 shows a set of padlocks comprising a padlock in accordance with FIG. 1 and a padlock having an identical interior and the same shackle engagement length (clearance) but a smaller sized standard housing.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring now to FIG. 1 , where a section through a padlock 10 is illustrated. The padlock comprises a lock body 12 , a U-shaped shackle 14 and a lock actuator 18 that are secured within the lock body 12 . The lock body 12 is incorporated in a housing 20 and terminated at an end (bottom side) by a plastic bumper 22 of the housing 20 . The lock body 12 further defines first and second passages 28 , 30 , within which respective first and second shanks 32 , 34 of the shackle 14 are slidably disposed.
The first and second shanks 32 , 34 include respective notches, which are selectively engaged by respective locking members 40 , 42 or bolt drivers of the lock actuator 18 to inhibit axial movement of the shackle 14 in the direction A when the lock is locked. The first shank 32 is shorter than the second shank 34 and may be withdrawn from the first passage 28 . The second shank 34 is slidably disposed within the second passage 30 but can not be withdrawn therefrom. More specifically, a shackle retaining pin 44 of the lock body 12 extends into a blocking notch 46 defined within the second shank 34 . The blocking notch 46 defines the range of slidable movement of the second shank 34 within the second passage 30 . The shackle retaining pin 44 inhibits a removal of the second shank 34 from the second passage 30 .
A rotatable plug 60 secured with a plug retaining pin 62 is operably engaged with the lock actuator 18 . The plug retaining pin 62 also serves as a rotational abutment for the plug 60 , i.e. a so-called stop pin. A key 48 is insertable into a keyhole of the plug 60 to enable rotation of the plug 60 between a first position and a second position. In the first position, which is shown in FIG. 1 , the plug 60 holds the lock actuator 18 in a locked condition. In the locked condition, the locking members 40 , 42 of the lock actuator 18 engage the notches of the first and second shanks 32 , 34 of the shackle 14 , thereby inhibiting axial movement of the shackle 14 in the direction A. In the second position, the plug 60 holds the lock actuator 18 in an unlocked condition (not shown). In the unlocked condition, the locking members 40 , 42 of the lock actuator 18 retreat from the notches of the first and second shanks 32 , 34 , enabling the shackle 14 to move in the direction A (and vice versa) by a distance X defined by the shackle retaining pin 44 and the blocking notch 46 of the second shank 34 . During the assembly of the padlock 10 the retaining pin 44 is only introduced into the lock body 12 in a loose manner as will be discussed in the following.
When the key 48 is turned to open the lock (not shown) it actuates the lock actuator 18 . A series of cylindrical pins 52 respectively biased with respect to a pin hole cover 84 via pin springs 54 permit the movement of the plug 60 via the key 48 only if bottom pins 56 align the cylindrical pins 52 at a shear line permitting movement of the plug 60 and hence of the lock actuator 18 .
As can be seen from FIG. 1 the housing 20 is of generally rectangular shape and is preferably made of plastic, as this is an electrically insulating and light weight durable material, which can be provided in a multitude of colors in a simple injection molding process. The different colors enable a color coding between different locks 10 and machine parts or operating/servicing personal (not shown).
In addition to housing the lock body 12 in a lock body reception space 64 , the housing 20 further comprises a head space 66 at its end 68 housing the second shank 34 of the shackle 14 . This means that a volume of the housing 20 between the lock body 12 and the end 68 (i.e. the top side) of the housing 20 is referred to herein as the head space 66 . For this purpose second shank 34 is guided within the head space 66 between the second passage 30 and the end 68 . The first shank 32 is guided in a reception groove 72 ( FIG. 2 ) arranged at an outside of the housing 20 in the region of the head space 66 adjoining the first passage 28 . In particular, the reception groove 72 is arranged at a corner of the housing 20 . The reception groove 72 extends coaxially with the first passage 28 and is parallel to the second passage 30 of the lock body 12 .
In the unlocked state of the padlock 10 , i.e. when the locking members 40 , 42 are retracted from the notches, the shackle 14 is slid upwardly (with respect to the drawing, it can naturally also slide in any direction A in which the padlock 10 is pointing in use) whilst the second shank 34 is retained in the housing 20 by means of the shackle retaining pin 44 . The distance X the shackle 14 is displaced in the direction A would actually be too small for allowing the pivoting of the first shank 32 about the second shank 34 since the first shank 32 still partly overlaps the housing 20 and the first shank 32 would thus still be stuck within the housing 20 . Accordingly, if the reception groove 72 were not provided, the padlock 10 would not function.
The shackle 14 and the lock body 12 are generally of metal or a metal alloy. For example, the lock body 12 can be formed by aluminum or an aluminum alloy to save weight. As can be seen from FIG. 1 the shackle 14 is at least partly covered with a plastic casing 76 at least in an external region of the padlock 10 , i.e. those parts of the shackle which in the locked state of the padlock are visible. The plastic casing 76 is provided to additionally electrically insulate the shackle 14 .
The housing 20 has a length which is at least substantially defined by the sum of a length of the lock body reception space 64 and a length of the reception groove 72 . In practice one would normally select the length of the reception groove 72 to correspond to at least 20% of a length of the housing 20 and to at most 80% of a length of the housing 20 . Other lengths are naturally possible, provided at least a part of the first shank 32 is still received by the reception groove 72 in the released state. In the example of FIG. 1 length of the reception groove 72 corresponds at least substantially to the length of the lock body reception space 64 .
A shank 32 , 34 is herein defined as a limb of the shackle 14 , the length of the shank 32 , 34 being defined as the dimension extending from a free end of the shank to the start of the curvature of the shackle 14 .
FIG. 2 shows a perspective rear view of the padlock 10 with an installed shackle 14 in the locked position. One can clearly see the reception groove 72 into and out of which the first shank 32 of the shackle 14 is pivoted in use in the released state of the padlock 10 , and which also allows a rectilinear movement of the first shank 32 of the shackle 14 along the direction A for inserting the first shank 32 into the first passage 28 of the lock body or for withdrawing the first shank 32 of the shackle 14 from the first passage 28 .
It also becomes clear from FIG. 2 that the front side of the housing 20 (hidden in FIG. 2 ) has a large surface not affected by the reception groove 72 . The large surface of the front side of the housing 20 offers enough space, for example, to print warning messages on the padlock 10 in multiple languages or to apply an identity photograph.
The invention also relates to a set of padlocks ( FIG. 3 ) comprising at least: a first padlock 110 and a second padlock 10 as herein described, the first padlock 110 including the same lock body as the second padlock 10 , but a smaller sized regular housing 120 and also a shorter shackle 114 (having first and second shanks 132 , 134 ). In general, the set can include multiple padlocks having a variety of housing lengths and associated reception groove lengths and shackle lengths. Since the plastic housing 20 can be manufactured very cheaply and since also the manufacture of the shackle 14 does not require great expense, the set of padlocks according to FIG. 3 can be provided based on the same type of internal lock body at low additional costs. As shown in FIG. 3 , both padlocks 10 and 110 have the same engagement length or clearance of their respective shackles 14 and 114 when the padlocks 10 and 110 are locked.
If a customer requires a lockout lock having a long housing 20 (for example having warning messages in multiple languages printed on the housing 20 ), it is possible to retroactively convert a standard size first padlock 110 according to FIG. 3 to a so-called “long-body” type second padlock 10 by simply exchanging only the housings 120 , 20 and shackles 114 , 14 . Such a method of retrofitting a padlock includes the steps of: removing the housing 120 and the shackle 114 of the first padlock 110 from its lock body; and mounting instead the second shackle 14 and the second housing 20 to the lock body.
More particularly, the step of mounting the shackle 14 and the housing 20 to the lock body may generally comprise: inserting the second shank 34 of the shackle 14 into the second passage 30 of the lock body 12 (see FIG. 1 ); retaining the second shank 34 in the second passage 30 ; and subsequently encasing the lock body 12 by means of the housing 20 .
For example, the second shank 34 is introduced into the lock body 12 of the padlock 10 via the second passage 30 until the second shank 34 of the shackle 14 abuts at an end of the second passage 30 (see FIG. 1 ). Once the second shank 34 abuts the end of the second passage 30 the retaining pin 44 is introduced substantially perpendicular to the second shank 34 into a bore 45 , i.e. the shackle retaining pin 44 and the bore 45 are oriented in a transverse direction with respect to an axis of the second shank 34 of the shackle 14 . In this way the shackle 14 is retained in the second passage 30 and can only move in the direction A by the distance X. The retaining pin 44 is only introduced into the bore 45 in a loose manner, such that the retaining pin 44 can be removed again if necessary and the housing 20 and/or the shackle 14 can be exchanged without the need of a tool. During the assembly the housing 20 can already be positioned partly over the lock body 12 such that the bore 45 is still accessible and the second shank 34 can be introduced into the lock body 12 . Once the retaining pin 44 has been introduced into the lock body 12 , the housing 20 is slid further over the lock body 12 and the plastic bumper 22 is placed over the end of the housing 20 (for example forming a snap-fit) in order to secure the housing 20 to the padlock 10 .
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The invention relates to a padlock in particular to a padlock for securing and monitoring a switch of an industrial plant. The invention further relates to a set of padlocks, to a padlock housing and to a method of retrofitting a padlock.
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TECHNICAL FIELD
The invention relates to apparatus and methods for collecting fluid samples from subsurface formations.
BACKGROUND OF THE INVENTION
The collection and sampling of underground fluids contained in subsurface formations is well known. In the petroleum exploration and recovery industries, for example, samples of formation fluids are collected and analyzed for various purposes, such as to determine the existence, composition and producibility of subsurface hydrocarbon fluid reservoirs. This aspect of the exploration and recovery process can be crucial in developing drilling strategies and impacts significant financial expenditures and savings.
To conduct valid fluid analysis, the fluid obtained from the subsurface formation should possess sufficient purity, or be virgin fluid, to adequately represent the fluid contained in the formation. As used herein, and in the other sections of this patent, the terms “virgin fluid”, “acceptable virgin fluid” and variations thereof mean subsurface fluid that is pure, pristine, connate, uncontaminated or otherwise considered in the fluid sampling and analysis field to be sufficiently or acceptably representative of a given formation for valid hydrocarbon sampling and/or evaluation.
Various challenges may arise in the process of obtaining virgin fluid from subsurface formations. Again with reference to the petroleum-related industries, for example, the earth around the borehole from which fluid samples are sought typically contains contaminates, such as filtrate from the mud utilized in drilling the borehole. This material often contaminates the virgin fluid as it passes through the borehole, resulting in fluid that is generally unacceptable for hydrocarbon fluid sampling and/or evaluation. Such fluid is referred to herein as “contaminated fluid.” Because fluid is sampled through the borehole, mudcake, cement and/or other layers, it is difficult to avoid contamination of the fluid sample as it flows from the formation and into a downhole tool during sampling. A challenge thus lies in minimizing the contamination of the virgin fluid during fluid extraction from the formation.
FIG. 1 depicts a subsurface formation 16 penetrated by a wellbore 14 . A layer of mud cake 15 lines a sidewall 17 of the wellbore 14 . Due to invasion of mud filtrate into the formation during drilling, the wellbore is surrounded by a cylindrical layer known as the invaded zone 19 containing contaminated fluid 20 that may or may not be mixed with virgin fluid. Beyond the sidewall of the wellbore and surrounding contaminated fluid, virgin fluid 22 is located in the formation 16 . As shown in FIG. 1 , contaminates tend to be located near the wellbore wall in the invaded zone 19 .
FIG. 2 shows the typical flow patterns of the formation fluid as it passes from subsurface formation 16 into a downhole tool 1 . The downhole tool 1 is positioned adjacent the formation and a probe 2 is extended from the downhole tool through the mudcake 15 to the sidewall 17 of the wellbore 14 . The probe 2 is placed in fluid communication with the formation 16 so that formation fluid may be passed into the downhole tool 1 . Initially, as shown in FIG. 1 , the invaded zone 19 surrounds the sidewall 17 and contains contamination. As fluid initially passes into the probe 2 , the contaminated fluid 20 from the invaded zone 19 is drawn into the probe with the fluid thereby generating fluid unsuitable for sampling. However, as shown in FIG. 2 , after a certain amount of fluid passes through the probe 2 , the virgin fluid 22 breaks through and begins entering the probe. In other words, a more central portion of the fluid flowing into the probe gives way to the virgin fluid, while the remaining portion of the fluid is contaminated fluid from the invasion zone. The challenge remains in adapting to the flow of the fluid so that the virgin fluid is collected in the downhole tool during sampling.
Various methods and devices have been proposed for obtaining subsurface fluids for sampling and evaluation. For example, U.S. Pat. No. 6,230,557 to Ciglenec et al., U.S. Pat. No. 6,223,822 to Jones, U.S. Pat. No. 4,416,152 to Wilson, U.S. Pat. No. 3,611,799 to Davis and International Pat. App. Pub. No. WO 96/30628 have developed certain probes and related techniques to improve sampling. Other techniques have been developed to separate virgin fluids during sampling. For example, U.S. Pat. No. 6,301,959 to Hrametz et al. and discloses a sampling probe with two hydraulic lines to recover formation fluids from two zones in the borehole. Borehole fluids are drawn into a guard zone separate from fluids drawn into a probe zone. Despite such advances in sampling, there remains a need to develop techniques for fluid sampling to optimize the quality of the sample and efficiency of the sampling process.
In considering existing technology for the collection of subsurface fluids for sampling and evaluation, there remains a need for apparatus and methods having one or more, among others, of the following attributes: the ability to selectively collect virgin fluid apart from contaminated fluid; the ability to separate virgin fluid from contaminated fluid; the ability to optimize the quantity and/or quality of virgin fluid extracted from the formation for sampling; the ability to adjust the flow of fluid according to the sampling needs; the ability to control the sampling operation manually and/or automatically and/or on a real-time basis. To this end, the present invention seeks to optimize the sampling process.
BRIEF SUMMARY OF THE INVENTION
In one aspect, the present invention relates to a probe deployable from a downhole tool positionable in a wellbore surrounded by a layer of contaminated fluid. The wellbore penetrates a subsurface formation having virgin fluid therein beyond the layer of contaminated fluid. The sampling probe comprises a housing and a sampling intake. The housing is engageable with a sidewall of the wellbore. The housing is also in fluid communication with the subsurface formation whereby the fluids flows from the subterranean formation through the housing and into the downhole tool. The sampling intake is positioned within said housing and in non-engagement with the sidewall of the wellbore. The sampling intake is adapted to receive at least a portion of the virgin fluid flowing through the housing.
In another aspect, the invention relates to a downhole tool useful for extracting fluid from a subsurface formation penetrated by a wellbore surrounded by a layer of contaminated fluid, the subsurface formation having virgin fluid therein beyond the layer of contaminated fluid. The downhole tool comprises a probe carried by the downhole tool. The probe is positionable in fluid communication with the formation whereby the fluids flow from the subterranean formation through the housing and into the downhole tool. The probe has a wall therein defining a first channel and a second channel. The wall is adjustably positionable within the probe whereby the flow of the virgin fluid through the first channel and into the downhole tool is optimized.
In another aspect of the invention, a downhole tool useful for extracting virgin fluid from a subsurface formation penetrated by a wellbore surrounded by contaminated fluid is provided. The downhole tool comprises a probe, first and second flow lines and at least one pump. The probe is positionable in fluid communication with the formation and has a wall therein defining a first channel and a second channel. The wall is adjustably positionable within the probe whereby the flow of virgin fluid into the first channel is optimized. The first flow line is in fluid communication with the first channel. The second flow line is in fluid communication with the second channel. The pump(s) draw the fluids from the formation into the flow lines.
In another aspect, the invention relates to a method of sampling virgin fluid from a subterranean formation penetrated by a wellbore surrounded by contaminated fluid, the subterranean formation having virgin fluid therein. The method comprises positioning a downhole tool in the wellbore adjacent the subterranean formation, the downhole tool having a probe adapted to draw fluid therein, positioning the probe in fluid communication with the formation, the probe having a wall therein defining a first channel and a second channel, drawing at least a portion of the virgin fluid through the first channel and into the downhole tool, and selectively adjusting the wall within the probe whereby the flow of virgin fluid into the downhole tool is optimized.
In yet another aspect, the invention relates to a method of sampling virgin fluid from a subterranean formation penetrated by a wellbore surrounded by contaminated fluid, the subterranean formation having virgin fluid therein. The method comprises positioning a downhole tool in the wellbore adjacent the subterranean formation, the downhole tool having a probe adapted to draw fluid therein, positioning the probe in fluid communication with the formation, the probe having a wall therein defining a first channel and a second channel, drawing at least a portion of the virgin fluid into the first channel in the probe and selectively adjusting the flow of fluid into the channels whereby the flow of virgin fluid into the probe is optimized.
Another aspect of the invention relates to a downhole tool useful for extracting virgin fluid from a subsurface formation penetrated by a wellbore surrounded by contaminated fluid. The apparatus comprises a probe, a contamination monitor and a controller. The probe is positionable in fluid communication with the formation and adapted to flow the fluids from the formation into the downhole tool. The probe has a wall therein defining a first channel and a second channel. The contamination monitor is adapted to measure fluid parameters in at least one of the channels. The controller is adapted to receive data from the contamination monitor and send command signals in response thereto whereby the wall is selectively adjusted within the probe to optimize the flow of the virgin fluid through the first channel and into the downhole tool.
Another aspect of the invention relates to a downhole tool useful for extracting virgin fluid from a subsurface formation penetrated by a wellbore surrounded by contaminated fluid. The downhole tool comprises a probe, first and second flow lines, at least one pump, a monitor and a controller. The probe is positionable in fluid communication with the formation and adapted to flow the fluids from the formation into the downhole tool. The probe has a wall therein defining a first channel and a second channel. The first flow line is in fluid communication with the first channel. The second flow line is in fluid communication with the second channel. The pump(s) draw the fluids from the formation. The contamination monitor is adapted to measure fluid parameters in at least one of the channels. The controller is adapted to receive data from the contamination monitor and send command signals in response thereto whereby the pump is selectively activated to draw fluid into the flow lines to optimize the flow of the virgin fluid through the first channel and into the downhole tool.
In another aspect, the invention relates to a method of sampling virgin fluid from a subterranean formation penetrated by a wellbore surrounded by contaminated fluid, the subterranean formation having virgin fluid therein. The method comprises positioning a probe in fluid communication with the formation, the probe carried by a downhole tool and having a wall therein defining a first channel and a second channel, flowing the fluids through the probe and into the downhole tool, monitoring fluid parameters of the fluid passing through the probe, and selectively adjusting the flow of fluids into the probe in response to the fluid parameters whereby the flow of virgin fluid through the first channel and into the downhole tool is optimized.
The invention also relates to a downhole apparatus for separating virgin fluid and contaminated fluid extracted from a subsurface formation. The downhole apparatus comprises a fluid sampling probe and means for separating virgin fluid. The fluid sampling probe has first and second pathways in fluid communication with each other and the subsurface formation. The means is capable of separating virgin fluid extracted from the subsurface formation and contaminated fluid extracted from the subsurface formation, whereby separation of the virgin and contaminated fluids occurs within said fluid sampling probe, and whereby contaminated fluid is extracted through said first pathway and virgin fluid is extracted through said second pathway.
Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of preferred embodiments of the invention, reference will now be made to the accompanying drawings wherein:
FIG. 1 is a schematic view of a subsurface formation penetrated by a wellbore lined with mudcake, depicting the virgin fluid in the subsurface formation.
FIG. 2 is a schematic view of a down hole tool positioned in the wellbore with a probe extending to the formation, depicting the flow of contaminated and virgin fluid into a downhole sampling tool.
FIG. 3 is a schematic view of down hole wireline tool having a fluid sampling device.
FIG. 4 is a schematic view of a downhole drilling tool with an alternate embodiment of the fluid sampling device of FIG. 3 .
FIG. 5 is a detailed view of the fluid sampling device of FIG. 3 depicting an intake section and a fluid flow section.
FIG. 6A is a detailed view of the intake section of FIG. 5 depicting the flow of fluid into a probe having a wall defining an interior channel, the wall recessed within the probe.
FIG. 6B is an alternate embodiment of the probe of FIG. 6A having a wall defining an interior channel, the wall flush with the probe.
FIG. 6C is an alternate embodiment of the probe of FIG. 6A having a sizer capable of reducing the size of the interior channel.
FIG. 6D is a cross-sectional view of the probe of FIG. 6 C.
FIG. 6E is an alternate embodiment of the probe of FIG. 6A having a sizer capable of increasing the size of the interior channel.
FIG. 6F is a cross-sectional view of the probe of FIG. 6 E.
FIG. 6G is an alternate embodiment of the probe of FIG. 6A having a pivoter that adjusts the position of the interior channel within the probe.
FIG. 6H is a cross-sectional view of the probe of FIG. 6 G.
FIG. 6I is an alternate embodiment of the probe of FIG. 6A having a shaper that adjusts the shape of the probe and/or interior channel.
FIG. 6J is a cross-sectional view of the probe of FIG. 6 I.
FIG. 7A is a schematic view of the probe of FIG. 6A with the flow of fluid from the formation into the probe with the pressure and/or flow rate balanced between the interior and exterior flow channels for substantially linear flow into the probe.
FIG. 7B is a schematic view of the probe of FIG. 7A with the flow rate of the interior channel greater than the flow rate of the exterior channel.
FIG. 8A is a schematic view of an alternate embodiment of the downhole tool and fluid flowing system having dual packers and walls.
FIG. 8B is a schematic view of the downhole tool of FIG. 8A with the walls moved together in response to changes in the fluid flow.
FIG. 8C is a schematic view of the flow section of the downhole tool of FIG. 8 A.
FIG. 9 is a schematic view of the fluid sampling device of FIG. 5 having flow lines with individual pumps.
FIG. 10 is a graphical depiction of the optical density signatures of fluid entering the probe at a given volume.
FIG. 11A is a graphical depiction of optical density signatures of FIG. 10 deviated during sampling at a given volume.
FIG. 11B is a graphical depiction of the ratio of flow rates corresponding to the given volume for the optical densities of FIG. 11 A.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Presently preferred embodiments of the invention are shown in the above-identified figures and described in detail below. In describing the preferred embodiments, like or identical reference numerals are used to identify common or similar elements. The figures are not necessarily to scale and certain features and certain views of the figures may be shown exaggerated in scale or in schematic in the interest of clarity and conciseness.
Referring to FIG. 3 , an example environment within which the present invention may be used is shown. In the illustrated example, the present invention is carried by a down hole tool 10 . An example commercially available tool 10 is the Modular Formation Dynamics Tester (MDT) by Schlumberger Corporation, the assignee of the present application and further depicted, for example, in U.S. Pat. No. 4,936,139 and 4,860,581 hereby incorporated by reference herein in their entireties.
The downhole tool 10 is deployable into bore hole 14 and suspended therein with a conventional wire line 18 , or conductor or conventional tubing or coiled tubing, below a rig 5 as will be appreciated by one of skill in the art. The illustrated tool 10 is provided with various modules and/or components 12 , including, but not limited to, a fluid sampling device 26 used to obtain fluid samples from the subsurface formation 16 . The fluid sampling device 26 is provided with a probe 28 extendable through the mudcake 15 and to sidewall 17 of the borehole 14 for collecting samples. The samples are drawn into the downhole tool 10 through the probe 28 .
While FIG. 3 depicts a modular wireline sampling tool for collecting samples according to the present invention, it will be appreciated by one of skill in the art that such system may be used in any downhole tool. For example, FIG. 4 shows an alternate downhole tool 10 a having a fluid sampling system 26 a therein. In this example, the downhole tool 10 a is a drilling tool including a drill string 29 and a drill bit 30 . The downhole drilling tool 10 a may be of a variety of drilling tools, such as a Measurement-While-Drilling (MWD), Logging-While Drilling (LWD) or other drilling system. The tools 10 and 10 a of FIGS. 3 and 4 , respectively, may have alternate configurations, such as modular, unitary, wireline, coiled tubing, autonomous, drilling and other variations of downhole tools.
Referring now to FIG. 5 , the fluid sampling system 26 of FIG. 3 is shown in greater detail. The sampling system 26 includes an intake section 25 and a flow section 27 for selectively drawing fluid into the desired portion of the downhole tool.
The intake section 25 includes a probe 28 mounted on an extendable base 30 having a seal 31 , such as a packer, for sealingly engaging the borehole wall 17 around the probe 28 . The intake section 25 is selectively extendable from the downhole tool 10 via extension pistons 33 . The probe 28 is provided with an interior channel 32 and an exterior channel 34 separated by wall 36 . The wall 36 is preferably concentric with the probe 28 . However, the geometry of the probe and the corresponding wall may be of any geometry. Additionally, one or more walls 36 may be used in various configurations within the probe.
The flow section 27 includes flow lines 38 and 40 driven by one or more pumps 35 . A first flow line 38 is in fluid communication with the interior channel 32 , and a second flow line 40 is in fluid communication with the exterior channel 34 . The illustrated flow section may include one or more flow control devices, such as the pump 35 and valves 44 , 45 , 47 and 49 depicted in FIG. 5 , for selectively drawing fluid into various portions of the flow section 27 . Fluid is drawn from the formation through the interior and exterior channels and into their corresponding flow lines.
Preferably, contaminated fluid may be passed from the formation through exterior channel 34 , into flow line 40 and discharged into the wellbore 14 . Preferably, fluid passes from the formation into the interior channel 32 , through flow line 38 and either diverted into one or more sample chambers 42 , or discharged into the wellbore. Once it is determined that the fluid passing into flow line 38 is virgin fluid, a valve 44 and/or 49 may be activated using known control techniques by manual and/or automatic operation to divert fluid into the sample chamber.
The fluid sampling system 26 is also preferably provided with one or more fluid monitoring systems 53 for analyzing the fluid as it enters the probe 28 . The fluid monitoring system 53 may be provided with various monitoring devices, such as optical fluid analyzers, as will be discussed more fully herein.
The details of the various arrangements and components of the fluid sampling system 26 described above as well as alternate arrangements and components for the system 26 would be known to persons skilled in the art and found in various other patents and printed publications, such as, those discussed herein. Moreover, the particular arrangement and components of the downhole fluid sampling system 26 may vary depending upon factors in each particular design, or use, situation. Thus, neither the system 26 nor the present invention are limited to the above described arrangements and components and may include any suitable components and arrangement. For example, various flow lines, pump placement and valving may be adjusted to provide for a variety of configurations. Similarly, the arrangement and components of the downhole tool 10 may vary depending upon factors in each particular design, or use, situation. The above description of exemplary components and environments of the tool 10 with which the fluid sampling device 26 of the present invention may be used is provided for illustrative purposes only and is not limiting upon the present invention.
With continuing reference to FIG. 5 , the flow pattern of fluid passing into the downhole tool 10 is illustrated. Initially, as shown in FIG. 1 , an invaded zone 19 surrounds the borehole wall 17 . Virgin fluid 22 is located in the formation 16 behind the invaded zone 19 . At some time during the process, as fluid is extracted from the formation 16 into the probe 28 , virgin fluid breaks through and enters the probe 28 as shown in FIG. 5 . As the fluid flows into the probe, the contaminated fluid 22 in the invaded zone 19 near the interior channel 32 is eventually removed and gives way to the virgin fluid 22 . Thus, only virgin fluid 22 is drawn into the interior channel 32 , while the contaminated fluid 20 flows into the exterior channel 34 of the probe 28 . To enable such result, the flow patterns, pressures and dimensions of the probe may be altered to achieve the desired flow path as will be described more fully herein.
Referring now to FIGS. 6A-6J , various embodiments of the probe 28 are shown in greater detail. In FIG. 6A , the base 30 is shown supporting the seal 31 in sealing engagement with the borehole wall 17 . The probe 28 preferably extends beyond the seal 31 and penetrates the mudcake 15 . The probe 28 is placed in fluid communication with the formation 16 .
The wall 36 is preferably recessed a distance within the probe 28 . In this configuration, pressure along the formation wall is automatically equalized in the interior and exterior channels. The probe 28 and the wall 36 are preferably concentric circles, but may be of alternate geometries depending on the application or needs of the operation. Additional walls, channels and/or flow lines may be incorporated in various configurations to further optimize sampling.
The wall 36 is preferably adjustable to optimize the flow of virgin fluid into the probe. Because of varying flow conditions, it is desirable to adjust the position of the wall 36 so that the maximum amount of virgin fluid may be collected with the greatest efficiency. For example, the wall 36 may be moved or adjusted to various depths relative to the probe 28 . As shown in FIG. 6B , the wall 36 may be positioned flush with the probe. In this configuration, the pressure in the interior channel along the formation may be different from the pressure in the exterior channel along the formation.
Referring now to FIGS. 6C-6H , the wall 36 is preferably capable of varying the size and/or orientation of the interior channel 32 . As shown in FIG. 6C through 6F , the diameter of a portion or all of the wall 36 is preferably adjustable to align with the flow of contaminated fluid 20 from the invaded zone 19 and/or the virgin fluid 22 from the formation 16 into the probe 28 . The wall 36 may be provided with a mouthpiece 41 and a guide 40 adapted to allow selective modification of the size and/or dimension of the interior channel. The mouthpiece 41 is selectively movable between an expanded and a collapsed position by moving the guide 40 along the wall 36 . In FIGS. 6C and 6D , the guide 40 is surrounds the mouthpiece 41 and maintains it in the collapsed position to reduce the size of the interior flow channel in response to a narrower flow of virgin fluid 22 . In FIGS. 6E and 6F , the guide 41 is retracted so that the mouthpiece 41 is expanded to increase the size of the interior flow channel in response to a wider flow of virgin fluid 22 .
The mouthpiece depicted in FIGS. 6C-6F may be a folded metal spring, a cylindrical bellows, a metal energized elastomer, a seal, or any other device capable of functioning to selectively expand or extend the wall as desired. Other devices capable of expanding the cross-sectional area of the wall 36 may be envisioned. For example, an expandable spring cylinder pinned at one end may also be used.
As shown in FIGS. 6G and 6H , the probe 28 may also be provided with a wall 36 a having a first portion 42 , a second portion 43 and a seal bearing 45 therebetween to allow selective adjustment of the orientation of the wall 36 a within the probe. The second portion 43 is desirably movable within the probe 28 to locate an optimal alignment with the flow of virgin fluid 20 .
Additionally, as shown in FIG. 6I and 6J , one or more shapers 44 may also be provided to conform the probe 28 and/or wall 36 into a desired shape. The shapers 44 have two more fingers 50 adapted to apply force to various positions about the probe and/or wall 36 causing the shape to deform. When the probe 40 and or wall 36 are extended as depicted in FIG. 6E , the shaper 44 may be extended about at least a portion of the mouthpiece 41 to selectively deform the mouthpiece to the desired shape. If desired, the shapers apply pressure to various positions around the probe and/or wall to generate the desired shape.
The sizer, pivoter and/or shaper may be any electronic mechanism capable of selectively moving the wall 36 as provided herein. One or more devices may be used to perform one or more of the adjustments. Such devices may include a selectively controllable slidable collar, a pleated tube, or cylindrical bellows or spring, an elastomeric ring with embedded spring-biased metal fingers, a flared elastomeric tube, a spring cylinder, and/or any suitable components with any suitable capabilities and operation may be used to provide any desired variability.
These and other adjustment devices may be used to alter the channels for fluid flow. Thus, a variety of configurations may be generated by combining one or more of the adjustable features.
Now referring to FIGS. 7A and 7B , the flow characteristics are shown in greater detail. Various flow characteristics of the probe 28 may be adjusted. For example, as shown in FIG. 7A , the probe 28 may be designed to allow controlled flow separation of virgin fluid 22 into the interior channel 32 and contaminated fluid 20 into the exterior channel 34 . This may be desirable, for example, to assist in minimizing the sampling time required before acceptable virgin fluid is flowing into the interior channel 32 and/or to optimize or increase the quantity of virgin fluid flowing into the interior channel 32 , or other reasons.
The ratio of fluid flow rates within the interior channel 32 and the exterior channel 34 may be varied to optimize, or increase, the volume of virgin fluid drawn into the interior channel 32 as the amount of contaminated fluid 20 and/or virgin fluid 22 changes over time. The diameter d of the area of virgin fluid flowing into the probe may increase or decrease depending on wellbore and/or formation conditions. Where the diameter d expands, it is desirable to increase the amount of flow into the interior channel. This may be done by altering the wall 36 as previously described. Alternatively or simultaneously, the flow rates to the respective channels may be altered to further increase the flow of virgin fluid into the interior channel.
The comparative flow rate into the channels 32 and 34 of the probe 28 may be represented by a ratio of flow rates Q 1 /Q 2 . The flow rate into the interior channel 32 is represented by Q 1 and the flow rate in the exterior channel 34 is represented by Q 2 . The flow rate Q 1 in the interior channel 32 may be selectively increased and/or the flow rate Q 2 in the exterior channel 34 may be decreased to allow more fluid to be drawn into the interior channel 32 . Alternatively, the flow rate Q 1 in the interior channel 32 may be selectively decreased and/or the flow rate (Q 2 ) in the exterior channel 34 may be increased to allow less fluid to be drawn into the interior channel 32 .
As shown in FIG. 7A , Q 1 and Q 2 represent the flow of fluid through the probe 28 . The flow of fluid into the interior channel 32 may be altered by increasing or decreasing the flow rate to the interior channel 32 and/or the exterior channel 34 . For example, as shown in FIG. 7B , the flow of fluid into the interior channel 32 may be increased by increasing the flow rate Q 1 through the interior channel 32 , and/or by decreasing the flow rate Q 2 through the exterior channel 34 . As indicated by the arrows, the change in the ratio Q 1 /Q 2 steers a greater amount of the fluid into the interior channel 32 and increases the amount of virgin fluid drawn into the downhole tool (FIG. 5 ).
The flow rates within the channels 32 and 34 may be selectively controllable in any desirable manner and with any suitable component(s). For example, one or more flow control device 35 is in fluid communication with each flowline 38 , 40 may be activated to adjust the flow of fluid into the respective channels (FIG. 5 ). The flow control 35 and valves 45 , 47 and 49 of this example can, if desired, be actuated on a real-time basis to modify the flow rates in the channels 32 and 34 during production and sampling.
The flow rate may be altered to affect the flow of fluid and optimize the intake of virgin fluid into the downhole tool. Various devices may be used to measure and adjust the rates to optimize the fluid flow into the tool. Initially, it may be desirable to have increased flow into the exterior channel when the amount of contaminated fluid is high, and then adjust the flow rate to increase the flow into the interior channel once the amount of virgin fluid entering the probe increases. In this manner, the fluid sampling may be manipulated to increase the efficiency of the sampling process and the quality of the sample.
Referring now to FIGS. 8A and 8B , another embodiment of the present invention employing a fluid sampling system 26 b is depicted. A downhole tool 10 b is deployed into wellbore 14 on coiled tubing 58 . Dual packers 60 extend from the downhole tool 10 b and sealingly engage the sidewall 17 of the wellbore 14 . The wellbore 14 is lined with mud cake 15 and surrounded by an invaded zone 19 . A pair of cylindrical walls or rings 36 b are preferably positioned between the packers 60 for isolation from the remainder of the wellbore 14 . The packers 60 may be any device capable of sealing the probe from exposure to the wellbore, such as packers or any other suitable device.
The walls 36 b are capable of separating fluid extracted from the formation 16 into at least two flow channels 32 b and 34 b . The tool 10 b includes a body 64 having at least one fluid inlet 68 in fluid communication with fluid in the wellbore between the packers 60 . The walls 36 b are positioned about the body 64 . As indicated by the arrows, the walls 36 b are axially movable along the tool. Inlets positioned between the walls 36 preferably capture virgin fluid 22 , while inlets outside the walls 36 preferably draw in contaminated fluid 20 .
The walls 36 b are desirably adjustable to optimize the sampling process. The shape and orientation of the walls 36 b may be selectively varied to alter the sampling region. The distance between the walls 36 b and the borehole wall 17 , may be varied, such as by selectively extending and retracting the walls 36 b from the body 64 . The position of the walls 36 b may be along the body 64 . The position of the walls along the body 64 may to moved apart to increase the number of intakes 68 receiving virgin fluid, or moved together to reduce the number of intakes receiving virgin fluid depending on the flow characteristics of the formation. The walls 36 b may also be centered about a given position along the tool 10 b and/or a portion of the borehole 14 to align certain intakes 68 with the flow of virgin fluid 22 into the wellbore 14 between the packers 60 .
The position of the movement of the walls along the body may or may not cause the walls to pass over intakes. In some embodiments, the intakes may be positioned in specific regions about the body. In this case, movement of the walls along the body may redirect flow within a given area between the packers without having to pass over intakes. The size of the sampling region between the walls 36 b may be selectively adjusted between any number of desirable positions, or within any desirable range, with the use of any suitable component(s) and technique(s).
An example of a flow system 26 b for selectively drawing fluid into the downhole tool is depicted in FIG. 8C. A fluid flow line 70 extends from each intake 68 into the dowuhole tool 10 b and has a corresponding valve 72 for selectively diverting fluid to either a sample chamber 75 or into the wellbore outside of the packers 60 . One or more pumps 35 may be used in coordination with the valves 72 to selectively draw fluid in at various rates to control the flow of fluid into the downhole tool. Contaminated fluid is preferably dispersed back to the wellbore. However, where it is determined that virgin fluid is entering a given intake, a valve 72 corresponding to the intake may be activated to deliver the virgin fluid to a sample chamber 75 . Various measurement devices, such as an OFA 59 may be used to evaluate the fluid drawn into the tool. Where multiple intakes are used, specific intakes may be activated to increase the flow nearest the central flow of virgin fluid, while intakes closer to the contaminated region may be decreased to effectively steer the highest concentration of virgin fluid into the downhole tool for sampling.
One or more probes 28 as depicted in any of FIGS. 3-6J may also be used in combination with the probe 28 b of FIG. 8A or 8 B.
Referring to FIG. 9 , another view of the fluid sampling system 26 c of FIG. 5 is shown. In FIG. 9 , the flow lines 38 and 40 each have a pump 35 for selectively drawing fluid into the channels 32 and 34 of the probe 28 .
The fluid monitoring system 53 of FIG. 5 is shown in greater detail in FIG. 9 . The flow lines 38 and 40 each pass through the fluid monitoring system 53 for analysis therein. The fluid monitoring system 53 is provided with an optical fluid analyzer 73 for measuring optical density in flow line 40 and an optical fluid analyzer 74 for measuring optical density in flow line 38 . The optical fluid analyzer may be a device such as the analyzer described in U.S. Pat. No. 6,178,815 to Felling et al., and/or U.S. Pat. No. 4,994,671 to Safinya et al., both of which are hereby incorporated by reference.
While the fluid monitoring system 53 of FIG. 9 is depicted as having an optical fluid analyzer for monitoring the fluid, it will be appreciated that other fluid monitoring devices, such as gauges, meters, sensors and/or other measurement or equipment incorporating for evaluation, may be used for determining various properties of the fluid, such as temperature, pressure, composition, contamination and/or other parameters known by those of skill in the art.
A controller 76 is preferably provided to take information from the optical fluid analyzer(s) and send signals in response thereto to alter the flow of fluid into the interior channel 32 and/or exterior channel 34 of the probe 28 . As depicted in FIG. 9 , the controller is part of the fluid monitoring system 53 ; however, it will be appreciated by one of skill in the art that the controller may be located in other parts of the downhole tool and/or surface system for operating various components within the wellbore system.
The controller is capable of performing various operations throughout the wellbore system. For example, the controller is capable of activating various devices within the downhole tool, such as selectively activating the sizer, pivoter, shaper and/or other probe device for altering the flow of fluid into the interior and/or exterior channels 32 , 34 of the probe. The controller may be used for selectively activating the pumps 35 and/or valves 44 , 45 , 47 , 49 for controlling the flow rate into the channels 32 , 34 , selectively activating the pumps 35 and/or valves 44 , 45 , 47 , 49 to draw fluid into the sample chamber(s) and/or discharge fluid into the wellbore, to collect and/or transmit data for analysis uphole and other functions to assist operation of the sampling process. The controller may also be used for controlling fluid extracted from the formation, providing accurate contamination parameter values useful in a contamination monitoring model, adding certainty in determining when extracted fluid is virgin fluid sufficient for sampling, enabling the collection of improved quality fluid for sampling, reducing the time required to achieve any of the above, or any combination thereof. However, the contamination monitoring calibration capability can be used for any other suitable purpose(s). Moreover, the use(s) of, or reasons for using, a contamination monitoring calibration capability are not limiting upon the present invention.
An example of optical density (OD) signatures generated by the optical fluid analyzers 73 and 74 of FIG. 9 is shown in FIG. 10 . FIG. 10 shows the relationship between OD and the total volume V of fluid as it passes into the interior and exterior channels of the probe. The OD of the fluid flowing through the interior channel 32 is depicted by line 80 . The OD of the fluid flowing through the exterior channel 34 is depicted as line 82 . The resulting signatures represented by lines 80 and 82 may be used to calibrate future measurements.
Initially, the OD of fluid flowing into the channels is at OD mf . OD mf represents the OD of the contaminated fluid adjacent the wellbore as depicted in FIG. 1 . Once the volume of fluid entering the interior channel reaches V 1 , virgin fluid breaks through. The OD of the fluid entering into the channels increases as the amount of virgin fluid entering into the channels increases. As virgin fluid enters the interior channel 32 , the OD of the fluid entering into the interior channel increases until it reaches a second plateau at V 2 represented by OD vf . While virgin fluid also enters the exterior channel 34 , most of the contaminated fluid also continues to enter the exterior channel. The OD of fluid in the exterior channel as represented by line 82 , therefore, increases, but typically does not reach the OD vf due to the presence of contaminates. The breakthrough of virgin fluid and flow of fluid into the interior and exterior channels is previously described in relation to FIG. 2 .
The distinctive signature of the OD in the internal channel may be used to calibrate the monitoring system or its device. For example, the parameter OD vf , which characterizes the optical density of virgin fluid can be determined. This parameter can be used as a reference for contamination monitoring. The data generated from the fluid monitoring system may then be used for analytical purposes and as a basis for decision making during the sampling process.
By monitoring the coloration generated at various optical channels of the fluid monitoring system 53 relative to the curve 80 , one can determine which optical channel(s) provide the optimum contrast readout for the optical densities OD mf and OD vf . These optical channels may then be selected for contamination monitoring purposes.
FIGS. 11A and 11B depict the relationship between the OD and flow rate of fluid into the probe. FIG. 11A shows the OD signatures of FIG. 10 that has been adjusted during sampling. As in FIG. 10 , line 82 shows the signature of the OD of the fluid entering the interior channel 32 , and 82 shows the signature of the OD of the fluid entering the exterior channel 34 . However, FIG. 11A further depicts evolution of the OD at volumes V 3 , V 4 and V 5 during the sampling process.
FIG. 11B shows the relationship between the ratio of flow rates Q 1 /Q 2 to the volume of fluid that enters the probe. As depicted in FIG. 7A , Q 1 relates to the flow rate into the interior channel 32 , and Q 2 relates to the flow rate into the exterior channel 34 of the probe 28 . Initially, as mathematically depicted by line 84 of FIG. 11B , the ratio of flow Q 1 /Q 2 is at a given level (Q 1 /Q 2 ) 1 corresponding to the flow ratio of FIG. 7 A. However, the ratio Q 1 /Q 2 can then be gradually increased, as described with respect to FIG. 7B , so that the ratio of Q 1 /Q 2 increases. This gradual increase in flow ratio is mathematically depicted as the line 84 increases to the level (Q 1 /Q 2 ) n at a given volume, such as V 4 . As depicted in FIG. 11B , the ratio can be further increased up to V 5 .
As the ratio of flow rate increases, the corresponding OD of the interior channel 32 represented by lines 80 shifts to deviation 81 , and the OD of the exterior channel 34 represented by line 82 shifts to deviations 83 and 85 . The shifts in the ratio of flow depicted in FIG. 11B correspond to shifts in the OD depicted in FIG. 11A for volumes V 1 through V 5 . An increase in the flow rate ratio at V 3 ( FIG. 11B ) shifts the OD of the fluid flowing into the exterior channel from its expected path 82 to a deviation 83 (FIG. 11 B). A further increase in ratio as depicted by line 84 at V 4 (FIG. 11 A), causes a shift in the OD of line 80 from its reference level OD vf to a deviation 81 (FIG. 11 B). The deviation of the OD of line 81 at V 4 , causes the OD of line 80 to return to its reference level OD vf at V 5 , while the OD of deviation 83 drops further along deviation 85 . Further adjustments to OD and/or ratio may be made to alter the flow characteristics of the sampling process.
It should also be understood that the discussion and various examples of methods and techniques described above need not include all of the details or features described above. Further, neither the methods described above, nor any methods which may fall within the scope of any of the appended claims, need be performed in any particular order. Yet further, the methods of the present invention do not require use of the particular embodiments shown and described in the present specification, such as, for example, the exemplary probe 28 of FIG. 5 , but are equally applicable with any other suitable structure, form and configuration of components.
Preferred embodiments of the present invention are thus well adapted to carry out one or more of the objects of the invention. Further, the apparatus and methods of the present invention offer advantages over the prior art and additional capabilities, functions, methods, uses and applications that have not been specifically addressed herein but are, or will become, apparent from the description herein, the appended drawings and claims.
While preferred embodiments of this invention have been shown and described, many variations, modifications and/or changes of the apparatus and methods of the present invention, such as in the components, details of construction and operation, arrangement of parts and/or methods of use, are possible, contemplated by the applicant, within the scope of the appended claims, and may be made and used by one of ordinary skill in the art without departing from the spirit or teachings of the invention and scope of appended claims. Because many possible embodiments may be made of the present invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not limiting. Accordingly, the scope of the invention and the appended claims is not limited to the embodiments described and shown herein.
It should be understood that before any action is taken with respect to any apparatus, system or method in accordance with this patent specification, all appropriate regulatory, safety, technical, industry and other requirements, guidelines and safety procedures should be consulted and complied with, and the assistance of a qualified, competent personnel experienced in the appropriate fields obtained. Caution must be taken in manufacturing, handling, assembling, using, and disassembling any apparatus or system made or used in accordance with this patent specification.
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The apparatuses and methods herein relate to techniques for extracting fluid from a subsurface formation. A downhole sampling tool is provided with a probe having an internal wall capable of selectively diverting virgin fluids into virgin flow channels for sampling, while diverting contaminated fluids into contaminated flow channels to be discarded. The characteristics of the fluid passing through the channels of the probe may be measured. The data generated during sampling may be sent to a controller capable of generating data, communicating and/or sending command signals. The flow of fluid into the downhole tool may be selectively adjusted to optimize the flow of fluid into the channels by adjusting the internal wall within the probe and/or by adjusting the flow rates through the channels. The configuraton of the internal wall and/or the flow rates may be automatically adjusted by the controller and/or manually manipulated to further optimize the fluid flow.
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The invention herein described was made in the course of or under a contract or subcontract thereunder with the Department of the Air Force.
RELATED APPLICATIONS
In U.S. application Ser. No. 413,473, filed Nov. 6, 1973, by applicant and others and now issued as U.S. Pat. No. 3,845,018, a new class of ethynyl substituted polyimide oligomers which cure by addition is disclosed. The present invention utilizes oligomers of the class disclosed in U.S. Pat. No. 3,845,018 to form copolymers having superior physical and mechanical properties when compared to other polyimide polymers and/or copolymers.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention may be classified as one relating to the preparation and formulation of polyimide polymers and copolymers.
2. Description of Prior Art
Composite materials have been used extensively as structural materials in aerospace and other applications where high strength, light weight materials capable of withstanding high temperatures are required. Considerable efforts to extend the thermal stability range, while retaining good structural strength without increasing the weight of such materials has been expanded. Currently, addition polymers such as epoxy resins are used in conjunction with fibers or fabrics to provide essentially void free composite structures which exhibit good structural properties and are light in weight. These structures, however, are limited in their use temperatures to about 150°-175° C because of the thermal stability characteristics of expoxy resins.
There are polyimides such as "P13N" from Ciba Geigy Corporation which give very low void content laminates which are useful at temperatures up to 288° C and there is a polyimide known as Kerimid 601 from Rhodia Corporation (a subsidiary of Rhone Poulenc Co.) which can provide void free laminates which can withstand temperatures of up to 260° C.
Higher temperature laminating resins which cure through addition were unknown prior to the development of the polyimides No. described in the Hughes Aircraft Company U.S. Pat. No. 3,845,018, although there are condensation type polyimides which can be used to produce laminates which withstand temperatures up to 300°-320° C. These resins are limited in their usefulness because the laminates and/or composite materials produced from them exhibit void contents as high as 20-40%. The voids are primarily caused by outgassing which occurs during the condensation mechanism cure.
Applicant herein, in conjunction with Drs. A. J. Landis and L. J. Miller of Hughes Aircraft Company, developed acetylene substituted polyimide oligomers which cure through addition rather than condensation in an attempt to solve the void problem discussed above and retain good thermal resistant properties. Polyimide composites with as little as several tenths to 1% voids were obtained even when molding pressures as low as 200 psi were used. These materials are described in U.S. Pat. No. 3,845,018.
Applicant's present invention constitutes a substantial improvement over the invention described in U.S. Pat. No. 3,845,018 as well as the prior art in that it facilitates the preparation of laminates and composites having high thermal stability, zero void content, and better mechanical properties because of the lower viscosity imparted by the incorporation of the reactive diluent. This is especially true in applications where inpregnation of the oligomer into a highly porous substrate is important.
SUMMARY OF THE INVENTION
Applicant has found that copolymers of diethynylbenzene and other di- or poly ethnyl-substituted diluents and an ethynylated polyimide oligomer such as one having the following general structure ##STR1## and wherein n = 0 to 5
m = 0 to 5 and
x = O, S, CH 2 , CO, SO 2
can be prepared which, when used to prepared fabricated laminates and other composite structures, result in void free structures having high thermal resistance with excellent mechanical properties.
DESCRIPTION OF THE INVENTION
My invention is a new composition of matter formed via the copolymerization of di- or polyethynyl-substituted diluents such as diethynylbenzene or diethynyldiphenyl ehter with ethynyl substituted polyimide oligomers.
One purpose of the invention is to provide a class of heat resistant copolymers which are thermosetting. A second purpose is to provide a class of heat resistant copolymers which cure through addition rather than through condensation. A third purpose is to provide thermosetting addition polymers which have sufficiently low viscosity to exhibit good melt flow characteristics, good molding properties and good coating characteristics, and a fourth purpose is to provide thermosetting resins which, when used in the fabrication of composite structures, yield cured resin matrices having very low or zero void contents. This latter purpose is very important since composite structures without voids can exhibit the optimum potential properties characteristic of their constituents.
I have discovered that the incorporation of diethynylbenzene and analogous copolymerizable acetylene substituted diluents in a polyimide oligomer such as one having the following structure ##STR2## wherein x, n, and m are as defined previously, will yield products which allow me to produce laminates with essentially zero void contents, and such laminates are considerably stronger than analogous laminates with larger void contents. In the specific case where n = 2 and m = 0, the oligomer is one which I call HR600. This is the one which was used in several of my experiments.
The advantage of this invention is largely attributed to the fact that my copolymer was produced from a polyimide oligomer and a liquid compound which could effectively interact with it during cure. The liquid effectively thins out the oligomer when the oligomer is heated and molded and allows the molten oligomer to flow readily into the pores and crevices in fillers and fabric reinforcements. Upon cure, the "thinner" coreacts with the oligomer and thus it doesn't have to be removed from the resin as an ordinary solvent wouuld have to be. The coreaction between the thinner and the oligomer during cure also yields a product with a higher cross link density than that which the cured oligomer alone would have. With HR600, the copolymers of this invention can be visualized as being formed as follows: ##STR3## Although the whole molecule is not illustrated, this partial structure adequately illustrates the high degree of complexity of the copolymers. Nuclear magnetic resonance spectroscopy supports the belief that cure occurs when aromatic rings are formed from the acetylene substituted polyimides. However, absolute proof of this theory has not been obtained and it may be that some other types of functional groups such as cyclobutadiene groups or bi-ethynyl groups might also be present to some degree. Nevertheless, the HR600 and diethynylbenzene obviously copolymerize as evidenced by the void free composite structure obtained when a laminate was made.
One copolymer of this invention can be produced by mixing diethynylbenzene with the ethynyl substituted polyimide oligomer. It is important, however, to avoid the use of excess diethynylbenzene since this compound can polymerize explosively. I thus prefer using less than 20% by weight of the diethynylbenzene in the oligomer. It is possible to pre-react these materials by careful heating of the mixtures at temperatures of about 400°-450° F, but prepolymerization is not essential since the oligomer can merely be diluted with the diethynylbenzene and used directly as a molding or laminating resin. Various other di- or polyethynyl-substituted diluents could also function in this capacity.
A specific example of how my copolymer may be prepared within the matrix of a laminate is described below.
EXAMPLE I
A section of glass cloth (181E glass having an A-1100 finish) was cut to 10 × 18 inches and then weighed. A quantity of powered HR600 was then weighed out sufficient to provide a 40% resin weight pick up on the fabric. To this amount of resin was added N-methylpyrrolidone, producing a coating varnish after heating the mixture to 325° F to promote dissolution. The glass fabric was dipped into, and slowly pulled through the hot solution in a dip tank at 350° F. The coating process was repeated until all of the varnish was consumed; however, the fabric was air dried for 30 minutes followed by 15 minutes at 350° F. after each coating. Subsequently the coated fabric was dried for 16 hours under vacuum at 160° F. Next it was cut in half, and 1 half was made into a 6 ply laminate by molding it at 485° F and 200 p.s.i. using a contact time of 90 seconds and a cure time of 2 hours.
The other half of the fabric was brushed with a solution of diethynylbenzene (DEB) in hexane (20 ml.). Sufficient DEB was used so that its weight was equal to 10% of the HR600 resin weight. After a 5 minute air dry the coated "prepreg" fabric was placed into a "Teflon" film bag and the bag was sealed and stored for 7 days. After aging the fabric, a laminate was molded at 485° F and 200 p.s.i. using a contact time of 90 seconds and a cure time of 2 hours.
A comparison of the properties of these two laminates showed the following:
______________________________________ WithoutProperty DEB With DEB______________________________________Thickness 0.050" 0.045"Density 1.91 g/cc 2.11 g/ccResin Content 23.0% 24.1%Void Content 5.0% 0%______________________________________
Void content calculations were based on a density of 1.40 g/cc for the HR600 resin and 2.51 g/cc for the glass fabric.
The difference between the two laminates was startling since under the specific molding conditions used the laminate without DEB had 5% voids and the laminate with DEB had 0% voids. Other molding conditions would show a different differential.
The advantage of adding DEB was even more evident when a comparison was made between the physical properties of the DEB containing laminate and several other HR600/181E glass laminates that had been fabricated earlier and tested previously. Results of this comparison are shown below
__________________________________________________________________________ Flexural Flexural Void Strength Modulus,Laminate No. Content p.s.i. at 550° F. p.s.i. at 550° F.__________________________________________________________________________G 1996-31 3.5 26.5 × 10.sup.3 1.25 × 10.sup.6(no DEB)G 1996-22B 1.4 28.5 × 10.sup.3 1.95 × 10.sup.6(no DEB)With DEB/HR600 0 34.5 × 10.sup.3 2.40 × 10.sup.6__________________________________________________________________________
EXAMPLE II
A chloroform solution of HR700 oligomer (whose structure is shown below) was mixed with sufficient diethynylbenzene (DEB) ##STR4## such that the oligomer DEB weight ratio was 10 to 1 and the mixture was poured into a small crystallizing dish. After the chloroform had evaporated, the oligomer mixture was pulverized and molded with heating at a pressure of 200 p.s.i. Microscopic examination of the cured resin showed no evidence of porosity.
Having described my invention with sufficient particularity so as to let one know what is intended, the scope of my claims may now be understood as follows.
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A new class of copolymers obtained via copolymerizing diethynylbenzene with an ethynyl substituted polyimide oligomer has been developed. The copolymers are thermosetting in character and are particularly useful for the fabrication of composite structures such as glass fiber reinforced laminates and molding compounds and graphite fiber reinforced laminates and molding compounds having zero void content.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device used to dynamically separate at least two zones in which there are different environments, to enable objects or products to be transferred from one zone to the other at high speed without breaking the confinement.
The process according to the invention may be used in many industrial sectors.
Thus, this process is applicable to all industries (food processing, medical, biotechnologies, high technologies, nuclear, chemical, etc.) in which different environments have to be maintained in zones communicating with each other to enable frequent passage of objects or products. The term “environment” refers particularly to aeraulic conditions, gaseous and particular concentrations, temperature, relative humidity, etc.
2. Discussion of the Background
At the present time, there are two types of solutions for dynamically separating two zones communicating with each other, for example in order to allow objects to be brought in and out; these two types are protection by ventilation and protection by air curtain.
Protection by ventilation consists of artificially creating a pressure difference between the two zones so that the pressure in a zone to be protected is greater than the pressure inside a contaminating zone. Thus, if the zone to be protected contains a product that could be contaminated by ambient air, a laminar flow is injected into the zone to be protected that blows outwards through the access opening to this separation zone. In the opposite case in which personnel and the environment outside a contaminated space need to be protected, dynamic confinement is achieved by using extraction ventilation in this contaminated space. In each case, an empirical rule imposes a minimum ventilated air speed of 0.5 m/s in the plane of the opening through which the two zones communicate in order to prevent contamination from being transferred into the zone to be protected.
However, the efficiency of this ventilation protection technique is not perfect, particularly in a so-called “infractions” situation, in other words when objects are transferred between the two zones. Furthnermore, this type of protection makes it necessary to process and control the entire zone to be protected ron the contaminating external atmosphere or the entire contaminated zone. When the zone to be processed and controlled is large, this introduces a particularly high investment and operating cost. Finally, this technique of protection by ventilation only provides protection in one direction, in other words it is onlv useful when contamination transfers are only possible in one direction.
The air curtain protection technique consists of simultaneously injecting one or several adjacent clean air jets in the same direction into the separation zone between the two zones, which form an immaterial door between the zone to be protected and the contaminating zone.
Note that according to the theory of turbulent plane jets, a plane air jet is composed of two separate zones; a transition zone (or core zone) and a development zone.
The transition zone corresponds to the central part of the jet adjacent to the nozzle in which clean air is injected. Within this zone in which there is no mix between the injected air and the air on each side of the jet, the speed vector is constant. Considering a cross-section through a plane perpendicular to the plane of the separation zone, the width of the transition zone gradually decreases as the distance from the nozzle increases. This is why this transition zone is called a “tongue” throughout the rest of the text.
The-development zone of the jet is the part of this jet located outside the transition zone. In this jet development zone, outside air is entrained by the jet low. This results in variations in the speed vector and mixing of air. Air entrainment on both surfaces of the jet within this development zone is called “induction”. Thus an air jet induces an air flow on each of its surfaces which depends particularly on the injection flow of the jet considered.
Documents FR-A-2 530 163 and FR-A-2 652 520 propose an air curtain to separate a polluted zone from a clean zone. in both cases, the air curtain consists of twio adjacent clean air jets blowing in the same direction. Nllore precisely, dynamic separation is provided by a first relatively slow jet (called the “slow jet”), for which the tongue entirely covers the opening. The second jet (called the “fast jet”) is faster than the slow jet, and is installed between the slow jet and the zone. Its function is to stabilize the slow jet by a suction effect which brings this slow jet into contact with the fast jet.
In these documents, it is specified that the tongue of the slow jet is sufficiently long to cover any opening when the width of the slow jet injection nozzle is equal to at least ⅙ th of the height of the opening to be protected.
Document FR-A-2 652 520 also proposes to simultaneously inject clean ventilation air at a temperature adapted to the requirements, inside the clean zone to be protected. Note that this clean ventilation air must be injected at a rate approximately equal to the rate induced by the surface of the fast jet which is in contact with clean ventilation air.
Furthermore, document FR-A-2 659 782 proposes to add a third relatively slow clean air jet to the two clean air jets used in documents FR-A-2 530 163 and FR-A-2 652 520 so that the fast jet is located between two adjacent slow jets in the same direction. The flow of clean ventilation air injected inside the zone to be protected is then considerably reduced due to the fact that induction in this zone is produced by the development zone of one of the slow jets, rather than by the development zone of the fast jet as in the case of an air curtain with two jets. Furthermore, dynamic confinement is provided in both directions, which was not the case in the previous documents.
Document WO-A-96 241011 also describes an installation in which a chamber containing a confined atmosphere, communicates with the same outside atmosphere through one or two openings, with which gas curtains are associated. Each gas curtain is formed of a slow jet sustained by a fast jet as described in documents FR-A-2 530 163 and FR-A-2 652 520. The chamber can be used for continuous processing of products due to the injection of a reagent inside it. Products pass from the outside atmosphere into the confined atmosphere in this chamber to be processed in it before being taken out again to the external atmosphere.
Despite the improvements made to the air curtain technique described in these various documents, the problem of transferring objects or products at a high rate between two zones in which there are different environments without breaking the confinement has not been satisfactorily solved by any known device, particularly if there is a risk of cross-contamination between the two zones.
SUMMARY OF THE INVENTION
More particularly, the purpose of the invention is a device for dynamic separation of at least two zones in which there are different environments authorizing high speed transfer of objects or products between these zones, without breaking the confinement, even in the case in which there is a risk of cross-contamination between the two zones.
According to the invention, this result is obtained by means of a dynamic separation device separating at least two zones in which there are different environments, characterized by the fact that it comprises:
at least one buffer zone with controlled atmosphere used for communication between the zones to be separated;
dynamic confinement means placed between each pair of adjacent communicating zones to create an air curtain between these zones comprising a first relatively slow clean air jet which comprises a tongue which completely closes off communication between the zones, and a second relatively fast clean air jet in the same direction as the first jet and adjacent to it, on the side of the buffer zone.
The expression “with controlled atmosphere” means that all characteristics of the air present in the buffer zone such as temperature, relative humidity, aeraulic conditions, gaseous and particular concentrations, etc., are controlled.
The expression “adjacent communicating zones” means each group of two zones in the assembly formed by the zones to be separated and by the buffer zones, that communicate directly with each other. Thus in the case in which the device comprises a single buffer zone located between two zones to be separated, there are two pairs of adjacent communicating zones each formed by the single buffer zone and one of the zones to be separated. When there are several buffer zones, there is at least one other pair of adjacent communicating zones formed of two buffer zones.
The arrangement consisting of one of several buffer zones between the zones to be separated, and air curtains formed from at least two jets of clean air between adjacent communicating zones, enable objects or products to be transferred at high speed while preventing contaminants present in either of the controlled environment zones from reaching the other controlled environment zone, and vice versa. Each buffer zone thus acts as a dynamic lock between the zones to be separated.
Preferably, the dynamic confinement means that are inserted between each pair of adjacent communicating zones are such that the second (fast) jet in each air curtain is injected at a flow such that the air flow induced by the surface of the second jet in contact with the first (slow) jet is less and preferably approximately equal to half the first jet injection rate.
In one special embodiment, these dynamic confinement means are such that each air curtain comprises a relatively slow third jet in the same direction as the first and second jets and adjacent to the second (fast) jet on the same side as the buffer zone. This third jet then comprises a tongue that completely closes off communication between the zones and it is injected at a flow significantly equal to the injection flow in the first jet, so that the air flows induced by the surfaces of the second jet in contact with the first and third jets respectively are less than, or preferably approximately equal to half of the injection flows of the jets.
In practice, each of the dynamic confinement means comorises at least two adjacent air supply nozzles and an intake grille facing the supply nozzles and located in a plane parallel to them. The supply nozzles and the intake grilles are advantageously located in line with the upper and lower surfaces of the buffer zone.
In order to further improve the behavior of the device particularly in infraction situations through air curtains, the buffer zone preferably comprises ventilation, such as a blower ceiling, associated with the injection means that inject clean air into this zone. The flow from these injection means is then equal to at least the sum of the air flows induced by each of the surfaces of the jets in the air curtains in contact with the buffer zone. Furthermore, the flow from the injection means is such that it provides a minimum speed of 0.1 m/s across the areas of the planes at the ends of the buffer zone.
In this case, the buffer zone may also comprise an intake grille distributed over its entire lower surface. The flow from the injection means is then equal to at least the sum of the air flow drawn in by the intake grille and the air flow induced by each of the surfaces of the air curtain jets in contact with the buffer zone. Furthermore, the flow from the injection means must always be sufficient to provide a minimum speed of 0.1 m/s across the areas of the planes at the ends of the buffer zone. This arrangement corresponds particularly to the case in which the buffer zone is used to carry out an elementary operation (proportioning, packaging, etc.) on objects or products transferred between the zones to be separated.
In the latter case, several buffer zones may be placed in series between the zones to be separated. The air curtains inserted between the two buffer zones are then delimited by side walls with a width equal to the width of the adjacent air supply nozzles.
Furthermore, regardless of the number of buffer zones used on the device, the air curtains inserted between a buffer zone and one of the zones to be separated are delimited by side walls with a width equal to at least the maximum thickness of these air curtains.
BRIEF DESCRIPTION OF THE DRAWINGS
We will now describe some non-limitative examples of different embodiments of the invention with reference to the attached drawings in which:
FIG. 1 is a perspective view that diagrammatically illustrates the use of a single buffer zone to provide communication between two zones with controlled environments through two air curtains each formed of two adjacent clean air jets according to a first embodiment of the invention;
FIG. 2 is a perspective view comparable to FIG. 1 which illustrates the case in which each air curtain is formed of three adjacent clean air jets according to a second embodiment of the invention; and
FIG. 3 is a perspective view that diagrammatically illustrates the use of several buffer zones in series between two zones with controlled environments, with the insertion of an air curtain between each pair of adjacent communicating zones.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows two zones denoted by reference 10 a and 10 b , in which there are different environments and in which it is required to be able to transfer objects or products at high speed in at least one direction. These zones 10 a and 10 b are called the “zones to be separated” or “zones with controlled environments” throughout the rest of this text. For example, it is assumed non-restrictively that objects or products must be transferred at high speed from zone 10 a to zone 10 b.
Zones 10 a and 10 b are delimited by air tight surfaces (not shown) and the environment in each zone is different, in other words at least one of the characteristics, specifically such as gaseous and particular concentrations, aeraulic conditions, temperature, relative humidity, etc. is different in the two zones.
According to the invention, zones 10 a and 10 b are linked to each other through at least one dynamic separation system which, in the embodiment shown in FIG. 1, includes a buffer zone 12 through which zones 10 a and 10 b communicate. More precisely, the buffer zone 12 is a zone with a controlled atmosphere, in other words a zone in which various parameters such as gaseous and particular concentrations, aeraulic conditions, temperature, relative humidity, etc., are controlled.
The dynamic separation device according to the invention also comprises dynamic confinement means denoted in general by references 14 a and 14 b on FIG. 1, which are inserted between zone 10 a and buffer zone 12 , and between buffer zone 12 and zone 10 b respectively, in other words eacn pair of adjacent communicating zones in the installation.
Dynamic confinement means 14 a create a first air curtain 16 a between zone 10 a and buffer zone 12 . imilarly, dynamic confinement means 14 b create a second air curtain 16 b between buffer zone 12 and the zone 12 b with controlled environment.
As illustrated diagrammatically in FIG. 1, the buffer zone 12 is delimited by air tight surfaces in order to form a horizontal corridor with a rectangular cross-section, the ends of which lead into zone 10 a and into zone 10 b through air curtains 16 a and 16 b created by dynamic confinement means 14 a and 14 b.
The upper horizontal surface of the buffer zone 12 forms a blower ceiling 18 . This blower ceiling 18 is associated with injection or ventilation means (not shown) that output clean air to the buffer zone 12 at a determined flow. As will be seen later, this flow depends on the characteristics of the air curtains 16 a and 16 b and whether or not there is an intake grille in buffer zone 12 .
In the embodiment shown in FIG. 1, the horizontal lower surface 20 of the buffer zone 12 forms a working plane. As a variant, an intake grille may be distributed over this entire lower surface 20 , to recover part of the ventilation air flow injected into buffer zone 12 through the blower ceiling 18 .
In addition to its upper horizontal surface that forms the blower ceiling 18 and its lower horizontal surface 20 , the buffer zone 12 is delimited by two side walls 22 , also oriented vertically parallel to the plane of FIG. 1 .
The dynamic confinement means 14 a and 14 b are placed in line with the air tight walls that delimit the buffer zone 12 so as to form the air curtains 16 a and 16 b when these confinement means are used.
More precisely, in the embodiment shown in FIG. 1, dynamic confinement means 14 a and 14 b are designed to create air curtains 16 a and 16 b each of which are formed of two clean air jets adjacent to each other and in the same direction. Consequently, dynamic confinement means 14 a comprise two air supply nozzles 24 a and 26 a that extend across the entire width of buffer zone 12 in line with the blower ceiling 18 on the zone 10 a side. Similarly, dynamic confinement means 14 b comprise two air supply nozzles 24 b and 26 b that extend across the entire width of buffer zone 12 in line with the blower ceiling 18 on the zone 10 b side. All air supply nozzles 24 a , 26 a , 24 b and 26 b output into the same horizontal plane located in line with the lower surface of the blower ceiling 18 .
The dynamic confinement means 14 a also comprise a horizontal intake grille 28 a located on the surface of the air supply nozzles 24 a and 26 a and extend over the entire width of buffer zone 12 , in line with its lower surface 20 . Similarly, dynamic confinement means 14 b comprise a horizontal intake grille 28 b placed below the air supply nozzles 24 b and 26 b and extending over the entire width of buffer zone 12 , in line with its lower surface 20 .
Each of the dynamic confinement means 14 a and 14 b also comprises means (not shown) of injecting air at a controlled speed and flow through the air supply nozzles 24 a and 26 a , and through the air supply nozzles 24 b and 26 b respectively, and means (not shown) of drawing in all air flows injected through the nozzles and induced air flows, through intake grilles 28 a and 28 b respectively.
As shown diagrammatically in FIG. 1, the air tight side walls 22 that delimit the buffer zone 12 extend beyond the ends of this zone over a length equal to at least the maximum thickness of the air curtains 16 a and 16 b , in order to avoid any break in the confinement at the sides of air curtains.
As already mentioned, the embodiment in FIG. 1 corresponds to the case in which each air curtain 16 a and 16 b is formed of two adjacent clean air jets in the same direction. The two air curtains 16 a and 16 b have exactly the same characteristics which will now be described in more detail.
When the dynamic confinement means 14 a and 14 b are used, each of the air supply nozzles 24 a and 24 b outputs a relatively slow clean air jet, for which only tongues 30 a and 30 b are shown. Furthermore, each of the air supply nozzles 26 a and 26 b located on the same side of the blower ceiling as the nozzles 24 a and 24 b outputs a relatively fast clean air jet compared with the jets output by nozzles 24 a and 24 b . FIG. 1 only shows the tongues 32 a and 32 b of these relatively fast jets. To simplify the description, the relatively slow and relatively fast jets are called “slow jets” and “Last jets” in the rest of the text.
Since the air supply nozzles 24 a , 26 a , 24 b and 26 b extend over the entire width of the buffer zone 12 , the air curtains 16 a and 16 b also extend over the entire width of the burrer zone between the buffer zone side walls 22 .
As shown diagrammatically in Iigure 1 , each of the slow jets injected by nozzles 24 a and 24 b is sized such that its tongue 30 a , 30 b covers tne entire cross-section of the buffer zone at the ends of the buffer zone adjacent to zones 10 a and 10 b respectively. This result is obtained by making sure that the range, or length, of the tongues 30 a and 30 b is at least as long as the height of the buffer zone 12 . This is achieved by making the width of the injection slit for each nozzle 24 a and 24 b parallel to the plane of the figure equal to at least ⅙ th and preferably ⅕ th of the height of the buffer zone 12 .
Furthermore, the speed of each of the slow jets emitted by nozzles 24 a and 24 b is advantageously equal to 0.5 m/s, in order to minimize turbulence and for economic reasons. Since the length of the tongues 30 a and 30 b of the slow jets is equal to at least half of the height of the buffer zone 12 and since these jets are relatively slow, the air streams go around the contours of the objects or products that pass through the air curtains 16 a and 16 b without breaking the confinement.
However, the low speed of the slow jets injected by nozzles 24 a and 24 b mean that these jets, if they were alone, could be destabilized by aeraulic or mechanical disturbances that could occur close Lo the air curtains, thus breaking the confinement of zones 10 a and 10 b . This is why fast jets injected by nozzles 26 a and 26 b are added to each of the slow jets. The highest speed of these fast jets stabilizes the slow jets and consequently improves the confinement efficiency of zones 10 a and 10 b in infraction situations through the dynamic barriers forred by each of the air curtains 16 a and 16 b . As a nonrestrictive example, the width of each fast jet air supply nozzle 26 a and 26 b may be equal to about {fraction (1/40)} th of the width of the slow jet air suoplv nozzles 24 a and 24 b.
Preferably, in order to optimize the barrier effect provided by air curtains 16 a and 16 b , the injection flow of each fast jet through nozzles 26 a and 26 b is adjusted such that the air flow induced by the surfaces of these fast jets that are in contact with the slow jets injected through nozzle 24 a and 24 b is less than, or preferably approximately equal to half of the injection flow through these slow jets.
As already noted, the intake grilles 28 a and 28 b recover the entire air blown through the supply nozzles under which they are placed, and all entrained air by each air curtain 16 a and 16 b . In practice, air recovered through intake grilles 28 a and 28 b may be purified by specific purification means (not shown) before being recycled to air supply nozzles 24 a , 26 a ; 24 b , 26 b . Excess air is then released outside after a second specific purification.
Note that the horizontal orientation of the air supply nozzles that determines a vertical orientation of the air curtains, and the horizontal arrangement of the intake grilles facing the air curtains, optimize the barrier effect obtained using each of the dynamic confinement means 14 a and 14 b.
Furthermore, internal ventilation of the buffer zone 12 provided by the blower ceiling 18 produces a purifying effect in this zone. This purifying effect contributes to the efficiency of the dynamic separation of zones 10 a and 10 b , particularly in the case of a high transfer rate of objects or products between these two zones.
More precisely, in the embodiment shown in FIG. 1 in which each of the air curtains 16 a and 16 b is formed of two adjacent jets in the same direction, the clean ventilation air flow injected in the buffer zone 12 through the blower ceiling 18 is equal to at least the air flow induced by the fast jets output from nozzles 26 a and 26 b , on the surfaces of these fast jets that are in contact with the buffer zone 12 . Furthermore, the clean ventilation air is injected into the buffer zone 12 through the blower ceiling 18 at a speed such that the air speed across the areas of the planes at the ends of the buffer zone 12 that lead into zones 10 a and 10 b , is equal to at least 0.1 m/s.
Furthermore, note that the physical characteristics (temperature, relative humidity, gaseous and particular concentrations, etc.) are controlled by appropriate means (not shown), so as to establish and maintain a determined atmosphere in Lhe buffer zone 12 . This atmosphere may be identical to the atmosphere in one of the two zones 10 a and 10 b , or it may be different from this atmosphere, depending on the application being considered.
Each of the intake grilles 28 a and 28 b has a width approximately equal to the total width of the air supply nozzles 24 a and 26 a , and 24 b and 26 b respectively. However this width may be varied, particularly to take account of some aeraulic conditions in zones 10 a and 10 b , tending to deviate the jets forming the air curtains 16 a and 16 b from the vertical. Thus, it is desirable to reduce the width of the corresponding intake grille towards the inside of buffer zone 12 , When the jets forming the air curtain Lend to be deviated towards the outside of this zone. Conversely, the width of the intake grille must be increased towards the inside of the buffer zone 12 when the jets forming the air curtain tend to be deviated towards the inside of this zone.
FIG. 2 illustrates a second embodiment of the invention which is essentially different from the embodiment in FIG. 1 due to the fact that each air curtain denoted by references 16 ′ a and 16 ′ b comprises three jets of adjacent clean air in the same direction.
This is achieved by providing each of the dynamic confinement means denoted by references 14 ′ a and 14 ′ b , in addition to the air supply nozzles 24 a , 26 a and 24 b and 26 b respectively, with a third supply nozzle 34 a and 34 b adjacent to nozzles 26 a and 26 b respectively on the side of the blower ceiling 18 . More precisely, nozzles 34 a and 34 b extend over the entire width of the buffer zone 12 and their output is arranged in the same horizontal plane as the other nozzles 24 a , 26 a ; 24 b , 26 b , in other words in a horizontal plane which is coincident with the plane of the lower surface of the blower ceiling 18 .
When dynamic confinement means 14 ′ a and 14 ′ b are implemented, each of the air supply nozzles 34 a and 34 b outputs a third clean air jet which is relatively slow with respect to fast jets emitted by nozzles 26 a and 26 b , between this fast jet and the buffer zone 12 . The tongues of these third jets are illustrated as 36 a and 36 b in FIG. 2 .
The dimensions of nozzles 34 a and 34 b are chosen such that the tongues 36 a and 36 b of the third jets in each of the air curtains 16 ′ a and 16 ′ b cover the entire section of the buffer zone 12 . Consequently, the lower slit in each of the nozzles 34 a and 34 b has a width equal to at least ⅙ th , and preferably ⅕ th of the height of the buffer zone 12 , in the cross section parallel to the plane of FIG. 2 . In practice, the widths of nozzles 24 a , 34 a and 24 b , and 34 b are identical.
In the second embodiment of the invention illustrated in FIG. 2, the injection flow from the slow jets output by nozzles 34 a and 34 b is adjusted to be approximately equal to the injection flow from the slow jets output by nozzles 24 a and 24 b . Thus, the air flows induced by the surfaces of the fast jets output through nozzles 26 a and 26 b in contact with each of slow jets in the corresponding air curtain, are less than or preferably approximately equal to half of the injection flows in these slow jets.
As is also shown in FIG. 2, the width of each of the intake grilles 28 ′ a and 28 ′ b is adapted to the width of the air curtains 16 ′ a and 16 ′ b , so that it is approximately equal to the total width of the nozzles forming these air curtains. Obviously, this width may be varied as described previously with reference Lo FIG. 1, when the aeraulic conditions in at least one of the zones 10 a and 10 b tend to deviate the air curtains from the vertical.
The second embodiment that has just been described briefly with reference to FIG. 2 provides dynamic confinement in both directions between buffer zone 12 and each of zones 10 a and 10 b . Furthermore, the clean ventilation air flow injected through the blower ceiling 18 may be considerably reduced. The air injection flow through the blower ceiling 18 is then equal to at least the air, flows induced by the slow jets emitted through the injection nozzles 24 a and 24 b , on the surfaces of these jets in contact with the buffer zone 12 , and it is such that it provides a minimum speed of 0.1 m/s across the areas of the planes at the ends of the buffer zone.
In the embodiments described above with reference to FIGS. 1 and 2, the buffer zone 12 is a passive zone in which no operations are carried out on objects or products that are transferred between zones 10 a and 10 b.
In other embodiments of the invention, the buffer zone 12 is an active zone, in other words it is used to carry out an elementary operation (proportioning, packaging, etc.) on objects or products transferred between zones 10 a and 10 b.
The architecture of the dynamic separation device is then identical to the architecture described above with reference to FIGS. 1 and 2. However, an intake grille is distributed over the entire lower surface 20 of buffer zone 12 . The intake speed through this intake grille varies for example between about 0.1 m/s and 0.2 m/s. The internal ventilation supply flows through the blower ceiling 18 is then larger, and is equal to at least the sum of the air flows induced by each of the surfaces of the air curtains in contact with the buffer zone 12 and the intake flow through the intake grille.
Furthermore, this internal ventilation supply rate should correspond to a minimum speed of 0.1 m/s across the areas of the planes at the ends of the buffer zone.
Note that the ventilation flows through the blower ceiling 18 and the intake flows through the intake grille may be higher. However, the operating cost of the installation will then be higher.
As shown diagrammatically in FIG. 3, several successive individual operations (proportioning, packaging, etc.) may be carried out between zones 10 a and 10 b during the transfer of objects or products. In this case, the dynamic separation device according to the invention will comprise several buffer zones 12 laid out in series, through which zones 10 a and 10 b can communicate. Each buffer zone 12 then has characteristics similar to the characteristics described above, and particularly a blower ceiling 18 and an intake grille 20 ′ facing it.
In this case, dynamic confinement means denoted by references 14 a , 14 b and 14 c are inserted between each pair of adjacent communicating zones. More precisely, dynamic confinement means 14 a are inserted between zone 10 a and buffer zone 12 which leads into zone 10 a , the dynamic confinement means 14 c are inserted between each pair of adjacent buffer zones 12 and dynamic confinement means 14 b are inserted between zone 10 b and buffer zone 12 that leads into this buffer zone.
Dynamic confinement means 14 a , 14 b and 14 c are identical with each other and they may be made as described above with reference to FIG. 1, or as described above with reference to FIG. 2, depending on the case.
As described above, the air curtains formed by the dynamic confinement means 14 a and 14 b separating zones 10 a and 10 b are delimited at the sides by side walls 22 of the buffer zones considered which extend into zones 10 a and 10 b , so as to have a width equal to at least the maximum thickness of the air curtains considered.
On the other hand, the air curtains formed by dynamic confinement means 14 c that separate two consecutive buffer zones 12 are delimited at the sides by extensions of the side walls 22 of these buffer zones over a width equal to the width of the supply nozzles forming these air curtains.
As illustrated as an example in the case of the central buffer zone 12 in FIG. 3, note that a single buffer zone can provide dynamic separation of more than two zones 10 a , 10 b and 10 c . In this case, one or several openings are formed in at least one of the side walls 22 of the buffer zone considered and each of the openings is controlled by dynamic confinement means 14 d , the characteristics of which are similar to the characteristics of the dynamic confinement means 14 a and 14 b in FIG. 1, or dynamic confinement means 14 ′ a and 14 ′ b in FIG. 2 .
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A device for dynamically separating two zones by a bufer zone and two clean air curtains. When transferring objects at high speed between two zones, a buffer zone which is connected to the two zones, forms a dynamic lock in order to separate them. a dynamic confinement system placed between each pair of adjacent communication zones forms an air curtain including two or three clean air jets. The buffer zone includes a blower ceiling and an intake grill facing it.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a continuation of, and claims priority to, U.S. application Ser. No. 12/360,845 entitled “Antihelix-Conforming Ear-Mount for Personal Audio-Set”, filed Jan. 27, 2009, which is a continuation of U.S. application Ser. No. 10/358,120 entitled “Antihelix-Conforming Ear-Mount For Personal Audio-Set”, filed on Feb. 3, 2003, which claims priority to U.S. Provisional Application No. 60/361,490 entitled “Antihelix-Conforming Ear-Mount For Personal Audio-Set”, filed on Mar. 2, 2002, and which is a continuation-in-part of, and claims priority to, the following U.S. Design Applications: U.S. Design Application No. 29/161,922, filed on Jun. 5, 2002, which issued as U.S. Design Pat. No. D469,755 on Feb. 4, 2003; U.S. Design Application No. 29/161,923, filed on Jun. 5, 2002, which issued as U.S. Design Pat. No. D470,128 on Feb. 11, 2003; U.S. Design Application No. 29/161,924, filed on Jun. 5, 2002, which issued as U.S. Design Pat. No. D470,122 on Feb. 11, 2003; and U.S. Design Application No. 29/161,926, filed on Jun. 5, 2002, which issued as U.S. Design Pat. No. D470,123 on Feb. 11, 2003, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a mount for a headset and the like that compresses to conform with the inner ridge of a wearer's ear known as the antihelix, thereby comfortably and detachably securing the headset in place.
BACKGROUND OF THE INVENTION
Personal audio-sets, commonly known as headphones, earphones, headsets, and the like, are gaining in popularity. The typical audio-set includes a frame containing an earphone which is usually positioned over or in a wearer's ear. In cases where the audio-set is a headset, a microphone is also typically positioned on the frame near the wearer's mouth.
It is important that the frame of the audio-set securely hold these components in their proper places with respect to the wearer, without being unduly heavy and without causing discomfort to the wearer. Historically, the frames of personal audio-sets have included a headband that the wearer positions over or behind their head to hold an earphone portion over one or both ears. However, some headband-type personal audio-sets inadvertently compress the wearer's head and/or ears thereby causing discomfort, particularly when the personal audio-set is worn for extended periods.
More recently, personal audio-sets have been mounted to a wearer without using a headband. For example, headphones have been clipped around a wearer's ear as shown in Marshall (U.S. Pat. No. 5,625,171). However, these types of mounts are relatively bulky structures and some wearers feel discomfort supporting the personal audio-set in this matter. In addition, most ear clip designs do not easily lend themselves to being worn over either a wearer's left or right ear.
Also, some personal audio-set rely on ear plug-type mounts, which are also commonly known as ear bud-type mounts, that are either physically wedged either into the wearer's ear canal or hooked on the intertragal notch of the wearer's ear as shown in Nagayoshi et al. (U.S. Pat. No. 5,544,253). However, the size of a wearer's ear and ear canal differ greatly between wearers. Accordingly, different sized ear plugs must typically be offered to account for these differences in ear and ear canal sizes. Moreover, since the entire weight of the assembly is supported by such a small portion of the ear, these types of mounts feel uncomfortable for some wearers.
In addition, in order to optimize the sound qualities of the audio-set, it is desirable for the sound pressure producing device, such as the headphone driver or other audio transducer, to be pneumatically coupled to the tympanic membrane (also known as the “eardrum”) via the external auditory meatus (also known as the “ear canal”). However, many typical ear bud-type mounts permit an excessive amount of pneumatic leakage between the ear bud and the wearer's ear. This excessive leakage is usually perceived as a loss in the low frequency region of the sound transmission spectrum.
More recently, some manufacturers of ear bud-type mounts have attempted to reduce this pneumatic leakage by completely occluding the ear canal with the ear bud. While such occlusion blocks a large portion of background noise, they also tend to increase the passive attenuation of the system. Accordingly, such designs are often perceived as unnatural by the wearer. In addition, under some circumstances, such as when using a headset in an office or while driving, it is undesirable to completely block all ambient noise by occluding the ear canal with the ear bud. Accordingly, such ear bud designs tend to be undesirable for many uses.
SUMMARY OF THE INVENTION
Accordingly, despite the available improvements offered by personal audio-set ear-mounts, there remains a need for an ear-mount that is lightweight, not bulky, and comfortable to wear, that also minimizes pneumatic leakage between the ear bud and the ear without substantially increasing the passive attenuation of the system. In addition to other benefits that will become apparent in the following disclosure, the present invention fulfills these needs.
The present invention is a personal audio-set, such as a headphone, earphone, or headset, that includes a mounting portion and an ear bud. The mounting portion preferably has an ear bud mounting portion and an antihelix mounting portion. The antihelix mounting portion is preferably a band or loop of resilient material that has an opening therethrough. The band compresses into the opening to conform with the antihelix of the wearer, thereby detachably securing the personal audio-set within a wearer's ear. More preferably, the mounting portion is substantially kidney-shaped and biased to a neutral position such that the antihelix mounting portion acts like a compression spring.
The ear bud contains a headphone driver or other audio transducer (collectively referred to herein as a “speaker” or “headphone”) and is operably secured to the wearer's ear at the ear's tragus. Accordingly, the weight of the audio-set is evenly distributed between a surface area of the ear defined by a relatively large portion of the wearer's antihelix at the mounting portion and the ear's tragus at the ear bud. The biasing force of the mounting portion urges the mounting portion to conform with the unique shape of each wearer's antihelix, thereby detachably securing the personal audio-set to the wearer's ear and forcing the ear bud against the wearer's tragus.
The opening in the mounting loop prevents the total occlusion of the ear canal, thereby allowing desirable ambient sounds to be heard by the wearer, while still allowing the headphone driver to remain in substantially pneumatic communication with the wearer's eardrum.
Preferably, the mounting portion and personal audio-set are shaped to fit in both a wearer's left or right ear.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric, front view of a personal audio-set having a large sized mounting portion in a neutral position and an elongate boom microphone operably secured thereto in accordance with an embodiment of the present invention.
FIG. 2 is a side view of the personal audio-set of FIG. 1 showing a possible orientation with respect to a wearer's left ear.
FIG. 3 is an isometric, back view of the personal audio-set of FIG. 1 .
FIG. 4 is an isometric, front view of a personal audio-set having a small sized mounting portion a neutral position with a microphone operably secured thereto in accordance with an embodiment of the present invention.
FIG. 5 is an isometric, side view of the personal audio-set of FIG. 4 .
FIG. 6 is a back view of the personal audio-set of FIG. 4 .
FIG. 7 is a side view of the personal audio-set of FIG. 4 showing a possible orientation with respect to a wearer's right ear.
FIG. 8 is a back view of a personal audio-set with medium sized mounting portion in a neutral position and a headphone operably secured thereto in accordance with an embodiment of the present invention.
FIG. 9 is an isometric view of an alternative personal audio-set having a mounting portion in a neutral position in accordance with an embodiment of the present invention.
FIG. 10 is a side view of the personal audio-set of FIG. 9 showing a possible orientation with respect to a wearer's right ear.
FIG. 11 is a side view of the personal audio-set of FIG. 9 showing a possible orientation with respect to a wearer's left ear.
FIG. 12 is as side view of an alternative personal audio-set having an alternative ear bud and showing a possible orientation with respect to a wearer's right ear.
FIG. 13 is an enlarged isometric view of an alternative personal audio-set having an earphone with a mounting portion in a neutral position in accordance with an embodiment of the present invention.
FIG. 14 is a side view of the personal audio-set of FIG. 13 showing a possible orientation with respect to a wearer's right ear.
FIG. 15 is a side view of the personal audio-set of FIG. 13 showing a possible orientation with respect to a wearer's left ear.
DETAILED DESCRIPTION
A personal audio-set 10 , such as a head phone, earphone 10 ′ (FIGS. 8 and 13 - 15 ), or headset 10 ″ ( FIGS. 1-7 , and 9 - 12 ), that includes a compressible mounting portion 12 that compresses to conform with the antihelix 90 of the wearer's ear 92 thereby detachably securing the personal audio-set 10 within the wearer's ear 92 is disclosed in FIGS. 1-15 .
A. Kidney-Shaped Ear Loop
In a first preferred embodiment, shown in FIGS. 1-3 , the personal audio-set 10 is a headset 10 ″ having a frame 14 with a boom microphone 16 extending longitudinally from an ear bud 18 . The ear bud 18 preferably contains driver or other audio transducer (collectively referred to herein as a “speaker 20 ” or earphone), and wiring (not shown) usually extends from the headset 10 ″ to operably connect the headset 10 ″ to an appropriate audio device (not shown).
As best shown in FIG. 2 , the ear bud 18 is sized to be received within a wearer's ear 92 such that the speaker 20 is positioned over the ear canal 94 of the wearer's ear 92 with the outer portion 24 of the ear bud 18 positioned adjacent to the tragus 96 of the wearer's ear 92 .
A compressible mounting portion 12 , which is biased to a neutral position shown in FIG. 1 , extends from the frame 14 and is operably secured to the ear bud 18 . Preferably, the mounting portion 12 includes an ear bud mounting portion 21 and an antihelix mounting portion 23 . The ear bud mounting portion 21 is operably secured to the ear bud 18 . Preferably, the ear bud mounting portion 21 is pivotally secured around the ear bud 18 defining a pivot 25 . Accordingly, the position of the frame 14 relative to the mounting portion 12 may be adjusted about the pivot 25 .
More preferably, the ear bud mounting portion 21 is constructed from a resilient cushioning material such that the outer portion 27 of the ear bud mounting portion 21 contacts and cushions the wearer's ear 92 . Moreover, the ear bud mounting portion 21 preferably encircles the speaker 20 and has a thickness sufficiently large to operably engage the wearer's concha 97 around the ear canal as shown, thereby providing a quasi-pneumatic seal between the speaker 20 and the wearer's ear canal.
One known material having these properties is silicone rubber. One brand of silicone rubber having particularly desirable characteristics for this purposes has a Shore A hardness of about 50, a tensile strength of about 10.5 MPa, and a Specific Gravity of about 1.13 g/cm 3 . Such a product is commercially available. For example, the Dow Corning Corporation of Midland, Mich., USA sells such a product under the trademark SILASTIC NEW GP 500 .
The antihelix mounting portion 23 extends from the ear bud mounting portion 21 and is sized to operably engage the wearer's antihelix 90 . The mounting portion 12 is preferably a loop of resilient material 26 that compresses substantially in the direction of arrow 30 ( FIGS. 1 and 2 ) to conform with the particular shape of the antihelix 90 of the wearer's ear 92 . Accordingly, the mounting portion 12 functions essentially as a compression spring.
More preferably, the mounting portion 12 is substantially kidney-shaped, as best shown in FIG. 1 , defining an outer edge 31 that operably engages the antihelix 90 of the wearer and a concave inner edge 33 sized to avoid the wearer's crus of helix 99 . The loop of resilient material 26 preferably defines a substantially kidney-shaped opening 35 thereby allowing the loop of resilient material 26 to compress into the opening 35 during use. Moreover, this opening 35 also prevents the speaker 20 from totally occluding the ear canal thereby allowing some ambient noise to be heard by the wearer without unduly compromising the quasi-pneumatic seal between the speaker 20 and wearer's ear canal formed by the mounting portion 12 . Acoustic testing has confirmed the benefits of this structure.
A wearer detachably secures the personal audio-set 10 within one of their ears 92 by compressing the mounting portion 12 substantially in the direction of arrow 30 ( FIG. 1 ) while aligning the mounting portion 12 with their ear's antihelix 90 . He or she then positions the ear bud 18 adjacent to their tragus 96 and releases the mounting portion 12 . The mounting portion 12 seeks to return to its neutral position thereby urging the mounting portion 12 to conform to the shape of the antihelix 90 and urging the ear bud 18 against the wearer's tragus 96 . Accordingly, the personal audio-set is secured to the wearer's ear 92 , thereby securing the personal audio-set within the ear and evenly distributing the pressure along a large portion the wearer's antihelix 90 and tragus 96 .
Preferably, the mounting portion 12 is reversible so that it may fit equally well in either the wearer's left ear ( 92 b , FIG. 2 ) or right ear ( 92 a , FIG. 7 ). The mounting portion 12 of the present embodiment may be reversed simply by detaching the ear bud mounting portion 21 from around the ear bud 18 and turning the mounting portion 12 around so that the former exterior surface 37 a is now the interior surface 37 b , then re-attaching the ear bud 18 to the ear bud mounting portion 21 .
More preferably, the mounting portion is available with different sized antihelix mounting portions. For example, a mounting portion 12 having a small sized antihelix mounting portion 23 is shown in FIGS. 4-7 , a medium-sized antihelix mounting portion 23 is shown in FIG. 8 , and a large sized antihelix mounting portion 23 is shown in FIGS. 1-3 . These different sized mounting portions are preferably sold as a set and allow a wearer the opportunity to select the optimally sized mounting portion that best conforms with their ear.
Similarly, the personal audio device operably secured to the mounting portion can be an elongate boom microphone 16 as shown in FIGS. 1-3 , a shorter microphone assembly 16 ′ as shown in FIGS. 4-7 , or a simple driver 20 as shown in FIG. 8 .
B. Alternative Ear Loop
In a first preferred embodiment, shown in FIGS. 9-11 , the personal audio-set 10 is a headset 10 ″ having a frame 14 with a boom microphone 16 extending longitudinally from an ear bud 18 . The ear bud 18 preferably contains a speaker 20 and wiring 22 ( FIG. 2 ) extends from the headset 10 ″ to operably connect the headset 10 ″ to an appropriate audio device (not shown).
The ear bud 18 is sized to be received within a wearer's ear 92 such that the speaker 20 is positioned over the ear canal 94 of the wearer's ear 92 with the outer portion 24 of the ear bud 18 positioned adjacent to the tragus 96 of the wearer's ear 92 , as shown best shown in FIG. 2 .
A compressible mounting portion 12 , which is biased to a neutral position shown in FIG. 1 , extends from the frame 14 . Preferably, the mounting portion 12 is sized to be operably received against the antihelix 90 of the wearer's ear 92 . More preferably, the mounting portion 12 is a loop of resilient material 26 that compresses in the direction of arrow 30 ( FIG. 9 ) to conform with the particular shape of antihelix 90 of the wearer's ear 92 so as to function essentially as a compression spring.
A wearer detachably secures the personal audio-set 10 within one of their ears 92 by compressing the mounting portion 12 in the direction of arrow 30 ( FIG. 9 ) while aligning the mounting portion 12 with their ear's antihelix 90 . He or she then positions the ear bud 18 adjacent to their tragus 96 and releases the mounting portion 12 . The mounting portion 12 seeks to return to its neutral position thereby urging the mounting portion 12 to conform to the shape of the antihelix 90 and urging the ear bud 18 against the wearer's tragus 96 . Accordingly, the personal audio-set is secured to the wearer's ear 92 .
Preferably, the ear bud 18 includes padding to comfort the connection between the ear bud 18 and the wearer's tragus 96 . Similarly, the mounting portion 12 is shaped to conform with the wearer's antihelix 90 , thereby evenly distributing pressure along a large portion the wearer's antihelix 90 .
More preferably, the mounting portion and personal audio-set are shaped to fit in either a wearer's right ear 92 a as shown FIG. 10 or his left ear 92 b as shown in FIG. 11 .
Referring now to FIG. 12 , the ear bud 18 can also be a pad that rests over the wearer's ear canal. The pad includes an outer portion 24 , sized to operably engage the tragus 96 of the wearer's ear 92 when the mounting portion is operably secured to the wearer's antihelix 90 as shown in FIG. 12 .
Referring now to FIGS. 13-15 , the personal audio-set 10 can also be an earphone 10 ′ without a boom microphone extending therefrom. The earphone 10 ′ includes a frame 14 having an ear bud 18 . The ear bud preferably contains a speaker 20 and wiring 22 ( FIGS. 14 and 15 ) extending from the earphone 10 ′ to operably connect the earphone 10 ′ to an appropriate audio device (not shown).
The ear bud 18 is sized to be received within a wearer's ear 92 such that the speaker 20 is positioned over the ear canal 94 of the wearer's ear 92 with the outer portion 24 of the ear bud 18 positioned adjacent to the tragus 96 of the wearer's ear 92 , as best shown in FIG. 14 (right ear 92 a ) and FIG. 15 (left ear 92 b ). The mounting portion 12 of the first preferred embodiment is operably secured to the frame 14 , thereby allowing the earphone 10 ′ to be detachably secured to either the wearer's right or left ears 92 a or 92 b , respectively.
If desired, separate earphones 10 ′ can be secured in both the right and left ears 92 a and 92 b , respectively, of the wearer, thereby providing stereo sound to the wearer, and allowing the two earphones 10 ′ to operate like a pair of headphones.
Having described and illustrated the principles of our invention with reference to a preferred embodiment thereof, it will be apparent that the invention can be modified in arrangement and detail without departing from such principles. In view of the many possible embodiments to which the principles may be put, it should be recognized that the detailed embodiment is illustrative only and should not be taken as limiting the scope of our invention. Accordingly, we claim as our invention all such modifications as may come within the scope and spirit of the following claims and equivalents thereto.
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A light weight and comfortable ear mount for a personal audio-set is disclosed. The ear mount conforms with the antihelix of a wearer's ear, thereby operating substantially as a compression spring between the wearer's antihelix and tragus, to operably secure the personal audio-set in place. In a preferred embodiment, the ear-mount is substantially kidney-shaped and includes an opening to prevent the total occlusion of the ear canal by the personal audio-set. Alternatively, the ear-mount includes a loop of material sized to operably engage the antihelix of the wearer's ear. The ear-mount is preferably reversible to allow it to be placed in either the wearer's left or right ear.
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PRIORITY ENTITLEMENT
[0001] This application is entitled to priority based on Provisional Patent Application Ser. No. 61/393,824 filed on Oct. 15, 2010, which is incorporated herein for all purposes by this reference. This application and the Provisional Patent Application have at least one common inventor.
TECHNICAL FIELD
[0002] The invention relates to camera flash methods and associated systems. More particularly, the invention relates to methods and systems designed for use with flash driver circuits and systems for driving light sources in association with image capturing apparatus.
BACKGROUND OF THE INVENTION
[0003] Images recorded by image capturing apparatus can be poor if the lighting of the target locus is not well-suited to image capture. Problems may include under- or over-lighting, excessive glare, or with human subjects, red-eye effect. The red-eye effect in photography is the problem of rendering pupils red in color photographs. The red-eye problem occurs when a photographic flash is used in close proximity to the camera lens with a low ambient light target locus. It is known to attempt to eliminate the red-eye effect in a number of ways. For example, in some instances, a flash is aimed at a nearby surface such as a reflector or umbrella in order to change the direction of the flash and diffuse the light emitted from the flash. In another approach, the flash is positioned a distance away from the camera. Such positioning ensures that the light from the flash arrives at the target locus at an oblique angle. Thus, the light emitted by the flash enters the eye from a direction other than along the optical axis of the image capturing apparatus and is reflected back from the retina in the same direction, not directly toward the lens of the camera or video equipment. Because of this, the retina is not visible to the lens and the red-eye effect is avoided. A major problem with these approaches to red-eye reduction is that equipment external to the camera is required. This can be a major inconvenience in most non-studio settings. Another red-eye avoidance technique is to precede the main flash with one or more low-power flashes, designed to cause the pupils to contract prior to the activation of the main flash. This approach does not work when a target subject blinks or glances away during the low-power flash event. Additionally, subjects can sometimes look unnatural with constricted pupils. Moreover, these red-eye reduction techniques do not address the problem of reducing glare or softening light intensity, which can be problematic with metallic, reflective, or light-colored subjects.
[0004] Due to the foregoing and other problems and potential advantages, improved flash methods and systems, particularly for LED-lighted image capturing systems, would be useful contributions to the applicable arts.
SUMMARY OF THE INVENTION
[0005] In carrying out the principles of the present invention, in accordance with preferred embodiments, the invention provides advances in the arts with useful and novel methods and systems for reducing red-eye effect and providing improved lighting for image capture. All possible variations within the scope of the invention cannot, and need not, be shown. It should be understood that the invention may be used with various cameras and imaging apparatus.
[0006] According to one aspect of the invention, in an example of a preferred embodiment, a method is disclosed for providing illumination while capturing a digital image includes steps for providing image capturing apparatus and illumination apparatus. The illumination apparatus is positioned at an oblique angle relative to the image capturing apparatus and a selected target or location. Simultaneously, light is caused to be emitted from the illumination apparatus and the digital image is captured using the image capturing apparatus. The arrangement of the illumination and image capturing apparatus relative to the target ensures that the light reflected from the target directly towards the image capturing apparatus has an intensity less than the peak intensity of the emission from the illumination apparatus.
[0007] According to another aspect of the invention, preferred embodiments of methods for providing illumination while capturing a digital image include steps for dynamically changing the flash position angle. This may be accomplished by moving the flash apparatus, or by moving the image capturing apparatus.
[0008] According to another aspect of the invention, a preferred embodiment of a method for providing illumination while capturing a digital image includes steps for varying the intensity of light emitted by the flash apparatus.
[0009] According to another aspect of the invention, a preferred embodiment of a method for providing illumination while capturing a digital image includes the deployment of LED illumination apparatus.
[0010] According to another aspect of the invention, a preferred embodiment of a method for providing illumination while capturing a digital image includes steps for selecting from a plurality of images captured at multiple flash position angles or light intensities
[0011] According to another aspect of the invention, a preferred embodiment of a method for providing illumination while capturing a digital image includes steps for combining multiple images captured at multiple flash angles or light intensities
[0012] The invention has advantages including but not limited to providing one or more of the following features, reduced red-eye effect and/or generally improved image capture lighting. These and other advantageous, features, and benefits of the invention can be understood by one of ordinary skill in the arts upon careful consideration of the detailed description of representative embodiments of the invention in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will be more clearly understood from consideration of the description and drawings in which:
[0014] FIG. 1 is a simplified schematic drawing illustrating examples of preferred embodiments of illumination and image capture systems and methods of the invention;
[0015] FIG. 2 is a simplified schematic diagram depicting further examples of preferred embodiments of illumination and image capture systems and methods of the invention;
[0016] FIG. 3 is a simplified schematic diagram portraying additional examples of preferred embodiments of illumination and image capture systems and methods according to the invention; and
[0017] FIG. 4 is a simplified schematic diagram showing an example of a further details of a preferred embodiment of an illumination and image capture system and method according to the invention.
[0018] References in the detailed description correspond to like references in the various drawings unless otherwise noted. Descriptive and directional terms used in the written description such as front, back, top, bottom, upper, side, et cetera, refer to the drawings themselves as laid out on the paper and not to physical limitations of the invention unless specifically noted. The drawings are not to scale, and some features of embodiments shown and discussed are simplified or amplified for illustrating principles and features as well as advantages of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0019] Although the making and using of various specific exemplary embodiments of the invention are discussed herein, it should be appreciated that the systems and methods described and shown exemplify inventive concepts which can be embodied in a wide variety of specific contexts. It should be understood that the invention may be practiced in various applications and embodiments without altering the principles of the invention. For purposes of clarity, detailed descriptions of functions, components, and systems familiar to those skilled in the applicable arts are not included. In general, the invention provides improved illumination and image capture methods and systems. Preferred embodiments of the invention include methods and systems for use in association with image capturing apparatus of various types. The invention is described in the context of representative example embodiments representative of principles suitable for broader application. Although variations in the details of the embodiments are possible, each has advantages over the prior art.
[0020] Within the scope of the invention, methods have been devised through which red-eye reduction can be achieved by utilizing illumination apparatus, such as LED flash devices, in a novel way that takes advantage of their light emission characteristics. It should be appreciated that the techniques disclosed and described herein with respect to examples of red-eye reduction applications may also be used to reduce glare or provide even lighting in the general context of image capture. Illumination apparatus is also referred to herein generally as “flash” apparatus. In specific examples of presently preferred embodiments of the invention, LED flash apparatus are shown and described, although the systems and methods of the invention may be implemented with alternative illumination apparatus. It should be understood that the methods and systems described and shown may be used individually, or in various combinations. System embodiments of the invention may also combine various elements and methods for use with one or more flash apparatus including multiple LED elements, arrays of LED elements, and/or other illumination apparatus in a larger image capture system.
[0021] Referring initially to FIG. 1 , an arrangement is shown in which illumination apparatus, such as for example flash LEDs 100 , are mounted at angles 102 , 104 relative to the image capturing apparatus 105 and the object or area that is to be illuminated, herein generally referred to as the “target locus”, “subject”, or “target” 106 . Due to the deployment of the LEDs at selected angles relative to the target locus, the light emission, indicated at arrows 108 , from the LEDs 100 directly towards the target 106 , and reflected to the image capturing apparatus 105 , is less than the peak intensity of the LED light emission. The peak emission is oriented towards the target 100 , but at an angle, e.g., 102 , 104 , such that the peak emission strikes the target 106 at an oblique angle. This indirect illumination reduces or eliminates red-eye from the captured image. The angles at which the LEDs may be mounted are preferably independently adjustable, both in the horizontal and vertical axes. Preferably, the LEDs are affixed to a pivoting mechanism 109 to readily facilitate repositioning. In preferred embodiments, the pivotable LEDs 100 are equipped with actuators 110 such as electro-mechanical servos or MEMs devices. In this way, the illumination apparatus may be repositioned dynamically to adapt to ambient lighting conditions, distance to target locus, or other factors.
[0022] It should be appreciated that, without departure from the scope of the invention, the illumination apparatus may be implemented in the form of more than one light source. Light sources may include LEDs or arrays of LEDs mounted at different angles, which can preferably be positioned, repositioned, and illuminated independently and/or simultaneously. This technique can be used create a more uniform emission of light from the illumination apparatus and reduce the relative magnitude of the peak illumination compared to the average illumination. The peak light intensity directed toward the target locus at substantially the same angle as the lens relative to the target will be reduced, as a result eliminating or greatly diminishing the occurrence of red-eye effect, wash-out, or glare. In an alternative implementation, the angle of the image capture apparatus relative to the light sources can be adjusted mechanically and varied. To achieve this, the imaging apparatus may be mounted on a movable or adjustable surface and supplied with actuators which can be controlled electronically. This allows another degree of adjustability to the lighting system. Using the principle of controlling and maintaining the difference between the flash angle of incidence relative to the angle of the image capturing apparatus, multiple images at multiple illumination angles can be captured. The images can then be checked for the presence of red-eye or glare and the best image can then be selected from those available for outputting or further processing. Alternatively, the images can be combined to create an optimum image without red-eye, glare, or other defects, using suitable enhancement algorithms. Instead of or in combination with capturing multiple images at distinct angles, the angle of incidence can also be changed during a flash event. This technique distributes the peak illumination across the target locus, providing a more even exposure and reducing or eliminating red-eye, glare, or other problems in the image.
[0023] In another variation of an alternative embodiment of methods of the invention, the drive current of the illumination apparatus, e.g., LEDs, can be ramped up and multiple images can be made, preferably in rapid succession at various light levels. Images captured with overly bright illumination that results in red-eye can subsequently be deleted or processed by combining them with images captured at lower illumination levels. Along these same lines, another approach is to ramp the drive current of the LEDs and search for the onset of red-eye in the captured images. This may be done over a series of several image captures or by monitoring a single image during capture and adjusting the current accordingly. Those skilled in the arts will perceive that in addition to or instead of ramping the illumination source current continuously, the current may be pulsed using an adjustable pulse width modulation (PWM). The duty cycle, amplitude, and/or frequency of the PWM can be increased to increase the effective illumination current and thus the emitted light intensity. FIG. 2 depicts a system and method in which an image of the target locus 200 is captured using image capturing apparatus such as a digital camera 202 having a CMOS or CCD image sensor. Flash apparatus such as the two separate arrays of LEDs 204 , 206 shown, are arranged with a suitable flash angles 208 , 210 . Preferably, the image capturing apparatus 202 may be used to assist in controlling the LED intensity by providing feedback concerning the perceived quality of captured images. It should be appreciated that the system and method preferably provides flexibility as to adjusting one or more of the flash angle, duration of illumination, and intensity of illumination. This flexibility can be achieved by controlling the current supply to the flash apparatus. Additionally or alternatively, the image capturing apparatus may include processing capabilities for correlating multiple pixels, images, and illumination adjustments during and/or subsequent to image capture events. Another aspect of the invention is illustrated in FIG. 3 , in which actuators 110 are shown. The actuators 110 are configured for adjusting the illumination apparatus 100 and/or the image capturing apparatus 202 in order to affect the flash angle 300 , 302 and/or illumination intensity. Preferably, the image processing apparatus includes the capability for providing command and control suitable for doing so 304 , in addition to the features previously described herein.
[0024] As with target locus lighting techniques and image capture techniques disclosed herein, further variations in image processing steps may be used without departing from the scope of the invention. Image processing algorithms can be used to capture multiple images with different integration times. Then each pixel can be examined and a determination made, preferably using a suitable automated process, whether saturation has occurred (i.e., too bright), or if no photons where collected (i.e., too dark). Subsequently, the same pixels can be used from other captured images having a shorter integration time in the case where the examined pixel was saturated, or using an image having a longer integration time in the case where the examined pixel was too dark. The selected pixels may then be placed together to form an assembled composite image for outputting or further processing. Now referring primarily to FIG. 4 , a simplified schematic diagram is presented to show an example of a CMOS image sensor internal to image capturing apparatus such as those shown and described herein, e.g., 202 . As shown, the CMOS photodetector pixel element 400 is provided with two independent resets RST 1 , RST 2 . In operation, one photodetector, e.g., 402 , is used to capture the image, during which time the other photodetector, e.g., 404 , is held in reset and released at a later time to achieve a different integration time of the image. Thus, two different integration times may be provided for the active pixel element, allowing the processor 304 to then choose which to use for the final image. This is accomplished by using suitable image processing techniques available in the applicable arts.
[0025] It should be appreciated by those skilled in the arts that the above-described techniques may be used in various combinations to achieve improved image capture lighting, preferably adaptable to ambient light conditions, and reduces red-eye effect. The methods and systems of the invention provide one or more advantages including but not limited to improved performance and/or efficiency in driver circuits. While the invention has been described with reference to certain illustrative embodiments, those described herein are not intended to be construed in a limiting sense. Variations or combinations of steps or materials in the embodiments shown and described may be used in particular cases without departure from the invention. Although the presently preferred embodiments are described herein in terms of particular examples, modifications and combinations of the illustrative embodiments as well as other advantages and embodiments of the invention will be apparent to persons skilled in the arts upon reference to the drawings, description, and claims.
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The invention provides advances in the arts with useful and novel methods and systems for providing illumination in association with image capture. Disclosed preferred embodiments of the invention include illumination apparatus adjustable in angle with respect to the image capturing apparatus and target locus. Preferred embodiments also include variability of the illumination intensity by means of controlling the power to the illuminations apparatus. Additional preferred embodiments also include techniques for selecting from or combining a plurality of images based on their illumination characteristics for providing and improved image output.
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BACKGROUND OF THE INVENTION
[0001] The invention relates generally to concrete form apparatus and, more specifically, to components of concrete form systems, such as shore posts, that are configures to be stacked in neat and stable arrangements for compact shipping and orderly and safe stacks at work sites.
[0002] Concrete forming apparatus is in wide use in the construction of buildings, bridges, and other concrete structures. A common system for forming concrete structures uses a plurality of modular form components that are adapted to be assembled into a wide variety of configurations to conform to virtually any architectural requirement. Such forming apparatus components are typically made of metal so that they are strong enough to support the heavy weight of poured concrete and durable so that the components can be reused many times.
[0003] A common-application of concrete forming apparatus is in the formation of elevated sections, such as floors or horizontal beams of a concrete building. Typically, pluralities of modular form panels are assembled to form the surface on which the concrete will be poured. These panels are supported on metal shore posts that typically are constructed of an inner tube that is received for telescopic movement inside an outer tube. Metal tubes achieve high load capacity and the telescoping tubes provide adjustment to various heights. The shore posts typically have a foot pad on the bottom end portion and an adaptable top element on the upper end portion used to releasably secure and support other components of the concrete forming apparatus.
[0004] After the new slab of fresh concrete has cured sufficiently, workers remove the shore posts and strip the formwork they supported. Commonly, the shore posts are re-used at the project job site. Between uses, the shore posts are typically stored in an out of the way location. Because of the tubular shape of the shore posts, they do not stack one on top of the other, making it difficult or impossible to make a neat, orderly, compact or stable arrangement of the shore posts. The stacks or piles of shore posts are disorganized and unstable, and may form a safety risk to workers. Once the project is completed, the shore posts must be transported to a new project site. Again, the shape of the shore posts makes it difficult to band together in a stable, compact configuration for shipping and also makes it difficult to count for inventory purposes.
SUMMARY OF THE INVENTION
[0005] The preferred embodiment of the present invention consists of a component of concrete forming apparatus having a longitudinal tubular element with top and bottom end elements that intermesh to allow the components to be stacked atop each other in a stable arrangement. In a preferred embodiment consisting of a shore post, the bottom end element is a foot pad or plate and the top end element is an adapter plate. The end plates distribute the load on the shore post and assist in connecting the shore post to other components of the concrete forming apparatus during placement of concrete. While the posts are stored between uses or during transport, the end plates function to provide a stable stack of the tubular shore posts.
[0006] In the preferred embodiment, the top end plate is a flat plate having a preselected width and the bottom end plate has a web section with a width slightly larger than the width of the top end plate and a pair of upturned flanges on either side of the web section. Accordingly, the top end plate of a shore post is received inside the flanges of the bottom end plate of an adjacent shore post. In addition, notches are formed in the perimeter of the end plates to provide a receptacle for the tubular elements of adjacent shore posts. In a stack of shore posts, the posts are arranged parallel to each other in an alternating top-for-bottom pattern. The round tubes of an upper shore post rest in the notches of the end plates of the next lower shore post and the side flanges of both bottom end plates keep the upper post from sliding or rolling off of the lower shore post. This provides the novel ability to stack multiple tubular components vertically in a column. The neatly stacked components are stable, easy to inspect, easy to count, compact, and easy to bundle for transport.
[0007] An object of the present invention is to provide round or tubular concrete forming apparatus components with end elements which cooperate to permit the components to be arranged in neat, stable, and compact stacks.
[0008] Another object of the present invention is to provide a shore post with top and bottom end plates that interact with adjacent shore posts to permit the shore posts to be arranged in neat, stable, and compact stacks.
[0009] A further object of the invention is to provide an arrangement of a plurality of concrete forming apparatus components such that stacks of the components at a job site are neat and stable, can be easily inspected and counted, and can be easily bundled together for transport
[0010] These and other objects will be understood by those skilled in the art upon a review of this specification, the associated figures and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is elevational view of a shore post representing a preferred embodiment of the present invention.
[0012] FIG. 2 is a perspective view of a plurality of shore posts of FIG. 1 arranged in a stack.
[0013] FIG. 3 is an enlarged perspective view of a foot pad of a preferred embodiment of the present invention.
[0014] FIG. 4 is an enlarged perspective view of a top end plate of a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] Illustrated in FIG. 1 , generally at 10 , is a shore post representing a preferred embodiment of the present invention. The shore post 10 includes an outer telescoping tube 12 , an inner telescoping tube 14 , a bottom end plate or foot pad 16 and a top end plate or adapter plate 18 . The shore post 10 may be telescopically adjusted in length between a foreshortened or collapsed position and an lengthened or extended position. The shore post 10 may be set at a plurality of adjusted lengths by use of a pin 20 that is inserted into a pair of diametrically opposed holes in the outer tube 12 and a selected pair of a plurality of holes 22 in the inner tube 14 spaced at a regular interval. Fine adjustment of the length of the shore post 10 is made by rotation of a threaded linkage member 24 . Rotation of the linkage member 24 is facilitated by a pair of diametrically opposed handles 26 and 28 which extend radially from the linkage member 24 .
[0016] The top end plate 18 is a flat plate of a preselected width and having a pair of notches 30 and 32 formed in opposing ends ( FIG. 4 ). The notches 30 , 32 are preferably in the shape of a trapezoid. The corners of the trapezoid provide two contact points to the tubes of the post stacked above. The contact points are spread apart to provide a stable support to the above member The foot pad or bottom end plate 16 has a central web section 34 and an upturned flange 36 , 38 formed on either side of the web section 34 ( FIG. 3 ). The web section 34 is of a width slightly larger than the width of the top end plate 18 . A pair on notches 40 , 42 are formed in opposing ends of the web section 34 corresponding to the notches 30 , 32 of the top end plate 18 .
[0017] To arrange a plurality of shore posts 10 in a stack, a first shore post 10 a ( FIG. 2 ) is placed on the floor or other supporting surface. A second shore post 10 b is oriented top-to-bottom relative to the first shore post 10 a and placed on top of the first shore post 10 a with the top end plate 18 b adjacent the web section 34 a and between the flanges 36 a , 38 a at one end and with the top end plate 18 a adjacent the web section 34 b and between the flanges 36 b , 38 b at the other end. Note that the outer tube 12 b of the top shore post 10 b rests in the notch 30 a of the bottom shore post 10 a , and similarly, the notch 32 b of the top end plate 18 b of the top shore post 10 b rests on the outer tube 12 a of the bottom shore post 10 a . The end plates 16 a , 16 a stably support the bottom shore post 10 a and the flanges 36 , 38 of each of the bottom end plates 16 a , 16 b prevent the top shore post 10 b from rolling off of the bottom shore post 10 a by limiting movement of the top end plates 18 a , 18 b . In this way, stable stacks of multiple shore posts can be created. In a preferred arrangement illustrated in FIG. 2 , twenty-four shore posts are arranged in a stack six wide and four tall. Note that the handles 26 , 28 have been adjusted at an angle relative to the stacked arrangement so as not to interfere with the tubes or handles of adjacent shore posts.
[0018] While the invention has been described with respect to a shore post as the preferred embodiment, the invention is applicable other tubular form components such as wall form pipe braces as well as to components formed of solid round bars, such as taper ties.
[0019] The foregoing description and drawings comprise illustrative embodiments of the present inventions. The foregoing embodiments and the methods described herein may vary based on the ability, experience, and preference of those skilled in the art. Merely listing the steps of the method in a certain order does not constitute any limitation on the order of the steps of the method. The foregoing description and drawings merely explain and illustrate the invention, and the invention is not limited thereto, except insofar as the claims are so limited. Those skilled in the art that have the disclosure before them will be able to make modifications and variations therein without departing from the scope of the invention.
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A stackable component for concrete forming systems is described. End plates are secured to opposite ends of a longitudinal element having a round profile that prevents stacking of the components. The end plates nest together and receive for retention the longitudinal element to permit orderly and stable stacking of the components.
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BACKGROUND OF THE PRESENT INVENTION
The present invention relates generally to an activated carbon filtration system of drinking water, and more particularly to a monitoring process and device for an activated carbon filtration system of drinking water, which can monitor the drinking water machine to make purified and de-toxic drinking water having the quality of purity in conformity with the standard of public health. The present invention is used for notifying the maintenance personnel of the time to replace the purifying element of the filtration system or ceasing the water supply in response to expired purifying element service life.
The main culprits of the water pollution today include industrial waste, household waste, farm pesticide, and the animal waste produced by hog and poultry farms. As the pollution problems of the source of our drinking water, such as the river, become increasingly worrisome, people lose their confidence in the quality of their drinking water provided by the water company. Furthermore, people's anxiety about the quality of their drinking water is further aggravated by the fact that the conditions of the water supplying pipes and reservoirs are often found to be unsatisfactory. Accordingly, a variety of water-treating devices, such as water-filtering devices, water purifying devices, water softening devices, etc., have become ubiquitous in offices, homes, factories, schools, churches, and so forth. The conventional activated carbon filtration system of drinking water is effective in improving the quality of the drinking water. Nevertheless, the conventional activated carbon filtration system of drinking water is defective in design. The shortcomings inherent in the conventional drinking machines are described explicitly hereinafter.
Referring to FIG. 2A, a traditional activated carbon filtration system is illustrated, which comprises an activated carbon filter 4 for removing the poison contents in water, such as the pesticide pollution of water source near agricultural areas.
However, such activated carbon filter 4 has a service life, i.e. the activated carbon filter will become ineffective after filtering a certain total volume of water, such as 1500 gallons. The service life is usually indicated by the manufacturer in its operation menu. Therefore, the activated carbon filter 4 would gradually become ineffective after a certain period of serving time. Finally, the ineffective activated carbon filter 4 may form an excellent environment for bacteria, fungi and germs.
Sometimes, the activated carbon filter is incorporated with other purifying elements, such as an impurity filter device and/or a reverse osmosis filtration element in order to enhance the purifying quality of water. As shown in FIG. 1, the most common filtration system of drinking water is illustrated, which comprises a water pressure pump 1, an impurity filter device 2, a reverse osmosis filtration element 3, and an activated carbon filter 4. The activated carbon filter 4 is installed before or after the reverse osmosis filtration element 3 for removing the poison contents in water.
Since the most harmful contents in water which may hurt the human health are poison contents such as toxic chemicals, one of the main objects of a water purification system is to provide drinking water absolutely without poison contents. Thus, the activated carbon filter plays a very important role in the filtration system.
Accordingly, the activated carbon filter of the filtration system is normally replaced after a predetermined period of time of use without knowing the actual condition of the activated carbon. In many cases, overused activated carbon filter fails to be replaced in time and consumers are unknowingly led to drink the poor quality water produced by such ineffective water purification system. It happens from time to time that the cleaning schedule of the activated carbon filter is unintentionally disregarded or overlooked. Furthermore, the chore of replacing the activated carbon filter is not the task that people enjoy to do. It is an irresistible trend of the modern age that the consumers prefer an automated appliance rather than a manually operated appliance.
The activated carbon filtration system for drinking water as mentioned above is capable of removing the toxic contents in water. If such poison contents are allowed to accumulate in the activated carbon filter, its filtering effect will be seriously undetermined to an extent that bacteria and fungi will grow and flourish on the worn-out activated carbon. Thereby, a potential health hazard is brought about to the users of the activated carbon filtration system.
Moreover, if the activated carbon filtration system of drinking water is used less often, the service life of the activated carbon is prolonged accordingly. Therefore, the scheduled maintenance work of the activated carbon filtration system is likely to be delayed or even skipped. The operating performance of the activated carbon filtration system is often compromised by the lack of the routine maintenance work.
In fact, no matter what kind of the activated carbon filtration system of drinking water you have installed, none of the activated carbon filtration system is provided with a warning system which serves to notify the user of the system that the activated carbon filtration system is no longer working properly to ensure providing only of drinking water that is absolutely safe to drink.
SUMMARY OF THE PRESENT INVENTION
The primary object of the present invention to provide a monitoring process of an activated carbon filtration system of drinking water for monitoring the effectiveness of the activated carbon filtration system, warning of its undesirable condition, stopping the supply of drinking water from the activated carbon filtration system to protect the unaware consumers when an undesirable condition persists.
It is still another object of the present invention to provide a monitoring device of an activated carbon filtration system of drinking water, capable of automatically monitoring the quantity of the drinking water made by the activated carbon filtration system, advancing information signals when the output water quantity is under a predetermined standard so as to warn the users of the timing of the need for replacing the activated carbon filter, and to cause ceasing the supply of water from the activated carbon filtration system when the output drinking water is under the predetermined standard condition so as to ensure providing only of drinking water having the highest quality.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of an activated carbon filtration system of drinking water incorporating an impurity filter device and a reverse osmosis filtration element according to the present invention.
FIG. 2A is a schematic diagram illustrating water flow directions in a conventional activated carbon filter.
FIG. 2B is a schematic diagram illustrating water flow through an activated carbon filter having an electromagnetic gate installed according to the present invention.
FIG. 3 is a flow chart of a monitoring device for an activated carbon filtration system of drinking water of the present invention.
FIG. 4 is a circuit diagram of the monitoring device for an activated carbon filtration system having at least an activated carbon filter according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides a monitoring process and device for an activated carbon filtration system of drinking water, which comprises a predetermined number of purifying element.
As shown in FIG. 2B, an activated carbon filter 4 filters water by passing therethrough, which absorbs and removes toxic chemicals in water. The number of such activated carbon filters required depends on the amount of chemical toxins in the water supply.
Referring to FIG. 3, which is a block diagram of the monitoring device of the present invention the monitoring device of the present invention comprises a microprocessor 31, a LCD indictor circuitry 32 electrically connected to the microprocessor 31, a detecting means 33 electrically connected to the microprocessor 31, a warning means 34 electrically connected to the microprocessor 31, an electromagnetic gate 5 which is installed to a water passage connecting to the activated carbon filter 4 (as shown in FIG. 2B), a power switching means 35 electrically connected to the microprocessor 31, and an information input circuitry 36 (as shown in FIG. 4).
Operational signals from the detecting means 33, regarding a functional condition of each activated carbon filter made by detecting the quantity of the drinking water made, are sent to the microprocessor 31. When the microprocessor 31 receives such signals from the detecting means 33, the microprocessor 31 will process respective responses by respectively sending, corresponding signals to the warning means 34 and the power switching means 35 for activating them to process predetermined functions.
The microprocessor 31 controls the operation of the monitoring device and shares a power source with the activated carbon filtration system. A total water making volume value that is a total water volume of drinking water which can be made by the activated carbon filter of the activated carbon filtration system is formatted and input into the microprocessor 31 as a predetermined reference value. A preferred embodiment of the present invention uses a monolithic chip microprocessor 31 such as model number 8051 or 8052. The 1/0 memory of the microprocessor 31 is constituted by a monolithic chip. The programs stored in the microprocessor 31 control the entire operation of the monitoring device.
The LCD indicator circuitry 32 is electrically connected to the microprocessor 31 for notifying the users of the timing for replacing the disabling activated carbon filter 4 of the activated carbon filtration system and indicating a plurality of operational condition data which are sent from the microprocessor 31, including a current time, a recorded time of when was the previous replacement of the activated carbon filter, the current water making volume value that shows the current volume of drinking water produced by the activated carbon filter 4, the total water making volume value that is the total volume of drinking water which can be produced by the activated carbon filter 4 before the activated carbon filter 4 becomes ineffective, and a mechanical breakdown condition that illustrates whether the activated carbon filtration system is normally functioning or mechanically out of order, etc. All the operational condition data are stored in the microprocessor 31.
As shown in FIGS. 3 and 4, the detecting means 33 comprises an activated carbon filter detecting circuitry 33g electrically connected to the microprocessor 31 for monitoring the functional condition of the activated carbon filter by detecting the quantity of the drinking water made by the activated carbon filter by means of a water flowmeter which is used to determine the functional condition of the activated carbon filter. A detected signal sent from the water flowmeter is read and operated by the activated carbon filter detecting circuitry 33g which generates a related condition detecting value. When the condition detecting value reaches the predetermined reference value preset in the microprocessor, the detecting means will send a digital signal to the microprocessor.
The warning means 34 is electrically connected to the microprocessor 31 for advancing a warning information signal to notifying of the timing for the users to replace the activated carbon filter 4. The warning means 34 is activated by the microprocessor 31 of the monitoring device by the sending of an activating signal thereto when a condition detecting value is detected approximating to the predetermined reference value, so as to indicate that the service life of the activated carbon filter 4 is expired.
The power switching means 35 is electrically connected to the microprocessor 31 and activated by the microprocessor 31 for ceasing supply of drinking water form the activated carbon filtration system when the warning means 34 is activated to generate the warning information signal for a predetermined period of time. It means that the specific activated carbon filter has become ineffective and the drinking water so made is not safe for human consumption.
When the specific worn-out activated carbon filter is replaced by a new one, the activated carbon filtration system is manually restarted to produce drinking water again, the warning means 33 is manually operated to stop the warning information sound signal and the monitoring device is reactivated.
In accordance with the monitoring device of the activated carbon filtration system of drinking water as disclosed above, as shown in FIG. 4, the warning means 34 comprises a sound generating circuitry having a configuration that produces verbal or musical sound for warning consumers about a disabled condition of the activated carbon filter. Of course, the sound generating circuitry 34 can be substituted with a usual lighting generating circuitry. Moreover, the warning means 34 can comprise both a sound generating circuitry and a lighting generating circuitry so as to generate both warning sound and warning lighting.
The sound generating circuitry 34 comprises a sound circuit IC 341, a speaker driving circuit 342 and a speaker 343 electrically connected, in which the sound circuit IC 341 stores a verbal or music sound track. The speaker driving circuit 342 broadcasts the stored verbal sound or music of the sound circuit IC 341 via the speaker 343.
In accordance with the monitoring device of the activated carbon filtration system of the present invention, as shown in FIG. 4, the activated carbon filter detecting circuitry 33g comprises a calculator 331a and a water flowmeter 337 which is installed in a water outlet of the activated carbon filter 4. The water flowmeter 337 will generate a series of corresponding pulse waves which are transmitted to the calculator 331a when the drinking water produced from the activated carbon filter is flowing therethrough, for computing the amount of drinking water flowing out from the activated carbon filter 4. The calculator 331a receives and accumulates such pulse waves to achieve the current water making volume value as a condition detecting value that displays the current volume of drinking water made by the activated carbon filter 4. When the condition detecting value exceeds the predetermined reference value which represents the service life of the activated carbon filter 4, that is the total volume of drinking water that can be made by the activated carbon filter 4 until it becomes ineffective, a digital signal will be sent from the carbon filter detecting circuitry 33g to the microprocessor 31 to activate the microprocessor 31 to send out an activating signal to the sound generating circuitry 34 which will generate a warning verbal or music sound to notify the user to replace the activated carbon filter in order to ensure the drinking water quality.
When the activated carbon filtration system of drinking water only comprises the activated carbon filter 4 (i.e. without the reverse osmosis filtration filter 3 or pressure pump 1), an electromagnetic gate 5 is installed in a duct connecting with the outlet or inlet of the activated carbon filter 4. The electromagnetic gate 5 is electrically connected with the power switching means 35, as shown in FIG. 2B.
As shown in FIG. 4, the power switching means 35 comprises a transistor 351 and a photoelectric driving power transistor 352 which are electrically connected. The programmed microprocessor 31 will send an activated signal to the power switching means 35 when the warning means 34 is activated to generate a warning sound for a certain predetermined period of time. When the transistor 351 is activated to conduct electricity by the activated signal sent from the microprocessor 31, the photoelectric driving power transistor 352 activates the electromagnetic gate 23 to shut off the water flow through the activated carbon filter 4. If the activated carbon filtration system further incorporates a reverse osmosis filtration element and a water pressure pump C1, as shown in FIG. 1, the photoelectric driving power transistor 352 will cut off the electrical power of the water pressure pump C1.
As shown in FIGS. 3 and 4, since the service lives of various activated carbon filters may be varied due to their different sizes, the monitoring device of the present invention can further comprise an information input circuitry 36 which is electrically connected to the microprocessor 31. Through the information input circuitry 36, the users can format and store the specific service life of a specific activated carbon filter into the microprocessor 31 as the standard reference value.
As shown in FIG. 4, the information input circuitry 36 comprises an input keyboard 361 which has a plurality of numeral keys from 0 to 9, a "SET" key and a "CLEAR" key. If the "CLEAR" key is pressed, the previous standard reference value regarding the service life of the activated carbon filter 4 is detected. Then, a new service life data can be keyed in by means of the numeral keys to set up a new standard reference value. Finally, such new standard reference value can be saved by pressing the "SET" key.
The monitoring process of an activated carbon filtration system of drinking water is further described hereinafter.
The monitoring process of an activated carbon filtration system of drinking water having at least an activated carbon filter comprises the steps of:
(1) inputting and formatting specific service life data of the activated carbon filter into a microprocessor as a corresponding predetermined reference value,
(2) monitoring a functional condition of the activated carbon filter by detecting the quality of the drinking water produced by the activated carbon filter by means of a water flowmeter, wherein the flowmeter generates a series of corresponding pulse waves to a calculator, which is electrically connected to the microprocessor, for accumulating the amount of drinking water flowing out from the activated carbon filter;
(3) generating a condition detecting value regarding the functional condition of the activated carbon filter by the calculator by receiving and accumulating the pulse waves to achieve a total water volume value that is the total volume of the drinking water made by the activated carbon filter; comparing the condition detecting value with the respective predetermined reference value regarding the service life of the activated carbon filter.
(4) sending a digital signal, which is readable by the microprocessor, to the microprocessor when the condition detecting value of the activated carbon filter approximates the respective predetermined reference value, indicating that the service life of the activated carbon filter will soon be expired;
(5) sending an activating signal to a warning means which is electrically connected with the microprocessor and advancing a warning information signal to remind the user of the timing to replace the activated carbon filter;
(6) ceasing supply of drinking water from the activated carbon filtration system by a power switching means, which is electrically connected with the microprocessor and activated by the microprocessor, when the warning means is activated to generate the warning information signal for a certain predetermined period of time; and
(7) manually stopping the warning information signal of the warning means and restarting the activated carbon filtration system to produce drinking water again when the specified worn-out activated carbon filter is replaced by a new one.
Furthermore, after the formatting step (3), the monitoring process further comprises an indicating step of notifying the user of the timing to replace the activated carbon filter and indicating a plurality of operational condition data which are sent from the microprocessor, including the current time, the recorded time of when the previous replacement of the activated carbon filter was, the current value of water making volume which shows the current total volume of drinking water produced by the activated carbon filter, the total value of water making volume which shows the total volume of drinking waters which can be produced by the activated carbon filtration system, and the mechanical breakdown condition that illustrates whether the activated carbon filtration system is normally functioning or mechanically out of order, wherein all the operational condition data are stored in the microprocessor.
Furthermore, in the ceasing step (6), the ceasing of the drinking water supply can be operated by cutting off the electrical power be a water pressure pump of the activated carbon filtration system in order to stop the water pumping to the activated carbon filter.
Moreover, in the ceasing step (6), the ceasing of the drinking water supply can also be operated by shutting off an electromagnetic gate installed in a water outlet or inlet of the activated carbon filter.
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A monitoring device for a activated carbon filtration system of drinking water includes a microprocessor that controls the overall operations of the monitoring system, a LCD indicating circuit that relates information to maintenance personnel, a detecting component that analyses related data for determining the condition and extents of clogging of an activated carbon filter, a warning component that produces verbal or musical sound for warning consumers about the clogged condition of the water activated carbon filter, and a power switching component that cuts off the water supply of the system If the activated carbon filter is clogged, the monitoring device will make a sound to warn of such condition of the activated carbon filter and will eventually cut off the power supply to the pump for stopping water delivery if the clogged activated carbon filter is not replaced after a certain period of time.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Apl. Ser. No. 60/499,265, filed on Aug. 29, 2003, entitled SYSTEM FOR PERFORMING DOWNHOLE LOGGING WHILE CORING, which is expressly incorporated herein by reference in its entirety.
STATEMENT AS TO FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT
[0002] The invention described herein was made at least in part with U.S. government support under Contract No. JSC 2-94, which was awarded by the U.S. National Science Foundation to Joint Ocean Institutions, Inc. and subcontracted to the assignee and under Contract No. JSC 2-06, which was awarded by the U.S. Department of Energy to Joint Ocean Institutions, Inc. and subcontracted to the assignee. Accordingly, the government may have certain rights in the subject invention.
BACKGROUND
[0003] 1. Technical Field
[0004] The invention relates generally to a method and apparatus for wellbore coring and logging. More particularly, this invention relates to a method and apparatus for collecting data regarding geological properties of underground or undersea formations during coring operations.
[0005] 2. Discussion of Related Art
[0006] The desirability of a system which is able to measure downhole formation properties while simultaneously coring a geological sample has long been recognized. Until now it has not been possible to continuously collect large diameter core and in situ logging data simultaneously.
[0007] Geologists and geophysicists collect data regarding underground formations in order to predict the location of hydrocarbons (e.g., oil and gas). Traditionally, such information is gathered during an exploration phase. In recent years, however, the art has advanced to allow the collection of geophysical and geological data as a well is being drilled. These logging-while-drilling (LWD) measurements are typically made following coring in a separate borehole. Logging data are correlated to the core sample. Correlation accuracy depends on the yield recovery of the core and sample/data match-up. There is a pressing need in the industry for more accurate formation property data, such as provided by correlation of the core to a downhole data set.
[0008] Known systems (e.g., logging-while-drilling) use a series of tubes, referred to as drill pipe and collars, to drill a hole into the formation. The lower end of the drill string, called the bottomhole assembly, is provided with a cutting mechanism, referred to as drill bit, which has a concentric hole. A drill collar, disposed proximally to the drill bit, includes several formation properties sensors, referred to as an LWD tool. Formation property measurements are recorded in this LWD tool.
[0009] When a sample of the formation is required, a coring device is lowered inside the drill string and secured at the bottom end. By resuming drilling and/or pumping fluid down the drill string, the coring process is effected. The coring device is retrieved by a latching mechanism attached to a wireline.
[0010] Continuous wireline-retrievable coring, for example, is routine in nearly all Ocean Drilling program (ODP) drill holes, whereas industry coring programs are often limited in key intervals due to time and cost constraints. The ODP routinely drills holes up to 2000 m deep without a riser in water depths ranging from 300 m to 6000 m. Sea water is utilized at high pressure to clear the hole of cuttings. Conventional wireline logging tools are typically deployed if hole conditions are good. In cases where drilling is expected to be difficult, LWD technologies are employed in another hole in close proximity to the core hole. A dedicated LWD hole is often the only alternative to collect in situ log data in such difficult drilling environments.
[0011] In order to obtain logging-while-drilling data and a closely correlated core sample, the prior art requires two holes to be drilled. A first hole is drilled to collect a core sample. A coring bottomhole assembly is used to simultaneously drill a hole and core out a core column. A second hole, laterally spaced from the first hole, is drilled using a traditional logging-while-drilling bottomhole assembly. Logging-while-drilling tools measure formation properties of borehole that are, in theory, supposed to be closely correlated to the previously extracted core sample.
[0012] The prior art exhibits two significant disadvantages. The above described method is time consuming because it requires two separate drill holes: a first hole for obtaining core samples and a second hole for obtaining logging-while-drilling data. Specifically, a downhole coring assembly must be lowered to the ocean floor, in order to drill/core the first hole. Subsequently, the downhole coring assembly is raised to the surface so that a retooling can be executed. A logging-while-drilling downhole assembly is then lowered back down to the ocean floor in the area of the first hole. Following the positioning of the logging-while-drilling downhole assembly, the assembly drills the second hole while performing logging-while-drilling measurements. The time required in refitting the drillstring with the logging-while-drilling assembly and in drill the second hole adds to the total operating costs and time duration of this coring and logging operation.
[0013] The second disadvantage is the possible detrimental effect on the data correlation. Correlating a core sample with formation property data assumes that the data and sample are obtained from same location or even the same hole. When the logging data and core sample are obtained from different holes that are often located some distance from each other, one's ability to correlate the logging data with the core sample to obtain accurate result can be adversely affected.
SUMMARY OF THE INVENTION
[0014] A new logging-while-coring technology is proposed. A primary object of the present invention is the reduction of time required to log after drilling and coring has been completed in a hole. Another object of the present invention is to make in situ measurements using LWD over the same cored interval in a particular hole. Merging state-of-the-art wireline coring and logging while drilling technologies provides two vital data sets without sacrificing time or adding risk associated with longer open hole times.
[0015] The invention relates primarily to a downhole rotary coring device placeable in a drill string and having a head section, a drill collar, and a core barrel having LWD tools disposed within the drill collar. The coring device is used to obtain a sample of an earth formation. The invention provides a combined downhole coring device with a collar for performing LWD measurements.
[0016] The coring device has a core barrel with a coring bit at the lower end, which cuts an annular hole into the formation. The resulting pillar of rock enters the core barrel and held in place by a core catcher.
[0017] Formation property measurements are executed during the coring process. Formation property sensors are powered by an internal battery contained within the drill collar. Formation property data are stored in a memory storage device, such as, Random Access Memory (RAM), and/or communicated to a data transmission system.
[0018] The purpose of the present invention is to propose a solution to the problem set out above. One object of the invention is to procure a collar that allows both a core barrel pass through it and is able to perform logging-while-drilling measurements.
[0019] According to one aspect of the invention, a downhole assembly for performing logging operations while coring includes a core bit disposed at a distal end of the assembly and a core barrel having an inner surface and an outer surface. The core barrel is coupled to the core bit. The assembly further includes a collar having an inner surface and an outer surface and at least one logging sensor. The inner surface of the collar allows the outside surface of the core barrel to pass through it. At least one logging sensor is disposed on the outer surface of the collar.
[0020] According to another aspect of the invention, the downhole assembly further includes logging-while-drilling tools.
[0021] According to another aspect of the invention, the downhole assembly further includes a core catcher.
[0022] According to another aspect of the invention, the downhole assembly further includes one or more crossovers.
[0023] According to another aspect of the invention, the downhole assembly further includes one or more jarring devices.
[0024] According to another aspect of the invention, the downhole assembly further includes one or more stabilizers.
[0025] According to another aspect of the invention, the downhole assembly further includes a battery powering at least one of the logging sensors.
[0026] According to another aspect of the invention, the battery is disposed within the collar.
[0027] According to another aspect of the invention, the core barrel is powered by a motor, or another driving mechanism.
[0028] According to another aspect of the invention, the downhole assembly is disposed in a drillstring.
[0029] According to another aspect of the invention, the logging sensors measures formation properties of the surface of the wellbore.
[0030] According to another aspect of the invention, the logging sensors includes one or more sensors from a group consisting of: resistivity sensor; passive nuclear sensor; active nuclear sensor; gamma ray sensor; electromagnetic wave sensor; electric field telemetry sensor; acoustics sensor; and nuclear magnetic resonance sensor.
[0031] According to another aspect of the invention, the logging sensor communicates with a data transmission device.
[0032] According to another aspect of the invention, logging data is stored in a memory storage device.
[0033] According to another aspect of the invention, a method for executing logging measurement while performing coring operation is disclosed. The method includes providing a bottomhole assembly, coring a wellbore, and receiving measurements from one or more logging tools. At least one logging tool measures a formation property of a wellbore.
[0034] According to another aspect of the invention, the method for executing logging measurement while performing coring operation further includes the step of communicating the measurements to a data transmission device.
[0035] According to another aspect of the invention, the method for executing logging measurement while performing coring operation further includes the step of storing the measurements in a memory storage device.
[0036] According to another aspect of the invention, the method for executing logging measurement while performing coring operation further includes the step of receiving measurements from a least one measurements-while-drilling tools.
[0037] According to another aspect of the invention, the method for executing logging measurement while performing coring operation further includes the step of communicating the measurements from at least one measurements-while-drilling tools to a data transmission device.
[0038] According to another aspect of the invention, the method for executing logging measurement while performing coring operation further includes the step of storing the measurements from at least one measurements-while-drilling tools in a memory storage device.
[0039] According to another aspect of the invention, a method for performing logging operations while coring includes the steps of excavating a core sample, capturing the core sample through a core bit into a core barrel, and activating at least one logging sensor. Each of the logging sensors measures one or more formation properties. The method further includes the step of receiving sensor measurements from at least one logging sensor.
[0040] According to another aspect of the invention, the method for performing logging operations while coring further includes the step of communicating the sensor measurements to a data transmission device.
[0041] According to another aspect of the invention, the method for performing logging operations while coring further includes the step of storing the sensor measurements in a memory storage device.
BRIEF DESCRIPTION OF THE DRAWING
[0042] In the drawing,
[0043] FIG. 1 is a schematic of the prior art representing a logging-while-drilling downhole assembly;
[0044] FIG. 2 is an illustration of a logging-while-coring downhole assembly;
[0045] FIG. 3 is an illustration of an additional embodiment of a logging-while-coring downhole assembly with a retrievable memory module;
[0046] FIG. 4 is an illustration of an additional embodiment of a logging-while-coring downhole assembly with a mud pulsing unit;
[0047] FIG. 5A is a representation of a location map of the Hydrate Ridge test site off the coast of Oregon;
[0048] FIG. 5B is a bathymetrical representation of the Hydrate Ridge test site off the coast of Oregon;
[0049] FIG. 6 is an illustration of core recovered using the logging-while-coring system;
[0050] FIG. 7 is a representation of data acquired from Site 1249 B including resistivity images, resistivity and gamma curves and data from core collected through the logging while coring system;
[0051] FIG. 8 is a representation of data acquired using the GVR-6 and VDN tools from Hole 1249 A, adjacent to Hole 1249 B; and
[0052] FIG. 9 is representation of a comparison of responses between the data acquired using the GVR-6 and VDN tools and logging-while-coring tools.
DETAILED DESCRIPTION
[0053] The present invention combines a coring system with logging-while-drilling system, both of which are known in the art.
[0054] A schematic of the prior art is depicted in FIG. 1 . FIG. 1 illustrates a logging-while-drilling downhole assembly 100 . The logging-while-drilling downhole assembly 100 includes a bit 110 , a bit sub 120 , a measurement-while-drilling section 130 , a logging-while-drilling lower sub-assembly 140 , a mechanically-rotatable-turbine section 150 , and a logging-while-drilling upper sub-assembly 160 .
[0055] Bit 110 is comprised of three rotatable heads that break up rock when a force is applied to the logging-while-drilling downhole assembly 100 . Bit sub 120 is a pipe sub-assembly that couples the bit 110 to the rest of the logging-while-drilling downhole assembly 100 .
[0056] Measurement-while-drilling (MWD) section 130 performs measurements such as sensing ambient pressure and weight on bit 110. Logging-while-drilling lower assembly 140 performs logging measurements, such as, sensing shallow resistivity, medium resistivity, deep resistivity, ring resistivity, and gamma rays. Mechanically-rotatable-turbine 150 includes a hydraulic turbine motor, read out port magnets, and antennas.
[0057] Logging-while-drilling upper assembly 160 performs logging measurements. Logging-while-drilling upper assembly 160 includes a far neutron sensor, a near neutron sensor, a neutron source. Logging-while-drilling upper assembly 160 further includes a long density sensor, a short density, a density source, and a ultrasonic sensor.
[0058] FIG. 2 illustrates an embodiment of the present invention. Logging-while-coring downhole system 200 is disposed at the distal end of a drillstring (not shown) and is lowered into a wellbore to perform drilling, coring, and logging operations. Logging-while-coring downhole system 200 includes a core collar 210 , a retrievable core barrel 220 , a battery 230 , a ring resistivity electrode 270 , an azimuthal gamma ray detector 280 , a field replaceable stabilizer 290 , and bit resistivity electrode 295 . Logging-while-coring downhole system 200 further includes a shallow azimuthal resistivity electrode 240 , a medium azimuthal resistivity electrode 250 , and a deep azimuthal resistivity electrode 260 .
[0059] The current embodiment of the present invention was reduced to practice by selecting a core barrel to fit through the throat of a modified Schlumberger Resistivity-at-Bit TM (RAB-8 TM) Tool. A core barrel (MDCB) 220 was selected to fit within the 3.45-inch annulus of the RAB-8. Minor modifications of the MDCB 220 were required to accommodate the tool length and latching mechanism.
[0060] A typical RAB-8 battery ordinarily occupies the annular space in the tool. The RAB-8 battery was redesigned to retain the annular space, allowing the MDCB 220 to pass through. A new resistivity button sleeve and slick stabilizer were fabricated to accommodate a 9⅞-inches bit size which is considerably smaller than conventional bits used with the RAB-8 collar. The tool standoff from the borehole wall for the core collar 210 is nominally 0.185-inches in the present configuration.
[0061] Referring to FIG. 2 , the logging tools are disposed within the core collar 210 . The battery 230 in the present embodiment powers the sensors ( 240 , 270 , 280 , 295 , etc.) and any memory storage devices (not shown), such as RAM, EEPROM, flash, etc. However, in alternate embodiments, power can be supplied from the surface through a wireline (not shown).
[0062] Retrievable MDCB 220 rotate circumferentially and is driven by a motor (not shown). Rock and sediment ingress into the hollow body of retrievable MDCB 220 . Upon extraction of core from the wellbore into the retrievable MDCB 220 , retrievable MDCB 220 is unlatched and brought to the surface via a tether (e.g., slickline). The retrievable MDCB 220 can be replaced in situ by running another core barrel down from the surface. Within the scope of the present invention, the core barrel is not limited to a retrievable motor driven core barrel 220 . Other embodiments can include piston-type core barrel, a static core barrel, or non-retrievable core barrel.
[0063] Referring to FIG. 2 , three azimuthal resistivity electrodes are illustrated. Shallow azimuthal resistivity electrode 240 senses the resistivity of the surrounding rock formation at a depth shallower relative to the other sensors. Medium azimuthal resistivity electrode 250 senses the resistivity of the surrounding rock formation at medium depth relative to the other sensors. Deep azimuthal resistivity electrode 240 senses the resistivity of the surrounding rock formation at a depth deeper relative to the other sensors. The resistivity sensors of the present embodiment functionally operate in similar manners. Resistivity of the surrounding formation is measured by applying a voltage to one or more electrodes and measuring the current passing through the electrode as a function of the voltage in accordance with Ohm's law. Ring resistivity electrode measures 270 performs a similar measurement using a ring-shaped electrode by measuring resistances of all azimuths around the borehole.
[0064] Azimuthal gamma ray detector 280 senses gamma rays propagating through the formation of the wellbore. Gamma rays are produced by the nuclear decay of clays in the surrounding formation. Field replaceable stabilizer 290 maintains the collar 210 centralized and stabilizes the collar 210 in the hole. Field replaceable stabilizer 290 is also able to be changed on the surface. Bit resistivity electrode 295 measures the resistivity of the formation at the bit.
[0065] Other embodiments may employ active nuclear sensors in the logging-while-coring system. For example, a neutron source for neutron bombardment and neutron detector may be used in the outer surface of the core collar. Another example includes a electron source for electron emission and electron detector may be used in the outer surface of the core collar.
[0066] FIG. 3 illustrates an alternate embodiment of the present invention. Referring to FIG. 3 , the logging-while-coring tool 300 includes a core barrel 330 , a logging-while-drilling tool 320 , a drill bit 340 , a core barrel retrievable memory module 350 , and an inductive coupler 370 . The core barrel 330 and the retrievable memory module 350 are coupled to one another.
[0067] Logging-while-drilling tool 320 is similar in construction to the core collar 210 of the previous embodiment. Logging-while-drilling tool 320 includes drilling sensor sub assembly 310 and one or more logging tools (not shown) that are known in the art. Data from the logging tools (e.g., weight on bit, torque, and pressure) are communicated to the drilling sensor sub assembly 310 . The drilling sensor sub assembly 310 communicates the data through the inductive coupler 370 .
[0068] The inductive coupler comprises an inner inductor 370 and outer inductor 380 . The inner inductor 370 and the outer inductor 380 are disposed in the core barrel retrievable memory module and the drilling sensor sub assembly 310 , respectively. The outer inductor 380 transmits the logging data via an induced magnetic field which is produced by current passing through the outer inductor 380 in accordance with Ampere's law. The resultant magnetic field induces a current in the inner inductor 370 in accordance with Faraday's law. A retrievable memory module (not shown) of the core barrel retrievable memory module 350 recognizes and stores the signal received from the inner inductor 370 .
[0069] In one or more embodiments, the drilling sensor sub assembly 310 transmits the data via the inductive coupler 360 whether the core barrel retrievable memory module 350 is present or not. In some embodiments, the core barrel retrievable memory module 350 performs and stores its own measurements in addition to the logging data received from the drilling sensor sub assembly 310 . For example, the core barrel retrievable memory module 350 executes pressure and acceleration measurements which are stored with the data transmitted from the inductive coupler 360 .
[0070] In the present embodiment, the retrievable memory module 350 includes a 64 MB flash memory chip. In other embodiments, the retrievable memory module can include one or more of a variety of memory storage devices. Examples of memory storage devices include random access memory (RAM), electronically erasable programmable read only memory (EEPROM), and flash RAM.
[0071] The memory storage device stores the data received from the LWD tools and is downloadable at the surface following a logging-while-coring operation. During retrieval of the core barrel 330 , the core barrel retrievable memory module 350 is also brought to the surface. The data corresponding to the sample contained in the core barrel is retrieved at the surface through a computer interface.
[0072] FIG. 4 illustrates another embodiment of the present invention. Referring to FIG. 4 , the logging-while-coring tool 400 includes a core barrel 430 , a logging-while-drilling tool 420 , a drill bit 340 , a core barrel retrievable memory module 450 , a full gauge washer 470 , a mud pulsing telemetry unit 480 , and an inductive coupler 470 . The core barrel 430 and the retrievable memory module 450 are coupled to one another.
[0073] Logging-while-drilling tool 420 is similar in construction to the logging-while-drilling tool 320 of the previous embodiment. As such, logging-while-drilling tool 420 includes drilling sensor sub assembly 410 and one or more logging tools (not shown) that are known in the art. Data from the logging tools (e.g., weight on bit, torque, and pressure) are communicated to the drilling sensor sub assembly 410 . As in the previous embodiment, the drilling sensor sub assembly 410 communicates the data through the inductive coupler 470 . A retrievable memory module (not shown) of the core barrel retrievable memory module 350 recognizes and stores the signal received the inductive coupler 470 .
[0074] Data received from the inductive coupler is also communicated to the mud pulsing telemetry unit 480 . The mud pulsing telemetry unit 480 includes a circuit and transducer that receives the downhole data signal and produces a highly correlated pressure signal. The mud pulsing telemetry unit telemeters the data up the drill string to the surface. The transducer produces pressure waves 490 that propagate through the mud contained in the interior of the drill string. The transmission of downhole data to the surface occurs in real time.
[0075] The pressure waves 490 represent a binary signal that is decoded at the surface. In other embodiments of the present invention, the pressure waves 490 can represent an analog signal.
[0076] This embodiment can also include a core barrel retrievable memory module 450 which receives and stores downhole logging data. The core barrel retrievable memory module 450 can also be used as to buffer the data signal before transmission to the surface via the mud pulsing telemetry unit 480 . The retrievable memory module contained therein can include one or more of a variety of memory storage devices. Examples of memory storage devices include random access memory (RAM), electronically erasable programmable read only memory (EEPROM), and flash RAM.
[0077] As with the previous embodiment, the core barrel retrievable memory module 450 can be brought to the surface during the retrieval of the core barrel 430 . The data corresponding to the sample contained in the core barrel is retrieved at the surface through a computer interface.
[0078] Following the reduction to practice of the logging-while-coring system, the logging-while coring system was tested. A coring test through low-grade cement was successfully conducted prior to deployment of the system at sea.
[0079] Proof of concept ocean drilling test were performed during Ocean Drilling Program Leg 204 on Hydrate Ridge off the coast of Oregon. The logging-while-coring system was deployed on a vessel called D/V JOIDES Resolution for use on ODP Leg 204 , offshore Oregon, in July 2002. The test was conducted in 788.5 m water depth at the crest of southern Hydrate Ridge at ODP Site 1249 ( FIGS. 5A & 5B ). Drilling proceeded to 30 m below sea floor where coring operations began with sequential 4.5-m, then 9-m-long cores recovered through gas hydrate-bearing clay sediments to 74.9 m depth. A 9⅞-inch-diameter four-cone bit (not shown) was used and the rotation rate increased from 15 to 45 RPM with depth. Average penetration rate was approximately 8 m/hr.
[0080] Eight cores were recovered from Hole 1249 B with 32.9% recovery, on average, through a 45 m interval. Cores recovered using plastic liners have a slightly narrower diameter (2.35″) than more standard cores, yet recovery as high as 67.8% was reached. Two 9-m (2.56″ diameter) cores were taken without MDCB liners and achieved up to 42.3% recovery after being extruded from the barrel. Without liners, however, handling and further core processing and archiving is limited.
[0081] All eight cores were processed and archived normally on board the D/V JOIDES Resolution. FIG. 6 illustrates the first core recovered from Hole 1249 B prior to measurement and processing. Core measurements including density and magnetic susceptibility were made onboard the JOIDES Resolution using a multi-sensor track. Bulk density, porosity and grain density core measurements were made on discrete samples. The occurrence of gas hydrates in the core material and their rapid dissociation precluded the measurement of natural gamma activity in the cores. These measurements require an extended length of time to complete the measurement process.
[0082] High quality logs and image data were recorded in the downhole memory of the logging-while-coring tool over the entire 74.9 m drilled interval in Hole 1249 B. The RAB-8 system was also calibrated post-deployment in salt water calibration tanks at Sugar Land, Tex. The tool functioned properly during this test and the calibration showed the field data are reliable.
[0083] FIG. 7 shows a summary of the primary core and drilling data acquired in Hole 1249 B including resistivity images, and the resistivity and gamma ray logs from the logging-while-coring system. Core measurements of discrete samples from Hole 1249 B are presented at discrete depths from 29.9-75.0 m below seafloor (mbsf) as well as multi-sensor track core measurements. Core measurements have a depth accuracy of ±0.5 meters. Since core recovery averages only 32.9% in this hole, depth matching between core and log measurements may be somewhat imprecise at specific depths. Ties are made using density, magnetic susceptibility and gamma ray data, and for example, all three measurements increase near 60 mbsf, indicating a change in lithologic content.
[0084] Downhole drilling parameters recording during coring in Hole 1249 B are also indicated in FIG. 7 . Hole 1249 B was drilled to maintain a rate of penetration of 20 n/hr over each cored interval. Weight-on-bit ranged widely, however, as it was difficult to control precisely in these shallow and soft sediments. The time after bit (of the LWD system measurements) varies due to the time required to drill and recover each core, and substantially more time than standard drilling or LWD operations without coring is required. The difference between drilling ahead and coring time may introduce some uncertainly in the core to log depth correlation.
[0085] Core photographs of core 5 -A (43 mbsf) indicates a gas hydrate rich core that largely dissociated creating a “mousse”-like fabric. The reflective areas are an indication of where the gas hydrate existed. Core 6 -A (49 mbsf) indicates a change in the composition of the cored material. The mixed recovery in these materials is reasonable given that the MDCB core barrel 220 is designed primarily for use in harder rocks. The MDCB system cuts core by rotation, filling of the barrel slowly as the bit advances. A piston-type core barrel is more conducive to high recovery of low-strength materials. The MDCB core barrel 220 will be modified in the future to shorten the core length and reduce friction as the core enters the barrel. These are important changes aimed at improving core recovery with this system.
[0086] A comprehensive suite of LWD data was acquired in nearby Hole 1249 A using GeoVision Resistivity (GVR-6) TM and Vision Density Neutron (VDN) TM tools ( FIG. 8 ) which are known in the art. The lateral offset between Hole 1249 A and 1249 B is 40 m. A difference of approximately 0.5 meters in water depth exists between the two sites. The logs from Hole 1249 A show the rate of penetration and time after bit curves are lower than in Hole 1249 B and remain relatively constant for the drilled interval ( FIG. 8 ).
[0087] The logging-while-coring data collected in Hole 1249 B are compared with GVR-6 data from nearby Hole 1249 A in FIG. 9 , which shows important similarities and differences. The large increase in resistivity in the upper interval in both holes corresponds to the presence of gas and gas hydrate. Some variation in the image quality between the holes may be associated with the greater time after bit for the logging-while-coring system measurements (e.g. coring versus drilling operations). The gamma ray shows a linear trend with an offset that may be attributed to the difference in lateral standoff between logging-while-coring and GVR-6 tools. In general, the image data in Hole 1249 A and 1249 B correlate well, with differences due to environmental conditions and lateral variations in geologic heterogeneity between the two sites.
[0088] The deployment of a new logging-while-coring system on Hydrate Ridge successfully acquired resistivity and gamma ray logs, and resistivity image simultaneously with core in Hole 1249 B. This system offers the significant advantages of providing core and log data over the same drilled interval, and saving rig time. Time requirements for the logging while coring system are the same as for coring operations alone. Core recovery during this test reached 68.9% and averaged 32.8% over a 45 m drilled interval in shallow, soft marine sediments. Alternate deployments of the logging-while-coring system in harder rock environments offer the potential for improved core recovery using a motor driven core barrel. Core recovery in soft sediments may be increased by modifying other core barrels to fit within the 3.45 inch annulus of the core collar 210 . Measurements on recovered core may be correlated directly with log data over the same drilled interval. LWD data from both conventional and while-coring operations at a nearby site agree well, and indicate the presence of gas and gas hydrate in clay rich sediments at this location.
[0089] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of the equivalency of the claims are therefore intended to be embraced therein.
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A method and apparatus for downhole coring while receiving logging-while-drilling tool data. The apparatus includes core collar and a retrievable core barrel. The retrievable core barrel receives core from a borehole which is sent to the surface for analysis via wireline and latching tool The core collar includes logging-while-drilling tools for the simultaneous measurement of formation properties during the core excavation process. Examples of logging-while-drilling tools include nuclear sensors, resistivity sensors, gamma ray sensors, and bit resistivity sensors. The disclosed method allows for precise core-log depth calibration and core orientation within a single borehole, and without at pipe trip, providing both time saving and unique scientific advantages.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This continuation application claims the benefit of U.S. patent application Ser. No. 10/592,180 filed 18 Oct. 2006 which is the U.S. designated national phase of PCT Application No. NO2005/000082 filed 7 Mar. 2005, which claims priority to Norwegian Patent Application No. 20040993 filed 8 Mar. 2004. PCT Application No. NO2005/000082 was published in English on 15 Sep. 2005 under Publication No. WO 2005/085580A1.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
REFERENCE TO SEQUENCE LISTING
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] This invention relates to a method for establishing an underground well, in particular a petroleum well. By establishing is meant to drill, completely or partially, a hole and further to line the hole, so that the wall of the hole is sealed, and to place a completion string in the well for production or injection. If a hole exists from earlier, the method may also be used in order to line the hole or in order to place a completion string, whereby the possibility for downhole measuring and control is improved.
[0006] More particularly, the invention relates to a method, in which a lining is transported into the borehole together with the drilling tool and positioned in the borehole before the drilling tool is pulled to the surface. The method is particularly suitable for use in so-called deviated drilling, in which the direction of the borehole may deviate considerably from a vertical direction.
[0007] In addition, the method includes the positioning of a completion string, maybe with integrated electric or optical cables, and possibly with sensors and actuators for completion of the well for production or injection. The invention also includes a device for practicing the method.
[0008] In the description, upper and lower refer to relative positions when the tool is in a vertical borehole.
[0009] When drilling an underground deviating borehole, it can be difficult to have sufficient thrust transferred to a drill bit. The reason may be that a substantial part of the weight of the drill string and the weight of possible drill collars placed above the drill bit is absorbed by friction between the borehole wall and the drill string. It has turned out that to move casing, for example, forward in a deviation borehole can be difficult when relatively long and approximately horizontal borehole portions are involved. The reason for this is the considerable frictional forces, which arise between the borehole and the casing as the casing is being moved, and which have to be overcome.
[0010] Norwegian patent 179261 deals with a device, in which there is arranged, above the drill bit, a piston sealingly movable against the borehole. The fluid pressure in the borehole exerts a force on the piston, which is arranged to move the drill bit into the borehole. The document describes to a limited degree the lining and completion of boreholes.
BRIEF SUMMARY OF THE INVENTION
[0011] The invention has as its object to remedy the drawbacks of the prior art.
[0012] The object is realized in accordance with the invention through the features specified in the description below and in the following Claims.
[0013] A lower tool assembly includes a drilling tool of a kind known per se, which is arranged to drill a borehole with a larger diameter than the opening through which the drilling tool can be moved. The lower tool assembly also includes a driving motor for the drilling tool, necessary valves and instruments for controlling the drilling tool. It is advantageous also to provide the lower tool assembly with logging tools for measuring positions, pressure and formation parameters, and a blow-out preventer (BOP) mounted on the return flow line for pressure control and in order to prevent a blow-out.
[0014] The lower tool assembly is connected to at least two pipe conduits extending to the surface. A drill string in the form of a double coiled tubing can be used with advantage, in which a coiled tubing extends inside an outer coiled tubing of a greater dimension, or there may be a dual channel pipe of some other type or two coiled tubings side by side. A drill string of this kind has at least two separate conduits.
[0015] A drill string in the form of a double coiled tubing is chosen as an example, but the method and device according to the invention are also applicable for joined coilable pipes and joined pipes which are not coiled.
[0016] The drill string extends from the lower tool assembly up to the surface, the first coiled tubing conduit being used for pumping down drilling fluid whereas a second coiled tubing conduit, maybe the inner conduit, is used for returning drilling fluid and cuttings.
[0017] A casing, which is connected by its lower portion to the lower tool assembly, encircles the coiled tubing along its length from the lower tool assembly upwards. The casing may favourably be of a deformable and expandable kind by being arranged to be plastically deformed and expanded both before and after being positioned in the borehole. From here on, the casing will be referred to as the expandable casing, even though, in one form of method an embodiment may be chosen, in which this pipe is not expanded.
[0018] An upper tool assembly encircles, in a movable and sealing manner, the coiled tubing and is connected to the upper portion of the expandable casing. The upper tool assembly includes a displaceable packer sealing against the borehole wall. This packer may possibly be expandable, it being arranged to be expanded to seal against the borehole wall controlled from the surface, for example by means of back pressure on the packer. This packer may also have a built-in controllable valve, which can allow flow past packers in particular situation, for example when the drilling equipment is lowered into the well.
[0019] The upper tool assembly may also include a rolling anchor, which is arranged to absorb torques, for example from the drilling tool. Further, the upper tool assembly may include an expansion mandrel for the expansion of the casing. This expansion mandrel may with advantage be provided with wheels or other forms of rotating devices arranged to reduce friction and facilitate expansion of the expandable casing. Said wheels may be used entirely or partially as a rolling anchor in order to absorb the above-mentioned torques.
[0020] A running tool according to the invention thus includes a lower and an upper tool assembly, a casing and two pipe conduits extending from the lower tool assembly up to the surface.
[0021] The method for drilling and setting a casing in the borehole includes lowering the running tool to the bottom of the borehole, where a casing has already been set and cemented. The fluid pressure in the annulus above the upper tool assembly acts on the running tool, causing the drilling tool to be pressed against the bottom of the borehole, as the movable sealing packer of the upper tool assembly seals against the set casing.
[0022] Drilling fluid is pumped from the surface through the first pipe conduit down to the driving motor of the drilling tool, which is preferably located in the lower tool assembly. It is possible, however, for the driving motor to be placed in the upper tool assembly. The torque of the drilling tool may favourably be absorbed via the expandable casing by friction against the bore wall or by the rolling anchor, which is preferably located in the upper tool assembly.
[0023] Return fluid and cuttings flow from the bottom of the hole via the second pipe conduit to the surface. The inlet into the second pipe conduit may be either at the centre of the drill bit and be directed in pipes through the lower tool assembly, or it may be in an annulus behind the drill bit and be directed through one or more channels and from there into the second pipe conduit. When the return is through the centre of the drill bit, this will also enable continuous coring with return of the core to the surface in the liquid flow up through the return conduit during drilling.
[0024] It is also possible to flush and place liquid externally to the expandable casing. This may also be carried out by using controllable valves in the lower tool assembly. Here may be placed valves, which can be controlled from the surface. These valves may direct liquid which is pumped from the surface, to flow via the lower tool assembly and back to the upper tool assembly in an annulus between the coiled tubing and the expandable casing, in order then to flow back down to the bottom of the hole on the outside of the expandable casing. In this way this annulus may periodically or continuously be washed clean of particles and possible gas. Further it is possible to place cementation mass in the annulus, which may subsequently be placed outside the expandable casing, maybe in connection with expansion of the pipe.
[0025] As the drilling tool extends the borehole, the running tool is moved downwards until the upper portion of the expandable casing approaches the lower portion of the set casing. If it is chosen to expand the casing after drilling is finished, this may be done with the following procedure: By increasing the pressure in the borehole above the upper tool assembly to a predetermined level, the upper tool assembly is released from the expanding casing, after which the expansion mandrel is urged through the expanding casing. The expanding casing is thereby expanded to its predetermined dimension.
[0026] Before a possible expansion of the casing, cementation mass, which is pumped down from the surface, or which is most preferably located in the expandable casing during the drilling operation, can be directed into the annulus between the expandable casing and the borehole wall.
[0027] During the expansion the drill string may favourably be kept tightened in order to provide extra compression on the expanding casing.
[0028] After a possible expansion, the lower tool string will be disconnected from the lower portion of the expanding pipe, after which the running tool may be pulled out of the borehole in order for it to be fitted with a new expandable casing.
[0029] Preferably, the process is repeated several times with desired lengths of casing until the desired drilling depth has been reached. There are no or just insignificant differences in diameter between the expanded lengths of casing.
[0030] For drilling in a petroleum reservoir, casing may in some well portions be replaced with flow-through sand screens of an expandable or non-expandable kind.
[0031] Energy and control signals may be transmitted to the device by means of methods known per se, like downhole telemetry and cable along the drill string.
[0032] The motor for driving the drill bit is supplied with energy from the drill string, either via drilling fluid, which is pumped from the surface, electrical energy through the drill string, or chemically by fuel being carried down to the motor from the surface, possibly through separate channels in the drill string.
[0033] The drill string, casing and completion string may be of a conventional kind made of steel of different qualities, or they may be made of other materials, for example of a light metal like aluminium, possibly in combination with an antiwear coating and electrical insulation coating on the inside and/or on the outside.
[0034] Using new materials in this way enables the drill string to be lighter. The drill string may be made approximately weightless in that, as circulation liquid inside the drill string, there is used a liquid with a lower density than the liquid located externally to the double drill string. In the same way as the drill string, the casing and the completion string may be a complete coilable pipe length, joined coilable pipes or joined pipes, which are not coiled.
[0035] In an alternative embodiment, the transmission of electrical power and transmission of signals may be effected in that at least one pipe in the drill string has an electrical insulating material applied on one or both sides, whereby at least one pipe is electrically insulated from the earth potential. Thereby it will be possible to send considerable amounts of electrical energy with relatively little loss through the insulated pipe due to the relatively large metallic cross-sectional area of the pipe. The good supply of electrical energy may favourably be used for the transmission of both effect and signals, as for example for driving a downhole electric motor for the rotation and operation of the drill bit. The electric conductor can also be used for driving a downhole electric pump for pressure control of return fluid, and for controlling downhole actuators, data acquisition and telemetry to the surface.
[0036] Electric and/or optical conductors of relatively small cross-sections for signal transmission between the surface and sensors or actuators placed downhole in the drill string may be placed in the insulating material. These signal transmission cables may possibly be protected against wear, for example by lying protected in a reinforced composite material.
[0037] Permanent pipe strings like casing and completion strings can also be used according to the method described above for communication with downhole sensors and actuators with cables built into a protective insulating material on the inside or on the outside. Such permanent pipe strings will have particular advantages, for example in the recovery of petroleum, in which they may also easily be used for downhole monitoring and control of production or injection. Involved here may be a pipe string of the expanding casing kind which is forced out and seals against the existing lining of the well, thereby also helping to ensure tightness and also to increase the strength of the lining of the well. It may also be a string of the same kind, but which is not expanded and which may be fixed by cementation in the borehole, in this way becoming part of the lining in the well.
[0038] Together with downhole sensors and actuators the above-mentioned string, with cables built into a protective insulating material on the inside or on the outside, may be pullable and be set in the well without cementation. This string, possibly in combination with a downhole packer element, will thereby make up a pullable completion string which enables monitoring and control of the production and injection in different zones.
[0039] It is advantageous to provide the inside of the external drill pipe with an electrical insulating material, in which signal cables are extended. In this way there may be provided in the drill string a possibility for electrical communication, and for the outer pipe of the drill string to be used subsequently as a so-called completion string.
[0040] The method and the device according to the invention offer advantages through efficient establishing of wells, as regards both on-land wells and subsea wells. Particular advantages are achieved in establishing subsea wells because the riser is built into the drill string, that is to say in principle it is not imperative to have an outer pipe round the drill string, or an extra pump device for return transport of the drilling fluid from the sea floor to the sea surface. This means particular advantages in great sea depths because of weight saving.
[0041] The method and the device also offer advantages through increased safety during drilling, as an extra barrier can be established for well control. The drilling fluid above the upper tool assembly may favourably be a so-called kill fluid, that is to say it has a specific gravity which is chosen to be such that the pressure within the well will always be greater than the pore pressure in the surrounding formation and therefore represents a well control barrier. A BOP (Blow-Out Preventer) at the top of the well is another form of well control barrier.
[0042] According to this method, a novel well control barrier is formed by the movable packer of the upper tool assembly in combination with a preferably fail-safe valve on the return flow pipe, said valve being integrated in the lower tool assembly and controllable from the surface. These elements represent an additional barrier for preventing uncontrolled flow of formation fluid into the well in given situations. These elements also offer increased safety and control, for example in under-balanced drilling, as it enables controlled production from the well during drilling.
[0043] On the background of what has been mentioned above, the drilling fluid, which is circulated, may be designed with a very low density without this making the drilling safety suffer. The method and the device according to the invention thus enable improved monitoring and control of the pressure within the open hole of the well.
[0044] In connection with the use of a light-weight drill string with buoyancy, as described above, this method permits drilling of particularly far-reaching and deep holes. This may give more efficient draining of fields for the recovery of petroleum. It may also be advantageous in other application areas, as for example in connection with the recovery of geothermal energy. An approximately weightless drill string will also allow a drilling ship to be less demanding as to accurate positioning and response time on drift, and enables simplified heave compensation in the drilling of a subsea well in that heave is compensated through flexing of the drill string.
[0045] For a subsea well the drill string may extend through the open sea, or it may be directed from the sea floor to the surface through a guide pipe, which may be filled with water or drilling fluid of a desired density. This guide pipe itself may also have integrated floating elements, so that it does not itself represent any great load in the form of forces exerted on the drilling vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] In what follows is described a non-limiting example of a preferred method and embodiment visualized in the accompanying drawings, in which:
[0047] FIG. 1 shows schematically a well, which is being established by means of a vessel located on the sea surface;
[0048] FIG. 2 shows schematically, and on a larger scale, a running tool, which is placed at the lower end portion of a borehole;
[0049] FIG. 3 shows schematically the running tool after the borehole has been drilled further, so that the upper end portion of the expanding casing corresponds with the lower end portion of a previously set casing;
[0050] FIG. 4 shows schematically the running tool as the expandable casing is expanded to its expanded diameter;
[0051] FIG. 5 shows schematically the expandable casing as expansion is completed, the lower tool assembly being pulled up through the expanded casing;
[0052] FIG. 6 shows schematically the running tool on a larger scale; and
[0053] FIG. 7 shows a well, in which there are placed a reinforcing casing and a completion string.
DETAILED DESCRIPTION OF THE INVENTION
[0054] In the drawings the reference numeral 1 identifies a running tool including a lower tool assembly 2 , an upper tool assembly 4 , an expandable casing 6 extending between the upper and lower tool assemblies 4 , 2 , and a double coiled tubing 8 extending from the lower tool assembly 2 to the surface.
[0055] The running tool 1 is placed in a borehole 10 , which is provided with a casing 12 .
[0056] The lower tool assembly 2 , see FIG. 5 , includes a drilling tool 14 of a kind known per se, which is of such configuration that it may be moved through an opening of a smaller diameter than the diameter of the borehole 10 which the drilling tool 14 is arranged to drill. A motor 16 drives the drilling tool 14 , see FIG. 6 .
[0057] Drilling fluid and cuttings can flow to the surface via a return inlet 22 in the lower tool assembly 2 connected to a second pipe conduit 24 of the double-coiled tubing 8 . Alternatively, the return inlet 22 may be at the centre of the drill bit (not shown in the figure) in order also to transport cores 25 from the bottom of the hole directly into the second pipe conduit 24 .
[0058] The lower tool assembly 2 is releasably connected to the lower portion of the expanding casing 6 , for example by means of lower shear pins 26 .
[0059] The double-coiled tubing 8 extends sealingly and movably through the upper tool assembly 4 . In this preferred embodiment the upper tool assembly 4 includes a movable packer 28 sealing against the casing 12 , a rolling anchor 30 with rollers 31 and an expansion tool 32 . The components 28 , 30 and 32 are each known per se and are not described in further detail.
[0060] The upper tool assembly 4 is releasably connected to the upper end portion of the expanding casing 6 , for example by means of upper shear pins 34 .
[0061] After the running tool 1 has been assembled on the surface, it is sluiced into the borehole 10 possibly through a riser 36 and wellhead valves 38 . Subsequently the running tool 1 may be moved down into the borehole by gravity forces or by fluid being pumped into the borehole 10 above the upper tool assembly 4 , the packer 28 sealing against the casing, and by the fluid pressure acting on the upward-facing area of the tool assembly 4 . The fluid located below the running tool 1 can be drained to the surface through the second pipe conduit 24 of the double-coiled tubing 8 . The draining from the running tool 1 to the surface can be improved by means of a not shown, preferably electrically driven booster pump in the lower tool assembly 2 .
[0062] When the drilling tool 14 of the running tool 1 hits the bottom of the borehole 10 , see FIG. 2 , the drilling tool 14 is set in a manner known per se to drill at a desired diameter, after which the motor 16 is started. The torque of the drilling tool 14 is absorbed via the expanding casing 6 by the rolling anchor 30 of the upper tool assembly 4 .
[0063] The feed pressure of the drilling tool 14 against the bottom of the borehole 10 can be adjusted by adjusting the fluid pressure against the topside of the upper tool assembly 4 . This feed pressure can also be adjusted by changing the density or flow rate of the circulating drilling fluid, or it can be adjusted by means of a not shown pump, as described above.
[0064] After a distance corresponding to the length of the expandable casing 6 has been drilled, so that the end portion of the expanding casing 6 corresponds with or approaches the lower end portion of the casing 12 , see FIG. 2 , the drilling is stopped.
[0065] If desirable, the expandable casing 6 may be provided internally with cementation mass, which is forced, during this part of the operation, into an annulus 40 between the expandable casing 6 and the borehole 10 , or the annulus 40 may be flushed.
[0066] The pressure of the fluid above the upper tool assembly 4 is increased, so that the upper shear pins 34 break, after which the expansion tool 32 is moved down the expandable casing 6 . The expandable casing 6 is thereby given a desired, expanded diameter.
[0067] As the expansion tool hits the lower tool assembly 2 , the lower shear pins 26 break, whereby the lower tool assembly 2 is released from the expandable casing 6 . The running tool 1 with the exception of the expandable casing 6 , is then pulled up from the borehole 10 , see FIG. 5 .
[0068] In FIG. 4 is shown that the entire upper tool assembly 4 is moved into the expandable casing 6 together with the expansion tool 32 . In an alternative embodiment not shown, parts of the upper tool assembly 4 , for example the rolling anchor 30 , may be left at the upper portion of the expandable casing during the expansion operation.
[0069] After the drilling to the desired drilling target has been completed, one or repeated actions of reinforcement of the casing 12 in the well may be carried out by expansion of a reinforcement casing 42 , which may form the entire length of the well or parts thereof, against the casing 12 already standing in the borehole. Alternatively, the reinforcement casing 42 can be cemented to the casing 12 . This reinforcement casing 42 which makes the casing 12 be reinforced, may favourably be provided with built-in electrical or optical cables 44 , and not shown downhole sensors and actuators for monitoring and controlling production or injection. This reinforcing operation may be repeated in order to increase the strength of the lining of the borehole 10 to the desired level.
[0070] After the lining of the borehole 10 has been completed, there is placed, preferably when production wells are involved, a pullable completion string 46 in the borehole 10 . This completion string 46 may, in the same was as the reinforcement casing described above, be provided with built-in electrical or optical cables 44 , and not shown downhole sensors and actuators.
[0071] The completion string 46 is preferably provided with at least one downhole packer 48 which is arranged to seal against the casing 12 , possibly the reinforcement casing 42 in order thereby to isolate the annulus between the completion string 46 and the casing 12 in at least one well zone 50 .
[0072] If it is desirable to drain from or inject into several well zones 50 simultaneously, it is advantageous for the completion string 46 to be provided with two or more conduits, in the same way as for the drill string 8 .
[0073] The establishing of the borehole 10 is carried out by means of a vessel 60 on the sea surface 62 ; see FIG. 1 , the vessel 60 being provided with drilling equipment 64 . The drill string 8 is typically reeled onto a drum, not shown, on the vessel 60 before being moved down into the borehole 10 .
[0074] The drill string 8 can be disposed freely in the sea, or it may be encapsulated in a riser 66 . The riser 66 may be provided with floating elements, not shown.
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A method and device for a running tool for drilling or cleaning and setting a lining and a completion string in an underground borehole, The running tool comprising a drilling tool, an expandable casing, an expansion tool, a packer arranged to seal against the wall of the borehole, and at least one conduit extending up to the surface. The drilling tool is releasably connected to the lower portion of the expanding casing, and the expansion tool and the packer are releasably connected to the upper portion of the expanding casing. The running tool is arranged to communicate with the surface through at least one pipe conduit.
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This application claims the benefit of provisional application No. 60/216,841, filed Jul. 7, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for dispensing a filled, or threaded, bobbin when an empty bobbin is deposited into the apparatus.
2. Description of the Related Art
Bobbins are used in the sewing industry to supply thread to a sewing machine. Thread is pre-wound onto the bobbin, and the bobbin is then placed on the sewing machine. The thread is pulled from the bobbin as the machine functions. Bobbins are useful in that the amount of thread and type of thread can be controlled. Specifically, a bobbin can be pre-wound with a pre-determined quantity of thread to minimize waste, and make changing a machine from one sewing job to another more efficient.
A problem associated with the use of bobbins in this manner is controlling the inventory of new and used bobbins. As known in the art, when the thread on a bobbin is exhausted, the empty bobbin may be re-used. Specifically, new thread may be wound onto the used, empty bobbin and the bobbin can then be re-circulated with a different type and/or amount of thread. Empty bobbins, however, are sometimes carelessly discarded or lost, thereby depleting the supply of empty bobbins to be re-used.
Therefore, it is desirable to provide an apparatus for dispensing a filled, or re-threaded, bobbin, once an empty bobbin has been exhausted and deposited into the apparatus.
SUMMARY OF THE INVENTION
According to one aspect of the invention, an apparatus is provided for dispensing a fully threaded bobbin to an operator upon the depositing of an empty bobbin into the apparatus. The apparatus comprises a housing defining a storage compartment for storing the bobbins. The housing has a first opening for depositing the empty bobbins therein and a second opening for dispensing the full bobbins therefrom. A tray is mounted to the housing within the storage compartment for orienting and feeding fully threaded bobbins. At least one slide is provided for transporting the full bobbins from the tray to the second opening. An actuator lever is slidably coupled to the housing for activating the apparatus. A release hinge is mounted to a portion of the slide and operatively coupled to the actuator lever for releasing a single full bobbin from the slide and the second opening in response to the actuator lever being activated from a fully extended position to an actuated position and an empty bobbin being deposited into the first opening. An accommodator is operatively coupled between the actuator lever and the tray for orienting the bobbins for transportation in the slide for cooperation with the release hinge.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
FIG. 1 is a perspective view of a bobbin dispenser in accordance with the present invention;
FIG. 2 is a perspective view of a center divider;
FIG. 3 is another perspective view of the bobbin dispenser shown with a tray removed;
FIG. 4 is a perspective view of the tray;
FIG. 5 is an exploded perspective view of a top slide and related components;
FIG. 6 is a perspective view of a bottom slide; and
FIG. 7 is an exploded perspective view of a lever channel and related components.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a bobbin dispenser apparatus of the present invention is generally shown at 10 in FIG. 1 .
The dispenser 10 includes a housing 12 that defines a storage compartment 14 . The housing 12 can be made from any material such as steel, plastic, wood, or the like. The housing 12 includes a top 16 which is either removable, or in the alternative, hinges in such a way that the top 16 can be opened up to allow access to the compartment 14 . A center divider 18 is disposed in the compartment 14 and is supported by the housing 12 such that the compartment 14 is divided into an upper compartment 20 and a lower compartment 22 .
Referring to FIG. 2 , the center divider 18 includes a full bobbin opening 24 for allowing bobbins to fall from the upper compartment 20 into the lower compartment 22 as will be discussed below. The center divider 18 further includes an empty bobbin opening 26 located adjacent to the full bobbin opening 24 , the function of which is discussed below.
As best shown in FIG. 3 , the housing 12 further includes a first planar wall 28 and a second planar wall 30 opposite the first wall 28 . The first 28 and second 30 walls are interconnected by a third planar wall 32 and an opposite fourth planar wall 34 . The walls 28 , 30 , 32 , 34 define the storage compartment 14 and support the center divider 18 between the upper and lower compartments 20 , 22 . A first opening 36 and a second opening 38 are formed in the first wall 28 . The first opening 36 communicates with the upper compartment 20 of the compartment 14 and the second opening 38 communicates with the lower compartment 22 of the compartment 14 . A third opening 40 and a fourth opening 42 are formed in the fourth wall 34 and are in communication with the upper compartment 20 and the lower compartment 22 , respectively.
As discussed in the background section, bobbins as shown at 8 , which are pre-wound with thread, are used in the sewing industry to supply thread to a sewing machine. The dispenser 10 is designed to accept a used bobbin, i.e. a bobbin without thread, and dispense a new or full bobbin, i.e. a bobbin with thread. In particular, the used bobbin is inserted into the third opening 40 and the full bobbin is dispensed out the second opening 38 . The specifics of how the bobbin is dispensed and the working components of the dispenser 10 are discussed in greater detail below.
Referring again to FIG. 1 , the dispenser 10 includes a tray 44 that holds and orients the full bobbins 8 in the upper compartment 20 . The tray 44 is mounted above the divider 18 and supported by the side walls 28 , 30 , 32 , 34 . As best shown in FIG. 4 , the tray 44 includes a reservoir 46 defined by sidewalls 48 and a bottom 50 for holding the full bobbins. The bobbins 8 are placed to move in a rolling orientation in order to be easily dispensed from the tray 44 . The reservoir 46 is tilted to cause the full bobbins 8 to roll along the bottom 50 toward a release channel 52 . The release channel 52 runs along one side of the tray 44 and includes an angled, or ramped, sidewall 54 to assist in aligning the full bobbins in a manner to be dispensed. The tray 44 also includes an opening 56 in the sidewall 48 adjacent the end of the release channel 52 for insertion of an accommodator 58 . The accommodator 58 is a wedge shaped block slidably supported by the housing 12 for movement in and out of the opening 56 so as to assist in orienting the dispensing of the bobbins as is further discussed below.
Referring also to FIG. 5 , full bobbins are fed from the tray 44 to a top slide 60 . An upper guide 62 is mounted to an upper end 64 of the top slide 60 to assist in guiding the full bobbins from the release channel 52 to within the top slide 60 . A lower end 66 of the top slide 60 is mounted to the center divider 18 over the full bobbin opening 24 .
The top slide 60 , including the attached upper guide 62 , includes a generally U-shaped channel 68 defined by first and second side walls 70 , 72 and a floor 74 extending between the side walls 70 , 72 . The floor 74 is slightly wider than the thickness of a bobbin standing on edge. In particular, the floor 74 is wide enough to allow the bobbin to freely roll thereon and is narrow enough to prevent the bobbin from toppling over so as to keep the bobbin on its edge, thereby allowing the bobbin to roll. The full bobbin opening 24 , show in FIG. 2 , is of a complementary width to the floor 74 such that a bobbin can fall through the opening 24 and into the lower compartment 22 while maintaining its rolling orientation.
The top slide 60 further includes an arcuate groove 76 formed in each of the side walls 70 , 72 approximately half way between the upper end 64 and the lower end 66 of the top slide 60 . A release hinge 78 is disposed in the groove 76 perpendicular to the longitudinal length of the top slide 60 . The release hinge 78 includes a lateral bar 80 having a pair of spaced apart bushings 82 . The bar 80 is seated in the groove 76 with the bushings 82 straddling the side walls 70 , 72 so as to limit lateral movement of the release hinge 78 .
A valve 84 is mounted to the lateral bar 80 between the bushings 82 . The valve 84 is an arcuate shaped member made of metal, plastic or the like. The valve 84 has a major portion 86 that hangs from the lateral bar 80 towards the lower end 66 of the top slide 60 , and a minor portion 88 that hangs from the lateral bar 80 towards the upper end 64 of the top slide 60 . As is discussed below, the valve 84 is used to control the movement of the bobbins in the channel 68 .
An actuation rod 90 extends downwardly from the lateral bar 80 and outside of the channel 68 and along side of the side walls 70 , 72 . The actuation rod 90 is used to rotate the lateral bar 80 and valve 84 to facilitate releasing the bobbins one at a time from the top slide 60 .
Referring to FIGS. 1 and 3 , a bottom slide 92 is mounted within the lower compartment 22 of the dispenser 10 . As best shown in FIG. 6 , an upper end 94 of the bottom slide 92 includes a lower guide 96 for connecting the bottom slide 92 to the center divider 18 opposite the lower end 66 of the top slide 60 . The lower guide 96 is therefore aligned with the full bobbin opening 24 in the center divider 18 . The bottom slide 92 includes a channel 98 defined between spaced apart sidewalls 100 , 102 , similar to the channel 68 within the top slide 60 , for maintaining the bobbin on its edges and thus allowing the bobbin to roll downward.
A lower end 104 of the bottom slide 92 extends through the second opening 38 within the second wall 30 . The lower end 104 includes U-shaped cutouts 106 in each sidewall 100 , 102 to allow an operator to retrieve a full bobbin that has been dispensed.
As shown in FIG. 1 , the dispenser 10 includes an actuator lever 108 to facilitate the release of a bobbin from the dispenser 10 once an empty bobbin has been inserted into the third opening 40 . As best shown in FIG. 7 , the actuator lever 108 rests within a lever channel 110 , defined by spaced apart and parallel sidewalls extending between a front end 112 and rear end 113 . As shown in FIG. 3 , the lever channel 110 is supported by the divider 18 within the upper compartment 20 . Referring to FIGS. 3 and 7 , the front end 112 of the lever channel 110 mates with the inside of the first wall 28 and aligns with the first opening 36 therein. The actuator lever 108 is slidably disposed into the upper compartment 20 through the first opening 36 for movement between a fully extended position and an actuated position. A lever spring 114 is disposed about the lever 108 and between opposite ends thereof for biasing the lever 108 outwardly from the compartment 14 to the fully extended position. The actuator lever 108 also includes a forked end 116 defined by spaced apart and parallel fingers 118 , 120 that is located within the lever channel 110 .
An accommodator bracket 122 including opposing L-shaped ends 124 , 126 is mounted to the top side of the actuator lever 108 by the end 124 . The accommodator 44 is mounted to the other end 126 of the accommodator bracket 122 opposite the actuator lever 108 , and aligns with the accommodator opening 56 in the tray 44 , as shown in FIG. 4 .
An actuation spring support bracket 128 is fixedly mounted to the sidewalls of the lever channel 110 . The actuation spring support bracket 128 straddles the lever channel 110 and includes a mounting clip 130 . An actuation spring 132 , such as a compression coil spring, interconnects the clip 130 and the distal end of the actuation rod 90 opposite the lateral bar 80 , as shown in FIG. 3 . The actuation spring 132 biases the release hinge 78 to a starting position where the major portion 86 of the valve 84 is rotated downwardly into the channel 68 of the top slide 60 . When hinge 78 is in the starting position, the actuation rod 90 extends into the lever channel 110 .
An empty bobbin slide 134 attaches generally perpendicularly to the lever channel 110 . The empty bobbin slide 134 includes spaced apart and parallel sidewalls 136 , 138 extending between first and second ends 140 , 142 defining a channel 144 therebetween for receiving a bobbin. The first end 140 is connected to the sidewall of the lever channel 110 adjacent the rear end 113 and the opposite second end 142 is connected to the fourth wall 42 and aligned with the third opening 40 therein. The rear end 113 of the lever channel 110 ends directly aligned with the empty bobbin opening 26 in the center divider 18 .
In operation, the tray 44 of the dispenser 10 is initially filled with full bobbins 8 . At least a few of the full bobbins fall into the release channel 52 and subsequently roll down the top slide 60 until stopped by the major portion 86 of the valve 84 . Specifically, when a bobbin rolls down the channel 68 , the bobbin rolls under the minor portion 88 and is stopped by the major portion 86 .
A user may deposit an empty bobbin 146 through the third opening 40 and into the empty bobbin slide 134 such that the bobbin is standing on an end face. When the actuator lever 108 is in the fully extended position, the forked end 116 is biased to a position closest to the front wall 28 which is behind the point where the empty bobbin slide 134 mates with the lever channel 110 . In addition, the release hinge 78 is in the starting position with the distal end of the actuation rod 90 extending into the lever channel 110 in front of the point where the empty bobbin slide 134 mates with the lever channel 110 . Therefore, when the empty bobbin is deposited to the empty bobbin slide 134 , the bobbin will slide downward on its end face and topple over on its edges into the lever channel 110 in front of the forked distal end 116 and behind the distal end of the actuation rod 90 . The channels and intersection of the empty bobbin slide 134 and the lever channel 110 are configured such that when the empty bobbin reaches the lever channel 110 , the bobbin is positioned in a rolling orientation.
To receive a new full bobbin, the operator activates the actuator lever 108 to move the lever 108 to the actuated position. Specifically, the operator pushes the actuator lever 108 toward the first wall 28 against the bias of the lever spring 114 . As the actuator lever 108 advances, the forked end 116 slides forward to contact the empty bobbin that is standing in the lever channel 110 . Upon further advancement of the lever 108 , the forked end 116 extends to the rear end 113 of the lever channel 110 , thereby pushing the empty bobbin past the rear end 113 and causing the empty bobbin to fall through the empty bobbin opening 26 and into the lower compartment 22 .
As the empty bobbin is pushed along the lever channel 110 toward the rear end 113 , the empty bobbin contacts the distal end of the actuation rod 90 and causes the release hinge 78 to rotate counter-clockwise as viewed by FIGS. 3 and 5 . The counter-clockwise rotation rotates the lateral bar 80 such that the major portion 86 of the valve 84 is rotated upward and out of the channel 68 . Simultaneously, the minor portion 88 is rotated downward into the channel 68 . The minor portion 88 lowers into the channel 68 in front of a subsequent full bobbin directly behind the bobbin held by the major portion 86 of the valve 84 . After the major portion 86 is rotated fully upward and out of the channel 68 , a single full bobbin will roll freely down the channel 68 while all the other full bobbins stacked behind are being held by the minor portion 88 of the valve 84 .
The single full bobbin rolls forward down the remainder of the top slide 60 , until the bobbin falls downward through the full bobbin opening 24 . The bobbin is then caught by the lower guide 96 which delivers the bobbin further downward into bottom slide 92 . The bobbin rolls down through bottom slide 92 and exists out the first opening 36 into the cutouts 80 for retrieval by an operator. The remaining full bobbins continue to be held in place by the minor portion 88 of the valve 84 .
Once the empty bobbin has been pushed beyond the rod 90 , the actuation spring 134 causes the actuation rod 90 to snap back to the starting position. Hence, the lateral bar 80 rotates clockwise back to the starting position. The major portion 86 of the valve 84 will rotate back downward into the channel 68 , and the minor portion 88 will rotate upward out of the channel 68 . The subsequent full bobbins within the channel 68 will roll forward until the first bobbin rests against the major portion 86 of the valve 84 .
Simultaneously with the actuation of the actuator lever 108 , the accommodator 58 is forced into the accommodator opening 56 and into the supply of bobbins. The accommodator 58 helps to shift the bobbins so the bobbins may fall within the release channel 52 and become correctly oriented such that they may roll forward to the top slide 60 .
The actuation of the actuator lever 108 therefore deposits an empty bobbin into the lower compartment 22 while simultaneously releasing a single full bobbin for retrieval by the operator. Actuation of the actuator lever 108 without first depositing an empty bobbin will not release a full bobbin. Without an empty bobbin placed in the lever channel 110 , the forked distal end 116 will pass underneath the actuation rod 90 . Hence, the empty bobbin acts as a coupler to couple the forked distal end 116 to the actuation rod 90 .
Once the actuator lever 108 has been fully actuated, the empty bobbin has dropped into the empty bobbin opening 26 , and the fill bobbin has been dispensed, the operator will release the actuator lever 108 . The lever spring 114 automatically biases the lever 114 to the original starting position such that the dispensing operation may be repeated.
The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.
Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practised other than as specifically described.
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An apparatus for dispensing a fully threaded bobbin to an operator upon the depositing of an empty bobbin into the apparatus. The apparatus comprises a housing defining a storage compartment for storing the bobbins. The housing has a first opening for depositing the empty bobbins therein and a second opening for dispensing the full bobbins therefrom. A tray is mounted to the housing within the storage compartment for orienting and feeding fully threaded bobbins and a top and bottom slide are provided for transporting the full bobbins from the tray to the second opening. An actuator lever is slidably coupled to a lever channel for activating the apparatus. A release hinge is mounted to the top slide and operatively coupled to the acutator lever for releasing a single full bobbin from the top slide and to the second opening in response to the actuator lever being activated from a fully extended position to an actuated position and an empty bobbin being deposited into the first opening and lever channel. An accommodator is operatively coupled between the actuator lever and the try for orienting the bobbins for transportation in the top slide for cooperation with the release hinge.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a §371 national stage of International Application PCT/EP2014/066140, filed Jul. 28, 2014, which claims the priority benefit of U.K. patent application Ser. No. 1313721.1, filed Jul. 31, 2013, both of which are hereby incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates to a leak detection sensor for a stoma pouch and a process for making same.
BACKGROUND OF THE INVENTION
[0003] In the treatment of certain medical conditions, such as cancer of the colon, it is known to establish an opening in the body for the discharge of body wastes. Such opening is typically known as an ostomy. There are three types, namely urostomy, ileostomy and colostomy, depending upon where such opening is located. A stoma is an outlet from the intestine through the abdominal wall. Such openings are typically connected to an exchangeable bag for receiving the body wastes, such bag typically being known as a stoma pouch. The stoma pouch is typically connected to the ostomy via a flange attachable to the skin around the stoma by means of an adhesive layer. The pouch may be detachable from the flange to permit replacement of the pouch.
[0004] The adhesive layer of the flange gradually loses its effectiveness over time, leading to leakages having unpleasant consequences. Therefore it is desirable to have a reliable and cost effective system capable of detecting the leakage of fluid beneath the adhesive layer of the flange of a stoma pouch to warn the patient that the pouch requires replacement.
[0005] There are approximately 120,000 people in the UK with some form of “ostomy” and it is estimated that 21,000 operations to create them are performed each year. The US has, as expected, a far higher number with more than 650,000 ostomates. The cost to the NHS alone for the cost of accessories (pouches, flanges etc.) for the effective management ranges from £780 to £2300 per person per year with the total annual spend in the region of £200 m. The most pressing complaint raised by patients is not the inconvenience of the pouch system but rather the consequences of its failure, especially in social settings. There is a tremendous psychological burden on the patient when trying to lead a normal, proactive life where there is a constant fear of the pouch leaking and the associated embarrassment. An object of the present invention is to provide an early warning system which will alert the patient to the impending leak and give them sufficient time to take preventative action and thus avoid the debilitating scenario of having to deal with a pouch failure in public.
SUMMARY OF THE INVENTION
[0006] According to a first aspect of the present invention there is provided a leak detection sensor comprising a pair of electrodes, each electrode being coated with an electrically insulating coating having fractures formed therein having a breadth of less than 500 nm, and optionally 100 nm or less, whereby a current can flow between the electrodes when the electrodes are exposed to an electrically conductive fluid.
[0007] Optionally, the fractures are formed by a process of laser ablation.
[0008] In one embodiment the electrodes may comprise a pair of intertwined wires.
[0009] Optionally, the electrically insulating coating comprises a polymeric coating, for example a thermopolymer. The polymeric coating may comprise polyvinylacetate, polyimide, polyurethane, or polyester or any other suitable thermopolymer.
[0010] The electrodes may be intertwined with an absorbent wick.
[0011] According to a further aspect of the present invention there is provided a stoma pouch assembly comprising a flange having an opening for receiving an ostomy or stoma, the flange being provided with an adhesive layer for adhering the flange to a patient's skin, the flange being provided with a leak detection sensor in accordance with the first aspect of the invention for detecting the passage of fluid between the adhesive layer of the flange and the patient's skin.
[0012] Optionally, the sensor defines a loop encircling the flange opening.
[0013] The leak detection sensor may be coupled to a detection circuit having an alarm, such as a vibration and/or audible alarm, for alerting the patient to the leakage of fluid beneath the adhesive layer of the flange.
[0014] According to a further aspect of the present invention there is provided a method of making a leak detection sensor comprising providing a pair of electrodes each having an electrically insulating coating thereon formed from a thermopolymer, and creating fractures in the coating of the electrodes having a breadth of less than 500 nm, and optionally 100 nm or less, through which fluid may permeate to enable current to flow between the electrodes when exposed to an electrolyte.
[0015] The electrodes may comprise a pair of wires, the method optionally comprising the step of intertwining the wires following creation of the fractures in the respective coating thereof.
[0016] The method may comprise the further step of intertwining an absorbent wick with the wires.
[0017] In another embodiment, the step of creating fractures in the coating of the electrodes may comprise creating successive troughs at spaced intervals in the coating of the electrodes by laser ablation of the coating, exposing the surface of the respective electrode in the troughs, whereby the transmission of heat along the length of the respective electrode during the creation of a respective trough results in the partial melting of the coating surrounding a previously ablated adjacent trough which recovers the previously exposed surface of the electrode, fractures arising in the remelted coating as it solidifies as a consequence of the previous thermal degradation of the coating.
[0018] The laser ablated troughs may have a length of approximately 25 microns and may be created at a spacing of approximately 2 mm.
[0019] These and other objects, advantages and features of the invention will become apparent upon review of the following specification in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:—
[0021] FIG. 1 shows a stoma pouch leak detection assembly in accordance with an embodiment of the present invention;
[0022] FIG. 2 is an electron microscope image of a portion of the leak detection sensor of the assembly of FIG. 1 ; and
[0023] FIG. 3 is a higher magnification image of the surface of the sensor showing the nanoscale fractures formed in the surface of the insulating coating of the wires thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] In accordance with an embodiment of the present invention, a stoma pouch leak detection assembly comprises a leak detection sensor 10 comprising two intertwined copper wires 12 , 14 , each wire being coated with a thermopolymer, such as polyvinylacetate or polyester, to define an electrically insulating coating, the coating of the wires being treated by laser ablation to create nanoscale fractures 16 (see FIG. 3 ) in the insulating coating of the wires 12 , 14 through which fluid may permeate, allowing conduction between the wires and thus detection of leaks. The term “nanoscale fractures” used herein is hereby defined as fractures having a breadth of less than 500 nm, or 100 nm or less. The fractures may have a length of between 500 nm and 5 microns.
[0025] The sensor 10 may also include a porous wick (not shown) intertwined with the wires 12 , 14 . This may increase the sensitivity of the device such that, upon a leak emerging at a discrete point, the fluid is transported along the wire network by capillary action and thus contacts a greater proportion of nanoscale fractures 16 , increasing the sensitivity of the sensor 10 .
[0026] As shown in FIG. 1 , the sensor 10 is shaped and dimensioned to encircle an opening in a flange 2 of a stoma pouch 4 to sit between the skin 24 and an adhesive layer of the flange 2 when the flange 2 is located over a stoma 20 protruding through the skin 24 from the small intestine 22 , such that fluid leaking behind the adhesive layer may be detected by the sensor 10 , triggering a discrete alarm device 18 .
[0027] A process of laser ablation of the insulating coating covering the intertwined copper wires 12 , 14 of the sensor 10 creates nanoscale fractures in the coating through which fluid may permeate to enable the detection of leaks between the adhesive layer and the skin of the patient without the risk of short circuits between the wires 12 , 14 .
[0028] The leak detection sensor 10 of the present invention can be applied to conventional stoma pouch and thereby alert the wear to the early onset of a potential leak. The leak detection sensor 10 may be connected to an alarm device or detector 18 , which may comprise a conductivity circuit connected to a vibration alarm or other user perceptible alert, such as an audible and/or visually perceptible alarm. The leak detection sensor 10 defines a loop encircling the opening in the flange 2 of the stoma pouch 4 to be located between the skin of the patient and the adhesive layer of the flange 2 .
[0029] Fluid draining into the pouch has a tendency to undermine the adhesive layer of the flange 2 and, if left untreated, can lead to the failure of the flange 2 and the release of bowel or bladder contents. The leak detection sensor 10 may be located on or adjacent the adhesive layer, near the periphery of the flange opening such that, upon contact with fluid leaking past the adhesive layer and coming into contact with the sensor, the fluid, defining an electrolyte, completes the detection circuit and activates the vibration alarm, which may provide a discrete alarm signal to inform the patient that the pouch needs to be changed.
[0030] The sensor wires 12 , 14 define two electrodes, such as in the form of intertwined polyvinylacetate copper wires coated with an electrically insulating polymer coating, wherein the coating has been laser treated to create nanoscale factures 16 in the insulating coating, through which the stoma fluid can permeate and hence enable charge transfer between the two wires and thereby raise the alarm. The bulk of the coating however is complete, preventing circuit shorting and avoiding direct contact of the copper wire with the skin and overcomes issues with biocompatibility and peristomal irritation. Acid from the stoma fluid can corrode uncoated copper wires if placed directly in contact with the skin and thus lead to copper ions being mobilised. The copper ions could lead to skin complications and potential copper poisoning. The provision of the coating on the wires 12 , 14 prevents this.
[0031] The insulating coating may comprise polyvinylacetate or any other suitable thermopolymer, such as polyimide, polyurethane or polyester.
[0032] By using laser ablation to create nanoscale fractures 16 in the coating, such cracks allow the permeation of the stoma fluid through to the underlying copper, hence enabling the charge to transfer between the two electrodes. However, the coating remains intact and thus prevents the copper from coming into direct contact with one another and with the patient's skin, preventing short circuits. The sensor itself lies between the skin and the flange, and thus the provision of an insulating coating eases issues of biocompatibility. While the stoma fluid can still corrode the copper, the surface area of copper exposed via the nanoscale fractures is minimal and transport through the factures of the mobilised copper ion would be significantly restricted (a diffusion based transport process) and thus would be unlikely to cause any irritation issues.
[0033] In one embodiment the nanoscale fractures 16 in the insulating coating may be created by rastering across the polymer coated copper wire using a 25 W carbon dioxide laser to create 25 micron troughs at intervals of 2 mm along the length of the sensor and which partially exposes the underlying metal. The polyvinylacetate (PVAc) coating is a thermopolymer and the laser processing results in the partial ablation of the polymer. A critical issue however is the thermal conductivity of the underlying copper. After removing one segment the laser may be repositioned to remove another. The transmission of heat along the length of the wire however results in the partial melting of the polymer surrounding the previously ablated segment which recovers the metal with molten polymer. When cool, nanoscale fractures 16 arise as a consequence of the previous thermal degradation.
[0034] The copper wires 12 , 14 may then be intertwined with a polyester thread (to create a wick) and the final assembly may serve as a two electrode sensor 10 which can be placed onto the pouch flange around the periphery of the flange opening. The adhesive coating of the pouch flange enables easy positioning of the sensor 10 . The flange plus sensor can then be placed directly over the stoma onto the skin and the sensor connections attached to the detector 18 . It is envisaged that the wire 12 , 14 may be intertwined prior to the process of laser ablation.
[0035] As fluid is released form the stoma, some will begin to seep under the flange and will gradually undermine the adhesive seal. The detector 18 is activated when the fluid reaches the sensor 10 and effectively completes the circuit. The degree of warning can be controlled by the user through the placement of the sensor 10 with respect to the adhesive layer around the flange opening. The closer to the flange periphery, the shorter the period before warning and flange failure.
[0036] FIG. 2 comprises a scanning electron micrograph highlighting the morphology of the sensor structure. The troughs 30 created by the laser are clearly visible in FIG. 2 but it is important to note that the ablated portion does not reveal the underlying copper. The transmission of heat along the length of the wire however results in the partial melting of the polymer surrounding the previously ablated segment which recovers the metal with molten polymer. When cool, the nanoscale fractures 16 are created in the coating as a consequence of the previous thermal degradation of the coating. The nanoscale fractures 16 can be seen in greater detail in FIG. 3 .
[0037] The operation of the sensor 10 in accordance with the present invention has been tested ex vivo with stoma fluid. There is a high electrolyte concentration in the stoma output which yields a positive response at the detector.
[0038] The crux of the issue relates to the design of a conductivity sensor that can be mounted onto a biomedical flange which can provide 360° detection of impending leaks. The electrodes of the sensor can be intertwined into a single loop using low cost material and which enables continuous monitoring without inducing skin irritation.
[0039] The detector assembly itself can be re-usable, with the sensor 10 comprising a low cost disposable component. Crucially, the sensor can integrated within existing pouch systems without alteration. The flexible nature of the sensor 10 allows it to be tailored to a wide range of stoma pouches (independent of shape and size) by the patient themselves.
[0040] The invention is not limited to the embodiment(s) described herein but can be amended or modified without departing from the scope of the present 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 leak detection sensor includes a pair of electrodes, each electrode being coated with an electrically insulating coating having fractures formed therein having a breadth of less than 500 nm, whereby a current can flow between the electrodes when the electrodes are exposed to an electrically conductive fluid. An alarm is activatable in response to current flowing between the electrodes.
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BACKGROUND OF THE INVENTION
The invention relates generally to the area of servomechanism control circuits. Specifically, the invention provides a method and apparatus for causing a cutting tool to initially contact a rotating workpiece at the same angular position of the workpiece independent of the velocity of the cutting tool.
In numerically controlled machine tools, a cutting tool is moved relative to a workpiece through a pattern of motions defined by a number of predetermined input signals. Typically, the input signals are divided into blocks of signals. Each block of signals defines a change in position and velocity of the cutting tool over a segment of the pattern of motions. The numerical control responds to the input signals and produces command signals to a servomechanism circuit which controls the operation of the cutting tool.
In every servomechanism, there is an error defined by the inherent lag between the input and output which is a function of the rate of variation of the input. The terms following error, a velocity lag error or a steady state error are used interchangably to define this error. For purposes of this disclosure, the term following error will be used to identify the error condition defined in this paragraph. In a numerical control, the input represents a displacement of the cutting tool; and therefore, the rate of variation of the input corresponds to velocity. Restating the above-definition relative to numerically controlled machine tools, the following error is defined by the lag between the desired position of the cutting tool and its actual position; and the following error is proportional to the velocity of the cutting tool.
In most situations, the change in relative position between the cutting tool and the workpiece due to variations in the following error does not affect the quality of the machining process. However, there is at least one exception to the general rule in the which the disclosed method and apparatus will provide an improved machining process.
The preferred embodiment discloses a thread cutting operation. In cutting a thread on a turning machine, the numerical control causes a single point cutting tool to move iteratively through a number of thread cutting passes over the rotating workpiece. The total depth of cut is increased with each pass; and when the final thread depth is achieved, the cycle of iterative motion is terminated.
Typically, on a thread cutting numerically controlled turning machine, a transducer is connected to the rotating spindle holding the workpiece; and a spindle signal is generated therefrom which represents the angular velocity of the spindle. The numerical control uses the spindle signal in conjunction with a programmed input signal defining the thread lead to generate command pulses to a servomechanism circuit for controlling the motion of the cutting tool relative to the rotating workpiece. At least once every revolution, an index for gating pulse is generated from the spindle signal. With each iterative cutting pass, the cutting tool is moved to the same start point; and the index pulse is used to initiate motion of the cutting tool relative to the rotating workpiece. Therefore, with each cutting pass the cutting tool makes contact with the workpiece at approximately the same angular position of the workpiece.
In the prior art systems, the spindle speed remained constant through all the thread cutting passes. This was required because a change in spindle speed would cause a corresponding change in the velocity of the cutting tool thereby changing the following error. Further, the change in following error would cause the cutting tool to initially contact the workpiece at a different angular position, and consequently, the cutting tool would not track the threading groove created by a previous thread cutting pass thereby ruining the workpiece.
Due to the fragile nature of a thread cutting tool, the rough thread cutting passes are executed at a relatively low spindle speed. However, during a finish thread cutting pass, the depth of cut is minimal; and it is desirable to increase the spindle speed and therefore the velocity of the cutting tool to improve the surface finish and efficiency of the process. With the prior art systems, the increase in following error resulting from the increased velocity would cause a loss of synchronization between the cutting tool and the threading start point on the workpiece. Consequently, a constant spindle speed had to be used during the whole thread cutting operation. However, the disclosed method and apparatus permits a spindle speed change without a loss of synchronization between the cutting tool and the threading start point. Therefore, the surface finish of the final thread and the efficiency of the overall process is improved.
SUMMARY OF THE INVENTION
According to one embodiment of the invention, a method and apparatus are disclosed for use with a numerically controlled turning machine which is operative to maintain a constant initial contact point between a cutting tool and an angular position of a rotating workpiece in response to a constant following error during successive machining passes. Said numerical control generates command signals in response to input signals to cause a servomechanism circuit to move the cutting tool relative to the rotating workpiece. The input signals include a position signal representing a desired change in position of the cutting tool and a velocity signal representing a desired velocity of the cutting tool. The improvement is comprised of a method and apparatus for moving the tool through a first machining pass in response to first velocity and position signals whereby the tool initially contacts the rotating workpiece at a first angular position of the workpiece. The first velocity signal and a subsequent velocity signal for a subsequent machining pass are used to generate a compensation signal representing the difference in following errors between the first and subsequent velocity signals. Command signals are generated to cause the servomechanism circuit to move the tool as a function of the compensation signal. Finally, further command signals are generated in response to a subsequent position signal and the subsequent velocity signal to cause the servomechanism circuit to move the cutting tool through the subsequent machining pass whereby the cutting tool initially contacts the rotating workpiece at the first angular position defined during the first machining pass.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general block diagram illustrating the parts of a turning machine and numerical control system in which the invention may be embodied.
FIG. 2 is a flow chart illustrating the general steps required by the data preparation program in executing a following error compensation cycle.
FIG. 3 is a flow chart of the sequence of steps that comprise a following error compensation cycle.
FIG. 4 is a detailed flow chart of a routine for testing for following error compensation parameters.
FIG. 5 is a detailed flow chart of a routine for testing for a base machining pass in a following error compensation cycle.
FIG. 6 is a detail flow chart of a routine for testing for a compensation machining pass in a following error compensation cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a general block diagram illustrating the basic components of a computer numerical control which are pertinent to the disclosed invention and in which the invention may be embodied. The elements as shown are those used in an ACRAMATIC computer numerical control manufactured by Cincinnati Milacron Inc. However, the exact definition and association of these elements may vary from one numerical control to another; and the disclosed invention may be implemented in any of the available computer numerical controls. Therefore, the exact details of the association of the elements shown in FIG. 1 should not be considered as limitations on the claimed method and apparatus.
The numerical control is shown generally at 10. Information is transferred into and out of the control by peripheral devices connected to a control interface 12. Such peripheral devices include a cathode ray tube 14, keyboard 16, input data decoder 18, output data encoder 19 on-line storage unit 20 and control push buttons and lights 22. The input information is processed by a computer 24 including a central processing unit 26, data store 28 and a program store containing a number of specific programs. The flow of information into and out of the computer as well as its overall operation is controlled by an operating system program 30. This program is generally a function of the particular computer used and is relatively independent of the application of the computer.
An input control program 32 controls the transfer of input information from a particular source connected to the control interface to a buffer data store in the computer. The input information is received by the N/C block processor program 33 which reads the information from the buffer store, performs error checks for syntax and executes the appropriate code conversions, e.g. BCD to binary, etc. The data preparation program 34 processes all axis motion information. This program calculates span length, feed rate information, controls the interpolation mode and controls optional features which influence axis motion, e.g. tool offsets, tool length compensation, etc. After data preparation is complete, an output control program 36 receives all the processed information and separates the axis motion information from machine function control information. In addition to transferring the machine function control information to a machine function program 38, the output control program 36 controls the sequence of occurrence of machine functions relative to the axis motions. A cycle control program 40 controls the serial sequence of operations of the N/C block processor program 33, data preparation program 34 and output control program 36.
Machine function control information is transferred under the control of the operating system program 30 to and from a machine interface 42. The machine interface 42 distributes process information to and receives input information from the specific machine function elements 44 and machine push buttons and lights 46. At times determined by the operating system program 30, axis motion information is transferred by the output control program 36 through the machine interface 42 to feed rate control and interpolation circuits 48. The interpolation circuit 48 generates a command signal to the servomechanism circuit 50 which is also responsive to a feed back signal on line 51 and produces an error signal to a slide driver 52. The slide driver controls the operation of a machine slide 54 which is mechanically connected to a feedback element 56. The feedback element monitors the motion of the machine slide and generates the feedback signal on the line 51 as a function of said motion.
In the preferred embodiment, the invention is used in association with a thread cutting process executed on a turning machine. In this situation, a single point thread cutting tool 58 moves relative to a rotating workpiece 60 which is held in a spindle 62. A spindle transducer 64 is mechanically connected to the spindle 62 and produces signals back to the feed rate control circuit 48.
In a threading process, it is necessary to synchronize the motion of the cutting tool 58 along an axis parallel to the center line of the workpiece 60 with the rotation of the spindle 62. To accomplish this, the spindle transducer 64 generates a signal back to the feed rate control circuit 48 which creates two further signals. A first signal represents the angular velocity of the spindle, and a second signal is an index or gating pulse which is generated once every revolution of the spindle. A thread is cut by making a number of passes of the thread cutting tool over the workpiece 60. With each thread cutting pass, the tool is initially brought to approximately the same position from which the thread cutting pass is started. The index pulse is used to initiate the thread cutting pass, therefore, the thread cutting tool will initially contact the rotating workpiece at the same angular position with each thread cutting pass.
The elements described thus far are shown in the prior art and represent the starting point from which the present invention is made. As discussed earlier, the elements described thus far have the disadvantage that a change in the velocity of the cutting tool from one machining pass to another will result in a different following error. Therefore, even though a machining pass is initiated from the same starting point with the index pulse, the different following error will cause the cutting tool to intially contact the rotating workpiece at a different angular position. Therefore, the cutting tool will not track a previously cut thread groove, and the thread will be ruined.
To overcome the above-mentioned disadvantage, and permit different cutting tool velocities between machining passes, the invention provides a following error compensation program 68 which is part of the data preparation program 34. The purpose of the program 68 is to determine the difference in following error between a first machining pass and a subsequent machining pass and modify the starting point of the next machining pass as a function thereof. For example, assume a thread has been cut by means of a series of iterative rough thread cutting passes at a relatively low spindle speed, and it is desired to make a final thread cutting pass at a higher spindle speed to improve the finish of the thread. Before the final thread cutting pass is executed the disclosed apparatus determines the difference in velocities between a roughing pass and the final thread cutting pass and calculates the difference in the following errors therebetween. The cutting tool is then displaced an amount proportional to the difference in following errors. The direction of displacement is determined by the direction of change in following errors. If the following error has increased, the cutting tool is moved closer to the workpiece; and if the following error has decreased, the cutting tool is moved away from the workpiece.
FIG. 2 is a flow chart illustrating the general tests made by the data preparation program. The numerical control continuously cycles through the data preparation program in servicing the functions which are required during a machine operation. Many functions may be processed simultaneously; and after a number of cycles of the data preparation program, the data required for a particular function is determined and output via the operating system program.
In FIG. 2, block 70 tests for the following error compensation parameters. These parameters control the operation of the compensation cycle and will be discussed in more detail later. Block 72 tests for a base machining pass. In order to execute the following error compensation, a reference following error must be established from which the amount of compensation is determined. Therefore, one of the machining passes is chosen as the base pass, and the following error during the base machining pass is used as a reference value for the following error compensation of subsequent machining passes.
Process block 74 tests for a compensation machining pass. After the base pass has been executed, any of the subsequent machining passes may be selected for compensation. The difference in following error between the base and a subsequent machining pass is determined, and the cutting tool is moved through a near displacement equal to said difference. Thereafter, the subsequent machining pass is executed; and the cutting tool will contact the workpiece at the same angular position as during the base pass.
FIG. 3 is a flow chart illustrating the general sequence of steps that comprise a following error compensation cycle.
The first process step 76 requires the detection of a following error compensation cycle start signal. After the detection of the start signal, process step 78 requires the execution of the base pass. During the execution of the base pass, information defining the velocity of the cutting tool is stored. This information may be generated by measuring the actual velocity of the machine slide holding the cutting tool or the information may be obtained from the programmed input information defining said velocity. Next, process step 80 detects an execute compensation signal which initiates the actual following error compensation.
In the example of a thread cutting operation, a number of roughing passes may be necessary before the compensated finish thread cutting passes are made. The compenation start signal of step 76 may be programmed in conjunction with any one of the roughing passes. However, the execute compensation signal of step 80 must occur before the first finish thread cutting pass in which the following error changes.
Process step 82 calculates a compensation signal representing the difference in following error caused by the difference in velocities between the base pass and a programmed but unexecuted finish pass. This compensation signal is transferred to the servomechanism circuits and represents a motion of the cutting tool along a coordinate axis. Process step 84 commands the execution of the finish thread cutting pass after the following error compensaton has been affected. Consequently, during a finish pass, the cutting tool will initially contact the work at the same angular position which was established during the execution of the base pass. After the compensation has been started by the execute compensation signal detected in step 80, it continues for each subsequent machining pass until process step 86 detects a signal which terminates the following error compensation cycle.
FIG. 4 is a flow chart of a routine illustrating the steps for testing the following error compensation parameters. These parameters start and stop the following error compenation cycle and control the actual execution of the compensation. First, decision block 88 determines whether or not a following error compensation parameter has been programmed.
In programming the following error compensation codes using the numerical control described in FIG. 1, a special function block of information must be utilized. this special function block may be implemented at any point in a standard part program between the standard blocks of tape defining axis motions and machine functions. However, these special function blocks are literally distinguished from the standard functions blocks by the use of parentheses. The decision block 88 determines whether or not the parenthetical expressions have in fact been programmed. If not, the process continues through the standard data preparation cycle. If they have, the process continues to decision block 90 which detects a G0 which is programmed within the parenthetical expression and is used to start and stop the following error compensation cycle.
If the G0 code is detected, the process moves to decision block 92 which determines whether or not the compensation is active. Since in the disclosed embodiment the G0 code is used to turn the compensation on and off, if the compensation is active, the presence of a G0 code is used to turn off the compensation via process block 94. If the compensation is not active, the G0 code sets a base pass request flag as defined in process block 96.
Returning to decision block 90, if the programmed parameter is not a G0, decision block 98 determines whether or not it is a G1. If the programmed parameter is neither a G0 or a G1, an error is reported via process block 104. If decision block 98 detects a G1, decision block 100 determines whether or not a base pass has been executed. If the base pass which establishes a reference following error has not occurred, a G1 code cannot initiate the compensation span. Therefore, upon decision block 100 detecting no base pass, process block 104 will report an error condition. If the base pass has been executed, process block 102 sets a compensation active flag.
FIG. 5 is a detailed flow chart of a routine illustrating the steps required in testing for a base machining pass. Decision block 106 determines whether or not a threading span has been programmed. In the preferred embodiment, after the following error compensation cycle has been initiated, it remains dormant until a threading span is programmed. Therefore, if decision block 106 does not detect a subsequent threading span, the process continues in the standard data preparation cycle. If the threading span is detected, the process moves to decision block 108 which determines whether or not the base pass request flag is set. If not, the process continues in the standard data preparation program. If it is, the process moves on to process block 110 which calculates axis motion values for a threading pass in a manner heretofore known in the art. Specifically, input position and velocity signals are used to generate command signals representing the axis motion values which are transferred to the servomechanism circuit.
Process block 112 stores whatever factors are relevant to the determination of velocity of the cutting tool. The stored number may represent a programmed velocity lead, spindle speed or any combination thereof. Process block 116 transfers these threading values to the feed rate control circuits 48. Consequently, the servomechanism moves the tool through the base thread cutting pass which accomplishes two things. First, an initial contact point of the cutting tool relative to an angular position of the workpiece is established. The object of the invention is to maintain this initial contact point for all the thread cutting passes regardless of the velocity of the cutting tool. Second, a following error from which subsequent thread cutting passes may be referenced is determined.
FIG. 6 is a detailed flow chart illustrating the steps required to test for a compensation machining pass. Decision block 118 determines whether or not a threading span has been programmed; and if not, the process continues through the data preparation program. If a threading span has been programmed, decision block 120 determines whether or not the compensation active flat is set. If it is not set, the process continues through the standard data preparation program. If the flag is set, decision block 122 determines whether or not the compensation span has been executed. If a compensation span has not been executed, process block 124 calculates the compensation dimension.
The compensation dimension may be calculated in any one of a number of ways. By dimensional definition, the following error is equal to the quotient of the velocity in inches per minute divided by the gain or the velocity constant of the servomechanism circuit as measured in inches per minute per 0.001 inches. In the preferred embodiment, it is assumed that the gain of the servomechanism is constant, and this constant may be permanently stored in the computer. However, as will be appreciated by those who are skilled in the art, if there are appreciable differences in the gain during the operation of the machine, the gain of the servomechanism may be measured and stored during the execution of the base pass. Therefore, the difference in following error may be determined by calculating the following error during the base pass and subtracting therefrom the following error to be expected during the finish pass. Similarly, the difference in velocities between the base and finish passes may be calculated; and this difference divided by the velocity constant of the servomechanism circuit.
In a typical threading program, the velocity of the cutting tool is not directly programmed; however, the lead of the thread or the displacement of the cutting tool relative to the rotation of the workpiece is programmed as well as the desired angular velocity of the spindle. Dimensionally, velocity is determined by the product of the lead times the angular velocity of the spindle. Further, in cutting a thread, the lead will remain constant from the roughing to the finish thread cutting passes. Therefore, during the roughing or base thread cutting pass, only the angular velocity of the spindle need be stored. Again, the stored number may represent the programmed angular velocity or the result of an actual measurement of angular velocity. When the input information defining the finish thread cutting pass is processed, the difference in angular velocities between the rough thread cutting pass and the finish thread cutting pass is determined; and this difference is multiplied by the lead and divided by the velocity constant of the servomechanism circuit to determined the difference in following errors between the roughing and finish thread cutting passes. Obviously, with servomechanisms having a gain of one, the division by the velocity constant is not required. The exact technique used to calculate the compensation dimension in process block 124 is a function of an individual system designer. Therefore, any particular calculation technique disclosed herein is not to be considered a limitation on the invention.
After the compensation dimension has been determined in block 124, process block 126 transfers this dimension to the feed rate control circuits which in turn cause the interpolation circuit to generate command signals corresponding thereto. These command signals cause the servomechanism circuit to move the tool through a displacement corresponding to the calculated difference in following error.
If decision block 122 determines that the compensation span has already been executed, process block 128 calculates the axis motion values required for making the finish thread cutting pass. Process block 132 transfers the threading values to the feed rate control circuit. This causes the finish thread cutting pass to be executed at a different velocity from the base thread cutting pass, however, the execution of the compensation span will cause the cutting tool to initially contact the work at the same angular position as was defined by he base thread cutting pass.
While the invention has been illustrated in some detail according to the preferred embodiments shown in the accompanying drawings and while the preferred illustrated embodiments have been described in some detail, there is no intention to thus limit the invention to such detail. On the contrary, it is intended to cover all modifications, alterations and equivalents falling within the spirit and scope of the appended claims.
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On a machine having a cutting tool moving relative to a rotating workpiece, a method and apparatus are disclosed for holding a constant relationship between the cutting tool and an angular position of the workpiece for different velocities of the cutting tool which produce correspondingly different following errors. The invention is applicable to a numerically controlled turning machine of the type maintaining a constant initial contact point between the cutting tool and an angular position of a rotating workpiece in response to a constant following error during successive machining passes. A first machining pass is executed in response to a first velocity signal which causes the cutting tool to initially contact the rotating workpiece at a first angular position thereof. Before the execution of a subsequent machining pass, the velocity signals associated with the first and subsequent machining passes are used to calculate the difference in following errors between machining passes. The cutting tool is moved through a displacement corresponding to the difference in following errors after which the subsequent machining pass is executed. By changing the starting point of the subsequent machining pass as a function of the difference in following errors, the cutting tool in executing the subsequent machining pass will initially contact the rotating workpiece at the first angular position of the workpiece defined by the first machining pass.
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BACKGROUND OF THE INVENTION
This invention relates to the purification of zinc sulphate solution and, in particular, relates to the removal of chloride impurity from aqueous solutions of zinc sulphate intended for use in the electrolytic recovery of zinc.
The presence of chloride in zinc sulphate solution, which may be introduced into the solution during hydrometallurgical treatment of zinc sulphide concentrate, e.g., during pressure leaching with sulphuric acid, has a deleterious effect on electrodes during electrolysis. For example, leaching of a typical Mississippi Valley-type concentrate containing 55% Zn and 0.08% Cl in a single pass of return acid from zinc electrolysis may dissolve about 145 mg/L chloride. To avoid deleterious effects of chloride during electrolysis, this chloride should not exceed 100 mg/L. Use of return acid initially containing 100 mg/L chloride would produce a leach solution containing about 245 mg/L in the next pass and, without chloride removal, the amount of chloride in solution would increase as cycling of return acid continues. It is therefore evident that a process is required in which all the solution being used in electrolysis is treated to decrease the chloride to not more than 100 mg/L or a portion of the electrolyte is treated for substantially complete removal of chloride and then mixed with untreated solution. The latter is considered to be more economic.
It is noted in U.S. Pat. No. 1,403,065 that corrosion of electrodes is largely reduced if chloride is removed from the electrolyte prior to the electrolysis of zinc-bearing solution. A method of chloride removal is provided wherein a portion of solution is withdrawn from the circuit, treated with a soluble silver salt to precipitate silver chloride, and purified solution is returned to the circuit. The silver chloride is reduced to metallic silver and reconverted into a soluble salt for re-use. In more detail, the portion of zinc-bearing solution to be treated is made slightly acid with sulphuric acid and finely powdered silver sulphate is added. The mixture is agitated for about one hour and then rendered neutral or slightly basic to coagulate silver chloride. The precipitate is allowed to settle and clear solution is decanted and treated with zinc dust to remove traces of silver. Sulphuric acid and zinc dust are added to bottom solution and silver chloride filter cake to reduce silver chloride to metallic silver. When reduction is complete, the precipitate of metallic silver is agitated for some time in slightly acid solution to ensure complete dissolving of excess zinc dust. The silver precipitate is washed with water until free of chloride and then dried and heated with pure sulphuric acid to 250°-300° C. to convert all the silver to sulphate. This is ground to a fine powder for re-use. Each cycle takes nearly 3 days to complete and, in an ongoing operation, a large inventory of costly silver is required. In 1936 AIME Transactions 121, pages 503-4, silver recoveries by this method are reported to be 97.5 to 98 percent per cycle, i.e., silver losses are about 2 percent per cycle.
SUMMARY OF THE INVENTION
We have found that chloride impurities can be substantially removed from zinc sulphate solution by reacting the solution with elemental silver dispersed on a particulate inert support material and with an oxidizing agent at a temperature between about 60° and 100° C., preferably between about 60° and 80° C. to form silver chloride precipitate, separating purified zinc sulphate solution from the support material containing silver chloride by filtration and treating the silver chloride with a reductant in an aqueous alkaline medium to conver the silver to its elemental state for cyclic re-use in the process. More particularly, our invention comprises treating zinc sulphate solution with elemental silver in the presence of an oxidizing agent in the form of ferric iron, e.g., ferric sulphate, to precipitate silver chloride and form ferrous sulphate. In a preferred modification of the invention, a small amount of ferric iron that remains in the zinc sulphate solution as an impurity after an iron precipitation step is used as the oxidant and this ferric iron is maintained in adequate abundance by stage-wise additions of hydrogen peroxide to provide almost immediate re-oxidation of ferrous sulphate that is formed.
It is the principal object of the present invention to provide an efficient process for the purification of zinc sulphate solution to a desired extent by the removal of chloride impurity as a silver chloride precipitate with minimum loss of silver.
DESCRIPTION OF PREFERRED EMBODIMENTS
The process of our invention will now be first described with reference to a series of small scale tests for treatment of zinc sulphate solutions containing 140-150 mg/L Zn, 3-5 g/L free acid as H 2 SO 4 and 300 g/L Cl with elemental silver reagent dispersed on a particulate inert support material in the presence of an oxidant in sufficient amount to provide stoichiometric oxidation of the silver required to precipitate the chloride as AgCl. Preparation of supported silver reagent was effected by mixing the support material in water and adding an appropriate quantity of silver nitrate solution. Sufficient sodium chloride solution was then added to precipitate the silver as silver chloride. The slurry was mixed for about 15 minutes and filtered on a pressure filter. The filter cake was repulped with water and filtered again. The silver was reduced to the elemental state by reaction of the aqueous slurry under pressure at 95° C. with hydrogen in the presence of sodium hydroxide. Chloride precipitation tests were carried out in which stoichiometric quantities of silver comprised 10 or 20 percent of the dry weights of the beds containing silver and support material. The following support matrix materials were tested:
Diatomite (fine powder)
Carbon (-12+40 mesh and powdered)
Fused alumina (150 mesh)
Silicon carbide (180 grit powder)
Chloride precipitation tests were carried out between 60° and 80° C. with sufficient agitation of slurries to maintain good suspension of the solids.
Although some differences due to matrix materials were observed, choice of matrix material was not critical. In the preparation and regeneration of diatomite beds, reduction of precipitated silver chloride to elemental silver was more rapid at 45 psig hydrogen pressure than the reduction of silver chloride precipitated on fused alumina and silicon carbide beds. For example, hydrogen regenerations of diatomite beds were substantially complete in 60 minutes, while regenerations of fused alumina beds were only about 75% complete in 60 minutes and about 97% complete in 120 minutes. At 200 psig pressure, diatomite beds were completely regenerated in 30 minutes. At 45 psig hydrogen pressure, silicon carbide beds were similar to fused alumina beds, but required 30 minutes at 200 psig pressure for 97% regeneration.
Moisture retained in filter cakes obtained with fused alumina and silicon carbide beds was 40-60% of the dry weight of the beds, while, with diatomite beds, filter cake moisture was about 100% of the dry weight. Zinc sulphate solution was removed more readily from the silicon carbide and alumina beds.
Weight losses of diatomite beds due to dissolving of some silica during regeneration in an alkaline medium were observed. The other materials had an advantage over carbon which had a tendency to absorb ions other than chloride ions.
In order to precipitate chloride ions as AgCl, an oxidizing agent is required to oxidize the elemental silver to the monovalent state. Several oxidizing agents were tested. Potassium permanganate and ozone were effective oxidants. However, when they were used, manganese, which is usually present in the zinc sulphate solution, precipitated as difficult-to-filter manganic oxides.
Ninety percent of the chloride was removed from solution containing 300 mg/L Cl by precipitation with silver at 70° C. in the presence of 25 g/L potassium peroxidisulphate (K 2 S 2 O 8 ). This method led to accumulation of K 2 SO 4 in the solution which could not be removed conveniently. With operation at 70° C. and use of hydrogen peroxide in the amount of seven times the stoichiometric requirement to oxidize the elemental silver combining with chloride, 90 percent of the chloride was removed from solution containing 300 mg/L Cl in 20 minutes. With less hydrogen peroxide, results were erratic. For example, as little as 28 percent of the chloride was precipitated when 3-5 times the stoichiometric requirement of hydrogen peroxide for the reaction were used according to equation:
2Ag°+H.sub.2 O.sub.2 +2HCl→2AgCl+2H.sub.2 O (1)
Titration of treated solutions with potassium permanganate showed complete consumption of added hydrogen peroxide within 15 minutes. It was evident that the hydrogen peroxide was decomposing rapidly in the presence of the elemental silver by the reaction of equation 2:
H.sub.2 O.sub.2 →H.sub.2 O+1/2O.sub.2 ( 2)
Successive additions of hydrogen peroxide did not result in adequate precipitation of chloride.
Chloride precipitation using ferric iron as the oxidant was successfully carried out by the following reaction:
Fe.sub.2 (SO.sub.4).sub.3 +2Ag°+2HCl→2AgCl+2FeSO.sub.4 +H.sub.2 SO.sub.4 ( 3)
For the removal of 300 mg/L chloride, a stoichiometric requirement of 470 mg/L ferric iron is indicated. With this amount of ferric iron, 76 percent of the chloride was precipitated in 30 minutes while 83 percent was precipitated in 90 minutes. With the use of twice this stoichiometric amount of ferric iron, obtained by adding ferric sulphate, 96 percent of the chloride was removed in 45 minutes.
In downstream neutralization of zinc sulphate solution, the presence of 100-200 mg/L ferric iron is acceptable. It assists in removing trace impurities such as As, Ge and Se. Larger amounts of ferric iron tend to impede the filtration which follows the neutralization. A test was made in which use of 200 mg/L ferric iron, i.e. 0.43 or about one-half the PG,8 stoichiometric requirement for removal of 300 ml/L chloride, was supplemented by slowly sparging the slurry with an excess of gaseous oxygen. After a retention time of 90 minutes, only 56 percent of the chloride was precipitated. Tests in which the 200 mg/L ferric iron were supplemented by stagewise additions of hydrogen peroxide resulted in the removal of as much as 85 percent of the chlorine within 30 minutes, a third of the time required as compared to the use of oxygen as an oxidant. Additional tests revealed that oxidation of ferrous iron with hydrogen peroxide, according to Equation 4, is almost quantitative and instantaneous under conditions prevailing during chloride removal:
2FeSO.sub.4 +H.sub.2 SO.sub.4 +H.sub.2 O.sub.2 →Fe.sub.2 (SO.sub.4).sub.3 +2H.sub.2 O (4)
We then discovered that staged additions of stoichiometric amounts of hydrogen peroxide during chloride precipitation by the reaction of Equation 3 resulted in regeneration of ferric iron in situ by the reaction of Equation 4 before decomposition of hydrogen peroxide by the reaction of Equation 2 occurred. This is valuable in the treatment of zinc sulphate solutions obtained by pressure leaching of zinc sulphide concentrates wherein solutions containing 100-200 mg/L ferric iron are obtained. By successive regeneration of this ferric iron by additions of hydrogen peroxide to oxidize ferrous iron formed, additions of ferric iron that may lead to downstream filtration problems are not required.
Also in small scale tests, formaldehyde and hydrogen regenerations of silver chloride containing beds of precipitant were carried out in aqueous suspensions containing sodium hydroxide. With formaldehyde treatments at 70° C., conversions to elemental silver were virtually 100 percent within 15 minutes according to the following equation:
2AgCl+HCHO+2NaOH→2Ag°+2NaCl+HCOOH+H.sub.2 O (5)
Although formaldehyde is an effective reductant of silver chloride, it is costly and there are environmental problems associated with the disposal of waste solutions containing formaldehyde and the formic acid produced by the reaction. Regeneration with hydrogen at 100° C. and 45-200 psig pressure in an alkaline solution was found to be reasonably rapid and produced no noxious by-products. This reaction proceeds according to the following equation:
2AgCl+H.sub.2 +2NaOH→2Ag°+2NaCl+2H.sub.2 O (6)
Larger scale tests were then carried out in which beds comprising the foregoing matrix materials and 10% or 20% silver were used cyclically wherein washed filter cakes from chloride precipitation were repulped to 1.5 liters with water, sodium hydroxide was added and the slurry was treated in an autoclave with hydrogen at 95° C. for re-use. Hydrogen pressures of 45, 100 and 200 psig were applied for periods of 0.25 to 20 hours in different tests. Treated slurries were filtered and the beds containing regenerated silver precipitant were washed with water. In the precipitation of chloride, 25 liter batches of zinc sulphate solution containing 300 mg/L chloride, 200 mg/L ferric iron and 3 to 5 g/L free acid as H 2 SO 4 were stirred with beds containing elemental silver for periods of 15, 30 or 60 minutes at temperatures between 60° and 80° C. during which time stage-wise additions of stoichiometric quantities of hydrogen peroxide for the oxidation of FeSO 4 formed by Equation 3 were made. The temperature could be raised to the boiling point of the solution without need of a pressure vessel. At temperatures below 60° C., longer reaction times were found to be required. The slurries were then filtered and the filter cakes were washed and weighed.
In one test, a bed containing 22.75 g elemental silver in 91 g fine fused alumina matrix material was prepared as previously stated and added to 25 liters of impure zinc sulphate solution containing 200 mg/L ferric iron and 300 mg/L chloride. The slurry was agitated at 70° C. while 36 ml hydrogen peroxide solution containing 100 g/L H 2 O 2 were added in stages over the first 10 minutes of processing. After 30 minutes the slurry was filtered. The filtrate assayed 15 mg/L chloride, indicating that 95 percent of the chloride in the impure solution had been removed. The bed containing the silver chloride was washed on the filter and then transferred to an autoclave where the volume was adjusted to 1.5 liter by addition of water, 12.65 g sodium hydroxide was added and the autoclave was pressurized with hydrogen gas to 45 psig. The temperature was raised to 95° C. and strong agitation was provided to ensure adequate gas incorporation. Stirring was continued for 2 hours. Then the pressure was released and the slurry was filtered and washed. Chloride remaining in the bed was determined to be 0.15 g, i.e., 98% of the chloride retained by the bed from the previous treatment of the zinc sulphate solution was removed in the hydrogen regeneration. The bed was then ready for another cycle of chloride precipitation and silver regeneration. With the same amount of silver comprising 10% of another fused alumina bed, there were 4 cycles with 45 psig hydrogen pressure during regeneration followed by 2 cycles at 100 psig and one at 200 psig hydrogen pressure. Regeneration was more rapid at elevated pressures, being 95 percent complete in 15 minutes at 200 psig. Operation with a silicon carbide bed containing 10 percent silver was similar, with regeneration at 200 psig providing 97 percent regeneration of the silver in 30 minutes.
In a test wherein 22.75 g elemental silver comprised 10 percent of a 227.5 g bed having a diatomite matrix material, the bed was mixed with 25 liters impure zinc sulphate solution containing 200 mg/L ferric iron and 300 mg/L chloride. In a cyclic operation having 6 chloride removal and silver regeneration steps, chloride removals ranged between 85 percent and 91 percent for the first 4 steps which had 30 minute retention times, and were 82 percent in the 5th and 6th steps when the retention time was decreased to 15 minutes. Regeneration with hydrogen at 45 psig of silver chloride in the bed after each chloride removal step was 97 percent complete within 45 minutes when compared with formaldehyde regenerations of portions of the beds in three of the regeneration steps. Formaldehyde has been previously shown to regenerate all the silver chloride in the bed. In this sequence of chloride removals and silver regenerations, losses in weight of the diatomite totalling 18 percent of that initially present was believed to be due to dissolving of part of the diatomite silica in the sodium hydroxide in the regeneration steps. Therefore it is advantageous to use more refractory materials such as fused silica, sand, fused alumina and silicon carbide powder as matrices for the elemental silver precipitant. These materials also retain less water than diatomite or carbon and are more easily washed after precipitation and regeneration.
The foregoing tests indicate that about 90% of the chloride in impure zinc sulphate solution containing about 300 mg/L chloride may be removed in about 15 minutes by treatment between about 60° and about 100° C. with vigorous mixing of a slurry comprising the solution, elemental silver dispersed on an inert particulate support material and an oxidizing agent in the form of ferric iron. Less than stoichiometric quantities of ferric iron provide effective oxidation when ferrous iron formed in the reaction is oxidized to ferric iron by stage-wise additions of hydrogen peroxide during the mixing period. Silver chloride precipitated in the bed of support material may be converted to the elemental silver by hydrogen reduction in an aqueous alkaline medium with vigorous stirring at elevated temperature and pressure, 95% regeneration of elemental silver being obtained in 15-30 minutes at about 100° C. and 40-200 psig pressure. The particulate inert support material may be diatomite, fused silica, sand, fused alumina or silicon carbide powder. Beds comprising silver supported on these matrices may be used cyclically. Silver losses to hydrogen reduction filtrate (purified zinc sulphate solution) and wash waters have been estimated to be about 0.25 percent per cycle.
Since chloride removal and bed regeneration reactions are rapid, continuous treatment of zinc sulphate solution produced for electrolytic recovery of zinc may be carried out without maintaining a large inventory of silver-containing reagent.
It will be understood, of course, that modifications can be made in the embodiments of the invention described herein without departing from the scope and purview of the invention as defined by the appended claims.
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A process is described for the removal of chloride impurity from zinc sulphate solution. The process comprises the steps of forming a slurry of said solution with an inert particulate support material having elemental silver dispersed thereon, and an oxidizing agent, agitating said slurry at a temperature between about 60° and about 100° C. for precipitation of silver chloride on said support material, filtering said slurry to separate purified zinc sulphate solution from the support material containing the precipitated silver chloride, and treating said separated support material containing precipitated silver chloride with a reductant in an aqueous alkaline medium to regenerate elemental silver on said support material.
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BACKGROUND
The present invention relates generally to the field of internal combustion engines. More particularly, this invention relates to methods and compositions for increasing fuel efficiency and modifying emissions characteristics of internal combustion engines.
The internal combustion engine is unequaled in its primary applications as a portable power source. However, internal combustion engine use has been increasingly criticized largely because of polluting emissions and consumption of finite fuel sources. Consequently, much research has been directed to improving the efficiency (in terms of conserving fuels) and to reducing the production of undesirable emissions (in terms of protecting the environment) of the internal combustion engine. Interestingly, this research has indicated that engine efficiency and emissions abatement do not go hand in hand, but rather are in opposition. A breakthrough that would reverse this situation is still being sought.
Thus, despite extensive research efforts, there remains a need for methods and compositions for enhancing fuel efficiency of internal combustion engines as well as for advantageously modifying their emissions. The present invention addresses these needs.
SUMMARY OF THE INVENTION
One object of this invention is to provide methods for enhancing the fuel efficiency of an internal combustion engine.
Another object of this invention is to provide compositions for enhancing the fuel efficiency of an internal combustion engine.
A further object of this invention is to provide methods for advantageously modifying emissions of an internal combustion engine.
Still another object of this invention is to provide compositions for advantageously modifying emissions of an internal combustion engine.
Still another object of the invention is to provide methods and compositions for improving the combustion properties of fuel oil.
These and other objects are accomplished by preferred embodiments of the invention, one of which relates to a method of enhancing fuel efficiency of an internal combustion engine. This method includes the step of providing in the fuel an effective amount of selenium to enhance the fuel efficiency of the engine.
Another preferred embodiment of the invention relates to a method of advantageously modifying exhaust emission of an internal combustion engine operating on a fuel. This method includes the step of providing in the fuel an effective amount of selenium to modify the exhaust emission of the engine.
Another preferred embodiment of the present invention relates to a modified internal combustion engine fuel which includes an effective amount of selenium to increase the fuel efficiency of an internal combustion engine operating on the fuel.
Still another preferred embodiment of the invention provides a modified internal combustion engine fuel which includes an effective amount of selenium to modify the exhaust emission of an internal combustion engine operating on the fuel.
Still another embodiment of the invention provides a method for improving the combustion properties of fuel oil which comprises adding to the fuel oil an effective amount of selenium to increase the thermal energy generated upon combustion of the fuel oil.
Additional objects, advantages and embodiments of the invention will be apparent from the description which follows.
DESCRIPTION OF PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain preferred embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications and applications of the principles of the invention being contemplated as would normally occur to one skilled in the art to which the invention relates.
As used herein, the term "internal combustion engine" is used in its broad sense to include engines which operate based upon the internal combustion of a fuel. There are numerous engines based upon this principal, and these will readily be recognized by those of ordinary skill in the area.
Also, the term "fuel efficiency" is used herein in it usual sense, and relates to the efficiency of an internal combustion engine as regards consumption of fuel, i.e. increased fuel efficiency is obtained when the amount of engine output per unit fuel consumed is increased, and vice versa.
Internal combustion engine fuels are also well known and include gasolines, diesel fuels, aviation fuels, jet fuels, etc. These fuels can contain various common additives such as antioxidants, copper deactivators, corrosion inhibitors, anti-icing additives, anti-static additives, contaminants, octane boosters, etc.
In accordance with preferred embodiments of the invention, the fuel for the internal combustion engine will contain an effective amount of selenium. This amount will be effective to increase the fuel efficiency of the engine operating on the fuel and/or to modify the exhaust emissions of the internal combustion engine. In this regard, the form in which selenium is included in the fuel has not proven critical. It may be included as elemental selenium, or in the form of a selenium compound, including organic selenium compounds such as organic selenides, e.g. di-organic substituted selenides such as dialkyl selenides, for instance dimethyl selenide, diethyl selenide, dipropyl selenide, dibutyl selenide, dipentyl selenide, etc. Other compounds of selenium, for example selenium salts and/or oxides, may also be used. Particularly preferred are those selenium compounds which form stable solutions or suspensions with the fuel of interest. In this regard, organic selenium compounds which are soluble in the fuel have been preferred.
The amount of selenium (incorporated as elemental selenium or a selenium compound) included in the fuel to be combusted will vary in accordance with the desired level of enhancement of fuel efficiency and/or modification of emissions. In any event, however, the selenium will be included in the fuel in an amount sufficient to produce a significant, recognizable increase in engine fuel efficiency and/or a significant, recognizable modification of engine emissions.
As to fuel efficiency, it is preferred that sufficient selenium be included to increase fuel efficiency by at least about 5%, more preferably at least about 10%. Regarding emissions, sufficient selenium is desirably included to reduce one or more of carbon monoxide, carbon dioxide, hydrocarbon, and nitrogen oxide emissions by at least about 5%, more preferably at least about 10% (based on total weight of the exhaust). In testing using a level of up to about 1 to 2 parts per million (ppm) by weight of selenium, fuel efficiency increases from about 10% to greater than 50% have been obtained both in testing in a stock automobile powered by an 6-cylinder engine (as measured by increase in miles per gallon obtained under normal driving conditions), in testing as set forth in Examples 1-20 below (as measured by engine run-time per unit fuel consumed) and in testing as set forth in Examples 22-27 below (dynamometry employing a 4-cylinder, 151 cubic inch automobile engine). Using this same amount (1-2 ppm) of selenium, emissions of each of the above-named pollutants has been reduced by greater than 10% and even greater than 20%, as demonstrated in Example 21 below.
In use, the elemental selenium or selenium compound is dissolved or suspended in the fuel to be combusted. This modified fuel can then be used to operate the engine in a conventional fashion. The selenium may be provided directly into the fuel at the desired level, or, alternatively, a premix containing the selenium can be prepared at a higher concentration so that when a predetermined amount of the premix is added to a predetermined amount of fuel, the desired level of selenium is achieved. For example, in one instance, elemental selenium was dissolved in carbon disulfide, and this solution added to gasoline to form a modified fuel for a gasoline-powered internal combustion engine. Of course, other solvents or suspending agents will also be suitable, and those ordinarily skilled in the art will be able to recognize and utilize these other materials without any undue experimentation.
As indicated above, another embodiment of the invention provides a method and composition relating to fuel oil such as that combusted to heat enclosed structures such as homes, commercial facilities, etc. In this embodiment, an effective amount of selenium is added to fuel oil to increase the thermal energy generated upon combusting the fuel oil. The amount of selenium added may vary broadly, but in preferred embodiments will be sufficient to provide at least a 5% increase in the thermal energy generated upon combustion. These amounts may include low amounts, for example from up to about 1 to 2 parts per million of selenium to about 100 ppm of selenium.
For the purposes of promoting a further understanding and appreciation of the present invention and its preferred aspects and embodiments, the following specific Examples are provided. It will be understood, however, that these Examples are illustrative and not limiting of the invention.
EXAMPLES 1-10 (Control) And 11-20 (Inventive)
A series of tests was conducted using a Model 1700 Weedeater (gas powered) mounted onto a ladder which provided a stable platform. The engine was first warmed up by running it for ten minutes on regular fuel which consisted of unleaded 87 Octane Sunoco gasoline. Poulan oil was added to the fuel in the usual fashion with this type of engine. The test fuel (Examples 11-20) consisted of the same fuel as the control fuel (Examples 1-10) except that dimethyl selenide was added to make up a solution containing 1.5 ppm (by weight) of dimethyl selenide.
The control tests 1-10 were made first using gasoline which had no additive. Ten runs were made using 100 ml of regular gasoline and running with the throttle wide open until the engine ran out of fuel. The runs were carefully timed using a stop-watch. These times were the test results.
The inventive runs 11-20 were done in the same fashion except that dimethyl selenide had been added to the fuel in the amount of about 1.5 ppm as previously described.
The run times for both Control and Test runs are set forth in Tables 1 and 2, respectively.
TABLE 1______________________________________ControlEx. Time (min.) Decimal______________________________________1 8:32 8.532 8:29 8.483 8:30 8.504 8:28 8.475 8:27 8.456 8:28 8.477 8:30 8.508 8:31 8.529 8:29 8.4810 8:30 8.50Average: 8.49 minutes/100 ml of control fuel.______________________________________
TABLE 2______________________________________InventiveEx. Time (min.) Decimal______________________________________11 13:48 13.8012 13:42 13.7013 13:28 13.4614 13:49 13.8215 13:30 13.5016 13:25 13.4217 13:35 13.5818 13:30 13.5019 13:35 13.5820 13:25 13.42Average: 13.58 minutes using 1.5 ppm of dimethyl selenideCalculations:Average control run time: 8.49 minutesAverage test run time: 13.58 minutes______________________________________
These results illustrate the dramatic enhancement of fuel efficiency achieved by the present invention, with the average fuel efficiency being increased by about 60% in the inventive runs.
EXAMPLE 21
Emissions Testing
Samples of automobile exhausts were secured from a 1971 Plymouth Fury and used to conduct comparative tests to observe any reduction in pollutants upon the addition of selenium to the automobile's fuel. All samples were obtained during controlled idling conditions. The samples from the selenium-containing fuel runs were obtained after riding 50 miles with the additive in the fuel tank. The results of exhaust testing are shown in Table 2.
TABLE 2______________________________________Pollutant Without Selenium With Selenium______________________________________Carbon Monoxide 1.30% 0.79%Carbon Dioxide 11.7% 9.0%Hydrocarbons 0.12% 0.039%Nitrogen Oxides 0.048% 0.033%Acidity (pH) 6.5 6.3Conductivity 0.03% 0.11______________________________________
In addition to the above results, no difference in carbon deposits were found. It was thus demonstrated that remarkable and advantageous modification of engine exhaust emission characteristics can be obtained by the inclusion of selenium in the combusted fuel.
EXAMPLE 22-27
Control and test fuels were combusted in a 4-cylinder 151 cubic inch automobile engine while monitoring various parameters of engine performance with a Superflow Model 901T dynamometer from Superflow, Colorado Springs, Colo. U.S.A. The engine was mounted in an engine room with all services supplied remotely and with all operational parameters being measured by remote sensors and with data being recorded and analyzed by computer. In particular, one control, denoted "C-1" was Sunoco 87 octane gasoline. Another control, "C-2" was Jiffy 87 octane gasoline (which contains 10% alcohol). The test fuels were as follows:
T-1: Sunoco 87 octane gasoline containing 1 part per million dimethylselenide;
T-2: Sunoco 87 octane gasoline with 10 ppm dimethylselenide;
T-3: Jiffy 87 octane gasoline with 10 ppm dimethylselenide;
T-4: Sunoco 87 octane gasoline with 100 ppm dimethylselenide;
Details and results of the testing are set forth in Tables 3-9 below, in which the following standard abbreviations are used: CBTrq=foot pounds torque; CBPwr=horsepower; FHp=frictional horsepower; VE %=volumetric efficiency; ME %=mechanial efficiency; FA=pounds of fuel used per hour; A/F=air to fuel ratio; BSFC=pounds of fuel per hour/horsepower; CAT=carburator air temperature; Oil=oil temperature; Wat=water temperature. It will be noted that the fuel denoted T-1 was run in two tests to demonstrate reproducability. As can be seen, horsepower, torque and certain other parameters remain almost constant, and certainly within significant limits, and the air to fuel ratio goes from about 11 with the control gasolines to about 15 with the test gasolines. Thus, the engine is employing 36% less fuel when the fuel contains dimethylselenide. Similarly, the amount of fuel used per horsepower (lb/Hphr) is reduced from about 0.80 (0.76-0.83) in the control gasoline, to about 0.60 (0.58-0.63) in the test gasoline. This again demonstrates that the engine is using about 36% less fuel with the dimethylselenide present, to produce the same power. These results further indicate that selenium has the capacity to increase power output by an engine employing either regular gasoline or gasoline blended with 10% alcohol. The increase in each case is approximately 36% in the tests performed.
TABLE 3__________________________________________________________________________Fuel C-1Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.15 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1938 127.4 47.0 6.6 105.0 87.3 34.5 87.3 11.6 0.76 49 0 166 8.811940 127.2 47.0 6.6 105.6 87.2 35.3 87.9 11.4 0.78 49 0 166 8.871941 127.4 47.1 6.7 106.1 87.3 36.2 88.4 11.2 0.79 49 0 166 8.951940 127.4 47.1 6.6 106.5 87.3 37.1 88.7 11.0 0.82 49 0 166 8.951940 127.4 47.1 6.6 106.8 87.3 37.1 88.9 11.0 0.82 49 0 166 8.971943 127.4 47.1 6.7 106.8 87.3 37.0 89.1 11.1 0.81 49 0 166 8.971943 127.4 47.2 6.7 107.1 87.3 36.8 89.3 11.1 0.81 49 0 166 8.971940 127.6 47.1 6.6 107.4 87.3 36.7 89.6 11.2 0.80 48 0 166 9.001939 127.3 47.0 6.6 107.5 87.3 36.8 89.6 11.2 0.81 48 0 166 9.041943 127.3 47.1 6.7 107.4 87.3 37.4 89.7 11.0 0.82 48 0 166 9.031942 127.6 47.2 6.7 107.5 87.3 37.4 89.8 11.0 0.82 48 0 166 9.021939 126.7 46.8 6.6 107.7 87.2 37.7 89.8 10.9 0.83 48 0 166 9.10__________________________________________________________________________
TABLE 4__________________________________________________________________________Fuel C-2Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.15 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1941 125.1 46.2 6.7 106.4 87.1 35.2 88.6 11.6 0.79 49 0 168 9.081938 125.1 46.2 6.6 106.8 87.1 32.4 87.8 12.6 0.72 49 0 168 9.121936 124.4 45.9 6.6 107.0 87.0 30.1 88.9 13.6 0.68 49 0 168 9.191938 124.4 45.9 6.6 107.0 87.0 30.2 88.0 13.5 0.68 49 0 168 9.201938 121.4 45.9 6.6 107.3 87.0 30.8 89.2 13.3 0.69 49 0 168 9.221940 124.1 45.8 6.6 107.3 87.0 31.2 89.3 13.1 0.70 49 0 168 9.231941 124.1 45.9 6.7 107.4 87.0 30.7 89.5 13.4 0.69 49 0 168 9.251941 124.1 45.9 6.7 107.6 87.0 30.4 89.6 13.5 0.68 49 0 168 9.261941 123.9 45.8 6.7 107.7 86.9 30.3 89.7 13.6 0.68 49 0 168 9.29__________________________________________________________________________
TABLE 5__________________________________________________________________________Fuel T-1(a)Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.15 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1937 126.4 46.6 6.6 106.2 87.2 28.3 88.1 14.3 0.63 50 0 167 8.991940 126.4 46.7 6.6 106.4 87.2 27.8 88.4 14.6 0.62 50 0 167 9.001941 126.4 45.7 6.7 106.7 87.2 27.1 88.7 15.0 0.60 50 0 167 9.031940 126.4 45.7 6.6 106.0 87.2 26.8 88.7 15.2 0.59 51 0 167 9.031939 126.2 45.6 6.6 106.2 87.1 26.6 88.8 15.3 0.59 51 0 167 9.061939 125.9 45.5 6.6 106.2 87.1 26.4 88.8 15.4 0.59 51 0 167 9.081941 125.9 45.5 6.7 106.2 87.1 26.2 88.9 15.6 0.58 51 0 167 9.091940 125.9 45.5 6.6 106.4 87.1 26.1 89.0 15.7 0.58 51 0 167 9.101939 125.7 45.4 6.6 106.5 86.1 26.1 89.0 15.7 0.58 51 0 167 9.121939 125.7 45.4 6.6 106.6 86.1 26.1 89.1 15.7 0.58 51 0 167 9.13__________________________________________________________________________
TABLE 6__________________________________________________________________________Fuel T-1(b)Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.15 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1937 126.4 46.6 6.6 106.2 87.2 28.3 88.1 14.3 0.63 50 0 167 8.991940 126.4 46.7 6.6 106.4 87.2 27.8 88.4 14.6 0.62 50 0 167 9.001941 126.4 46.7 6.7 106.7 87.2 27.1 88.7 15.0 0.60 50 0 167 9.031940 126.4 46.7 6.6 107.0 87.2 26.8 88.7 15.2 0.59 51 0 167 9.031939 126.2 46.6 6.6 107.2 87.1 26.6 88.8 15.3 0.59 51 0 167 9.061939 125.9 46.5 6.6 107.2 87.1 26.4 88.8 15.4 0.59 51 0 167 9.081941 125.9 46.5 6.7 107.2 87.1 26.2 88.9 15.6 0.58 51 0 167 9.091940 125.9 46.5 6.6 107.4 87.1 26.1 89.0 15.7 0.58 51 0 167 9.101939 125.7 46.4 6.6 107.5 87.1 26.1 89.0 15.7 0.58 51 0 167 9.121939 125.7 46.4 6.6 107.6 87.1 26.1 89.1 15.7 0.58 51 0 167 9.131936 125.7 46.7 6.6 105.8 87.2 27.1 88.1 15.9 0.60 48 0 166 8.931936 125.7 46.7 6.6 106.1 87.2 27.1 88.3 15.0 0.60 48 0 166 8.951936 125.7 46.7 6.6 106.3 87.2 26.8 88.5 15.2 0.59 48 0 166 8.971938 125.7 46.8 6.6 106.3 87.2 26.8 85.6 15.2 0.59 48 0 166 8.981937 125.7 46.7 6.6 106.7 87.2 26.9 88.8 15.2 0.59 48 0 166 9.001938 125.7 46.8 6.6 106.7 87.2 26.7 88.9 15.3 0.59 48 0 166 9.011930 125.7 46.8 6.6 106.7 87.2 26.5 89.0 15.4 0.58 48 0 166 9.001932 125.6 46.8 6.7 106.8 87.2 26.4 89.3 15.5 0.58 47 0 166 9.031931 125.4 46.7 6.7 106.9 87.2 26.5 89.4 15.7 0.58 47 0 166 9.061932 125.4 46.7 6.7 107.0 87.2 26.4 89.5 15.6 0.58 47 0 166 9.07__________________________________________________________________________
TABLE 7__________________________________________________________________________Fuel T-2Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.14 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1934 125.7 46.3 6.6 105.0 87.1 26.3 86.9 15.3 0.58 50 0 167 8.921936 125.9 46.4 6.6 105.4 87.1 26.8 87.3 15.3 0.58 50 0 167 8.941934 126.2 46.5 6.6 105.9 87.1 26.1 87.6 15.3 0.59 50 0 167 8.961933 125.7 46.3 6.6 106.2 87.1 26.8 87.8 15.3 0.59 50 0 167 9.021935 125.9 46.4 6.6 106.3 87.1 26.6 88.0 15.5 0.58 50 0 168 9.021935 125.7 46.3 6.6 106.5 87.1 25.4 88.2 15.9 0.57 50 0 168 9.061936 125.9 46.4 6.6 106.6 87.1 25.2 88.3 16.0 0.57 50 0 168 9.051933 125.7 46.3 6.6 106.8 87.1 25.1 88.3 15.9 0.57 50 0 168 9.071933 125.2 46.1 6.6 106.9 87.0 25.1 88.4 15.7 0.58 50 0 168 9.121934 125.2 46.1 6.6 106.8 87.0 26.1 88.4 15.6 0.59 50 0 169 9.121932 125.2 46.1 6.6 175.2 87.0 26.1 88.5 15.4 0.59 50 0 169 9.13__________________________________________________________________________
TABLE 8__________________________________________________________________________Fuel T-3Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.12 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1935 125.0 46.1 6.6 106.5 87.0 26.3 88.2 15.4 0.59 50 0 167 9.121934 125.0 46.0 6.6 107.2 87.0 26.5 88.6 15.4 0.60 50 0 167 9.161934 124.8 46.0 6.6 107.3 87.0 26.7 88.7 15.3 0.60 50 0 166 9.191935 124.3 45.8 6.6 107.3 86.9 26.6 88.8 15.3 0.60 50 0 167 9.221939 124.5 46.0 6.6 107.3 87.0 26.4 88.9 15.5 0.60 50 0 167 9.211940 124.5 46.0 6.6 107.3 87.0 26.4 89.0 15.5 0.59 50 0 167 9.201940 124.5 46.0 6.6 107.3 87.0 26.1 89.0 15.7 0.59 50 0 167 9.201939 124.8 46.1 6.6 107.4 87.0 25.8 89.0 15.8 0.58 50 0 167 9.181938 124.6 46.0 6.6 107.4 87.0 25.5 89.2 16.1 0.57 49 0 167 9.221933 124.2 45.7 6.6 107.5 87.0 25.4 89.1 16.1 0.57 49 0 167 9.25__________________________________________________________________________
TABLE 9__________________________________________________________________________Fuel T-4Standard Corrected Data for 29.92 Inches Hg, 60° F. Dry AirTest: Data Recorded Manually Fuel Spec. Grav: 0.703 Air Sensor: 6.5Vapor Pressure: 0.40 Barometric Pres.: 29.11 Ratio: 1.00 to 1Engine Type: 4-Cycle Spark Engine Displacement: 151.0 Stroke: 3,000Speed CBTrq CBPwr FHp FA Al BSFC BSACrpm lb-Ft Hp Hp VE % ME % lb/hr scfm A/F lb/Hphr CAT Oil Wat lb/Hphr__________________________________________________________________________1944 125.9 46.6 6.7 106.2 87.1 26.4 88.2 15.3 0.59 50 0 166 9.021947 126.1 46.7 6.7 106.4 87.1 26.3 88.5 15.5 0.58 50 0 166 9.011947 126.4 46.9 6.7 106.5 87.1 26.0 88.6 15.6 0.58 50 0 166 9.001942 125.9 46.6 6.7 106.7 87.1 25.7 88.6 15.8 0.57 50 0 166 9.061942 125.9 46.6 6.7 106.9 87.1 25.7 88.7 15.8 0.57 50 0 166 9.071939 125.2 46.2 6.6 106.9 87.0 26.1 88.8 15.6 0.59 49 0 166 9.141940 124.7 46.1 6.6 106.8 87.0 26.3 88.8 15.5 0.59 49 0 166 9.161943 124.7 46.1 6.7 106.7 87.0 25.8 88.8 15.8 0.58 49 0 166 9.16__________________________________________________________________________
EXAMPLE 28
Dimethylselenide is added to fuel oil amounts ranging from 1 to 100 ppm. The fuel oil is conventionally combusted and upon doing so the amount of thermal energy (e.g. BTU's) obtained per unit (weight or volume) of fuel combusted is increased, ranging up to 5% and above.
While the invention has been illustrated and described in detail in the foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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Disclosed are methods and compositions for increasing the fuel efficiency of and/or advantageously modifying the emissions of an internal combustion engine. These preferred embodiments involve the addition of elemental selenium or a selenium-containing material to the fuel upon which the engine is operated.
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FIELD OF THE INVENTION
The present invention relates to efficient energy accumulation element for actuators and other devices.
OBJECTIVE
The objective is to invent a mechanical energy accumulation element using springs which can be prepared for assembly with ease.
Another objective is to invent a mechanical energy accumulation element using a spring which can be deployed for accumulating higher energy and in which the energy accumulation is independent of the assembly construction.
BACKGROUND OF THE INVENTION
Accumulation and release of mechanical energy is a phenomenon deployed in several devices. Springs are one of the commonest elements used for this purpose. Both compression as well as extension springs are made use of.
For using compression springs, pre-compression is the first pre-requisite. Pre-compression is either achieved by surfaces external to the spring or by constraining the spring modularly. The first method viz. pre-compression by external surfaces requires skillful and time consuming assembly.
The second method viz. modular constraining is described, particularly for actuators in German patent DE 9314412, a U.S. Pat. No. 8,181,947 and also in patent Application WO2010/063514. In all these, the minimum length of cartridge is fixed. So even if the spring can be compressed to the solid length, the limitation of cartridge design does not allow. Further, these methods cannot be used efficiently for varying diameter compression springs which can be otherwise compressed up to coil thickness.
STATEMENT OF INVENTION
Our invention is an efficient energy accumulation compression spring assembled with a flexible yet sturdy rope entangled between two end caps, each cap being fixed at the respective end of the compression spring, allowing the spring to compress to any length up to solid. It is not driven by the stroke needed.
The length of the rope is shorter than the compression spring. The difference in length is according to the pre-compression or energy accumulation required. The end caps entrap the hammer or suitably shaped end of the rope. The spring is ready to be deployed without depending on external surface construction or even spring end construction.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows the efficient energy accumulation element of a progressively varying diameter compression spring in a pre-compressed state, ready to be assembled in devices like actuators etc.
FIG. 2 shows the efficient energy accumulation element of a constant diameter compression spring in pre-compressed state, ready to be assembled in devices like actuators etc.
FIG. 3 shows the efficient energy accumulation element in the compressed state, as it becomes during use in the device like actuators etc.
FIG. 4 shows preferred embodiment of construction of end cap.
FIG. 5 shows preferred embodiment of construction of flexible rope.
FIG. 6 shows a sectional view of an actuator using the efficient energy accumulation element of the compression spring.
DETAILED DESCRIPTION OF INVENTION
The preferred embodiment of an efficient energy accumulation compression spring assembled with a flexible yet sturdy rope will now be described in detail, with reference to the accompanying drawings. The terms and expressions which have been used here are merely for description and not for limitation.
Efficient Energy Accumulation Element ( 10 ) comprising a compression spring ( 5 ), whether having a constant diameter or a varying diameter is pre-compressed by using end caps ( 7 , 8 ) and the flexible yet sturdy rope ( 6 ) having hammer shaped heads at each of its ends. The end caps ( 7 , 8 ) have a diameter (D 1 ) slightly less than a corresponding outer diameter of the compression spring ( 5 ) so that the end caps ( 7 , 8 ) are simply inserted in the compression spring ( 5 ) at spring ends.
Each of the end caps ( 7 or 8 ) have a through slot ( 11 ) through which the hammer shaped head ( 13 ) of the rope ( 6 ) is inserted inside the spring ( 5 ) and taken out from the end cap ( 7 or 8 ) at the other end.
Each of the end caps ( 7 or 8 ) have a blind slot ( 12 ) substantially at 90 degrees to the through slot ( 11 ) in which the hammer shaped heads ( 13 ) sits with interference and therefore needs to be pushed in with certain definite force such that it cannot come out without using a screw driver or a tool. The through slot ( 11 ) and the blind slot ( 12 ) are collectively called an opening construction.
The length ( 16 ) of the rope ( 6 ) is less than the length ( 17 ) of compression spring ( 5 ).
To assemble Efficient Energy accumulation element ( 10 ) with the compression spring ( 5 ), the compression spring is required to be held in a compressed state by any simple device like vice, etc. so that its length becomes less than the length of rope ( 16 ). A first hammer shaped head ( 13 ) of the rope is inserted from one of the end caps ( 7 ) and taken out from another end cap ( 8 ), while a second hammer shaped head follows, so that the first hammer shaped head and second hammer shaped head are present at each of the end caps. The Hammer shaped heads ( 13 ) i.e. the first hammer shaped head and the second hammer shaped head, within both the end caps ( 7 ) and ( 8 ) are turned so that the hammer shaped heads ( 13 ) sits over the blind slots ( 12 ). The compressed spring ( 5 ) is then released from the device used for holding it in the compressed state. Due to the compression spring ( 5 ) trying to regain its uncompressed state, both the hammer shaped heads ( 13 ), which were so far just partially engaged with the blind slots ( 12 ) now get fully trapped in the blind slot ( 12 ) due to its interfering construction. The compression spring remains compressed corresponding to the length difference between its free length and the effective length of the rope, as calculated & suited for the application. This is also known as the pre-compressed state of the element ( 10 ).
One application described here is actuator ( 40 ). When a piston ( 30 ) moves in direction 31 -A, the efficient energy accumulation element ( 10 ) of the compression spring compresses as shown in FIG. 3 , and accumulates energy. Since the rope ( 6 ) is flexible as shown in FIG. 3 , the extent of cumulating energy is possible up to a solid length of the spring or as much as the spring permits. The action of accumulating and releasing energy is free from mechanical noise and does not need lubrication as there are no rubbing components
The construction of the through slot ( 11 ) and the blind slot ( 12 ) of the end caps ( 7 , 8 ) and ends ( 13 ) of flexible rope are possible in several ways such that they are assemble-able as described above or in any sequence and therefore the above embodiment is merely a preferred one and not limiting the invention. “Hammer” shape, in other words, is not a limitation of this design but is merely an embodiment and what is important is that the contour of the ends of rope and slots in the end caps are such that the rope can be passed thru’ the end cap ( 7 or 8 ) as well as trapped in the end cap ( 7 or 8 ) as required.
Also, the construction of end caps ( 7 , 8 ) could be such as to entangle with the spring ends for facilitating assembly.
The flexible yet sturdy rope ( 6 ) can be of any material so long as it is flexible to allow spring compression without any limitation due to itself. The term “rope”, “flexible rope” and “flexible yet sturdy rope” are used interchangeably.
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An efficient energy accumulation element comprising a compression spring which uses end caps and flexible rope to pre-compress the spring for using in actuators and other devices. The efficient energy accumulation element is independent of external surfaces or end construction of the spring. The accumulation and release of energy happens noiselessly.
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BACKGROUND OF THE INVENTION
The present invention relates to factory-built fireplaces and, more specifically, to fireplace constructions designed for ease of replacement of individual parts.
Among the more popular types of fireplace constructions are the so-called prefabricated or factory-built fireplaces which are usually shipped in a fully assembled condition, ready for permanent installation. The hearth and sometimes the rear wall of the firebox are formed of a cast refractory material in order to withstand the high heat commonly encountered, as well as the loads which must be supported by the hearth floor. Other portions of such fireplaces are entirely or chiefly of sheet metal.
In order to provide the cooling air necessary to maintain the exterior of the fireplace at acceptable levels, the hearth must be elevated from the underlying structure to form the required air passages. Hearth support structure commonly comprises a plurality of rigid beams or the like, extending from front to rear beneath the hearth, and/or other underlying support structure physically attached to the metal pan in which the refractory material is cast. U.S. Pat. Nos. 3,744,477, and 3,762,391 for example, include illustrations of common hearth supporting structure.
In the event of cracking or breakage of the refractory material, it is usually necessary to replace the hearth. In some factory-built fireplaces this has been altogether impractical and, in any case, is a difficult and time-consuming job. The principal object of the present invention is to provide a factory-built fireplace having structural features which permit simple and rapid removal and replacement of the refractory hearth.
Other objects will in part be obvious and will in part appear hereinafter.
SUMMARY OF THE INVENTION
In the fireplace construction of the invention, the hearth is formed from a refractory material which is poured while in a freshly mixed, semi-liquid condition, into a sheet metal pan and allowed to harden. The side and rear walls of the inner shell, or comparable portions of the fireplace structure, include inwardly directed, horizontal flanges along their lower edges. The hearth rests upon and is entirely supported by these flanges and its side and rear surfaces are in contact with, but unattached to, the side and rear walls of the inner fireplace shell.
The front hearth cover is attached in the usual manner to the front surface of the hearth pan and is also attached at its ends, which extend beyond the sides of the hearth pan, to the fireplace structure itself, thereby preventing forward movement of the hearth after installation. The lower edges of the sheet metal side and rear walls or liners of the firebox contact the upper hearth surface to prevent upward movement of the hearth and migration of ashes or other combustion products into the spaces beneath the hearth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view, with some portions broken away and others shown in phantom lines, of a fireplace structure embodying the invention.
FIG. 2 is a plan view, partly in section, of the fireplace of FIG. 1.
FIG. 3 is a front elevational view of the fireplace, with a portion broken away.
FIG. 4 is a side elevational view in section on the line 4--4 of FIG. 3.
FIG. 5 is an enlarged partial sectional view of the rear lower corner of the firebox.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 is shown a typical factory-built fireplace unit, denoted generally by reference numeral 10, of the general type wherein the present invention is intended to be employed. Fireplace 10, as is typical of such units, is principally of sheet metal construction, the only significant exceptions being layers of conventional insulating material 12 (FIGS. 2 and 4) between the two outermost walls and hearth 14 which is a monolithic slab of refractory material. The slab may conveniently be formed to the desired dimensions and configuration by pouring the refractory material, while in a flowable condition, into a sheet metal hearth pan 16, formed for such purpose. Prior to pouring the refractory material into pan 16 and allowing it to harden, bushings 18 are inserted through holes in what becomes the front edge of the pan upon assembly of the hearth with the fireplace unit, thereby becoming a permanent part of the hearth.
The elements of the fireplace with which the present invention is most closely concerned are shown in solid lines in FIG. 1, outer enclosure 20 and upper hood 22 being outlined in phantom lines. An inner enclosure 21 is spaced inwardly from outer enclosure 20 and includes side walls 24 and 26 and rear wall 28. Spaced inwardly from the inner surfaces of walls 24, 26 are wing panels 30 and 32, respectively. These are generally parallel to and spaced from the corresponding walls 24, 26 of the inner shell 21, by virtue of flanges along their front and rear vertical edges. Because the wing panels are held in spaced relation to the inner shell side walls, they absorb the most intense heat on a separate, more easily replacement element rather than on the inner shell itself. The inwardly facing surfaces of the wing panels and rear liner may be plain, or, if desired, may be provided with an embossed brick pattern, as shown, for decorative effect and enhanced structural rigidity. A rear fire block 34 is mounted on the interior surface of rear wall 28 and is made of masonry or other fire resistant material similar to the material used for hearth 14.
Spaced inwardly within outer hood 22 is an inner hood 38 (FIG. 4), through which smoke and other products of combustion are led to a suitable chimney structure (not shown). Adjustable damper 40 is provided in the usual manner for movement by chain 42, having an end portion or handle manually accessible at the front of the fireplace. Upper and lower hearth covers 44 and 46, respectively, are attached to the lower front side of fireplace unit 10, as explained later in more detail, and cooperate to form an opening for entry of room air into the open space beneath hearth 14.
A pair of flanges 50 and 52 extend inwardly from the lower edges of inner shell side walls 24 and 26, respectively, being securely attached thereto or, preferably, formed integrally therewith. Likewise, flange 54 extends inwardly of the firebox, or forwardly of the fireplace unit, from the lower edge of inner shell rear wall 28. These three flanges serve as the entire underlying support for hearth slab 14 and pan 16. Accordingly, the width of inward extent of the flanges and the strength or load-bearing capacity of the material thereof are determined by the weight of the hearth.
A support bracket 55 engages flange 54 and supports it and shell 21 in spaced relation above an insulated pad 57. Other supports (not shown) similar to brackets 55 support flanges 50, 52 and shell 21 in rigid fashion above pad 57.
In assembly, the hearth is laid upon side flanges 50 and 52, and slid rearwardly until the rear edge of the hearth engages inner shell rear wall 28. The configuration and dimensions of the hearth side and rear edges correspond substantially to those of the inner shell walls, whereby the hearth side and rear edges engage the portions of the inner shell adjacent flanges 50, 52, and 54 when the hearth is in place. The lower edges of wing panels 30 and 32, and rear liner 34, are each spaced above the plane of flanges 50, 52 and 54 by a distance substantially equal to the thickness of hearth slab 14 and pan 16, whereby the lower edges of the firebox walls rest upon the upper surface of hearth 14 adjacent the marginal edges thereof.
After the hearth and other elements are in place, upper hearth cover is attached to the fireplace unit. The ends of the hearth cover extend past the edges of the front edge of hearth pan 16, which is entirely covered when hearth cover 44 is attached by screws 58 to the fireplace housing on each side, outwardly of the hearth. Cover 44 is also attached to the front of hearth 14 by screws 56, in order to hold the cover in snug contact with the hearth front. Screws 58 pass through openings formed for such purpose in hearth cover 44 for engagement in previously mentioned bushings 18.
From the foregoing, it is evident that the fireplace structure of the invention allows simple and rapid removal and replacement of the hearth without the necessity of disassembling and reassembling a number of elements to which accessibility is difficult after final installation of the fireplace unit. All that is required is to remove the upper hearth cover, by removing a few screws from the front of the unit, and slide the hearth forwardly. The new or repaired hearth may then be slid into place on the inner shell flanges and the hearth cover replaced. Although the hearth is not physically attached to the structure by which it is supported, it is restrained against sideward or rearward movement by the upper hearth cover which is affixed to the fireplace unit laterally of the front edge of the hearth. The wing panels and rear liner 30, 32, 34, having lower edges in substantially continuous contact with the upper surface of the hearth slab, prevent upward movement thereof. The wing panels and rear liner, together with the underlying flanges, effectively prevent migration of ashes or other combustion products into the space beneath the hearth.
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A factory-built fireplace having a refractory hearth floor which is supported from beneath only at the side and rear marginal edges, and is not physically connected to any fireplace structure other than a sheet metal cover plate which extends across and is supported by the front edge of the hearth. Thus, the hearth may be removed, in the event of cracking or for any other reason, and replaced simply be removing the hearth cover without disturbing other portions of the fireplace structure.
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BACKGROUND OF THE INVENTION
This invention relates to radio frequency pulse generating devices and, in particular, to high energy microwave pulse generators having a spark gap immersed in liquid.
It is known to produce bursts of microwave energy by switching power across a gap or gaps in the central conductor of a coaxial line or waveguide, as shown in U.S. Pat. No. 3,521,121 issued July 21, 1970 to J. M. Proud, JR., U.S. Pat. No. 3,484,619 issued Dec. 16, 1969 to J. M. Proud, Jr., U.S. Pat. No. 3,748,528 issued July 24, 1973 to H. Cronson and copending U.S. Patent application Ser. No. 661,677 entitled, "High Voltage Control Devices" to J. M. Proud, Jr., filed Feb. 26, 1976. These devices are capable of providing high energy pulse bursts of microwave power up to approximately 10 GHz. In the waveguide device disclosed in the patent to H. Cronson, the center conductor of the coaxial line is provided with one or more switching gaps along its length and/or the end post spaced from the interior wall of the waveguide. A radio frequency (RF) block or impedance is disposed around the post adjacent the first switching gap with the gaps so dimensioned that energy switched by the first gap can pass the block or impedance, but oscillations caused by the discharge at the second gap cannot pass the block. The spark gap functions to steepen the leading edge of the traveling wave. The prior art structures possess several shortcomings which the instant invention overcomes. These shortcomings include, but are not limited to, poor efficiency, since the capacitance of the RF block, to be effective, must be relatively large compared to the distributed capacity of the end post. The capacitance of the RF block stores most of the initial energy and, upon discharge, tends to react with the lumped value of inductance in the post, resulting in low frequency oscillations which typically are less than one-half the desired operating frequency. In the Cronson waveguide device, mentioned hereinbefore, such oscillations lie below the waveguide cut-off frequency and would not be observed. However, the existence of such oscillations have been observed by the applicant using coaxial resonators operating in the lowest TEM mode with no cut-off frequency. This problem cannot be overcome by reducing the capacitance of the RF block since this would permit the microwave oscillations to leak out of the resonant structure.
Furthermore, the Cronson device requires a spark gap of relatively small dimensions to provide rapid charging of the end post. This causes the small electrode surface of the gap to wear rapidly under sparking causing rapid deterioration of the fast switching properties of the closely spaced spark gap. A sliding short is also used to adjust the coupling between the waveguide and the end post. However, it does not enable tuning of the generator since the microwave frequency generated is determined primarily by the cross sectional dimensions of the waveguide.
It is also known, by those knowledgeable in the art, to use liquid or gaseous sparking mediums since their insulation and self-repairing properties may be superior to air. However, prior known liquids were found to decompose under repetitive sparking (arcing) conditions, thereby lowering the dielectric breakdown strength of the liquid. Insulating gases, to offer practical operating ranges, require pressurization in the spark area.
Therefore, it is an object of the present invention to overcome the shortcomings of presently known radio frequency generators.
It is a further object of the present invention to provide a highly efficient, high power radio frequency generator with a liquid insulating medium.
Another object of the present invention is to provide a liquid insulating medium which may be utilized in numerous spark gaps.
Still another object of the present invention is to provide a liquid sparking medium which does not substantially decompose under repetitive sparking conditions.
Yet another object of the present invention is to provide a sparking medium which also serves to remove heat from the sparking region.
A still further object of the present invention is to provide a novel microwave frequency generator which is small in size and relatively inexpensive to manufacture as compared to conventional RF microwave generators of equal output power.
The foregoing and other objects and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawing which forms a part thereof, and in which is shown by way of illustration, a specific embodiment for practicing the invention. This embodiment will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims.
SUMMARY OF THE INVENTION
A radio frequency generator for providing high energy pulses, according to the principles of the instant invention, comprises, in combination, an elongated resonant cavity having an open end and an essentially closed end; insulator means adapted to cooperate with the cavity open end and having an inwardly extending portion, the inwardly extending portion being provided with support means; and a elongated resonant element centrally disposed within the resonant cavity, one end thereof being disposed within the insulator support means, the resonant element being provided with input receiving means at its other end proximate the longitudinal axis thereof; switching means disposed on the other end of the resonant element and connected to the closed end of the resonant cavity; housing means for enclosing the switching means; liquid disposed within the housing, means and input terminal means adapted to be coupled to a source of pulsed voltage and including an electrically conductive means for providing a conductive path to the resonant element input receiving means.
BRIEF DESCRIPTION OF THE DRAWING
In order that the invention may be more fully understood, it will now be described by way of example, with reference to the sole illustration which is a pictorial representation, in cross section of the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the liquid dielectric radio frequency generator 10 of the present invention is shown in the sole illustration. An elongated resonant cavity 12 of the coaxial type (coaxial resonator) is provided with an open end 14 and an essentially closed end 16. An insulator element 18 is of generally circular shape and fabricated to be inserted into and seal the open end 14 of the conductive coaxial resonator 12, thereby confining all of the microwave energy within the coaxial resonator.
The insulator element 18 is provided with an inwardly extending portion 20 having a circular aperture 22 centrally disposed therein which functions as a receptacle and support for the anti-node end 26 of an elongated cylindrically-shaped resonant element 24 which preferably is one-quarter wavelength long.
The other end 28 of the resonant element 24 is provided with an aperture 30 which functions as the input voltage receiving terminal and is in electrically conductive contact with the input terminal means 32 at point 33 via an electrically conductive wire path which forms the inner conductor of a coaxial input line. The coaxial input line includes an outer conductor 35 and a dielectric 34.
The edge portion 36 of the end 28 of the resonator element 24 is provided with a first annular ring 38 transverse to the longitudinal axis 40 of the resonant element 24. A second annular ring 42 is displaced from and in juxtaposition with the first annular ring 38 and coaxially aligned therewith and connected to the closed end 16 of the coaxial resonator 12, thereby forming a spark gap 44.
An electrically non-conducting housing support member 46 maintains the end 28 of the resonant element 24 in a fixed position, thereby fixing the spark gap 44 at a predetermined distance.
The housing 46 is sealed in a conventional manner and is provided with means, not shown, for introducing the aprotic molecular liquids, molten sulfur, sulfur monochloride (S 2 Cl 2 ) and polyflourinated ether 47 which are capable of being subjected to repetitive sparking without serious decomposition or degradation, thus maintaining a substantially constant dielectric.
The principal advantage of utilizing liquid dielectric media over gaseous dielectric media is the fact that liquids do not require pressurization to achieve a high value of dielectric constant. For electrical stresses applied for relatively short times, such as microseconds, a typical liquid dielectric strength is approximately 10 6 volts/cm, whereas a typical gas at atmospheric pressure will exhibit a strength of 2 × 10 4 volts/cm. To achieve a dielectric strength of comparable value, a gas must be pressurized to a value of approximately 50 atmospheres or about 700 pounds per square inch. Thus, where small size is critical, the high dielectric strength of a liquid may be utilized to advantage permitting close spacing of the sparking electrodes without requiring reinforcement to support an elevated gas pressure.
The use of a liquid dielectric offers the additional advantage of having a greater density than a gas, thus providing a means of removing heat generated by the sparking by means of convection and condition without requiring means for moving the liquid.
The preferred liquids described hereinbefore also have the capability of rapidly recovering from sparking without decomposing or expanding with the added heat encountered, thus making containment thereof an easy matter.
It is to be noted that the conductive path from the input terminal means 32 passes through apertures 48 and 50 provided in rings 42 and 38, respectively, thus permitting internal connection to the resonant element 24 at point 33. The point of contact 33 from input terminal 32 is made at virtually zero microwave field so that little or no conducted microwave loss can occur via the input terminal means 32 and conductive path. Since the contact point 33 is at virtually zero microwave field, the requirement for a RF block used in the prior art resonant structures is obviated. Input terminal 32 is adapted to be coupled to a source of high voltage pulsed DC, not shown.
A conventional output probe 52 may be unobstructively provided in the cavity wall 54 at a convenient position between the open 14 and closed 16 ends of the cavity 12. Pick-up loops and capacity-type signal couplers may also be used.
In operation, the rapid breakdown of spark gap switch 44 generates microwave oscillations within the resonant cavity 12 which are confined to the space between the resonant element 24 and the walls 54 of the cavity 12. Output energy is obtained via probe 52.
The use of annular rings for electrodes to form the spark gap in conjunction with a liquid dielectric clearly reduces the wear occasioned by the use of a conventional spark gap which utilizes centrally located electrodes. The wear characteristics of the annular ring electrodes has been found to be one order of magnitude better, which more than offsets the initial increased difficulty in maintaining parallelism and accurate spark gap spacing over the annular region. The nature of wear with the annular ring electrodes tends to be in the direction to maintain parallelism.
It will be understood that various changes in the details, materials, arrangements of parts and operating conditions which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principles and scope of the invention.
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A liquid dielectric radio frequency pulse generator capable of providing high energy pulses having an in-line construction includes an annularly shaped spark gap immersed in an aprotic liquid such as molten sulfur, sulfur monochloride or mixtures thereof. The input voltage is connected to the resonant element through a central aperture provided in the spark gap rings for high efficiency operation.
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This application is a continuation in part of patent application Ser. No. 08/527,661, filed Sep. 13, 1995, for THREE RING BINDER PAGE FOR HOLDING COMPACT DISCS now U.S. Pat. No. 5,620,271.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to means for efficiently storing compact discs (CDs) in a conventional and well known three-ring binder having standard size covers. More particularly, this invention relates to means for storing a number of compact discs in individual one-disc pockets that are provided on the two opposite sides of a thin, flat, and flexible multi-ply page, so as to facilitate both physical and visual access to eight compact discs, or to four compact discs and printed and graphic information that relates to the four discs.
2. Description of the Related Art
Traditionally, compact discs (CDs) are sold and stored in well-known rigid and relatively thick plastic jewel boxes. Typical jewel boxes include removable printed inserts having one, or more, narrow title bars along at least one narrow edge to thereby permit the owner to find a particular compact disc when a number of the jewel boxes are stacked, or stored, next to each other.
Additionally, jewel boxes typically contain a multi-page insert that lists the songs on the CD and shows a related graphic illustration.
CDs are thin, circular, about 43/4-inch in diameter, and are relatively rugged. The amount of protection that is provided by a jewel box is more than necessary in most circumstances. However, jewel boxes are unnecessarily bulky; thus, limiting the number of CDs that can be carried or stored in any given carrier or cabinet.
As is well known, the construction and arrangement of a CD provides a relative thick and transparent plastic disc. A first side of this plastic disc is exposed to a laser beam for the purpose of reading the CD. The other side of this plastic disc is embossed in order to record a data pattern in a spiral or concentric pattern. This other side of the plastic disc carries a thin disc-shaped metal foil, usually aluminum. In this manner, the laser beam is enabled to read the data, for example music, that is contained on the metal foil side of the plastic disc. The exposed side of the metal foil usually carries text/graphics that is associated with the disc's recorded data. In order to adequately protect such a CD, it is necessary to protect both sides of the disc from scratches and the like. Scratches to the disc's plastic side may provide interference with reflection of the laser beam from the CD's data patterns, whereas scratches to the disc's text/graphics side may remove reflective portions of the metal foil, and thereby render portions of the CD's recorded data difficult to read.
Accordingly, relatively thin sleeves for storing individual CDs have evolved to protect the disc surface from dust, scratching and the like.
The art provides a variety of conventional means for mounting and holding articles in a three-ring binder, as is exemplified by the following patents; Des. 261,155, utility U.S. Pat. Nos. 4,263,357, 4,447,973, 4,508,366 and 4,850,731. In addition, multilayer packaging of disk type articles is known as exemplified by U.S. Pat. Nos. 4,620,630 and 5,101,973.
U.S. Pat. No. 5,396,987 describes a container for a compact disc wherein three thin layers of polypropylene are heat sealed together using line type heat seals, the intermediate one of the three layer being relatively soft.
It is also known in the art to provide a three-ring binder page for the storage of CDs in binders of a nonstandard size. That is, known CD storage pages of this prior type have a planar size that are too large to mount within the covers of a standard size three-ring binder that has multiple and general purpose binding utility. In addition, such known binder pages are constructed and arranged to store, or hold, four CDs on only one side of the page, and the CD storage pockets are provided with a wide and upward facing insertion/removal slot that does not adequately protect the surface of the CD.
FIG. 16 is an end view of a well-known standard size three-ring binder 70 having two covers 71,72 that are hinged on a binder edge 73 that carries three openable metal rings 74. In this figure, the horizontal width dimension 75 that extends from the innermost edge of rings 74 to the outermost edge of covers 71,72 is nominally 9.0-inches, but can vary in the general range of from about 8.5 to 9.5-inches, depending upon the manufacturer of binder 70. Known three-ring binder pages for storing four CDs are too large to fit within dimension 75.
A need remains in the art for a three-ring binder punched page that holds a number of CDs, and perhaps their multi-page illustrative literature, wherein the page's hole pattern facilitates use with a number of different standard three-ring binders of different thicknesses and binder types, wherein the page's binder-edge hole/slot pattern ensures that the pages will not bind as they are turned within the binder, and wherein the page construction requires minimal storage volume, while protecting both surfaces of the CDs from scratches and the like, all in a manner that permits the user to quickly identify and locate a desired CD and/or its related literature.
SUMMARY OF THE INVENTION
This invention provides a flexible, plastic, two-sided, loose leaf page for storing a number of compact discs within a number of one-disc pockets that are contained on the two sides of the page. In this manner, both physical and visual access is provided to eight discs, or physical and visual access is provided to four discs, and printed and graphic information that relates to these four discs.
A preferred embodiment of the invention releasably holds, or stores, four CDs on each side of the flat page or sheet, or if desired, two CDs on each side of the page along with the two liner notes or booklets that relate to each of the two CDs per page side.
A CD storage page in accordance with the invention contains a hole pattern that facilitates releasably mounting the CD storage page in a 1/2-inch, 1-inch, 11/2-inch, 2-inch, or 3-inch thick three-ring binder, or notebook, that has a standard cover size generally associated with a general utility of holding text/graphics pages that have an 8.5 to 9.0 wide (called horizontal herein) by 11 high (called vertical herein) inch size format.
In one embodiment of the invention, the CD storage page includes a binder edge that is foldable. In other embodiments of the invention, the foldable binder edge is eliminated.
The first named embodiment of the invention finds utility when mounting the CD storage pages in narrow three-ring binders; for example, in the 1/2 and 1-inch three-ring binders. In addition, the mounting hole pattern that is provided in this first embodiment of the invention facilitates mounting the CD storage pages in a Chicago-posted binder.
Standard and well-known three-ring binders 70, shown in FIG. 16, have two external covers 71,72 that measure about 111/2-inches high and about 10-inches wide, the height dimension being measured parallel to the binder's linear ring-containing edge 73, and the width dimension being measured perpendicular to the edge 73 that carries the three binder rings 74. As shown in FIG. 16, the horizontal dimension 75 that is available for page storage is nominally 9.0-inches.
Standard size CDs are about 1/16-inch thick and have a diameter of about 43/4-inch. Thus, in order to provide four one-CD pockets per page side, the construction and arrangement of the present invention positions the CD pockets so as to take advantage of the vertical space that exists between the binder's three rings 74 of FIG. 16; i.e., a circumferential edge of a CD resides slightly within a vertical cylinder that is defined by the three closed and vertically aligned binder rings 74.
In addition, and in order to prevent physical interference or obstruction between the two inner CDs that reside closest to the vertically oriented binder rings 74 of FIG. 16 when binder 70 contains multiple pages, and when a user opens binder 70 and then manually leaves through the pages, in one embodiment of the invention, the page contains a six-hole pattern, and in another embodiment of the invention, the page contains a three-hole/three-slot pattern, that ensures that a vertical pivot line on the page being turned will move past the vertical leading edge of the three-binder rings 74, and then backward under the three binder rings 74.
In addition, the construction and arrangement of the page's hole/slot pattern allows the entire page to hinge over the binder's three rings 74 in a manner to accommodate the narrowing circle that is defined by the two mating portions of binder rings 74, as the three-ring binder 74 become generally full of binder pages in accordance with this invention.
When CD storage pages in accordance with the invention are used in a relatively thin 1/2-inch or 1-inch three-ring binder, the pages of embodiments of the invention containing a foldable hinge flap are nested in pairs, with one page's hinge flap fitting inside the other page's hinge flap. When CD storage pages in accordance with this embodiment of the invention are used in the thicker three-ring binders, all pages install individually, as will be apparent. When CD storage pages in accordance with this embodiment of the invention are used in Chicago-posted binders, the pages lay flat, that is the page's hinge flap is not folded, as will be apparent.
In other embodiments of the invention, the CD storage page is configured without a fold line or a hinge flap, and these pages install in the same manner in all size standard three-ring binders.
In accordance with a preferred embodiment of the invention, each CD storage page was provided with four one-CD storage pockets per page side; i.e., eight pockets per page. The CD storage pockets were arranged in a square matrix comprising two vertical columns and two horizontal rows. Each of the four stored pockets was about 4.843-inches in vertical height and horizontal width. The four CD storage pockets were each provided with a linear and vertically extending CD insertion/removal edge opening of this same vertical height, with the insertion/removal openings facing in a direction away from the binder's three rings 74; i.e., facing toward the vertical open edge of three-ring binder 70.
Each of the four CD storage pockets per page side included a centrally located and circular central finger hole or opening about 1-inch in diameter. A horizontal slot, or slit, about 0.025-inches in vertical height was generally centered in the area of the CD storage pocket, and extended from the pocket's insertion/removal opening to the pocket's finger hole. This horizontal slit diverged, or widened, as it approached the circular finger hole, and met the circular hole as the slit vertically opened to a tear-drop shape that was formed by upper and lower horizontally extending surfaces that were each formed about a 1/2-inch radius.
In alternate embodiments, the above-described centrally located finger holes were not used. Rather, each of the four CD storage products per page side included a horizontal slot, or slit, about from 0.50 to 0.75-inches in vertical heights. This slot was generally centered in the area of the CD storage product, and extended from the pocket's insertion/removal opening to the general center of the storage product.
In accordance with the invention, many types of CD removal slots may be used, as long as the widest portion of the selected slot configuration does not exceed about 0.75-inch in vertical height.
Since it is contemplated that a standard three-ring binder 70, as shown in FIG. 16, will hold a number of CD storage pages in accordance with the invention, the facing surfaces of these pages will physically engage and rub together as binder 70 is moved, and the like. The above-described configuration of storage pocket finger holes and horizontal slots, or a horizontal slot about 0.75-inch high, provides substantially complete coverage of the facing CD surfaces, thus protecting these facing surfaces from undesirable scratches and the like.
A user removes a CD from its pocket by first inserting a finger into the central opening that is provided in a CD. The user then pulls the CD to the left and out of the pocket's insertion/removal opening, as the user's finger moves along and through the above-described 0.25, 0.50 or 0.75-inch high horizontal slit.
A CD storage page in accordance with an embodiment of the invention, included two outer transparent polypropylene layers and an inner opaque layer that comprised an intermediate adhesive layer, and two outer polypropylene layers that were formed of a soft nonwoven construction. In another embodiment of the invention, the above-described three-layer configuration that comprised (1) outer nonwoven-polypropylene layer, (2) adhesive layer, and (3) outer nonwoven-polypropylene layer was replaced by a single layer of a woven material, such as polypropylene, polyethylene, or a like material.
These and other objects, features and advantages will be apparent to those of skill in the art upon reference to the following detailed description of the invention, which description makes reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1, consisting of FIG. 1A and FIG. 1B, is a plan view of a loose leaf, two-sided, CD storage page in accordance with the invention, this page being usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page, so as to provide physical and visual access to eight CDs, wherein four CDs are held on each side of the page, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of the page, the opposite side plan view of the page being a mirror image of FIG. 1A.
FIG. 2 is an enlarged section view of a portion of a multi-ply CD storage page in accordance with the invention, this figure being useful in explaining the page's multiple ply construction and arrangement.
FIG. 3 is a plan view similar to FIG. 1A showing one embodiment of the two transparent outer sheets that are included in the binder page of FIG. 1, and showing the cut line pattern that is formed in each of the two outer sheets of the binder page.
FIG. 4 is a plan view similar to FIG. 3 showing another embodiment of the two transparent outer sheets that comprise the page of FIG. 1, wherein each of the two outer sheets is formed from a two member assembly.
FIG. 5 is a plan view similar to FIG. 1B showing the three-ply opaque middle sheet of the invention, and showing the three-ring binder openings that are formed in this middle sheet.
FIG. 6 is a plan view similar to FIG. 1B showing the line-type, double bar, heat sealing pattern that is used to bind two outer sheets, as shown in FIG. 3, and one middle sheet, as shown in FIG. 5, into the unitary page assembly shown in FIG. 1, this figure also showing how a fold line is formed in the resulting page by operation of a deep heat seal line.
FIG. 7 is a side view of an open and standard three-ring binder of the either the 1-inch, 11/2-inch or 3-inch three size, wherein the CD storage page of FIG. 1 is shown in an elevated position vertically over the three open binder rings, prior to folding the binder page on its fold line, whereupon the folded binder page may be lowered onto the open binder rings, as is seen in FIG. 7A.
FIG. 8 is a view like FIG. 7 that shows the CD storage page of FIG. 1 lowered onto the three binder rings, and with the binder rings closed.
FIG. 9 is a view like FIG. 8 that shows the CD storage page in its folded state, such that the three-ring binder can be closed, as shown in FIG. 9.
FIG. 10 is an enlarged view of the binder side of two CD storage pages of FIG. 1 showing how the two storage pages are nested together and folded as a unit to accommodate mounting in a standard size 1/2-inch or a 1-inch thick three ring binder.
FIG. 11 is an enlarged view similar to FIG. 10 that shows the binder side of two CD storage pages of FIG. 1, showing how the two storage pages are placed one on top of the other and individually folded to accommodate mounting in a standard size 11/2-inch, 2-inch, or a 3-inch thick three-ring binder.
FIG. 12 is a side view similar to FIGS. 8 and 9 that shows how a CD storage page in accordance with the FIG. 1 embodiment mounts in a Chicago-posted binder without the need to fold the CD storage page.
FIG. 13 is a plan view of another folding embodiment of a loose leaf, two-sided, CD storage page in accordance with the invention, this page being usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page, so as to provide physical and visual access to eight CDs, wherein four CDs are held on each side of the page, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of the page, the opposite side plan view of the page being a mirror image of FIG. 13.
FIG. 14 shows the new and unusual utility of the circular through holes and the elongated through slots that are provided in CD storage pages in accordance with embodiments of the invention, this figure showing how the three folded through slots provide for a noninterfering acceptance of the right hand ring member when a three-ring binder is substantially filled with of a number of CD storage pages in accordance with the invention.
FIG. 15 is a plan view of one nonfolding embodiment of a loose leaf, two-sided, CD storage page in accordance with the invention that is intended for use in thin 1.0-inch binders, as well as in thicker 3.0 or 4.0-inch three-ring binders, this page being usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page, so as to provide physical and visual access to eight CDs wherein four CDs are held on each side of the page, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of the page, the opposite side plan view of the page being a mirror image of FIG. 15.
FIG. 16 is an end view of a well-known standard size three-ring binder having two covers that are hinged on a binder edge that carries three openable metal rings.
FIG. 17 is a plan view of another nonfolding embodiment of a loose leaf, two-sided, CD storage page in accordance with the invention that is intended for use in thin 1.0-inch binders, as well as in thicker 3.0 or 4.0-inch three-ring binders, this page being usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page, so as to provide physical and visual access to eight CDs wherein four CDs are held on each side of the page, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of the page, the opposite side plan view of the page being a mirror image of FIG. 17.
FIG. 18 is a plan view of another nonfolding embodiment of a loose leaf, two-sided, CD storage page in accordance with the invention, this embodiment being generally similar to the embodiment of FIG. 17, but having modified CD insertion openings from that shown in FIG. 17.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1A is a plan view of a rectangular shaped, loose leaf, two-sided, CD storage page 10 in accordance with the invention. As will be apparent, page 10 is foldable, and is usable to store a maximum of eight CDs within the four CD storage pockets that are provided on each side of page 10. Another utility of page 10 is to store two CDs on each side of the page, in which case, the printed/graphic information relating to a CD can also be stored on the same side of page 10 as its related CD. While FIG. 1A shows only one side of a CD storage page 10 in accordance with the invention, the other side of page 10 is a mirror image thereof.
In an embodiment of the invention shown in FIGS. 1A and 1B, the flat or unfolded horizontal width 11 of rectangular page 10 was about 11.336-inches, and the vertical height 12 of page 10 was about 10.25-inches. Page 10 includes a foldable mounting, or hinge flap 13, that is defined by vertically extending right hand page edge 14 and a vertically extending and deep heat seal fold line 15 that extends generally parallel to page edge 14. In an embodiment of the invention, the horizontal width 16 of flap 13 was about 1.75-inch.
Heat seal line 15 is characterized as a deep heat seal line in that the formation of heat seal line 15 compresses the multiple sheets that make up page 10 so that the page thickness along fold line 15 is about 0.0011-inch, thus providing less page thickness along fold line 15 then exists along the page's other heat seal lines that will be described.
Page 10 includes a horizontally extending upper edge 33, and a horizontally extending lower page edge 34 that is parallel to edge 33. As will be apparent, page edges 33,34 are defined by two horizontally extending and parallel heat seal lines. In an embodiment of the invention, the page's vertically extending left hand edge 35, that extends generally parallel to both fold line 15 and right hand page edge 14, was not heat sealed.
Each flat and generally planar side of page 10 includes four one-CD storage pockets 20, 21, 22, and 23 that are arranged in a square matrix comprising two horizontal pocket rows 20,22 and 21,23, and two vertical pocket columns 20,21 and 22,23. The following dimensions are a nonlimiting example of an embodiment of the invention. The two outer CD storage pockets 20,21 are of a square shape, about 43/4-inch on each side. The two inner, or binder side CD storage pockets 22,23, also occupy a generally 43/4-inch by 43/4-inch area. However, the binder side of each of the two inner pockets 22,23 comprises a semicircular portion 24,25 that is formed with a radius 26 of about 23/8-inch. As will be apparent, the bounds of CD storage pockets 20-23 are defined by heat seal lines that are used to seal the multiple plies of page 10 together.
Numeral 47 identifies a common horizontal spacing that is provided between the two upper CD storage pockets 22 and 20, and between the two lower CD storage pockets 21,23, distance 47 being about 0.063-inch in an embodiment of the invention.
Each of the four CD pockets 20-23 that exist on each side of page 10 includes a centrally disposed and circular finger opening 30 that is about 1-inch in diameter. The left hand side of each opening 30 is formed to have a tear-drop shape extension 31 having two sides that are formed about a 0.5-inch radius. The left hand side of each of the four tear-drop extensions 31 terminates at a thin horizontally extending slot 32 that is about 0.025-inches in vertical height. Preferably, slots 32 extend parallel to horizontal page edges 33,34.
The intended utility of a CD storage page 10 in accordance with the invention is that the CD's clear plastic beam-receiving surface be placed so as to face inward, and that the CD's text/graphics surface face outward. As is apparent, the use of the above-described small-size finger opening and horizontal slot construction and arrangement in accordance with the invention minimizes the likelihood that either side of a CD contained within a storage pocket can be physically damaged as by scratching, or the like, especially when multiple CD storage pages 10 in accordance with the invention are loaded into a standard size three-ring binder.
While use of this small-size finger opening 30 and horizontal slot 32 is of adequate utility, it is to be understood that within the spirit and scope of this invention, opening 30 and slot 32 can be replaced by any similar shape, and in an embodiment of the invention, the FIG. 1B shape 30,32 was replaced by a slot 1000 having a uniform vertical height 1001 that did not exceed about 0.50-inch.
The right hand binder portion of CD storage page 10 includes three circular through-holes 36,37,38 that are each about 0.1875-inch in diameter. Circular holes 36-38 lie on a common vertical axis 39 that extends generally parallel to page edge 14, and is offset a distance 40 from page edge 14. In an embodiment of the invention, distance 40 was about 1.125-inches. Binder hole 37 is generally centered on the vertical height of page 10, and in an embodiment of the invention, holes 36 and 38 were offset a distance of about 0.84375-inch inward from the page's upper and lower edges 33,34, respectively. In this embodiment of the invention, central hole 37 was spaced a distance of about 4.250 to about 4.281-inch from each of the two holes 36 and 38.
The right hand portion of page 10 also includes three horizontally extending and elongated through-holes 41,42,43. The three elongated holes or slots 41-43 are each about 0.1875-inch in vertical height 44, and are each about 0.875-inch in horizontal length 45, wherein the horizontal length of elongated holes 41-43 is measured from center to center of the two terminal radius. The two horizontal ends 46 of each elongated hole 41-43 preferably terminate two radius surfaces; for example, surfaces having a radius of about 0.09375-inch. As can be seen from FIG. 1B, each of the three elongated holes 41-43 is in horizontal alignment with an individual one of the three circular holes 36-38. Elongated holes 41-43 are also vertically aligned so that each of the holes 41-43 is equally horizontally spaced from circular holes 36-38, and from the page's right hand edge 14.
A feature of the invention provides that elongated holes 41-43 are positioned so that the center of the radius that is located at the left hand end 46 of each hole is located a distance 48 that is about 0.625-inch to the left of fold line 15.
As will be apparent, when CD storage page 10 is folded along fold line 15, each of the three circular holes 36-37 is brought into general alignment with the left hand end of an elongated hole or slot 41-43. In this aligned position, each hole/slot combination is in a position to be lowered onto the left hand one of a pair of mating ring portions that comprise an open binder ring. For example, FIG. 7A shows a page 10 in the above-described aligned position wherein each hole/slot combination is in a position to be lowered onto right hand one 704 of a pair of mating ring portions 704,705 that comprise an open binder ring.
FIG. 2 is an exploded and enlarged sectional view, of a portion of a multi-ply CD storage page in accordance with the invention, this figure being useful in explaining the multiple ply construction and arrangement of storage pages 10 in accordance with the invention.
As is apparent from FIGS. 1A and 1B, the two outer plies 50,51 of CD storage page 10 are substantially identical in form and construction, and each of these two outer plies 50,51 contains four circular finger holes 30 through which the two opposite planar surfaces 56 and 57 of a middle ply 52 can be viewed.
More specifically, and with reference to FIG. 2, each of the outer plies 50,51 is preferably formed of a thin extruded film or sheet of transparent polypropylene that is about 0.00055-inch thick, preferably having a matte finish. Inner ply 52 is formed, extruded, or laminated to form a thin, three-member, unitary ply 52 having an extrudate adhesive layer or member 55, and having two outer layers or members 53,54 that each comprise an opaque, nonwoven, and relatively soft polypropylene layer; for example, the Stearns brand nonwoven polypropylene having a weight of about 30 grams per square yard. As will be appreciated by those of skill in the art, the formation of inner ply 52 provides a unitary assembly having the three layers 53,55,54. In an embodiment of the invention, adhesive layer 55 was about 0.000125-inch thick, whereas outer layers 53,54 were each about 0.00055-inch thick. Layers 53,54 that are formed of nonwoven polypropylene have the visual appearance of a soft quilted surface.
The intent and purpose of CD storage page 10 is that the CDs that are stored therein reside in pockets 20-23 with their text/graphics side visible through transparent layers 50,51, and with their opposite and clear plastic sides in physical contact with soft surfaces 56,57 of inner ply 52.
Surfaces 56,57 are soft and protective of the clear plastic disc surfaces through which a laser beam reads the CD, whereas layers 50,51 have finger openings and slots that are of minimum area so as to maximize the protection that is afford to the text/graphics sides of the CDs, this side of the CD carrying a thin and reflective aluminum layer whose outer surface carries the CD's text/graphics material, and whose inner surface provides for reflection of a reading laser beam.
FIG. 3 is a plan view similar to FIG. 1 showing one embodiment of the two rectangular and transparent outer sheets 50,51 that comprise portions of the CD storage page of FIG. 1. In FIG. 3, the two outer sheets 50,51 are each formed from a single sheet, whereas in FIG. 4, another embodiment will be described wherein the two transparent outer sheets 50,51 are each formed from as a two member assembly.
FIG. 3 shows the cut line pattern that is formed in each of the two outer sheets 50,51, and shows by means of a dotted line 115 the position of FIG. 1's heat seal deep fold line 15. Through holes 36-38 and 41-43 are punched, or cut, into each of the outer sheets 50,51, as are tear drop shaped finger openings 30 and slots 32. In an embodiment of the invention, the above-mentioned through holes were punched in a fully assembled CD storage page; i.e., after the three page members 50,51,52 were heat sealed together.
In addition, linear or straight cuts 60,61 are formed in each of the outer sheets 50,51 to form the insertion/removal openings for CD storage pockets 22,23, respectively. Cuts 60,61 are aligned on an axis 62. In addition, cuts 60,61 are centered on slots 32, extend substantially parallel to dotted line 115 and to the right hand edge 114 of the sheet, and cuts 60,61 are each about 4.843-inches long.
Dotted lines 300,301 show the position that the right hand peripheral edge of two CDs that are stored in storage pockets 22,23, respectively. These two CDs occupy a position relative to fold line 15, as represented by numeral 115. As a feature of the invention, inner and outer sheets 50,51 may be provided with short linear cuts 302,303 that are located generally coincident with dotted line 115 and parallel to edge 114. Cuts 302,303 operate to accommodate movement of the right hand edge of the CDs that are stored in pockets 22,23, respectively. As will be apparent relative to the embodiment of the invention shown in FIG. 13, cuts 302,303, and the function that is provided thereby, can also be provided by the use of like-positioned through holes.
In another embodiment of the invention, sheets 50,51,52 are formed from three moving webs 50,51,52, wherein the CD insertion/removal openings 30 and slits 32 are first made in the two moving sheet webs 50,51 prior to heat sealing the three moving webs into a moving web assembly, whereupon the page's through holes 36-38 and 41-43 are punched in the now-sealed-together assembly of three moving webs 50,51,52.
FIG. 4 is a plan view similar to FIG. 3 that shows another embodiment of the two rectangular and transparent outer sheets 50,51 that comprise the exterior layers of storage page 10 of FIG. 1. In this embodiment of the invention, each of the two outer layers or sheets 50,51 is formed as a two-member, or two web, assembly 400,401.
With reference to FIGS. 1, 2 and 3, and as will be apparent from a following description of the heat seal procedure for CD storage page 10, a heat seal line pattern operates to bind the three members 50,51,52 of FIG. 2 together in order to form the unitary assembly of a CD storage page 10 in accordance with FIG. 1.
In the single sheet or web embodiment of outer sheets 50,51 that is shown in FIG. 3, a linear heat seal line is positioned closely to the left of vertical CD insertion/removal axis 62; for example, at axis 162. In this FIG. 3 embodiment of the invention, the horizontal distance 63 between axes 62 and 162 was about 0.063-inches.
In the two-member or two-web embodiment of outer sheets 50,51 that is shown in FIG. 4, each outer sheet 50,51 comprises a first sheet member, or web 400, and a second sheet member or web 401. While the two sheet members 400,401 function as a single member, as was described above relative to FIG. 3, they are separated by a small linear gap 64. Gap 64 performs the disc-insertion/disc-removal function that cuts 60,61 of FIG. 3 perform for CD storage pockets 22,23. In FIG. 4, heat seal line 62 remains in the same physical page position, as is shown in FIG. 3, but sheet member or web 401 is of slightly reduced horizontal width so as to provide for the presence of a vertically CD insertion/removal slot at the left hand side of each of the inner CD storage pockets 22,23.
This reduction in horizontal width of sheet member 401 results in somewhat less critical manufacturing tolerance in the placement of a heat seal line 62 during the heat seal manufacturing step, and also provides each of the two inner CD storage pockets with a vertically extending CD insertion/removal slot.
FIG. 5 is a plan view similar to FIGS. 1, 3, and 4 that shows the three-ply opaque and rectangular shaped middle sheet 52 of CD storage page 10 that is shown in the plan view of FIG. 1. As can be seen from this figure, middle sheet 52 contains only the six binder openings or through holes 36-38 and 41-43. As noted above, it may be desirable to punch these six binder openings 36-38 and 41-43 after the binder page has been assembled into a unitary assembly by operation of a heat sealing process.
In an embodiment of the invention, middle sheet 52 was somewhat smaller in the horizontal dimension than were outer sheets 50,51. As a result, the upper and lower edges 33,34, as well as the left hand edge 35 of middle sheet 52, were located coincident with the similar numbered edges of FIG. 1's CD storage page 10. However, the right hand edge 514 of middle sheet 52 was located at about the location of axis 515 shown in FIG. 1 that is just to the right of circular binder holes 36-38.
FIG. 6 is a plan view similar to FIG. 1 that shows a line-type heat sealing pattern that is used to bind two outer sheets 50,51 of FIGS. 2, 3 and 4, and one middle sheet 52 of FIGS. 2 and 5 into the unitary CD storage page assembly 10 that is shown in FIG. 1. FIG. 6 also shows how the page's deep fold line 15 is formed in the resulting page 10 by operation of a double heat seal line 601,602. For the purpose of orienting FIG. 6 to FIG. 1, the four orthogonal edges 14,33,35,34 of CD storage page 10 are shown in FIG. 6.
The specific manufacturing process for performing the heat sealing of two outer sheets 50,51 and a single middle sheet 52 into a unitary page assembly 10 is not critical to the invention. Since this manufacturing procedure is well known to those of skill in the art, it will not be described in detail herein.
As a first step in the assembly of the three FIG. 2 page members 50,52,51 into the unitary CD storage page assembly 10 that is shown in FIG. 1, the three page members 50,52,51 are brought into rectangular alignment. For example, three running webs, one outer web containing outer sheets 50, an inner web containing middle sheets 52, and a second outer web containing outer sheets 51 are brought into running alignment. With the three page members 50,52,51 accurately held in this aligned position, heat seals are now used to seal the three members together into a unitary page assembly 10. Thereafter, and while in web form, the above-described through holes 36-38 and 41-43 are accurately punched in each individual CD storage page 10 that is within the web.
The outer page edges 14,33,34 are each provided with a heat seal line 614,633 that is located generally coincident with page edges 14,33,34, respectively.
In addition, fold line 15 is formed by a pair of deep and closely spaced and linear heat seal lines 601,602 that are individually spaced on opposite sides of fold line 15, and individually extend generally parallel to heat seal line 614 and page edge 14. As shown, gaps 603,604,605 accommodate the location of elongated holes 41,42,43 within page 10.
CD storage pockets 20,21 are formed by, and bounded by, linear heat lines 620,621,622 and 623,624,625, respectively, whereas CD storage pockets 22,23 are formed by, and bounded by, linear/circular heat seal lines 626,627 and 628,629, respectively.
While the left hand page edge 35 may not include a heat seal pattern, if desired, three linear heat seal lines 670,671,672 may be provided generally coincident with the portions of page edge 35 that do not form the disc insertion/removal portion of CD storage pockets 20,21.
As a feature of the invention, the page area that is occupied by flap 13 of page 10, which is also identified by numeral 13 in FIG. 6, may be provided with a heat seal pattern (for example, a pattern of dots or a cross hatch pattern as is indicated at 650) in order to secure the three page members 50,52,51 together in a selected portion of, or in the entire area of, flap 13. In addition, it is within the spirit and scope of the invention to use such a heat seal pattern in other non-CD-storage areas of page 10.
It should be understood that heat seal lines 621,624 are located to the left of cuts 60,61 (see FIG. 3) that are formed in outer sheets 50,51. Thus, access to the two CD storage pockets 22,23 (see FIG. 1) that are on the two sides of CD storage sheet 10 is not obstructed.
As stated previously, in the FIG. 4 embodiment of the invention wherein the two rectangular and transparent outer sheets 50,51 that comprise the two exterior layers of storage page 10 are each formed as a two web, assembly heat seal lines 621 and 624 remain in the same physical page position as is shown in FIG. 6, but the web from which inner CD storage pockets 22,23 are formed is of slightly reduced horizontal width, so as to provide for the presence of a vertically CD insertion/removal slot at the left hand side of each of the inner CD storage pockets 22,23, and to the right of heat seal line 621,624. This reduction in horizontal width of this sheet web results in somewhat less critical manufacturing tolerance in the placement of heat seal line 621,624 during the FIG. 6 heat seal manufacturing step, while at the same time providing each of the two inner CD storage pockets 22,23 with the required vertically extending CD insertion/removal slot.
A new and unusual feature of this invention is the manner in which the three circular holes 36-38, the three elongated holes 41-43, and the linear fold line 15 of a CD storage page 10, in accordance with this invention, cooperate with a standard three-ring binder to facilitate mounting of the generally 10.25-inch (vertical) by 11.366-inch (horizontal) CD storage page 10 in a standard three-ring binder whose corresponding size profile, when closed, is about 11.5-inches by 10.5-inches.
FIG. 7 is a side view of the horizontal edge of an open and standard size three-ring binder 700, wherein one CD storage page 10 in accordance with FIG. 1 is positioned, or located, in an elevated vertical position directly over the three open binder ring mating pair 704,705. In FIG. 7, dimension 706 is about 10.5-inches.
FIG. 7 shows the two binder covers 701,702 in the well-known open and flat position, with centrally located binder portion or edge 703 being exposed. CD storage page 10 is located so that its three circular holes 36-38 are in vertical alignment with the right hand portions 704 of the three binder rings, and with the page's three elongated holes 41-43 in vertical alignment with the left hand portions 705 of the three binder rings. As can be seen, the page's fold line 15 is now positioned intermediate binder portions 704,705, page 10 not being folded on its fold line 15 in this figure.
FIG. 8 is a view similar to FIG. 7 that shows CD storage page 10 lowered onto the three binder rings 704,750, with binder rings 704,705 then being manually closed in the well-known manner, but prior to the folding of CD storage page 10 on its fold line 15, and prior to closing binder covers 701,702. As shown in this figure, the page's fold line 15 is now encircled by the three closed binder rings 704,705, the three circular holes 36-38 of page 10 contain or accommodate the three ring portions 704, and the three elongated holes 41-43 of page 10 contain or accommodate the three-ring portions 705.
In practice, and as shown in FIG. 9, binder page 10 is first folded on its fold line 15, whereupon the left hand end of elongated openings 41-43 are brought into alignment with circular openings 36-38. Folded binder page 10 is then lowered onto open three-ring binder member 705, and the rings 704,705 are then closed. This operation is shown in FIG. 7A.
FIG. 9 is a view similar to FIG. 8 that shows CD storage page 10 after it has been folded along its fold line 15, whereupon the three-ring binders 704,705 are closed, and the binder covers 701,702 are thereafter closed, as shown. Note that page 10 can be folded upward, as is shown in FIG. 9, or the page can be folded downward, as is desired by the user.
This folding of page 10 on its fold line 15 is enabled by virtue of the page movement that is provided by the page's three elongated holes 41-43. As a result of this page movement within binders 701,702,703, the page's fold line 15 moves toward binder portion 703, and this movement operates to pull the page's left hand edge 35 to the right, to a position that is within the confines of closed binder covers 701,702.
FIG. 10 is an enlarged view of the binder side of two CD storage pages 10 of FIG. 1, showing how the two storage pages are nested together, and folded as a unit to accommodate mounting in a 1/2 or a 1-inch size or thickness three-ring binder.
FIG. 11 is an enlarged view similar to FIG. 10 that shows the binder side of two CD storage pages 10 of FIG. 1, showing how the two storage pages are placed one on top of the other, and individually folded to accommodate mounting in the larger size or thickness three-ring binders.
FIG. 12 is a side view similar to FIGS. 8 and 9 that shows how a CD storage page 10 in accordance with FIG. 1 utilizes its three circular holes 36-38 to mount page 10 on the three upstanding posts 806-809 of a well-known Chicago-posted binder 800, without the need to fold CD storage page 10. In this utility of the invention, binder posts 806-809 are fixed to lower binder cover 801, and once a number of pages 10 have been mounted on posts 806-809, the binder's top cover 802, having three holes 803,805 located therein, is lower unto posts 806-809, whereupon cover 802 is secured by operation of three threaded fasteners 810-812. Note that in this utility of the invention, CD storage page 10 need not be folded along its fold line 15, since the covers 801,802 of Chicago-posted binder 800 are large enough to accommodate the 10.25-inch (vertical) by 11,366-inch (horizontal) size profile of CD storage page 10.
FIG. 13 is a plan view of another embodiment of a loose leaf, two-sided, CD storage page 10 in accordance with the invention. Storage page 10 of FIG. 13 is again usable to store eight CDs within a thin, flexible, multi-ply three-ring binder page or sheet 10. Page 10 provides physical and visual access to eight CDs that are housed within the four above-described CD storage pockets 220-223 that are located on each side of the page, or page 10 may optionally provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held in the four storage pockets that are on each side of page 10. The opposite side plan view of this embodiment of CD storage page 10 is a mirror image of FIG. 13.
In this embodiment of the invention, the horizontal width 211 of rectangular page 10 was about 11.147265-inches, and the vertical height 212 of page 10 was about 10.25-inches. Page 10 includes a mounting flap 213 that is defined by vertically extending right hand page edge 214 and a vertically extending, six-piece or segment, heat seal fold line 215 that extends generally parallel to page edge 214. Again, fold line 215 comprises the above-mentioned deep heat seal. In this embodiment of the invention, the horizontal width 216 of flap 213 was about 1.585-inch.
Page 10 includes a horizontally extending upper page edge 233, and a horizontally extending lower page edge 234 that is parallel to page edge 233. As will be apparent, page edges 233,234 are defined by two horizontally extending and parallel heat seal lines 634,635, respectively. In this embodiment of the invention, the page's vertically extending left hand edge 235 extends generally parallel to both deep fold line 215 and right hand page edge 214, and page edge 235 was not heat sealed by a vertical heat seal line.
Each flat and generally planar side of page 10 includes four one-CD storage pockets 220, 221, 222, and 223 that are arranged in a square matrix comprising two horizontal pocket rows 220,222 and 221,223, and two vertical pocket columns 220,221 and 222,223. All four CD storage pockets 220-223 have a square shape, about 4.7355-inch on each side, as measured mid-seal to mid-seal, for holding one CD. As will be apparent, the bounds of CD storage pockets 220-223 are defined by multi-function heat seal lines that are used to seal the multiple plies or sheets 50,51,52 (see FIG. 2) of page 10 together.
In this embodiment of the invention, the horizontal spacing that exists between the two upper CD storage pockets 222 and 220, and the horizontal spacing that exists between the two lower CD storage pockets 221,223 is very small, and is defined by a three-piece, vertically extending and aligned, heat seal line 247,248,249.
The spaces, or gaps, 250,251 that exist in heat seal line 247,248,249 allow horizontal movement to the right of the two CDs that are stored in storage pockets 220,221, respectively, and in fact, it is possible that the adjacent circumferential edges of the CDs that are stored in storage pockets 220,222 and 221,223 may physically engage as a result of gaps 250,251. The extent of such horizontal movement of the CDs within storage pockets 220,221 can be controlled by varying the vertical length or size of gaps 250,251. If desired, and by the use of this technique, physical engagement of the adjacent edges of the two CDs within outer storage pockets 220,222 with the edges of the two CDs within inner storage pockets 221,223 can be prevented.
Each of the four CD pockets 220-223 that exist on each side of page 10 includes a centrally disposed and circular finger opening 230 that is about 1-inch in diameter. The left hand side of each finger opening 230 is formed to have a tear-drop shaped extension 231 having two vertically opposed sides that are each formed about a 0.5-inch radius. The left hand side of each of the four tear-drop extensions 231 terminates at a thin, horizontally extending slot 232 that is about 0.25-inch in vertical height. Preferably, slots 232 extend parallel to horizontal page edges 233,234.
As stated, the unique configuration of finger hole 230 and slot 232 provide access to a CD in a storage pocket, while at the same time preventing CDs on one page from being scratched by CDs on an adjacent page, thus minimizing the likelihood of CD damage due to scratching and the like.
In this embodiment, finger opening 230, tear-drop shaped extension 231, and horizontal slot 232 can also be replaced by slot 1000 of FIG. 1B having a vertical height 1001 generally equal to, but not exceeding, 0.50-inch.
The right hand binder portion of page 10 includes three circular through-holes 36,37,38 that are each about 0.1875-inch in diameter. Circular holes 36-38 lie on a common vertical axis 239 that extends generally parallel to page edge 214, and is offset a distance 240 from page edge 214. In this embodiment of the invention, distance 240 was about 1.03125-inches. The three circular binder holes 36-38 are generally centered on the vertical height of page 10, and in this embodiment of the invention, holes 36 and 38 were offset a distance of about 0.844-inch inward from the page's upper and lower edges 233,234, respectively. In this embodiment of the invention, central hole 37 was spaced a distance of about 4.250 to about 4.281-inch from each of the two holes 36 and 38.
The right hand portion of page 10 also includes three horizontally extending and elongated through-holes 41,42,43. The three elongated holes or slots 41-43 are each about 0.1875-inch in vertical height, and are each about 0.875-inch in horizontal length as measured from center-to-center of the two end semicircle portions of slots 41-43. The two horizontal ends of each elongated hole 41-43 preferably terminate at a semicircle or radius surface; for example, a circle having a radius of about 0.09275-inch. As can be seen from FIG. 13, each of the three elongated holes 41-43 is in horizontal alignment with an individual one of the three circular holes 36-38. Elongated holes 41-43 are also vertically aligned so that each of the holes 41-43 is equally horizontally spaced from circular holes 36-38, and from the page's right hand edge 214.
A feature of the invention provides that elongated holes 41-43 are positioned so that the center of the semicircle, or radius that is located at the left hand end of each hole 41-43, is located a distance that is about 0.625-inch to the left of fold line 215.
A feature of the embodiment of the invention, shown in FIG. 13, eliminates CD-movement-cuts 302,303 that are shown in FIG. 4, and substitutes therefor a pair of elongated and vertically aligned through slots 390,391 that extend through page 10. Through slots 390,391 are vertically aligned on fold line 15. In this embodiment of the invention, both of the slots 390,391 had a vertical height 392 of about 1.50-inch, and had a horizontal width 394 of about 0.625-inch. If desired, slots 390,391 can be made vertically smaller in order to reduce the intrusion of a CD through a slot 390,391 As shown, the vertical physical locations of slots 390,391 are vertically centered on storage pockets 222,223, respectively.
Through openings 390,391 operate to accommodate horizontal movement to the right of the two CDs that are stored in pockets 222,223, respectively. Here also the extent of such horizontal movement of the CDs within storage pockets 222,223 can be controlled by varying the vertical size of openings 390,391.
In order to reduce the horizontal width 211 of CD storage page 10 shown in FIG. 13, the line-type heat sealing pattern that is used to bind two outer sheets 50,51 of FIGS. 2, 3 and 4, and one middle sheet 52 of FIGS. 2 and 5 into the unitary CD storage page assembly 10 has been modified.
Again, a deep fold line 15 is formed in page 10 by operation of two vertically extending and parallel deep heat seal lines 601,602 having gaps 603,604,605 formed therein to accommodate the location of elongated through holes 41,42,43. In addition, in this embodiment of the invention, deep heat seal lines 601,602 include two additional gaps 606 and 607 that are formed therein to accommodate the location of the above-mentioned elongated through slots 390,391. As a result, heat seal lines 601,602 are each made up of six vertically aligned segments.
The outer page edges 214,233,234 are each provided with a heat seal line 633,614,634 that is located generally coincident with page edges 214,233,234, respectively.
Square CD storage pockets 220,221 are formed by, and bounded by, linear heat lines 720,247,248,723 and 723,248,249,724, respectively, whereas square CD storage pockets 222,223 are formed by, and bounded by, heat seal lines 720,602,723 and 720,602,724, respectively. In this embodiment of the invention, the vertical spacing 815 of heat seal lines 720,724 from upper page edge 233 and lower page edge 234, respectively, was about 0.25-inch.
Note that in this embodiment of the invention, a reduction in horizontal page size is achieved by virtue of the fact that one of the two vertical fold-producing deep heat seal lines 602 is also used as a vertical pocket boundary of inner pockets 222,223. More specifically, in this embodiment of the invention, the right hand vertical boundary of the two inner square CD storage pockets 222,223 is formed by fold-producing, six-piece, heat seal line 602.
As a feature of the invention, the page area that is occupied by flap 213 of page 10 may be provided with a heat seal pattern; for example, a pattern of dots or a cross hatch pattern 650 of FIG. 6, in order to secure the three page members 50,52,51 of FIG. 2 together in a selected portion of, or in the entire area of, flap 13. In addition, it is within the spirit and scope of the invention to use such a heat seal pattern in other non-CD-storage areas of page 10.
It is to be understood that the FIG. 13 embodiment of the invention also utilizes the multiple ply construction and arrangement above described relative to FIG. 2, and may include either a single inner and outer transparent sheet, as described relative to FIG. 3, or an inner/outer sheet construction and arrangement like FIG.4 wherein the two outer sheets are formed from a two member or web assembly.
FIG. 14 shows a new and unusual utility of circular through holes 36-38 and elongated through slots 41-43 when a three-ring binder is substantially filled with a number of CD storage pages 10 in accordance with the invention. FIG. 14 is an enlarged edge view that is similar to FIG. 7. In FIG. 14, a stack of a number of CD storage pages 10 pages is designated by broken line 225, only the top and bottom page 10 of which are shown in detail.
Each page 10 within stack 225 is folded on its fold line 15. The upper page, or pages 10, are shown as occupying a narrowing and generally circular area or spacing that is defined by the two mating portions 704,705 of a closed three-ring binder.
All of the pages 10 within stack 225 are secured to the closed three rings by operation of the three circular holes 36-38, and the left hand end of the three elongated slots 41-43 that are provided in each page. The folding of the top page, or pages 10 on the fold line 15, has had the effect of providing an open slot or gap 41-43 that is coincident with the page's fold line 15. This open slot 41-43 provides a noninterfering acceptance of right hand ring member 704. It is noted that the lower page, or pages 10 also are provided with an open slot 41-43 that is formed by the folding of elongated slots 41-43 on fold line 15. However, fold line 15 of these lower sheets 10 does not physically hit or interfere with binder member 704 at the wider, and generally circular area or spacing that exists adjacent to the binder edge 703 (see FIG. 8) of the three-ring binder.
FIG. 15 is a plan view of another embodiment of a loose leaf, two-sided, CD storage page 10 in accordance with the invention, page 10 being usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page (see FIG. 2) so as to provide physical and visual access to eight CDs, wherein four CDs are held on each side of page 10, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of page 10, the opposite side plan view of page 10 being a mirror image of FIG. 15.
In this embodiment of the invention, the horizontal width 900 of rectangular page 10 was about 9.625-inches, and the vertical height 901 of page 10 was about 10.25-inches. Page 10 of this embodiment of the invention does not include a foldable mounting flap at its vertically extending right hand page edge 904.
Rather, the vertical binder edge 904 of page 10 is provided with a four-piece linear heat seal 905-908 and with three horizontally extending slots or notches 909-911, each notch of which functions as was described relative to FIG. 14 when a binder page 10 occupies the top of a stack of sheets 225 that substantially fill a three-ring binder.
Page 10 includes a horizontally extending upper page edge 912 that is coincident with a linear heat seal line 913, and horizontally extending lower page edge 914 is coincident with linear heat seal line 915. In this embodiment of the invention, the page's vertically extending left hand edge 916 extends generally parallel to right hand page edge 904, and edge 916 was not heat sealed by a vertical heat seal line.
Each flat and generally planar side of page 10 includes four, one-CD storage pockets 920, 921, 922 and 923 that are arranged in a square matrix comprising two horizontal pocket rows 920,922 and 921,923, and two vertical pocket columns 920,921 and 922,923. All four CD storage pockets 920-923 have a square shape, about 4.7355-inch on each side, for holding one CD in each of the storage pockets. As will be apparent, the bounds of CD storage pockets 920-923 are defined by multi-function heat seal lines that are used to seal the multiple plies or sheets 50,51,52 (see FIG. 2) of page 10 together.
In this embodiment of the invention, the horizontal spacing that exists between the two upper CD storage pockets 920 and 922 and the horizontal spacing that exists between the two lower CD storage pockets 921,923 is very small, and is defined by vertically extending heat seal line 924.
In this embodiment of the invention, there are no spaces, or gaps, in heat seal line 924 that allow horizontal movement to the right of the two CDs that are stored in storage pockets 920,921, respectively.
Each of the four CD pockets 920-923 that exist on each side of page 10 includes a centrally disposed and circular finger opening 930 that is about 1-inch in diameter. The left hand side of each finger opening 930 is formed to have a tear-drop shaped extension 931 having two vertically opposed sides that are each formed about a 0.5-inch radius. The left hand side of each of the four tear-drop extensions 931 terminates at a thin horizontally extending slot 932 that is about 0.25-inch in vertical height. Preferably, slots 932 extend parallel to horizontal page edges 913,914.
As stated, the unique configuration of finger hole and slot provide access to a CD in a storage pocket, while at the same time, minimizing the likelihood of disc damage due to scratching and the like.
As with previous embodiments of the invention, the constructions 930,931,932 can be eliminated, and the generally 0.50-inch high slot 1000 of FIG. 1B can be substituted therefor.
The right hand binder portion of page 10 includes three circular through-holes 36,37,38 that are each about 0.1875-inch in diameter. Circular holes 36-38 lie on a common vertical axis 933 that extends generally parallel to page edge 905-908, and is offset a distance 934 from page edge 905-908. In this embodiment of the invention, distance 934 was about 0.75-inches. The three circular binder holes 36-38 are generally centered on the vertical height of page 10, and in this embodiment of the invention, holes 36 and 38 were offset a distance of about 0.844-inch inward from the page's upper and lower edges 912,914, respectively. In this embodiment of the invention, central hole 37 was spaced a distance of about 4.250 to about 4.281-inch from each of the two holes 36 and 38.
As stated, the right hand portion of page 10 also includes three horizontally extending and elongated through-slots 909-911. The notches, or slots, 909-911 are each about 0.1875-inch in vertical height, and are each about 0.344-inch in horizontal length, which horizontal dimension includes the semicircular right hand end of slots 909,911. The two left hand horizontal ends of each elongated slot 909-911 preferably terminates at a radius surface; for example, a surface having a radius of about 0.09375-inch. As can be seen from FIG. 15, each of the three elongated slots 909-911 is in horizontal alignment with an individual one of the three circular holes 36-38. Elongated slots 909-911 are also vertically aligned so that each of the clots 909-911 is equally horizontally spaced from circular holes 36-38 and from the page's right hand edge 905-908.
An optional feature of the embodiment of the invention shown in FIG. 15 eliminates CD-movement-cuts 302,303 that are shown in FIG. 4, and eliminates the vertically aligned through slots 390,391 that are shown in FIG. 13.
The upper and lower page edges 912,914 are each provided with a heat seal line 935,936 that is located generally coincident with page edges 912,914, respectively.
Square CD storage pockets 920,921 are formed by, and bounded by, linear heat lines 937,924,938 and 938,924,939, respectively, whereas square CD storage pockets 922,93 are formed by, and bounded by, heat seal lines 937, 905,906,938 and 938,907,908,939, respectively. In this embodiment of the invention, the vertical spacing 940 of heat seal line 937 from upper page edge 912 and the vertical spacing of heat seal line 939 from lower page edge 914, respectively, was about 0.25-inch.
Note that in this embodiment of the invention, a reduction in horizontal page size is achieved by virtue of the fact that the heat sealed vertical binder edge of page 10 also forms a boundary of the inner column of CD storage pockets 922,923, and open notches/slots 909-911 are provided in the binder edge of page 10, these open slots functioning as was described relative to FIG. 14.
It is to be understood that the FIG. 15 embodiment of the invention also utilizes the multiple ply construction and arrangement above described relative to FIG. 2, and may include either a single inner and outer transparent sheets, as described relative to FIG. 3, or an inner/outer sheet construction and arrangement like FIG.4, wherein the two outer sheets are formed from a two member assembly.
As a feature of the invention, the FIG. 15 embodiment thereof may include the use of truncated vertical heat seal lines, as shown in FIG. 13, so as to provide a gap at the vertical right hand side of each of the outer CD storage pockets 920,921, and/or so as to provide a gap at the vertical right hand side of each of the inner CD storage pockets 922,923. As described previously, the use of these truncated vertical heat seal lines at these locations accommodates horizontal movement to the right of CDs with the CD storage pockets.
FIG. 17 is a plan view of another embodiment of a loose leaf, two-sided, CD storage page 10 in accordance with the invention. Page 10 is usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page (for example, as shown in FIG. 2), so as to provide physical and visual access to eight CDs, wherein four CDs are held on each side of page 10, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of page 10. The opposite side plan view of page 10 is a mirror image of FIG. 17.
In this embodiment of the invention, the horizontal width 1000 of rectangular page 10 was about 9.750-inches, and the vertical height 1001 of page 10 was about 10.25-inches. Page 10 of this embodiment of the invention does not include the foldable mounting flap of FIG. 1B at its vertically extending left hand binder edge 1002, nor does it include a notched binder edge, as is shown in the FIG. 15 embodiment of the invention.
Rather, vertical binder edge 1002 of page 10 is provided with a linear heat seal 1003, and with four 45-degree linear heat seals 1004-1007 that operate to stiffen and to isolate three binder through-holes 1008-1010 that are centered on a vertical axis 1011 spaced about 0.6875-inch from binder edge 1002. In this embodiment of the invention, center binder hole 1009 was about 0.236-inch in diameter, whereas binder holes 1008 and 1010 were elongated in the direction of axis 1011, had a width of about 0.236-inch, and a length of about 0.424-inch. The use of elongated holes 1008 and 1010 accommodates manufacturing variation that is sometimes found in the location of the three binder rings of a standard-utility three-ring binder. Preferably, through-holes 1008-1010 are each closely surrounded and enclosed by an edge disposed heat seal 1080.
Page 10 of FIG. 17 includes a horizontally extending upper page edge 1012 that is generally coincident with a linear heat seal 1013, and a horizontally extending lower page edge 1014 is generally coincident with a linear heat seal 1015. In this embodiment of the invention, the page's vertically extending right hand edge 1016 extends generally parallel to left hand binder edge 1002, and edge 1016 is not heat sealed. The two 45-degree heat seals 1005,1006 join to a linear and horizontally extending heat seal 1050 the operates to horizontally divide page 10 at its mid-portion.
The seven heat seals 1013,1003,1004,1005,1006, 1007,1015 form three closed page areas 1070,1071 and 1072 generally adjacent to the page's binder edge 1002. Areas 1070 and 1072 each comprise a generally right-triangle whose two sides are each about 1.328-inch long. Area 1071 also comprises a right-triangle area whose page-edge-disposed hypotenuse is about 2.656-inch long. As a feature of the FIG. 17 embodiment of the invention, one or more of the three closed areas 1070-1072 may contain a heat seal pattern that operates to stiffen these three portions of page 10.
In this embodiment of the invention, the vertical spacing of heat seal line 1013 from upper page edge 1012, and the vertical spacing of heat seal line 1015 from lower page edge 1014, respectively, was about 0.063-inch.
Each flat and generally planar side of FIG. 17's page 10 includes four, one-CD storage pockets 1020, 1021, 1022 and 1023 that are arranged in a square matrix comprising two horizontal pocket rows 1020,1022 and 1021,1023, and two vertical pocket columns 1020,1021 and 1022,1023. All four CD storage pockets 1020-1023 define a square-area shape, about 4.85-inch on each side, for holding one CD in each of the four storage pockets. As will be apparent, the bounds of CD storage pockets 1020-1023 are defined by multi-function heat seal lines that are used to seal the multiple plies of page 10 together.
When the nonwoven fabric plies 56,57 of FIG. 2 are used in FIG. 17, plies 56,57 are usually, but not necessarily, oriented so that the fibers within plies 56,57 extend generally in the vertical direction of FIG. 17; i.e., extend generally parallel to page edges 1002,1016, as shown by arrow 1090.
In this FIG. 17 embodiment of the invention, the multiple sheet construction and arrangement 50,51,52 shown in FIG. 2 may be replaced by a single layer of a woven fabric, such as polypropylene, polyethylene, or the like. In a woven material of this type, the fibers therein extend generally perpendicular to each other. Such a single layer of woven fabric is oriented in page 10 so that its orthogonal fibers extend generally parallel to the four edges of page 10, as shown by arrows 1090 and 1091.
The horizontal spacing that exists between the two upper CD storage pockets 1020 and 1022 and the horizontal spacing that exists between the two lower CD storage pockets 1021,1023 is very small, and is defined by vertically extending and linear heat seal 1024. Heat seal 1024 operates to vertically divide page 10 at its mid-portion.
In this embodiment of the invention, there are no spaces, or gaps, in heat seal line 1024 that allow horizontal movement to the left of the two CDs that are stored in storage pockets 1020,1021, respectively, as was provided at 302 and 303 of FIG. 3.
Each of the four CD pockets 1020-1023 that exist on each side of page 10 includes a centrally-disposed and half-circular finger opening 1030 that is about 0.75-inch in diameter. The right hand side of each finger opening 1030 is formed to have an extension slot 1031 having two vertically extending and parallel opposed sides that are vertically spaced about 0.75-inch. Preferably, slots 1031 extend parallel to horizontal page edges 1012,1014. In an embodiment of the invention, the horizontal length of each of the storage pocket finger openings, including both openings 1030 and extension slots 1031, was about 2.625-inch.
As stated, the unique configuration of finger holes 1030 and mating slots 1031 provide access to a CD that is stored in a storage pocket, while at the same time, minimizing the likelihood of CD damage due to scratching and the like (for example, when a number of loaded CD pages 10 are stacked adjacent to each other within a three-ring binder).
The left hand binder portion of page 10 includes three through-holes 1008,1009,1010. Holes 1008-1010 lie on a common vertical axis 1011 that extends generally parallel to page edges 1002,1016, and holes 1008-1010 are offset a distance 1034 from binder edge 1002. In this embodiment of the invention, distance 1034 was about 0.6875-inch. The binder hole 1009 is generally centered on the vertical height of page 10, and in this embodiment of the invention, the center of vertically elongated holes 1008 and 1010 were offset a distance of about 0.75-inch from the page's upper and lower edges 1012,1014, respectively. In this embodiment of the invention, central hole 1009 was spaced a distance of about 4.250 to about 4.281-inch from each of the two holes 1008 and 1010.
A feature of the invention shown in FIG. 17 eliminates CD-movement-cuts 302,303 that are shown in FIG. 4, and eliminates the vertically aligned through slots 390,391 that are shown in FIG. 13.
In a preferred embodiment of the invention as shown in FIG. 17, the two transparent outer sheets that are included in binder page 10 (i.e., sheets 50 and 51 of FIG. 2) are each formed from one individual sheet, this being the configuration that is shown in FIG. 3. In this embodiment, cuts 60,61 of FIG. 3 define the CD insertion/removal slots of inner/upper pocket 1020 and inner/lower pocket 1021, respectively.
In FIG. 17, the upper and lower page edges 1012,1014 are each provided with a horizontally extending linear heat seal 1013,1015 that is located closely adjacent to (i.e., about 0.063-inch from) page edges 1012,1014, respectively. Upper and lower page edges 1012,1014 may also include linear stitch-type heat seals 1032,1033 that are spaced closely adjacent to (i.e., about 0.0625-inch from) heat seals 1013,1015, respectively.
Since the two heat seals that are within heat seal pairs 1013,1032 and 1015,1033 are quite close together, the use of a stitch-type heat seal at 1032 and 1033 reduces the tendency of page 10 to buckle in the vicinity of page edges 1012 and 1014. This construction and arrangement using these two heat seal pairs 1013,1032 and 1015,1033 is of particular utility when the soft middle sheet of binder page 10 comprises the three-ply construction shown in FIG. 2, and more specifically, when the fibers within sheet 55 of FIG. 2 extend in the direction of FIG. 17's arrow 1090. However, when the soft middle sheet of binder page 10 comprises one ply of a soft woven material whose fibers extend as shown by arrows 1090 and 1091, then stitch-type heal seals 1032 and 1033 can be replaced by a generally continuous heat seal.
When the middle sheet of binder page 10 comprises a single sheet of a soft woven material, such as polypropylene, polyethylene, or the like, the two stitch-type heal seal lines 1032,1033 are located so as to substantially coincide with the upper and lower terminations, respectively, of FIG. 3's cuts 60,61. In this way, binder page 10 is strengthened at upper termination, or end of cut 60 and the lower termination or end of cut 61.
The three orthogonal sides of square CD storage pocket 1020 are formed and bounded by linear heat lines 1032,1004,1003,1005 and 1050. The three sides of square CD storage pocket 1021 are formed and bounded by linear heat lines 1050,1006,1003,1007 and 1033. The three sides of square CD storage pocket 1022 are formed and bounded by linear heat lines 1032,1024 and 1050. The three sides of square CD storage pocket 1023 are formed and bounded by linear heat lines 1050,1024 and 1033.
Note that in the FIG. 17 embodiment of the invention, a reduction in horizontal page size is achieved by virtue of the fact that the heat sealed and vertically extending binder edge 1002 of page 10 also forms a boundary for the inner column of CD storage pockets 1022,1021.
It is to be understood that the FIG. 17 embodiment of the invention may also utilize the multiple ply construction and arrangement above described relative to FIG. 2, and may include either single outer transparent sheets, as described relative to FIG. 3, or an outer sheet construction and arrangement like FIG.4 wherein the two outer sheets are formed from a two member assembly.
FIG. 18 is a plan view of another embodiment of a loose leaf, two-sided, CD storage page 10 in accordance with the invention, this embodiment having many features in common with the FIG. 17 embodiment. Page 10 of FIG. 18 is usable to store a number of compact discs (CDs) within a thin, flexible, multi-ply page (for example, as shown in FIG. 2), so as to provide physical and visual access to eight CDs, wherein four CDs are held on each side of page 10, or to provide physical and visual access to four CDs and the printed/graphic information that relates to the four CDs, in which case, two CDs and their printed/graphic information are held on each side of page 10. The opposite side plan view of page 10 is a mirror image of FIG. 18.
In the FIG. 18 embodiment of the invention, the various dimensions are generally the same as above stated for the FIG. 17 embodiment of the invention. Binder page 10 of FIG. 18 is provided with the heat seals as above stated relative to the FIG. 17 embodiment of the invention. Page 10 of FIG. 18 also includes the three above-mentioned binder through-holes 1008-1010, and the three closed page areas 1070,1071 and 1072 that are located generally adjacent to the binder edge of page 10.
Each flat and generally planar side of FIG. 18's page 10 includes four, single-CD storage pockets 1020, 1021, 1022 and 1023 that are arranged in a square matrix comprising two horizontal pocket rows 1020,1022 and 1021,1023, and two vertical pocket columns 1020,1021 and 1022,1023. All four CD storage pockets 1020-1023 define a square-area shape, about 4.85-inch on each side, for holding one disk-shaped CD in each of the four storage pockets. As with the FIG. 17 embodiment, in FIG. 18 the bounds of CD storage pockets 1020-1023 are defined by multi-function horizontal and vertical heat seals that are used to seal the multiple plies of page 10 together.
When the nonwoven fabric plies 56,57 of FIG. 2 are used in FIG. 18, plies 56,57 are usually, but not necessarily, oriented so that the fibers within plies 56,57 extend generally in the vertical direction of FIG. 18, as shown by arrow 1090.
In this FIG. 18 embodiment of the invention, the multiple sheet construction and arrangement 50,51,52 shown in FIG. 2 may be replaced by a single middle layer of a fiber material or fabric, such as polypropylene, polyethylene, or the like. In a woven material of this type, the fibers therein extend generally perpendicular to each other. Such a single layer of woven fabric is oriented in page 10 so that its orthogonal fibers extend generally parallel to the four edges of page 10, as shown by arrows 1090 and 1091.
The horizontal spacing that exists between the two upper CD storage pockets 1020 and 1022 and the horizontal spacing that exists between the two lower CD storage pockets 1021,1023 is very small, and is defined by a vertically extending and linear heat seal as described relative to FIG. 17. This vertical heat seal operates to vertically divide page 10 at its mid-portion.
As was described relative to FIG. 17, each of the four CD pockets 1020-1023 that exist on each side of FIG. 18's page 10 includes a centrally-disposed and half-circular finger opening 1030 that is about 0.75-inch in diameter.
In the FIG. 18 embodiment, however, the right hand side of each finger opening 1030 mates with a short, horizontally extending, extension slot 2031 having two horizontally extending and parallel sides that are vertically spaced about 0.75-inch. Preferably, the upper and lower sides of extension slots 2031 extend parallel to the upper and lower horizontal edges of page 10.
The two parallel and sides of each of the extension slots 2031 terminate at a half-circular portion 2030 that faces in the opposite direction to half-circular finger opening 1030. Half-circular portions 2030 are also about 0.75-inch in diameter.
In the FIG. 18 embodiment of the invention, the total horizontal length of each of the storage pocket finger openings 1030,2031,2030 was about 1.20-inch.
In addition, each of the four storage pockets 1020-1023 that are on each side of FIG. 18's binder page 10 includes a vertically extending, edge-disposed, finger slot or scallop opening 2050 that is cut from the two outer transparent sheets that comprise page 10 (see sheets 50 and 51 of FIG. 2). As shown, each of the four scallop openings 2050 per page side are generally horizontally centered on a respective storage pocket finger opening 1030,2031,2030. In an embodiment of the invention, the vertical dimension 2060 of each scallop opening 2050 was about 1.0-inch, and each scallop opening 2050 terminated at an end quarter-circle portion having a radius of about 0.25-inch.
A feature of this FIG. 18 embodiment of the invention is that the four CD storage pocket portions that are within each of the two outer plastic sheets of CD storage page 10 (see sheets 50 and 51 of FIG. 2) each include a web portion 3000 that operates to stiffen the outer sheet adjacent to each of the four CD insertion/removal openings. This construction and arrangement operates to prevent curling of the outer sheets as a result of a period of extended use.
In use, a user first inserts a finger into opening portion 1030, and into the center aperture of a CD that is stored in one of the CD storage pockets 1020-1023. This physical engagement with the stored CD enables the user to move the CD to the right, so that the CD's peripheral edge extends out of the pocket's scallop opening 2050. The user then removes the CD from its storage pocket. When replacing the CD, the user merely inserts the CD into the storage pocket by the use of scallop opening 2050.
This unique configuration provides access to a CD that is stored in a storage pocket, while at the same time, minimizing the likelihood of CD damage due to scratching and the like (for example, when a number of loaded CD pages 10 are stacked adjacent to each other within a three-ring binder).
The FIG. 18 embodiment of the invention may also utilize the multiple ply construction and arrangement above described relative to FIG. 2, and may include either single outer transparent sheets, as described relative to FIG. 3, or an outer sheet construction and arrangement like FIG.4, wherein the two outer sheets are each formed from a two member assembly.
While this invention has been described in detail while making reference to preferred embodiments thereof, it is recognized that those skilled in the art, upon learning of this invention, will readily visualize yet other embodiments that are within the spirit and scope of this invention. Thus, this detailed description is not to be taken as a limitation on the spirit and scope of this invention.
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A loose leaf page for selectively storing four compact discs (CDs) on each side of the page, or for storing two CDs and associated printed and graphic information on each side of the page. A flexible, plastic, two-sided, loose leaf page includes four CD storage pockets per side of the page, and includes a hole pattern that facilitates releasably mounting the page in a standard cover-size 1-inch, 1 1/2-inch or 3-inch three-ring binder notebook, certain embodiments also facilitating mounting of the page in a three-ring Chicago-posted binder. In order to prevent interference between two CDs that reside closest to the binder rings when a user manually leaves through binder pages, the page includes a six-hole pattern, a three-hole/three-notch pattern, or the page's binder-edge is configured to ensure that the vertical binder-edge, upon the page being turned, moves past the vertical leading edge of the three rings, and then moves backward under the three rings. The CD storage page includes two outer transparent polypropylene layers and an inner layer that is constructed of soft woven or nonwoven polypropylene.
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TECHNICAL FIELD
[0001] The field to which the disclosure generally relates includes hydrogen storage material, process, and device.
BACKGROUND
[0002] In addition to being stored as compressed hydrogen gas or cryogenic hydrogen liquid, hydrogen can be stored in and produced from certain solid compounds that are able to undergo hydrogenation (i.e., taking in hydrogen) and dehydrogenation (i.e., releasing hydrogen) reactions reversibly. A solid material capable of generating hydrogen under appropriate temperature and pressure offers a low pressure and light-weight option as a fuel source for hydrogen fuel cells and other hydrogen-consuming devices.
[0003] Various compositions comprising different metal hydrides have been explored as solid storage materials for hydrogen. Most of such materials have high dehydrogenation temperatures and/or un-desirable kinetic rate of hydrogenation or dehydrogenation. The mechanism and kinetic behaviors of hydrogenation and dehydrogenation of such solid materials have not been fully understood. An observed behavior in one metal hydride material does not always occur in another metal hydride.
SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0004] A multiphase hydrogen storage material comprises a lithium containing metal hydride and a lithium conductor. The hydrogen storage material is capable of undergoing hydrogenation and dehydrogenation cycles during which the rate of lithium transport within the hydrogen storage material is enhanced by the lithium conductor. A solid-state hydrogen storage device can be produced using the multiphase hydrogen storage material.
[0005] A process of storing and supplying hydrogen comprises: (a) providing a multiphase material capable of undergoing dehydrogenation and hydrogenation cycles, where the multiphase material comprises providing at least a lithium containing metal hydride; (b) providing a lithium conductor having a Log(σ·T) value of at least −6 at 100° C., where σ is lithium ionic conductivity in ohms −1 cm −1 and T is absolute temperature in Kelvin; and (c) combining the multiphase material with the lithium conductor by ball-milling, mechanochemical processing, planetary milling, vibro-milling, vapor phase deposition, dissolution-precipitation, dissolution-evaporation, solution-crystallization, melt mixing, or sputtering deposition method such that the lithium transport rate of the multiphase material during hydrogenation and/or dehydrogenation is enhanced.
[0006] Other exemplary embodiments of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0007] The following description of the embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0008] The hydrogen storage material according to one embodiment of the invention comprises at least two different phases of materials. The different phases of the hydrogen storage material have different lattice structures and/or chemical compositions. The hydrogen storage material may comprise a mixture, for example, of different chemical components. The mixture may be formed in such a manner that there are multiple phases of materials having different chemical compositions. The hydrogen storage material may have different crystalline regions with different lattice structures, or the hydrogen storage material may comprise a mixture of crystalline and amorphous regions within the material. Each of the chemical compositions or regions may exist as an individual phase with its size ranging from several thousand micrometers to several nanometers. The material having at least two different phases is herein referred to as a multiphase material.
[0009] The hydrogen storage material may be “loaded” with releasable hydrogen to form a hydrogenated state, and be depleted with releasable hydrogen at its dehydrogenated state. The loading and releasing of hydrogen gas in the alternating hydrogenation and dehydrogenation processes is herein referred to as the hydrogen cycle. The hydrogenated state and dehydrogenated state may have different chemical compositions and different crystalline structures. The hydrogen storage material may include mixed hydrogenated and dehydrogenated states of materials when only part of releasable hydrogen is removed.
[0010] At least the hydrogenated state of the hydrogen storage material comprises at least one metal hydride. The metal hydride may be selected from at least one of ionic, covalent, and complex hydrides. Ionic hydrides typically contain metal cations and negatively charged hydrogen ions. Examples of ionic hydrides include, but not limited to, lithium hydride, sodium hydride, calcium hydride, and potassium hydride. Alkaline metal amides, such as lithium amide, sodium amide, and potassium amide, are also included in the ionic hydride category in this application. In covalent hydrides, the metal-hydrogen bond is effected through a common electron pair between the metal and hydrogen atoms. Examples of covalent hydrides include, but are not limited to, beryllium hydride, magnesium hydride, aluminum hydride, zirconium hydride, silane, borane, ammonia borane, aminoboranes, and germane. The complex hydrides are a large group of compounds in which hydrogen is combined in a fixed proportion with at least two other constituents, generally metal elements. A complex metal hydride can be represented by a typical chemical formula: M 1 (M 2 H x ) n , where M 1 , M 2 are two different elements and n and x are each numbers that correspond to the balance of electroneutrality of the molecule. M 1 may be one of Li, Na, K, Ca, Mg, Sr, La, and Ti, and M 2 may be one of Al, B, Ni, Fe and Ga. A complex hydride typically exhibits ionic bonding between a positive metal ion M 1 with molecular anions containing the hydride (M 2 H x ) portion. In such materials the hydrogen is bonded with significant covalent character to the second metal M 2 or metaloid atoms. Examples of complex hydrides include, but are not limited to, lithium borohydride (LiBH 4 ), magnesium borohydride (Mg(BH 4 ) 2 ), calcium borohydride (Ca(BH 4 ) 2 ), potassium borohydride (KBH 4 ), aluminum borohydride (Al(BH 4 ) 3 ), beryllium borohydride (BeBH 4 ), lithium aluminum hydride (LAlN, sodium aluminum hydride (NaAlH 4 ), magnesium aluminum hydride (Mg(AlH 4 ) 2 ), calcium aluminum hydride (Ca(AlH 4 ) 2 ), potassium aluminum hydride (KAlH 4 ), Mg 2 FeH 6 , Mg 2 NiH 4 , and metallic hydrides such as, but not limited to, TiFeH 2 and LaNi 5 H 6 . The hydrogen storage material may comprise one or more of the complex hydrides or metallic hydrides described above.
[0011] A typical hydride-containing hydrogen storage material can contain several forms hydrogen at its different hydrogenation, storage, and dehydrogenation stages. A solid solution of hydrogen atoms can exist in a metal lattice or coexist with a monohydride phase of the hydride (e.g., ZH, where Z is a hydride-forming metal or other element). A monohydride phase and a dihydride phase can each exist alone. Both monohydride phases and dihydride phases (e.g., ZH 2 ) can coexist.
[0012] The hydrogen storage material may comprise a mixture of at least two different hydrides having different dehydrogenation temperatures or thermal decomposition temperatures. Mixtures of two different hydrides can exhibit lower dehydrogenation temperatures and faster kinetic rates than each of its constituent hydrides. One such example is the mixture of MgH 2 and LiBH 4 . When these compounds are combined, the free energy is less than the respective free energy for hydrogen release for the individual compounds. Combination of a stable hydride and a destabilizing hydride is described in US Patent Application Publication numbers 20060013766 and 20060013753, which are incorporated herein by references in their entirety. Any combination of two or more of metal hydrides described above may be used to create a multiphase hydrogen storage material. In one embodiment, the hydrogen storage material comprises at least one stable hydride selected from the group consisting of lithium borohydride (LiBH 4 ), lithium aluminum hydride (LiAlH 4 ), sodium borohydride (NaBH 4 ), magnesium borohydride Mg(BH 4 ) 2 , and any mixtures thereof. The hydrogen storage material may further comprise a simple hydride, such as an ionic or covalent metal hydride described above, as a destabilizing hydride to be mixed with a stable hydride.
[0013] The hydrogen storage material generally comprises lithium and one or more of other light elements such as hydrogen, beryllium, boron, carbon, nitrogen, sodium, magnesium, silicon, calcium, and aluminum. A compound comprising lithium in its chemical composition is herein referred to as a lithium compound. When fully hydrogenated, the hydrogen storage material typically has a releasable hydrogen content of at least 3%, at least 5%, or at least 8% by weight. Lithium element in the chemical composition not only affords light weight and high gravimetric storage density of hydrogen, but also provides possible desirable kinetic rates in the chemical and physical processes of hydrogenation and dehydrogenation, due to lithium's small atomic mass and high mobility.
[0014] The hydrogen storage material may comprise, for example, a lithium compound in the form of a lithium containing metal hydride at least in its hydrogenated state. Lithium containing metal hydrides may include, but are not limited to, lithium hydride, lithium aluminum hydride, lithium borohydride, and lithium amide. Other lithium compounds may be included in the hydrogen storage material in addition to the lithium containing hydride. Other lithium compounds may include, but are not limited to, lithium metals or lithium alloys. During the dehydrogenation process, the lithium-containing hydride undergoes a chemical reaction to release hydrogen gas. The dehydrogenation reactions of several exemplary lithium-containing hydrides are shown in the following chemical reaction schemes 1-3
[0000] LiBH 4 →LiH+B+1.5H 2 [1]
[0000] LiAlH 4 →LiH+Al+1.5H 2 [2]
[0000] LiNH 2 +LiH→Li 2 NH+H 2 [3]
[0000] The above reactions can be reversed in a hydrogenation process under appropriate hydrogen pressure and temperature. In solid state reactions as shown above, the rate of reaction and temperature of dehydrogenation and hydrogenation can be affected by the transport rate of chemical constituent of different species involved in the reactions, in addition to rates of recombinative hydrogen desorption and hydrogen transport through the solid state material matrix. Although the Applicant does not wish to be bound to or by any particular theories, it is believed that the lithium transport in the hydrogen storage material according to the invention plays a significant role in the kinetics of hydrogenation and dehydrogenation. The Applicant thus recognizes that the rate of hydrogenation and/or dehydrogenation can be improved by enhancing the transport rate of lithium element or lithium ion in the hydrogen storage material, particularly the lithium transport rate between different phases within the multiphase material.
[0015] The hydrogen storage material may comprise a lithium conductor. Any lithium conductors that can enhance the transport rate of lithium element or lithium ion may be used. The lithium conductor may or may not contain a lithium element or lithium ion. The lithium conductor may have a Log(σ·T) value of at least −6, −4, or −2 at 100° C., where σ is lithium ionic conductivity in the unit of ohm −1 ·cm −1 , and T is absolute temperature in Kelvin. Exemplary lithium conductors include, but not limited to, Lil (lithium iodide), (Li 4 SiO 4 ) x /(Li 3 PO 4 ) 1-x solid solution (x is a number between 0 and 1), Li 4 SiO 4 , Li/β-Al 2 O 3 mixture, LiAlCl 4 (lithium aluminum chloride), LiAlF 4 (lithium aluminum fluoride), Li 2 Ti 3 O 7 , LiAlSiO 4 (lithium aluminum silicate), Li 9 SiAlO 6 , Li 8 TaO 6 , Li 8 NbO 6 , Li 3 InBr 6 , Li 3x La 0.66-x TiO 3 (0.03≦x≦0.167), TiO 2 , V 2 O 5 , aluminum, Lithium aluminum alloy represented by the chemical formula Li 1+x Al (−0.15≦x≦0.2), magnesium aluminum alloy, LiWO 2 , LiMoO 2 and any combinations thereof. LiAlF 4 may be formed in-situ by milling or mixing LiF and AlF 3 together. Log(σ·T) values of several lithium conductors mentioned above are listed in Table 1 below.
[0000] TABLE 1 Log(σ · T) values of a few lithium conductors Lithium conductors Log(σ · T) values, at 100° C. LiI (lithium iodide) −2.3 LiAlCl 4 (lithium aluminum chloride) −2.0 (Li 4 SiO 4 ) 0.5 (Li 3 PO 4 ) 0.5 solid solution −1 Li 4 SiO 4 −6 Li 2 Ti 3 O 7 −2.2
The lithium conductor may be included in the hydrogen storage material at an amount less than about 50%, 20%, or 2% by weight.
[0016] The hydrogen storage material may further comprise a catalyst that can further enhance the rate of hydrogenation and/or dehydrogenation. Possible catalyst compositions, which may be used in concentrations from 0.1 to 10 atomic percent (based on the catalytic metal atom) include TiCl 3 , TiH x (0.1≦x≦2), TiF 3 , TiCl 2 , TiCl 4 , TiF 4 , VCl 3 . VF 3 , VH x (0.1≦x≦2), NiCl 2 , LaCl 3 and other similar transition metal compounds. Further examples of catalysts for the hydrogenation or dehydrogenation include halogen compounds or hydrides of scandium, chromium, manganese, iron, cobalt, copper, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, cerium, neodymium, erbium, and platinum, as well as combinations of one or more of these metal elements in a chemical composition. The catalyst could be processed and incorporated into the hydrogen storage material by mechanical milling, precipitation from solution, dissolution-evaporation, crystallization, re-crystallization, vapor phase deposition, chemical transport, or sputter deposition process.
[0017] The hydrogen storage material may also comprise a hydride destabilizing agent that can lower the dehydrogenation temperature and/or the increase the rate of dehydrogenation of a hydride. Examples of a hydride destabilizing agent, include, but are not limited to, other hydrides, elements, magnesium compounds, nanoparticles of inorganic materials, oxides, or carbides. Other hydrides may include MgH 2 and the like. Elements may include silica, silicon, aluminum, copper, sulfur, potassium, or boron. Magnesium compounds may include MgF 2 , MgS, MgSe, or the like. Nanoparticles of inorganic materials may include nanoparticles of oxides, hydroxides, halides, silicates, carbon, nitrides and metals. Those of skill in the art will appreciate that an oxide is any chemical compound which contains at least oxygen in its chemical formula and that a carbide is any chemical compound containing at least carbon in its chemical formula. The destabilization reactions of several exemplary lithium-containing hydrides are shown in the following chemical reaction schemes 4-6:
[0000] 2LiBH 4 +MgH 2 →2LiH+MgB 2 +4H 2 [4]
[0000] 2LiBH 4 +Al→2LiH+AlB 2 +3H 2 [5]
[0000] 2LiBH 4 +MgF 2 →2LiF+MgB 2 +4H 2 [6]
[0018] The components and phases of the hydrogen storage material described above may be combined using various mixing and/or synthesizing processes to form the multiphase hydrogen storage material. Different components and phases of materials may be combined in ball-milling, mechanochemical processing, planetary milling, vibro-milling, vapor phase deposition, dissolution-precipitation, dissolution-evaporation, solution-crystallization, melt mixing, re-crystallization, solid state synthesis and/or sputtering deposition processes. The combination or mixing process may involve simple physical mixing, crystallization, or chemical reactions to form a multiphase material with a desired size for each of the phases. The combination may also involve diffusion of one chemical component from one phase to another, and formation of molecular solutions or alloys. Furthermore, chemical reactions between different components may also take place, for example, in a mechanochemical process where structural changes and chemical reactions occur at a high pressure generated in the material during milling. Numerous chemical reactions in metal—aluminum or boron—hydrogen systems have been carried out successfully in solid state under solvent-free conditions. Ti-catalyzed decompositions of LiAlH 4 at room temperature, for example, can be achieved upon mechanical milling. In another example, instead of using a transition-metal catalyzed alkali metal aluminum hydride (such as lithium aluminum hydride) in the hydrogen storage material, the starting materials used for their preparation in the form of alkali metal hydrides or alkali metals (especially NaH and Na), Al powder, transition-metal catalyst (such as titanium tetrabutylate) along with a lithium conductor can be employed. The complex aluminum hydride formed in one hydrogenation step from such starting materials are immediately functioning in the multiphase hydrogen storage material and has improved storage properties and kinetic rates. In yet another example, a mixture of LiBH 4 and MgF 2 is prepared having a molar ratio of 2:1 that reacts according to the above described chemical reaction scheme 6. The LiBH 4 is commercially available from Lancaster Synthesis, Inc. of Windham, N.H. (and is specified to be ≧.95% purity) and the MgF 2 is commercially available at 99.99% purity from Aldrich. The starting powders are mixed in the molar ratio 2LiBH 4 :1 MgF 2 with 2 mole percent of a catalyst (TiCl 3 ), and 10% by weight of LiAlF 4 (lithium aluminum fluoride is a lithium conductor with a Log(σ·T) value of −3.5 at 25° C., which is estimated to be >−2.5 at 100° C.) added during milling. The materials are then high-energy ball milled for at least one hour in a Fritsch Pulversette 6 planetary mill at 400 rpm. The average particle diameter of the compound(s) remaining in the mill typically range from approximately 5 micrometers to about 15 micrometers. Optionally and alternatively, the individual constituents may be individually milled, if necessary, and mixed, or milled and mixed at the same time. Typical milling parameters using, for example, a Fritsch P6 planetary mill include: 400 rpm, 1 hour milling time, 80 cm 3 hardened steel vessel, thirty 7 mm diameter Cr-steel balls, and 1.2 gram total sample mass. Where dry milling and mixing is not preferred for a combination of constituents, other practices such as solution-based methods (such as dissolution-precipitation, dissolution-evaporation, and solution-crystallization), or approaches based upon direct synthesis of nanoscale (1-100 nm) particles may be used to combine different components and phases for improved reaction kinetics. When LiAlCl 4 (with a melting point of about 140° C.) is selected as the lithium conductor, for example, the lithium conductor can be incorporated into the multiphase hydrogen storage material by melt blending at a temperature greater than 140° C., where the liquid LiAlCl 4 can be easily absorbed and distributed throughout the rest of components. To avoid unwanted agglomeration of nanoparticles during hydrogen cycles, it is possible to support individual particles in an inert matrix support or scaffold.
[0019] As appreciated'by one of ordinary skill in the art, the hydrogen storage material may initially comprise the dehydrogenated products or mixture, and may be subsequently hydrogenated, thereby cyclically releasing and storing hydrogen in accordance with the present invention. For example, in one embodiment, the starting materials comprising LiF, MgB 2 , and a lithium conductor LiAlF 4 are milled together to form a multiphase material. The starting materials are exposed to hydrogen gas at an appropriate temperature and pressure, where they transform to LiBH 4 and MgF 2 in a hydrogenated state, and are able to subsequently and reversibly release and absorb hydrogen, as previously described above in reaction scheme 6.
[0020] A solid hydrogen storage and supply device may be manufactured by using the hydrogen storage material described above. The hydrogen storage material may be provided as a high surface area multiphase mixture. It can be loaded, for an example, into a microporous support structure (such as a macroporous aluminum foam structure) inside a solid container fitted with heating and cooling elements, along with other known temperature and pressure control elements. The device is insulated and sealed to prevent leakage or contact with environmental hazards. The device has a filling port to allow inflow of pressurized hydrogen to hydrogenate the hydrogen storage material at an appropriate temperature and pressure. The device may also have an outlet port that can be connected to a hydrogen fuel cell, a hydrogen battery, a hydrogen combustion engine, or other hydrogen-consuming devices. The outlet may include a pressure and temperature regulator to provide a controlled outflow of hydrogen gas to an external hydrogen-consuming device. The heat generated from a hydrogen-consuming device may be used to heat up the hydrogen storage material to maintain a desired rate of dehydrogenation (or hydrogen gas release). The heat produced by the hydrogen-consuming device may be transferred to the hydrogen storage material through a heat exchanger coil, heat conductive elements or other heat transfer apparatus known to an ordinary skill in the field.
[0021] The hydrogen storage and supply device may be used in military, aerospace, automotive, commercial, and consumer applications as stationary and mobile power sources, remote power source, low profile power source, primary and auxiliary fuel cell power supplies, and power source for combustion engines and consumer electronics.
[0022] The above description of embodiments of the invention is merely exemplary in nature and, thus, variations thereof are not to be regarded as a departure from the spirit and scope of the invention.
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A multiphase hydrogen storage material comprises a lithium compound and a lithium conductor. The hydrogen storage material is capable of undergoing hydrogenation and dehydrogenation cycles during which the rate of lithium transport is enhanced by the presence of the lithium conductor. A solid state hydrogen storage device and a process of storing and supplying hydrogen are also disclosed.
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PRIORITY CLAIM
This application claims the benefit of previously filed U.S. Provisional Patent Application entitled “SOUND DAMPENING FLAPPER CONFIGURATION FOR MARINE EXHAUST SYSTEM,” assigned U.S. Ser. No. 61/225,381, filed Jul. 14, 2009, and which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
The present subject matter relates to exhaust systems. More specifically, the present subject matter discloses methods and apparatus for reducing wear and noise generation as associated with a marine exhaust system.
BACKGROUND OF THE INVENTION
Water cooled marine exhaust systems have been previously employed to generally good effect, but have nevertheless possessed certain operational deficiencies. Prior exhaust tips have included various flapper configurations that are typically positioned downstream of a point at which cooling water flow mixes with exhaust gasses. Under normal operation, such positioning of exhaust flappers works well, but issues may arise upon generation of excessive heat levels within the exhaust systems.
In particular, flappers in such systems are often provided with sealing elastomeric, i.e., rubber, material along the edges of the perimeter of the flapper. With continued presence of excessive heat, as for example, from prolonged absence or reduction of cooling fluid, such elastomeric seals may become damaged to the point that direct metal-to-metal contact between the flapper and internal surfaces of the exhaust tips may occur. Such metal-to-metal contact may easily result in significant damage to the flapper as well as the exhaust tip. Additionally, such metal-to-metal contact often results in excessive noise generation during certain operational phases of the marine engine.
Various patents are known concerning marine exhaust related subject matter, including for example Zelinski U.S. Pat. No. 7,104,359 entitled “Muffler having a baffle with angled plates;” Zelinski U.S. Pat. No. 7,013,565 entitled “Removable collector for liquid cooled exhaust;” Zelinski U.S. Pat. No. 6,609,590 entitled “Exhaust system having angled baffle;” and Beson et al. U.S. Pat. No. 6,397,589 entitled “Exhaust pipes and assemblies.” The disclosures of all the patents cited herein are hereby incorporated by reference for all purposes.
In light of such deficiencies recognized herewith in the known exhaust tip flapper configurations, it would be desirable to provide a flapper configuration that avoids such heat damage, and provides possibilities for reduced noise generation.
While various configurations of marine exhaust flapper arrangements have been developed, no design has emerged that generally encompasses all of the desired characteristics as hereafter presented in accordance with the subject technology.
SUMMARY OF THE INVENTION
In view of the recognized features encountered in the prior art and addressed by the present subject matter, improved methodologies for providing both noise reduction and reduced flapper wear have been developed. It should be understood that the present subject matter equally encompasses both methodologies and corresponding apparatuses.
In an exemplary configuration, previously provided exhaust flappers haves been relocated to significantly reduce noise as well as wear potential.
In one exemplary form, the present subject matter provides an exhaust flapper located in an exhaust system generally upstream of previously designated locations.
In accordance with aspects of certain embodiments of the present subject matter, an exhaust flapper is located proximate an end point of an exhaust tip.
In accordance with certain aspects of other embodiments of the present subject matter, methodologies have been developed to reduce noise by positioning a flapper such that a portion thereof will, with normal movement, contact a sound-deadening surface.
In accordance with aspects of still further embodiments of the present subject matter, a flapper may be positioned to contact an elastomeric component to reduce contact generated noise.
One present exemplary embodiment relates to a flapper configuration for a marine exhaust system of the type having an exhaust pipe which has an exhaust tip with a pivot-mounted metallic flapper received therein. Such a present exemplary configuration comprises an elastomeric main body portion supported on such exhaust tip, an elastomeric lid portion, and a live hinge. Preferably, such live hinge joins such lid portion with such body portion such that such lid portion covers such metallic flapper, and such that such metallic flapper contacts such elastomeric lid portion during pivoting of such metallic flapper. With such exemplary present configuration, wear is reduced on such metallic flapper and sound is deadened in association with such contact.
In one exemplary alternative such flapper arrangement, an elastomeric lip portion may be included, defined by a face of such elastomeric body portion facing such lid portion, for receiving such lid portion whenever such flapper configuration is closed. In another present alternative of such exemplary flapper arrangement, such main body portion and such lip portion may both be annular.
Still further, in another present exemplary alternative for some embodiments, such exhaust pipe and such exhaust tip may comprise metal, and such elastomeric portions may comprise rubber. Another present exemplary exhaust system may comprise an exhaust pipe; a mounting flange secured on such exhaust pipe relatively adjacent an end thereof; an exhaust tip formed between such mounting flange and such end of such exhaust pipe; a metallic flapper pivotally mounted in such exhaust tip, so as to pivot in response to exhaust gases received there against from such exhaust pipe; and an elastomeric flapper arrangement. Preferably, such elastomeric flapper arrangement covers such exhaust tip, and is in contact with such metallic flapper in predetermined pivoted positions of such metallic flapper, for reducing contact wear and contact sound therewith.
In one exemplary alternative embodiment, such elastomeric flapper arrangement may include an elastomeric main body portion supported on such exhaust tip, an elastomeric lid portion, and a live hinge joining such lid portion with such body portion such that such lid portion covers such metallic flapper.
In another present alternative of such exemplary exhaust system, such exhaust system may comprise a marine exhaust system; and such elastomeric flapper arrangement may comprise a unitary device having a generally cylindrical main body portion configured to fit over such exhaust tip, and a lid portion configured to close over such exhaust tip so as to cover a portion of such main body portion during periods of very low or no exhaust gas flow through such marine exhaust system.
In yet further present alternatives, an exemplary such exhaust pipe may comprise an annular metallic pipe for a marine exhaust system; and such main body portion of such elastomeric flapper arrangement may be annular and form an annular lip portion for resting receipt of such lid portion thereon. Still further, such mounting flange may form openings therein for mounting of such exhaust pipe; and such exhaust tip may include a mounting pin received therein, for pivoting receipt of such metallic flapper. In some present alternatives, such elastomeric flapper arrangement may comprise rubber.
It should be understood by those of ordinary skill in the art that the present subject matter equally pertains to both apparatus and corresponding and/or related methodology. One present exemplary methodology involves reducing noise and wear on an exhaust system of the type having an exhaust pipe which has an exhaust tip with a pivot-mounted metallic flapper received therein, for pivoting in response to exhaust gases passing out such exhaust tip. Such methodology preferably comprises providing an elastomeric main body portion supported on such exhaust tip; providing an elastomeric lid portion; and joining such lid portion and such body portion with a live hinge, such that such elastomeric lid portion covers such metallic flapper for contact therewith during pivoting of such metallic flapper. Per such present exemplary methodology, contact between such metallic flapper and such elastomeric lid portion reduces wear on such metallic flapper and deadens sound associated with such contact.
In present variations of such methodology, in some instances such elastomeric portions may comprise rubber. In further present alternatives, such exhaust pipe may comprise an annular metallic pipe of a marine exhaust system; and such elastomeric main body portion may be annular and form an annular lip portion for resting receipt of such lid portion thereon.
Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the detailed description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referred and discussed features, elements, and steps hereof may be practiced in various embodiments and uses of the present subject matter without departing from the spirit and scope of the present subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like.
Still further, it is to be understood that different embodiments, as well as different presently preferred embodiments, of the present subject matter may include various combinations or configurations of presently disclosed features, steps, or elements, or their equivalents (including combinations of features, parts, or steps or configurations thereof not expressly shown in the figures or stated in the detailed description of such figures). Additional embodiments of the present subject matter, not necessarily expressed in the summarized section, may include and incorporate various combinations of aspects of features, components, or steps referenced in the summarized objects above, and/or other features, components, or steps as otherwise discussed in this application. Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the remainder of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
FIG. 1 illustrates an exemplary exhaust and flapper configuration in accordance with present technology with the exemplary flapper thereof in what is presently referenced as an open position;
FIG. 2 illustrates a left oblique view of an exemplary exhaust and flapper configuration in accordance with present technology with the exemplary flapper thereof in what is presently referenced as a closed position;
FIG. 3 illustrates a right oblique view of an exemplary exhaust and flapper configuration in accordance with present technology with the exemplary flapper thereof in what is presently referenced as a closed position; and
FIG. 4 illustrates an exploded partial view of an exemplary assembly in accordance with present technology.
Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features, elements, or steps of the present subject matter. It should be appreciated that the various illustrations are not intended as being drawn to the same scale but are variously sized to better comprehend selected aspects of components illustrated.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As discussed in the Summary of the Invention section, the present subject matter is particularly concerned with improved flapper configurations for use with marine exhaust systems.
Selected combinations of aspects of the disclosed technology correspond to a plurality of different embodiments of the present subject matter. It should be noted that each of the exemplary embodiments presented and discussed herein should not insinuate limitations of the present subject matter. Features or steps illustrated or described as part of one embodiment may be used in combination with aspects of another embodiment to yield yet further embodiments. Additionally, certain features may be interchanged with similar devices or features not expressly mentioned which perform the same or similar function.
Detailed reference is made herein to exemplary presently preferred embodiments of the subject marine exhaust flapper configurations. First with reference to present FIG. 1 , an exemplary exhaust and flapper configuration in accordance with present technology is described with the exemplary flapper thereof in a defined open position.
As shown in FIG. 1 , an exemplary flapper configuration generally 100 is illustrated. An exhaust tip (not visible in FIG. 1 ) is covered with an elastomeric flapper arrangement 110 having mounted therein a metallic flapper 120 by way of pivot device 122 mounted within the exhaust tip. Elastomeric flapper arrangement 110 generally corresponds to a unitary device having a generally cylindrical main body portion 114 configured to fit over the exhaust tip, and having a lid portion 112 configured to close over the exhaust tip so as to cover a portion of the main body portion 114 during periods of very low or no exhaust gas flow. Elastomeric flapper 112 is coupled to the main body portion 114 of elastomeric flapper arrangement 110 by way of a live hinge 116 .
Generally, per present subject matter, the elastomeric material from which flapper arrangement 110 is constructed provides some exhaust sealing properties by way of lid portion 112 as well as some noise reduction capabilities. More particularly with respect to noise reduction capabilities, it should be appreciated that main body portion 114 of flapper arrangement 110 preferably includes a lip portion 118 having a dimension “w” (illustrated between unmarked opposing arrows in FIG. 1 ) which is configured to provide a stop or contact portion for metallic flapper 120 . As illustrated per the present exemplary embodiment, such lip portion 118 preferably is generally annular in shape, although other shapes may be practiced in accordance with the present subject matter.
With more particular reference to present FIGS. 2 and 3 , the operational aspects of the present subject matter may be further appreciated with reference to present exemplary flapper assemblies generally 200 , 300 . As may be seen in FIGS. 2 and 3 , respective exemplary metallic flappers 220 , 320 have been repositioned from previously known positions to a position downstream of the exhaust system associated with a marine engine (not separately illustrated herewith, and details of which are either well known to those of ordinary skill in the art, or form no particular part of the present disclosure).
More specifically, exemplary flappers 220 , 320 may be positioned within an end portion of exemplary exhaust pipe portions 202 , 302 that are respectively covered by cylindrical main body portions 214 , 314 . Exemplary flappers 220 , 320 may be mounted therein by way of respective pivot devices 222 , 322 such that respective tip portions 224 , 324 of flappers 220 , 320 contact respective lip portions 218 , 318 of flapper arrangements 214 , 314 .
By mounting flappers 220 , 320 in the respective exhaust tips in such a manner, metallic flappers 220 , 320 may contact an external surface portion of respective elastomeric flapper arrangements 210 , 310 , thereby avoiding potential direct contact respectively between flappers 220 , 320 and any metallic portions of the associated exhaust tips.
It should further be appreciated by those of ordinary skill in the art based on the disclosure herewith that even under circumstances such that the subject elastomeric portions should deteriorate due to extreme heat levels within the exhaust system, noise levels will remain relatively low per present subject matter due to avoidance of metal-to-metal contact, as may otherwise occur in various known previous configurations.
With reference to present FIG. 4 , there is illustrated an exploded partial view of a presently exemplary assembly generally 400 in accordance with present technology. As may be seen in FIG. 4 , elastomeric flapper assembly 410 includes a main body portion 414 and a lid portion 412 . Lid portion 412 is coupled to main body portion 414 by way of a live hinge 416 . Also illustrated is a portion of an exemplary exhaust pipe 402 with which the present subject matter may be practiced, and including an exemplary mounting flange 404 secured to one end thereof. Mounting flange 404 may be secured to exhaust pipe 402 in any suitable manner including, but not limited to, welding.
With further reference to FIG. 4 , it will be seen that flange 404 includes a representative number of mounting holes 408 positioned in the periphery thereof for securing the exhaust pipe to a suitable portion of a boat or ship's exterior. The precise number, location, and type of such attachment features may be varied in order to best accommodate the needs of particular embodiments and implementations of the present subject matter.
It may be further observed that flange 404 is positioned back from the end of exhaust pipe 402 so as to provide or form an exhaust tip generally 430 on which exemplary elastomeric flapper assembly 410 may be mounted. It will be appreciated that while for clarity no metallic flapper has been illustrated in Figure, a mounting pin 422 as would be associated with such a flapper is illustrated in phantom. Accordingly, such exemplary mounting pin 422 partially illustrates pivot devices 122 , 222 , 322 previously illustrated in FIGS. 1-3 , respectively.
Those of ordinary skill in the art will appreciate that exhaust gas flow from the marine engine, not separately illustrated, provides a force that will open both the elastomeric flappers 110 , 210 , 310 , 410 and the metallic flappers 120 , 220 , 320 , 420 . Absent such exhaust gas flow, both flappers will close.
It should be noted with respect to FIG. 3 that representative elastomeric flapper 310 is shown in an open position only as a means to illustrate more clearly the position of metallic flapper 320 and, in particular, the position of the tip portion 324 of metallic flapper 320 in contact with lip 318 of elastomeric flapper assembly 314 . Such a positioning of elastomeric flapper 310 would not normally occur during practice as it too would be closed when metallic flapper 320 is closed, as should be understood by those of ordinary skill in the art per the totality of the disclosure herewith.
While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is intended by way of example rather than by way of limitation. Accordingly, the subject disclosure does not preclude inclusion of such modifications, variations, and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.
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Disclosed are apparatus and methodology for reducing noise and wear in a flapper configured exhaust tip for a marine exhaust system. A metallic flapper is located at an end portion of an exhaust tip of the exhaust pipe. An elastomeric flapper assembly is provided covering the exhaust tip and includes a lip portion configured to provide noise reduction by functioning as a stop for a tip portion of the metallic flapper. The metallic flapper is positioned such that a tip thereof contacts the elastomeric flapper assembly rather than the metallic exhaust pipe. Such contact with an elastomeric flapper assembly reduces noise previously produced by flapper contact with the hot exhaust pipe.
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PRIOR APPLICATION
This is a continuation of U.S. patent application Ser. No. 11/441,558, filed May 26, 2006, now abandoned.
FIELD OF THE INVENTION
The present invention relates to devices used for normalizing the flow of fluid in tubular organs of human bodies that have been injured by a disease or an accident. More specifically, the invention relates to probes and stents used in treating canalicular and nasolacrimal duct stenosis, obstruction, lacerations or other trauma.
BACKGROUND
The orbital portion of the lacrimal gland is located in the superotemporal orbit and the palpebral portion of the lacrimal gland is located on the posterior surface of the superotemporal upper lid. The lacrimal gland produces the aqueous portion of the tear film. Ductules from the orbital portion of the lacrimal gland pass through the adjacent palpebral lacrimal gland to empty in the superior conjunctival cul-de-sac. Smaller accessory lacrimal glands in the upper and lower lids also contribute to tear production. The tears bathe the surface of the eye and then drain into the puncta and canaliculi in the medial upper and lower lids. The superior and inferior canaliculi join as the short common canaliculus. The tears flow from the superior and inferior canaliculi through the common canaliculus, into the lacrimal sac, and down the nasal lacrimal duct into the nose.
The canaliculi can become obstructed or stenotic on a congenital basis or from trauma such as lacerations, from inflammation, from certain types of chemotherapy, such as taxotere or five-fluorouracil—which may also affect the nasolacrimal duct—or the obstruction can be idiopathic. When the upper and lower canaliculi or the common canaliculus become obstructed, tears can no longer drain from the surface of the eye through the lacrimal system into the nose. The tears well up in the eye as a result, and run down the face. The excess tears blur the vision and the patient has to constantly dab the eye.
The nasolacrimal duct can also become obstructed and, as a result, damaged as a result of a congenital obstruction or an acquired obstruction. Tears stagnating in the lacrimal sac and bacteria multiplying therein lead to an infection of the lacrimal sac in many patients suffering from nasolacrimal duct obstruction. The result is a painful enlargement of the lacrimal sac swollen with pus, and a discharge over the eye.
Canalicular obstruction or stenosis is usually treated by forming a new passage through the obstruction with a probe, also by dilatation with probes or with a balloon catheter. At times, a dacryocystorhinostomy (DCR) is performed. A DCR consists of the surgical creation of a new passageway from the lacrimal sac into the nasal cavity. This can be performed with a balloon catheter using an endoscope or externally through an incision. A silicon tube is most often placed in the lacrimal system whether or not a DCR is performed.
In the case of trauma to the lacrimal drainage system, an intubation is performed to prevent scars from permanently clogging the canaliculi or nasolacrimal duct. In cases of canalicular or nasolacrimal duct obstruction from chemotherapy, intubation is performed as quickly as possible to prevent complete, irreversible closure.
Congenital nasolacrimal duct obstruction is treated with probing or through balloon catheter dilatation. However, intubation is also needed in some resistant cases.
Accordingly, intubation of the lacrimal system preferably with a silicon tube, is often performed after lacrimal surgery or as a primary treatment for nasolacrimal duct obstruction, canalicular stenosis, or canalicular laceration. The easiest device to insert is the Mini-monoka tube that consists of a silicon tube attached to a punctal plug. The tube is inserted through one canaliculus into the lacrimal sac. The plug on the proximal end of the tube is positioned at the punctum. The tube will thus stay in place without having to enter the nasolacrimal duct or the nose. Indeed, the Mini-monoka tube cannot generally be placed in the nasolacrimal duct or nose. If, however, intubation of the nasolacrimal duct is needed, then one of the two ends of the silicon tube is threaded through the canaliculus and down the nasolacrimal duct into the nose. The distal end of the tube, or of any probe attached to it, must be grasped in the nose and pulled into position. It can be very difficult to locate and grasp the tube in the nose of some patients. In some cases, it is impossible to find the tube. That is because the nasolacrimal duct empties into the nasal cavity in the inferior meatus beneath the inferior turbinate. U.S. Pat. No. 6,383,192 discloses a way to push an intubation device by means of a rod. However this method still require pulling the device out of the lacrimal duct from inside the nasal cavity. The nasolacrimal duct is very hard or impossible to visualize even with the help of a flexible endoscope. It is also very difficult to locate the duct simply by tactile sensation with an instrument. U.S. Pat. No. 6,878,165 Makino teaches another verification method involving the insertion of a miniature light at the tip of a probe or stent. The illumination of the nasal cavity offers visual proof that penetration is complete, unless, as is usually the case, the light is blocked by an edema or an accumulation of blood.
Obstruction of the nasolacrimal duct occurs in 2 percent to 6 percent of newborns. Congenital nasolacrimal duct obstruction usually resolves with the use of antibiotic drops and massage of the lacrimal sac. However, a significant number of patients require surgical treatment for congenital nasolacrimal duct obstruction. A probing is usually performed in these children. If silicone intubation needs to be performed, then the location and course of the nasolacrimal duct may need to be confirmed by probing before performing intubation of the lacrimal system.
Probing is performed by inserting a probe horizontally through the punctum and canaliculus into the lacrimal sac. The probe is then oriented vertically and pushed down the nasolacrimal duct into the nasal cavity. The surgeon must then confirm that the probe has penetrated all obstructions in the nasolacrimal duct and reached the nasal cavity. This is commonly done by placing a metal instrument into the nose and touching the probe. The surgeon feels for metal on metal contact indicating that the probe has entered the nasal cavity.
The probe is then removed from the lacrimal system. A syringe filled with fluorescein stained water with an attached short cannula is placed in the canaliculus and the fluid is irrigated through the lacrimal system into the nose. The fluid is recovered in the nose with a suction catheter. This confirms that the lacrimal system is patent after the probing. If the fluid does not irrigate into the nose, then the probing is repeated.
Probing presents several problems. The probe enters the nasal cavity through the opening of the nasolacrimal duct in the lateral nasal wall beneath the inferior turbinate. This area is difficult to access, making it often impossible for the surgeon to touch the probe in the nose with another instrument. In this event, the surgeon cannot confirm if the probe has entered the nasal cavity. Another problem is that irrigation of the lacrimal system is required to determine if the nasolacrimal duct obstructions have been opened. If irrigation through the lacrimal system down to the nasal cavity is not verified, the probing must be repeated. As a result, multiple procedures are performed that can cause repeated trauma to the lacrimal drainage system with each placement of a probe or cannula.
Bleeding in the lacrimal system or nose often occurs during the probing, intubation or associated procedures. The applicant is not aware of any expedient and practical device for clearing blood from the lacrimal system. Furthermore, the only known method for removing blood from the nasal cavity is by introducing into the nose a suction catheter through the naris. It is often difficult if not impossible to position the catheter in the inferior meatus in order to remove blood around the nose end entry into the nasolacrimal duct.
The probes of the prior art are solid metal rods made of steel, bronze, silver or other metal. A flattened area in the center of the probe facilitates its manipulation.
The instant invention results from attempts to achieve intubation without having to retrieve the end of the tube inside the nose, to perform probing and irrigation in a single step, to expediously clear blood and other fluids from the nasal cavity and the nasolacrimal duct.
SUMMARY
The instant embodiments provide a simple and practical method for verifying that a nasolacrimal system probe or intubation sleeve has been inserted through all obstructions down to the nasal cavity. In some embodiments the new probe comprises a tube shaped and dimensioned to penetrate a patient's canaliculus and nasolacrimal duct. In some embodiments the tube has an axial lumen through which a tracing fluid can be injected. In some embodiments recovery of the fluid in the nasal cavity indicates that the probe has passed through any obstructions in any part of the system.
Some embodiments offer a novel method of intubation of the nasolacrimal system using a sleeve that fits over the aforesaid probe and can be threaded all the way down the nasal cavity through a patient's punctum, canaliculus, lacrimal sac and nasolacrimal duct. The tip of the sleeve can be inflated to stabilize its position before the probe is withdrawn. The probe can be used to irrigate the nasolacrimal system with a tracing fluid which once recovered through a suction apparatus in the nasal cavity provides a positive indication that the sleeve is in place.
A version of the probe can be adapted to suction blood, and other fluids from the nasolacrimal duct and tracing fluids from the nasal cavity.
In some embodiments there is provided a device for the treatment of a patient's canaliculus and nasolacrimal duct stenosis which comprises: a tube shaped and dimensioned to penetrate said canaliculus and duct; said tube being made of a substantially hard material, and having a proximal end, a blunted distal end, an axial lumen, a total length between approximately 4 and 50 centimeters and an outer diameter between 0.125 and 4.00 millimeters; a connector at said proximal end; said lumen having at least one orifice at said distal end.
In some embodiments said orifice comprises at least one radial outlet about 0.5 to 30 millimeters from said distal end, and said outlet has a diameter between about 0.025 and 2.5 millimeters. In some embodiments said material substantially is taken from a group consisting essentially of stainless steel, bronze, silver, aluminum, titanium, brass, and alloy thereof, Kevlar, Nitinol, polymide, Dacron, nylon, EPTFE and PVC; and said tube further comprises a slanted radial flange proximate to said connector. In some embodiments the device further comprises a flexible catheter having a distal end shaped and dimensioned to interlock with said connector, and a proximal end shaped and dimensioned to interlock with a syringe. In some embodiments said connector is shaped and dimensioned to interlock with a syringe. In some embodiments the device further comprises a stiffening rod diametrically sized to engage said lumen, and having a length at least equal said total length. In some embodiments said rod has an enlarged manipulable end section. In some embodiments the device further comprises a flexible sleeve having a proximal end, a distal end, an axial interior channel closed at said distal end and being dimensioned to allow said channel to be engaged by said tube, and a length shorter than said total length of said tube. In some embodiments said flexible sleeve has a radial hole proximate said distal end. In some embodiments said tube comprises a radial flange proximate to said connector, and wherein said sleeve comprises a first radial flange around said proximal end; said first radial flange being oriented at the same axial angle as the radial flange of said tube. In some embodiments said sleeve comprises a second radial flange distally proximate to said first radial flange. In some embodiments said sleeve further comprises a first sealing implement across said channel, proximate said proximal end. In some embodiments said sleeve further comprises an inflatable segment between said radial hole and said distal end. In some embodiments said sleeve further comprises a second sealing implement across said channel at a short proximal distance from said segment. In some embodiments said inflatable segment comprises said sleeve having a reduced wall thickness along said segment.
Some embodiments provide a method for probing the integrity of a patient's canaliculus and nasolacrimal duct which comprises the steps of: inserting the device of some embodiments through the patient's punctum and canaliculus down the lacrimal sac; tilting the device about 90 degrees into alignment with the nasolacrimal duct; pushing the device through the nasolacrimal duct down to the nasal cavity; injecting a tracing fluid through said connector; and recovering part of said fluid from the nasal cavity; whereby recovery of a trace of said fluid confirms that the device has penetrated all obstructions and entered the nasal cavity.
Some embodiments provide a method for intubating a patient's nasolacrimal duct which comprises the steps of: inserting the metallic tube and the sleeve of some embodiments through a patient's punctum, canaliculus into the lacrimal sac; tilting the sleeve and tube about 90 degrees into alignment with the patient's nasolacrimal duct; pushing the tube and sleeve through the nasolacrimal duct down to the nasal cavity; injecting a tracing fluid into the tube; verifying that the tube and sleeve have reached the nasal cavity by recovering traces of said fluid in said cavity; and withdrawing said tube from said sleeve.
Some embodiments provide a method for intubating a patient's nasolacrimal duct which comprises the steps of: inserting the tube and the sleeve of some embodiments through a patient's punctum, canaliculus into the lacrimal sac; tilting the sleeve and tube about 90 degrees into alignment with the nasolacrimal duct; pushing the tube and sleeve through the nasolacrimal duct down to the nasal cavity; injecting a volume of fluid through said connector sufficient to inflate said inflatable segment; partially withdrawing said tube from said sleeve by a distance sufficient to bring said outlet between said proximal end of the sleeve and said sealing implement at a short proximal distance from the inflatable segment; injecting a tracing fluid into the tube; verifying that the tube and sleeve have reached the nasal cavity by recovering traces of said fluid in said cavity; and withdrawing said tube from said sleeve.
Some embodiments provide a method which further comprises inserting a stiffening rod diametrically sized to engage said lumen and having a length greater than said total length into said tube, prior to insertion of said tube into said sleeve. Some embodiments provide a method which further comprises inserting a stiffening rod diametrically sized to engage said lumen and having a length substantially greater than said total length into said tube prior to insertion of said tube into said sleeve. Some embodiments provide a method which further comprises connecting said tube to a suction device during said step of pushing. Some embodiments provide a method which further comprises connecting said tube to a suction device during said step of pushing. In some embodiments said step of recovering comprises connecting a suction device to said tube. In some embodiments said step of recovering comprises connecting a suction device to the proximal end of said tube. In some embodiments said step of pushing further comprises pushing said second flange inside said punctum and resting said first flange against the external rim of said punctum.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view of a nasolacrimal probe according to the invention;
FIG. 2 is a cross-sectional view of an intubation sleeve;
FIG. 3 is a partial cross-sectional view of a combination of the aforesaid probe and sleeve;
FIG. 4 is a partial cross-sectional view of an alternate embodiment of the sleeve in the inflated position;
FIG. 5 is a cross-sectional view of the alternate embodiment of the sleeve in the irrigating position;
FIG. 6 is a perspective view of the proximal end of the probe and sleeve combination;
FIG. 7 illustrates the first positioning of the probe;
FIG. 8 illustrates the final position of the probe;
FIG. 9 illustrate intubation with sleeve having an inflatable end segment; and
FIG. 10 illustrates suction through the probe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawing, there is shown in FIG. 1 a cross-sectional view of nasolacrimal probe 1 specifically designed to probe obstructions in a patient's drainage system and nasolacrimal duct. The device comprises a tube 2 having a blunted distal end 3 , an open proximal end 4 equipped with a luer-lock 5 or other type of connector, and axial lumen 6 . An outwardly projecting radial flange 7 near the luer-lock is slanted at an angle from about 20 to 90 degrees, and can typically be 45 degrees to the axis of the probe. The probe can also be made without the flange. The device 1 is shaped and dimensioned for insertion through a patient's punctum and canaliculus, then through the lacrimal sac and into the nasolacrimal duct down to the nasal cavity down to the point where the flange 7 rests against the entry punctum. The device has a slight degree of flexibility resulting from the choice of material and its dimensions. The tube 2 and connector 5 are preferably made of a metal such as stainless steel, titanium, silver, aluminum, bronze, brass or any alloy of these metals, or of synthetic materials such as Kevlar, Nitinol, polymide, Dacron, nylon, EPTFE or PVC. The total insertable length A is preferably 10 centimeters, but may fall between approximately 5 and 50 centimeters. The outer diameter B of the tube, is preferably 0.64 millimeters, but may range from approximately 0.10 to 3.75 millimeters.
One or a pair of diametrically opposite radial orifices or outlets 8 are located 0.5 to 30 millimeters approximately from the distal end 3 . The diameter of each outlet is preferably 0.025 millimeters, but can reach 2.5 millimeters in large models. The distal end is blunted by a rounded or conical tip 9 . Alternately, a single axial orifice with a rounded lip to prevent abrasion may be provided at the distal end of the tube with a diameter of, preferably, 0.25 millimeters, but could fall anywhere between 0.025 and 2.5 millimeters. Although the tube is made of a rigid or semi-rigid material its length and the relative thinness of its wall may render it quite flexible and easily bendable. To avoid damaging the tube and generally increase its rigidity, a stiffening rod 10 diametrically sized to engage the lumen 6 of the tube is provided. The rod has a length slightly in excess of the total length A of the tube, and is made of the same type of material. A manipulable flattened or otherwise enlarged section 10 a at the proximal end of the rod facilitates its handling.
Probing of the nasolacrimal duct with the device 1 begins with inserting the tube through a patient's punctum 11 and canaliculus 12 down to the lacrimal sac 13 , as shown in FIG. 7 . A barrier is felt when the probe encounters the medial lacrimal sac wall and lacrimal fossa. At that point, the probe is then retracted about 0.5 millimeters and is tilted about 90 degrees into alignment with the nasolacrimal duct 14 as illustrated in FIG. 8 . The probe is pushed down the nasolacrimal duct through any obstruction 15 and into the nasal cavity 16 . A flexible conduit 17 is connected at one end to the connector 5 and at the other end to a syringe 18 loaded with fluorescein or methylene blue stained fluid 19 or any other colored liquid or gas tracer. Alternately the syringe may be applied directly to the connector 5 . The fluid is injected to irrigate through the probe into the nose. The fluid flows out of the outlets 8 into the nasal cavity. Traces of the fluid can be recovered in the nose with a suction catheter 20 . A lack of fluid recovery in the nose indicate that the probe has not penetrated all obstructions and reached the nose. The surgeon can then push with greater force or pull the probe back slightly and drive it into the nasal cavity at a slightly different angle. Detection of the tracer fluid into the nose is a positive indication that all obstructions have been cleared, and no divergent passage through tissues surrounding the nasolacrimal duct has been opened by the probe.
It should be noted that the surgeon does not have to perform the difficult and sometime impossible task of touching the tip of the probe in the nose with another metal instrument to confirm that the probe has duly entered the nasal cavity. Furthermore, the irrigation does not have to be performed as a second procedure after a solid probe of the prior art has been withdrawn from the lacrimal system. No second probing needs to be done if the irrigation is not successful.
The stiffening rod 10 must be withdrawn before the flexible tube or syringe is connected to the probe. Preferably, the rod is used when the probe encounters an obstacle and cannot readily and safely be pushed through it.
Referring now to FIG. 2 , there is shown an intubation sleeve 21 shaped and dimensioned to be used in connection with the above-described probe 2 . The outer diameter of the sleeve is preferably 1.125 millimeters, but could fall between 0.25 and 4.0 millimeters. The sleeve is flexible and preferably made of silicone, polypropylene or other medically approved synthetic material. The distal end of the sleeve 22 is preferably closed by a conical tip 23 or a rounded one substantially similar to the tip 9 of the probe. The proximal end 24 of the sleeve is open and is surrounded by a first outwardly projecting radial flange 25 that is oriented at an angle between 20 to 90 degrees and preferably approximately 45 degrees with the axis of the sleeve like the flange 7 of the probe. The internal channel 26 of the sleeve is dimensioned to be loosely engaged by the probe 1 as shown in FIG. 3 so that a fluid injected into the probe can readily exit the radial holes 8 or the axial orifice at the distal end of the probe and flow freely into the sleeve. The insertable length D of the sleeve is about 3 millimeters shorter than the insertable length A of the probe.
A hole 27 , or alternatively two diametrically opposite radial holes 27 , 28 , bored through the sleeve at approximately the same distance from the tip 23 as the distance between the outlets 8 of the probe are from its tip 3 , let tracing or irrigating fluid injected into the probe escape from the sleeve into the nasal cavity. An O-ring, self-sealing diaphragm 29 , or other type of sealing implement located between 0 and 100 millimeters and preferably about 3 millimeters from the proximal end 24 of the sleeve can be penetrated by the probe and maintain a hermetic barrier that will prevent any fluid in the channel 26 from leaking through the proximal end 24 of the sleeve. A second radial flange 30 distally proximate to the first flange 25 is designed to lie just inside the punctum to keep the first flange resting against the edge of the punctum. The second flange can have an oval shape, and have a maximum exterior diameter between 0.3 and 6 millimeters, preferably 2.5 millimeters, and is preferably orthogonal to the axis of the sleeve.
Intubation of the nasolacrimal duct is performed by first inserting the probe 1 , and optionally its stiffening rod 10 , into the sleeve 21 until the tip of the probe touches the closed distal end of the sleeve as shown in FIG. 3 . The combined probe and sleeve are then threaded through a patient's punctum, canaliculus, lacrimal sac, nasolacrimal duct all the way down to the nose in the same manner as described above and illustrated in FIGS. 7 and 8 in connection with the probe, until the second flange 30 is set into the patient's punctum and the first flange 25 rests against the external rim of the punctum.
The surgeon may encounter resistance when pushing the second radial flange 30 of the sleeve through the punctum into the proximal canaliculus if the punctum is somewhat small in diameter. The distal end of the probe will exert pressure upon the very distal end of the sleeve if the surgeon applies a large amount of force on the probe while attempting to push the second radial flange 30 through the punctum. However, puncture of the distal end of the sleeve is prevented by the slanted flange 7 of the probe coming into contact with the slanted flange 25 of the sleeve. This stops further penetration of the probe into the sleeve, while allowing the surgeon to apply pressure on the probe and sleeve assembly in order to push the second flange 30 of the sleeve through the punctum.
If the internal diameter of the sleeve closely matches the external diameter of the probe, irrigation may be facilitated by aligning the outlets with the holes, as shown in FIG. 6 . A mark 31 along the external wall of the probe that is aligned with one of the outlets 7 , 8 is brought to match an indicium 32 on the flange 25 of the sleeve 21 that is aligned with one of the holes 27 , 28 .
After the presence of the sleeve and probe in the nasal cavity has been verified by the collection of some of tracing liquid in the nasal cavity, the probe is withdrawn leaving the sleeve in place.
In an alternate version 33 of the sleeve illustrated in FIGS. 4 and 5 , an inflatable segment 34 is formed near the distal end of the sleeve. The inflatable segment is preferable implemented using a resiliently expandable material, or by a reduction in the thickness of the sleeve wall slightly distally from the radial holes 27 and 28 in order to create a resiliently expandable balloon under internal pressure. Alternatively a segment made of easily expanded material can be attached to the distal end of a non-expandable sleeve. The entire sleeve can also be made of easily expanded sheet material. A first O-ring, self-sealing diaphragm 35 or other self-sealing implements may optionally be positioned between the proximal end of the sleeve and the radial holes, preferably at a short distance from the proximal end of the sleeve. A second self-sealing implement 36 is positioned between the radial holes 27 , 28 and the inflatable segment 34 . A fluid can be injected through a probe 37 having an axial orifice 38 or, alternately, at least one radial orifice at its distant end, after the probe has been used to push the sleeve into position through the patient's punctum, canaliculus, lacrimal sac and nasolacrimal duct into the nasal cavity with the open tip of the probe resting in or just past the inflatable segment. The injection of the fluid causes the inflatable segment to bellow out and positively lock the sleeve in position as illustrated in FIG. 9 . The probe is then withdrawn to a distance sufficient to place the orifice 38 between the first 35 and the second 36 self sealing implements as shown in FIG. 5 . Additional injection of tinted fluid will cause the fluid to escape into the nasal cavity through the axial orifice 38 into the sleeve. The second self sealing implement 36 prevents fluid from leaking out of the inflated area 34 , thus maintaining the inflation. The first self sealing implement 35 prevents leakage of the fluid out of the proximal end of the sleeve, causing the fluid to exit through the radial holes 27 , 28 . Once the correct positioning of the sleeve has been verified through the collection of tracing fluid in the nasal cavity, the probe can be withdrawn while the sleeve distal segment remains inflated keeping the sleeve safely in place. In both cases, the sleeve can be later removed by grasping the flange 25 and pulling the sleeve out of the lacrimal system. Prior to removal, the end segment 34 can be deflated by pushing the probe through the second self sealing implement 36 , and letting the fluid escape into the nasal cavity or suctioning it through the probe as explained below. Otherwise, the fluid will be allowed to slowly leak out of the sleeve on its own, whereupon the sleeve can be removed days, weeks or even months later.
Each of the probes 1 , 37 can be used for suctioning blood from the lacrimal system or nasal cavity caused by the probing or intubating process, as well as for suctioning the tracer fluid from the nasal cavity as illustrated in FIG. 10 .
At the end of the probing or intubation procedure or after having been pushed through the lacrimal system as described above, the probe with or without either of the sleeves 21 , 33 is connected to a suction device 39 by way of a catheter 40 . Suction is then performed to either retrieve the tracer fluid out of the nasal cavity or to remove blood caused by abrasion during the procedure. The suction device may also be connected and activated during the insertion process of the probe or probe-and-sleeve combination through the nasolacrimal system in order to suction any obstructive tissue or blood. After installation of the probe or probe-and-sleeve combination, a tracer fluid may be injected with a syringe or eye dropper 41 through the nares 42 . The fluid is then retrieved through the probe connected to the suction device to confirm proper placement of the sleeve or that the probe has reached the nasal cavity.
It can thus be seen that the tubular probe of the invention is a very versatile instrument that can be used not only for probing the nasolacrimal ducts, but also to perform intubation, irrigation and even suction of obstructive material.
While the preferred embodiments of the invention have been described, modifications can be made and other embodiments may be devised without departing from the spirit of the invention and the scope of the appended claims.
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A device and method for performing probing and intubation of the nasolacrimal system includes a tubular probe through which a tracer fluid is injected and collected in the nasal cavity to verify that the tip of the probe has passed through an obstruction and reached the nasal cavity. A sleeve fitted over the probe has distal segment that is inflated in order to retain the sleeve in the nasolacrimal system once the tubular probe has been withdrawn. Removal of blood and other obstructions encountered during the probing or intubation process is accomplished by connecting the proximal end of the probe to a suction device.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The instant application is a continuation-in-part of U.S. patent application Ser. No. 10/406,575, filed Apr. 3, 2003, which claims priority to U.S. Provisional Patent Application Ser. No. 60/369,829, filed Apr. 3, 2002, the entire specifications of both of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
The present invention generally relates to the control of the output of a variable flow pump, and more specifically to control systems for an oil pump for oil pressure control in an internal combustion engine, transmission, and/or the like.
BACKGROUND OF THE INVENTION
It is desirable to properly lubricate the moving components in an internal combustion engine and provide hydraulic power. Typically, oil pumps used in engines are operably associated with the crankshaft of the engine (e.g., direct driven, chain driven, gear driven and/or the like) and have relatively simple fixed pressure regulation systems. While these systems are generally adequate, there are some disadvantages. For example, there is not much control of the actual discharge pressure relative to the pressure needed by the engine under certain/given operating conditions. By way of a non-limiting example, currently available pump technology typically provides high oil pressure at all engine operating conditions, where a lower oil pressure may be adequate at some of those engine conditions.
In commonly-assigned U.S. Pat. No. 6,896,489, the entire specification of which is expressly incorporated herein by reference, a mechanical hydraulic arrangement is shown for providing control of a variable displacement vane pump. This provides for a more optimized control of engine oil pressure. However, it is yet desirable to provide some further control depending on engine needs and/or variables.
Accordingly, there exists a need for a method of control and system for control of a variable flow pump (e.g., vane pump) by the use of an engine control unit which actuates a solenoid for directly and/or indirectly controlling the flow rate of a variable flow pump.
SUMMARY OF THE INVENTION
In accordance with the general teachings of the present invention, a control system for a variable flow hydraulic pump is provided, wherein electrical input from an engine control unit actuates a solenoid for controlling the engine oil pressure to the desired level under a wide range of operating conditions.
In accordance with a first embodiment, a pump system including a control system for controlling a variable flow pump for controlling oil flow and oil pressure in a hydraulic circuit in an engine is provided, comprising: (1) a pump member; (2) an actuating member capable of controlling the flow generated by the pump member; and (3) a solenoid valve system including a solenoid valve portion and a pressure regulator valve portion, wherein the solenoid valve system is operably associated with the pump, wherein the pressure regulator valve portion is operably associated with the actuating member for selectively controlling the flow generated by the pump member.
In accordance with a second embodiment, a pump system including a control system for controlling a variable flow pump for controlling oil flow and oil pressure in a hydraulic circuit in an engine is provided, comprising: (1) a pump member; (2) an actuating member capable of controlling the flow generated by the pump member; (3) a solenoid valve system including a solenoid valve portion and a pressure regulator valve portion, wherein the solenoid valve system is operably associated with the pump member, wherein the pressure regulator valve portion is operably associated with the actuating member for selectively controlling the flow generated by the pump member; and (4) an electronic control unit operably associated with the solenoid valve portion, wherein the electronic control unit is selectively operable to provide an input control signal to the solenoid valve portion for controlling oil flow and oil pressure.
In accordance with a third embodiment, a pump system including a control system for controlling a variable flow pump for controlling oil flow and oil pressure in a hydraulic circuit in an engine is provided, comprising: (1) a pump member; (2) an actuating member capable of controlling the flow generated by the pump member, wherein the pump member is a vane pump and the actuator member is at least part of an eccentric ring of the vane pump, wherein the vane pump and the eccentric ring operate to control the flow of oil to the engine; (3) a solenoid valve system including a solenoid valve portion and a pressure regulator valve portion, wherein the solenoid valve system is operably associated with the pump member, wherein the pressure regulator valve portion is operably associated with the actuating member for selectively controlling the flow generated by the pump member; and (4) an electronic control unit operably associated with the solenoid valve portion, wherein the electronic control unit is selectively operable to provide an input control signal to the solenoid valve portion for controlling oil flow and oil pressure.
In accordance with one aspect of the present invention, an electronic control unit is operably associated with the solenoid valve portion, wherein the electronic control unit is selectively operable to provide an input control signal to the solenoid valve portion for controlling oil flow and oil pressure.
In accordance with one aspect of the present invention, the electronic control unit is operably associated with and monitors the pressure in a portion of the hydraulic circuit, wherein the electronic control unit generates an input signal to the solenoid valve portion in response to pressure conditions in the portion of the hydraulic circuit for controlling flow generated by the pump member.
In accordance with one aspect of the present invention, the electronic control unit monitors engine conditions selected from the group consisting of engine speed, engine temperature, engine load, and combinations thereof, and selectively adjusts oil pressure based thereon.
In accordance with one aspect of the present invention, the pump member is a vane pump and the actuator member is at least part of an eccentric ring of the vane pump, wherein the vane pump and the eccentric ring operate to control the flow of oil to the engine.
In accordance with one aspect of the present invention, the solenoid valve system is disposed within a housing member.
In accordance with one aspect of the present invention, the solenoid valve system is operable to regulate a supply pressure down to a control pressure.
In accordance with one aspect of the present invention, the solenoid valve system is selectively operable to regulate a supply pressure down to a control pressure in response to the current supplied to the solenoid valve portion.
In accordance with one aspect of the present invention, a first biasable member is operably associated with the actuating member, wherein the first biasable member is selectively operable to cause the actuating member to control the flow generated by the pump member.
In accordance with one aspect of the present invention, the pressure regulator valve portion comprises a flow control spool valve, wherein the flow control spool valve is operably associated with the solenoid valve portion, wherein the flow control spool valve is selectively operable to control flow to the actuating member.
In accordance with one aspect of the present invention, a second biasable member is operably associated with a first end of the flow control spool valve, wherein the second biasable member maintains pressure on the flow control spool valve during regular operation, and provides return pressure on the flow control spool valve in the presence of low supply pressure conditions.
In accordance with one aspect of the present invention, the oil pressure can be controlled at a plurality of locations in the hydraulic circuit by applying the oil pressure to the actuating member.
In accordance with one aspect of the present invention, the plurality of locations is selected from the group consisting of a point within the pump, a point of the pump discharge to the engine, a point within the engine main oil gallery, and combinations thereof.
In accordance with one aspect of the present invention, the oil pressure can be supplied to the solenoid valve system from a plurality of locations in the hydraulic circuit.
In accordance with one aspect of the present invention, the plurality of locations is selected from the group consisting of a point within the pump, a point of the pump discharge to the engine, a point within the engine main oil gallery, and combinations thereof.
In accordance with one aspect of the present invention, the solenoid valve portion can be selectively actuated by a technique selected from the group consisting of electrical actuation, hydraulic pressure actuation, and combinations thereof.
In accordance with one aspect of the present invention, the solenoid valve system comprises a variable force solenoid.
A further understanding of the present invention will be had in view of the description of the drawings and detailed description of the invention, when viewed in conjunction with the subjoined claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 illustrates a hydraulic schematic of a variable displacement pump system, in accordance with the general teachings of the present invention;
FIG. 2 illustrates a sectional view of a pump element, in accordance with a first embodiment of the present invention; and
FIG. 3 illustrates a graph showing the performance characteristics of a solenoid valve module, in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description of the invention is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
Referring to drawings generally, and specifically to FIGS. 1 and 2 , a system and method is provided for controlling an oil pump 40 with either a variable displacement pump element or a variable output pump element. It should be appreciated that other types of pump systems can be used in the present invention, such as but not limited to other types of vane pumps, gear pumps, piston pumps, and/or the like.
In the engine system of the present invention, there is at least a lubrication circuit 10 , an oil sump 20 , an engine control unit (i.e., ECU) or computer 30 , and an oil pump 40 which draws oil from the oil sump 20 and delivers it at an elevated pressure to the lubrication circuit 10 .
In accordance with one aspect of the present invention, the lubrication circuit 10 includes at least an oil filter 11 and journal bearings 12 supporting the engine's crankshaft, connecting rods and camshafts, and can contain a variable pressure transducer 13 and/or an oil cooler 14 . The lubrication circuit 10 can also optionally contain items such as piston cooling jets, chain oilers, variable cam timing phasers, and cylinder de-activation systems, as are generally known in the art.
In accordance with one aspect of the present invention, the ECU 30 includes electrical inputs for the measured engine speed 31 , engine temperature 32 , and engine load, torque or throttle 33 . The ECU 30 can also have an electrical input for the measured oil pressure 34 from the transducer 13 . The ECU 30 also has an output 35 for an electrical control signal to the oil pump 40 .
In accordance with one aspect of the present invention, the oil pump 40 includes a housing 41 which contains a suction passage 42 , and a discharge passage and manifold 43 . The oil pump 40 can also include a pressure relief valve 44 and/or an internal oil filter 45 for cleaning the discharge oil for use inside the oil pump 40 .
In accordance with one aspect of the present invention, the oil pump 40 contains a variable flow pump element 50 , which is further comprised of a positionable element, such as an eccentric ring 51 , the position of which determines the theoretical flow rate discharged by the pump element 50 at a given drive speed, and which forms in conjunction with the housing 41 two control chambers on opposing sides of the eccentric ring 51 , which contain fluid of controlled pressure for the intended purpose of exerting a control force on an area of the eccentric ring 51 . The first chamber, e.g., the decrease chamber 52 , contains pressure applied to the eccentric ring 51 to decrease the flow rate of the variable flow pump element 50 , and the second chamber, e.g., the increase chamber 53 , contains pressure applied to the eccentric ring 51 to increase the flow rate of the variable flow pump element 50 . There is additionally a spring 54 positioned between the housing 41 and the eccentric ring 51 which applies a force to the eccentric ring 51 to increase the flow rate of the variable flow pump element 50 . The decrease chamber 52 can be supplied with oil pressure from either the oil pump discharge manifold 43 via channel 56 or some other point downstream in the lubrication circuit 10 (e.g., usually from the main oil gallery 15 ) via channel 55 .
In accordance with one aspect of the present invention, the oil pump 40 also contains a solenoid valve module 60 which includes a solenoid valve stage 70 and a pressure regulator valve stage 80 .
In accordance with one aspect of the present invention, the solenoid valve stage 70 includes a solenoid 71 , a spring 72 , and a housing 73 . The solenoid 71 includes a coil of electrical wire 74 and a ferrous armature 75 , configured so that an electric current passing through the coil 74 generates an electromagnetic field which moves the armature against the compression spring 72 and opens the valve hole 76 in the housing 73 , thereby allowing fluid to flow through it.
In accordance with one aspect of the present invention, the pressure regulator valve stage 80 includes a spool 81 , a spring 82 , and an area defining a bore 83 (i.e., in housing 73 ) for radial containment of the spool 81 . The spool 81 has in its outer diameter two annular grooves, a spool supply port 84 which is in continuous fluid communication with the housing supply port 86 , and a spool control port 85 which is in continuous fluid communication with the housing control port 87 . Housing supply port 86 can be supplied with oil pressure from either the oil pump discharge manifold 43 via filter 45 and channel 62 or some other point downstream in the lubrication circuit 10 (e.g., usually from the main oil gallery 15 ) via channel 61 . The spool supply port 84 is also in continuous fluid communication with fluid chamber 89 via the restrictive orifice hole 88 . The spool control port 85 is also in continuous fluid communication with fluid chamber 90 via hole 91 . The spool 81 is positioned axially in bore 83 by the resultant force of the control pressure in fluid chamber 90 , the spring 82 , and the supply pressure in fluid chamber 89 .
A change in the axial position of spool 81 will increase or reduce the area open for fluid communication between spool control port 85 and both housing supply port 86 and housing drain port 92 , which has the resultant effect of regulating the control pressure (e.g., see reference 61 in FIG. 3 ) in spool control port 85 and passage 87 to some level lower than the pressure in supply passage 86 (e.g., see reference 62 in FIG. 3 ). The lower pressure level is determined by the spring rate and assembled length of spring 82 and the area at each end of spool 81 . The lower pressure level is supplied to the increase chamber 53 through passage 87 where it acts on the eccentric ring 51 along with the spring 54 to increase the flow rate of the variable flow pump element 50 . The lower pressure level serves as a reference force for the eccentric ring 51 , along with spring 54 , so that if the pressure in the decrease chamber 52 exceeds them, the pressure in the decrease chamber 52 will move the eccentric ring 51 to reduce the pump flow, which will reduce the pressure in the decrease chamber 52 until it is in force equilibrium with the pressure in increase chamber 53 and the spring 54 .
Conversely, if the pressure in the decrease chamber 52 is lower than the reference pressure, the pressure in the increase chamber 53 and the spring 54 will move the eccentric ring to increase the pump flow. The pressure regulator valve stage 80 is shown in accordance with one aspect of the present invention to have a total of three fluid communication ports, i.e., the supply port 84 , the control port 86 and the drain port 92 .
FIG. 3 graphically illustrates the solenoid valve control pressure 61 (e.g., in port 85 and passage 87 ) on the vertical axis as a function of both the supply pressure 62 (e.g., in port 84 and passage 86 ) on the horizontal axis and the current to the solenoid valve 70 through the ECU electrical output line/wire 35 .
In accordance with one aspect of the present invention, the curves have three characteristic zones, e.g., the zero control pressure zone 63 , the offset control pressure zone 64 , and the variable control pressure zone 65 . The zero control pressure zone 63 is identical for all currents to the solenoid valve 70 . The transition from the offset control pressure zone 64 to the variable control pressure zone 65 occurs at decreasing supply pressure as the current to the solenoid valve 70 is increased. The pressure regulating stage 80 has a characteristic offset 66 between the supply pressure 62 and the control pressure 61 . Without being bound to a particular theory of the operation of the present invention, it is believed that this offset 66 is the reason that there is a zero control pressure zone 63 because the supply pressure 62 has not yet reached the level of the offset 66 , and the control pressure 61 cannot be negative (e.g., a vacuum).
At low supply pressure 62 , the spring 82 holds the spool 81 to the right in dominance over the supply pressure 62 acting on the end of spool 81 from fluid chamber 89 via restrictive passage 88 , thereby closing the area of fluid communication between the supply port 84 and the control port 86 and opening the area of fluid communication between the control port 86 and the drain port 92 . As the supply pressure 62 increases, it will move the spool 81 to the left against the spring 82 and will eventually close the area of fluid communication between the control port 86 and the drain port 92 , at which point the pressure can begin to build in the control port 86 via leakage between the spool 81 and the housing bore 83 from the supply port 84 to the control port 86 . As the supply pressure 62 continues to increase, it will further move the spool 81 to the point where the area of fluid communication between the supply port 84 and the control port 86 is opened, allowing the control pressure 61 to rise to the level of the supply pressure 62 . At that point, the spring force 82 together with the control pressure force in fluid chamber 90 , e.g., communicated via passage 91 , will overcome the supply pressure force in fluid chamber 89 and move the spool 81 to the right. The spool 81 will reach an equilibrium position where the control pressure force is reduced from the supply pressure force by the amount of the force applied to the spool 81 by the spring 82 , which thereby determines the characteristic offset 66 in the offset control pressure zone 64 .
As the supply pressure 62 continues to increase, the pressure in fluid chamber 89 will follow, and it can eventually overcome the spring 72 holding the solenoid armature 75 against the housing 73 , thereby opening valve hole 76 and attenuating further increase of the supply pressure 62 . When the valve hole 86 is open, and there is a restricted fluid flow through the restrictive passage 88 , the pressure in fluid chamber 89 is no longer equal to, but is reduced from, the supply pressure 62 at the supply port 84 . When the ECU 30 selectively routes current through the solenoid coil 74 via electrical output 35 , the solenoid armature 75 is also forced to the right against the spring 72 by the resulting electromagnetic field, which will also serve to reduce the pressure in fluid chamber 89 and thereby the control pressure 61 . The spring 72 provides a proportional characteristic to the solenoid valve system, such that increasing current provides increasing valve opening, e.g., a variable force solenoid. The control pressure 61 will maintain its characteristic offset 66 to the pressure in fluid chamber 89 , which is reduced from the supply pressure 62 because of the restricted flow through passage 88 .
In accordance with one aspect of the present invention, the oil pump 40 can be operated without the ECU 30 , because the solenoid valve module 60 performs some pressure regulation activity even without electrical power, as shown in the third operating zone 65 in FIG. 3 .
In accordance with one aspect of the present invention, the oil pump 40 can be operated by the ECU 30 in an open loop control mode because the ECU 30 can be reasonably certain of the oil pressure in the lubrication circuit 10 as a function of current to the solenoid 71 through electrical output 35 from an internal “look up” table in the ECU 30 , even without measuring the oil pressure through transducer 13 .
In accordance with one aspect of the present invention, the oil pump 40 can be operated by the ECU 30 in a closed loop mode to actively control the oil pressure by adjusting its electrical signal to the solenoid 71 through electrical output 35 according to software logic control programmed into the ECU 30 and the oil pressure measured in the lubrication circuit 10 by transducer 13 . The ECU 30 can also anticipate increasing oil demand in the lubrication circuit 10 . This can be accomplished by simultaneously actuating the pump and an oil-consuming engine subsystem, such as variable cam timing or cylinder deactivation. The ECU 30 , through the present invention, would also have the capability of selectively activating certain pressure-sensitive engine subsystems, by selecting a higher or lower oil pressure for the lubrication circuit 10 depending on any known condition, including but not limited to the measured engine speed 31 , engine temperature 32 , and/or engine load 33 .
In accordance with one aspect of the present invention, the oil pump 40 can be operated in a mixed control mode by combining elements of the previous three control modes. By way of a non-limiting example, it could be useful to allow the oil pump 40 to regulate itself without ECU control at conditions outside the range of normal parameters, and then to use open loop control to quickly achieve oil pressure near the desired value, and then use closed loop control to exactly achieve the desired oil pressure.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the scope of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A pump system including a control system for controlling a variable flow pump for controlling oil flow and oil pressure in a hydraulic circuit in an engine. The system includes a pump member, an actuating member capable of controlling the flow generated by the pump member, and a solenoid valve system including a solenoid valve portion and a pressure regulator valve portion. The solenoid valve system is operably associated with the pump and the pressure regulator valve portion is operably associated with the actuating member for selectively controlling the flow generated by the pump member. An electronic control unit is operably associated with the solenoid valve portion, wherein the electronic control unit is selectively operable to provide an input control signal to the solenoid valve portion for controlling oil flow and oil pressure.
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[0001] This application is a continuation of U.S. patent application Ser. No. 12/966,598, filed on Dec. 13, 2010, which is a continuation of U.S. patent application Ser. No. 11/600,471, filed on Nov. 15, 2006, and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/737,464 filed on Nov. 16, 2005, the entire content of each being incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to a system and method for providing content over a network. More particularly, the present invention relates to a system and method capable of providing content, such as broadband streaming multimedia and Internet Protocol (IP) data, to network devices, including mobile devices, with interactive functionality.
BACKGROUND
[0003] Many systems currently exist for providing various types of content to mobile devices. For example, most, if not all, mobile telephone service provider systems also provide text messaging, Internet access, and email services, to name a few. Various types of personal data assistants (PDAs) are also capable of accessing the Internet and providing types of voice, video and data services.
[0004] In spite of these existing systems, a continued need exists for improved systems and methods for providing broadband content, such as streaming multimedia, voice, data, and so on, to mobile and fixed devices in an effective and efficient manner, while also allowing for interactive functionality.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a conceptual block diagram of an example of a network for delivering content according to an embodiment of the present invention;
[0006] FIG. 2 is a conceptual block diagram of an example of a client employed in the network shown in FIG. 1 ;
[0007] FIG. 3 is a conceptual block diagram illustrating further features of the client shown in FIG. 2 ;
[0008] FIG. 4 is a conceptual block diagram illustrating one exemplary configuration of hardware employing the client shown in FIG. 2 ;
[0009] FIG. 5 is a conceptual block diagram illustrating another exemplary configuration of hardware employing the client shown in FIG. 2 ;
[0010] FIG. 6 is a conceptual block diagram illustrating a further exemplary configuration of hardware employing the client shown in FIG. 2 ;
[0011] FIG. 7 is a conceptual block diagram illustrating further features of the content handler employed in the client shown in FIG. 2 ;
[0012] FIG. 8 is a conceptual block diagram illustrating further features of the download handler employed in the client shown in FIG. 2 ;
[0013] FIG. 9 is a conceptual block diagram illustrating further features of the request handler employed in the client shown in FIG. 2 ;
[0014] FIG. 10 is a conceptual block diagram illustrating further features of the monitor and management system employed in the client shown in FIG. 2 ;
[0015] FIG. 11 is a conceptual block diagram illustrating an example of connectivity between the components of a client and the core as employed in the network as shown in FIG. 1 ;
[0016] FIG. 12 is a conceptual block diagram illustrating further features of the core employed in the network shown in FIG. 1 ;
[0017] FIG. 13 is a conceptual block diagram illustrating further features of the core shown in FIG. 12 ;
[0018] FIG. 14 is a conceptual block diagram illustrating an example of connectivity between the components of the core and other components of the network as shown in FIG. 1 ;
[0019] FIG. 15 is a conceptual block diagram illustrating further features of the content system employed in the core shown in FIG. 12 ;
[0020] FIG. 16 is a conceptual block diagram illustrating further features of the delivery system employed in the core shown in FIG. 12 ;
[0021] FIG. 17 is a conceptual block diagram illustrating further features of the request system employed in the core shown in FIG. 12 ;
[0022] FIG. 18 is a conceptual block diagram illustrating further features of the monitor and management system employed in the core shown in FIG. 12 ;
[0023] FIG. 19 is a conceptual block diagram illustrating an example of connectivity between the components of the core and other components of the network as shown in FIG. 1 ;
[0024] FIG. 20 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ;
[0025] FIG. 21 is a diagram illustrating an example of further details of a field of the message shown in FIG. 20 ;
[0026] FIG. 22 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ;
[0027] FIG. 23 is a diagram illustrating an example of further details of a field of the message shown in FIG. 22 ;
[0028] FIG. 24 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ;
[0029] FIG. 25 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ;
[0030] FIG. 26 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ;
[0031] FIG. 27 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 ; and
[0032] FIG. 28 is a diagram illustrating an exemplary configuration of a message used by the network shown in FIG. 1 .
DETAILED DESCRIPTION
[0033] An embodiment of the present invention is illustrated in FIG. 1 . As shown, the network 100 , which can be referred to as the “MC2E platform”, comprises a core 102 that communicates with a content network 104 . As discussed in more detail below, the content network 104 retrieves and provides various types of data and content, such as world wide web (www) page content 106 , real time streaming protocol (RTSP) content 108 and file transfer protocol (FTP) content 109 , to the core 102 . In this example, the core 102 operates as the platform service provider, or at least as a component of the platform service provider, and is able to fully utilize the available bandwidth of the broadcast channel and to give access to the content being provided.
[0034] The core 102 can further communicate over the Internet 110 , a broadcast network 112 , and an external network 114 , the details of which are discussed below. For example, the external network 114 can include or communicate with one or more authentication, authorization and accounting server 116 and other devices or servers 118 as can be appreciated by one skilled in the art. As further illustrated in FIG. 1 , the core 102 can thus communicate over the Internet 110 and broadcast network 112 via a telecommunications medium 120 and broadcast medium 122 , respectively, with one or more clients 124 . A client 124 includes, for example, the software components that run in terminal and receiver units that can be included in any type of wireless or wired mobile or stationary communication device, such as a PDA, cellular telephone, laptop computer, and so on, as can be appreciated by one skilled in the art.
[0035] FIGS. 2-11 illustrate examples of components of a client 124 according to an embodiment of the present invention. As shown in FIG. 2 , a client 124 is able to efficiently handle download of content from the broadcast channel and to provide users of the terminals and receiver units with access to that content. A client 124 can be configured as two separate system modules, namely, a terminal client 126 and a receiver module 128 . This exemplary division corresponds to the possible separation of software components. That is, as can be appreciated by one skilled in the art, the receiver module might 128 possibly run in a different operating system process than the terminal client 126 . Also, in this example, the terminal client 126 communicates via Transmission Control Protocol/Internet Protocol (TCP/IP), User Datagram Protocol/Internet Protocol (UDP/IP) and a Graphical User Interface (GUI), while the receiver module 128 communicates via UDP/IP. Naturally, other suitable protocols can be used.
[0036] As shown in FIG. 3 , the terminal client 126 comprises a monitor and management system 130 and a request handler 132 , and the receiver module 128 comprises a content handler 134 and download handler 136 . According to this embodiment, the monitoring and management system 130 fetches key variables provided by the other sub-systems (e.g., the request handler 132 , content handler 134 and download handler 136 ), and sets various properties of the client 124 , such as which ports and network protocols should be supported. In this example, access to the monitoring and management system occurs via a GUI, however, any suitable access protocol can be used. The request handler 132 responds to requests for access to the sources provided by the network 100 , after consulting the core 102 .
[0037] The content handler 134 according to this embodiment parses, decrypts and stores content that is downloaded from the broadcast channel. The content handler 134 hides the details of the under-lying storage mechanism from other parts of the client 124 . Content is served directly from the content handler 134 , so that no data need be stored by the request handler 132 . The download handler 136 in this example is responsible for downloading content from the broadcast channel, and interfaces with the receiver equipment 138 through IP. Hence, the download handler 136 can be independent of the particular bearer network. In this example the receiver equipment 138 (also referred to as radio frequency (RF) equipment) typically comprises an antenna, a radio receiver, and a base band unit and bearer system dependent processing software. The receiver equipment 138 is assumed to interface with the client 124 through IP, but can use any appropriate protocol as would be appreciated by one skilled in the art.
[0038] As discussed briefly above, a client 124 comprises, or is embodied in, at least one receiver unit 140 and at least one terminal unit 142 . The receiver unit in this example is the physical unit (e.g., hardware) that is used to receive data from the broadcast channel, while the terminal unit 142 is the physical unit (e.g., hardware) that runs user applications 144 and a management program 146 that monitors the information (e.g. provides an event viewer) and specifies configuration parameters. The receiver unit 140 in this example includes the receiver equipment 138 .
[0039] The external management program 146 provides a user of the device (e.g., a cellular telephone, PDA, laptop or the like) with an interface to control and monitor the client 124 . The external program will typically have a graphical user interface (GUI). Alarms that are generated are displayed in a clear and non-ambiguous way. Controls for the various subsystems of the client 124 as discussed below can also be provided by the management program 146 . In addition, the management program 146 can provide control of the receiver equipment 138 (e.g., which channel on which to listen) through a vendor-specific extension. The interface can be a graphical visualization of the platform on which alarms are visible, and the status of subsystems is obvious as well as various measurement variables (e.g., through put and load operations).
[0040] FIGS. 4-6 illustrate three different exemplary configurations of a client 124 . As shown in FIG. 4 , the receiver unit 140 and terminal unit 142 are configured as the same unit. The receiver equipment 138 is installed in the same hardware that runs the software of the client 124 . In the example of FIG. 5 , the receiver unit 140 and terminal unit 142 are two separate hardware modules. The receiver unit 140 in this example communicates directly to the receiver equipment 138 , and both the terminal client 126 and receiver module 128 are running in the terminal unit 142 . In the example of FIG. 6 , the receiver unit 140 includes the receiver equipment 138 and the receiver module 128 . The terminal unit 142 is physically detached from the receiver unit 140 . Interaction between the subsystems of the client 124 takes place over a communication link (e.g., Bluetooth, USB, and so on).
[0041] In each of the three examples shown in FIGS. 4-6 , the terminal client 126 does not store content since all requested files are streamed directly to the user. The receiver module 128 running in the receiver unit 140 is assumed to have access to its own storage memory, which means that little or no memory in the terminal unit 142 will be used by the client 124 . However, when the receiver module 128 runs in the terminal unit 142 (e.g., FIG. 5 ), a portion of the terminal unit's memory is allocated for the storage of download content. In either case, memory management is under the control of the receiver module 128 , so there is no difference in the architecture for the two examples.
[0042] Further details of the content handler 134 , download handler 136 , request handler 132 , and monitor and management system 130 will now be described.
[0043] As shown in FIG. 7 , the content handler 134 includes a decryption module 148 , content parser 150 , cache 152 and content access controller 154 . The content handler 134 accepts requests for content from the request handler 132 . If the content exists in the cache 152 and it still is valid, the content will be served directly. Otherwise, the request handler 132 supplies the content handler 134 with information to locate the content on the broadcast channel (e.g., an IP address or DSM-CC identifier of the content) in addition to the necessary key for decryption. Channel information is passed onto the download handler 136 , which in turn opens a stream of corresponding packets that are fed to the content handler 134 .
[0044] As can be further appreciated by one skilled in the art, the content handler 134 can communicate using a DSM-CC over IP transport protocol, which can be an adaptation of the DSM-CC framework. The DSM-CC over IP transport protocol is derived from the DSM-CC specifications for the DVB-T implementations. The substantive change in the protocol is the substitution of the MPEG-2 network layer with IP.
[0045] The protocol includes three main parts, a data module which is encapsulated in blocks named DownloadDataBlocks (DDB). An index into what modules are about to be transmitted is given by the DownloadInfoIndication (DII) message 300 as shown in FIG. 20 .
[0046] At the beginning of the DII message 300 is a dsmccMessageHeader 302 . This header gives a mechanism to differentiate between the DII and DDB messages. The DII message 300 also includes a DownloadInfoIndicationHeader 304 . The DownloadInfoIndication (DII) message 300 contains a list of all modules about to be broadcast.
[0047] As shown in FIG. 21 , DownloadInfoIndicationHeader 304 includes a download ID for the DII that is the same download ID as on the DDBs containing these modules. A size is given for the data of the DDBs, and all modules within a DII have the same block size. A timeout is given for the scenario, this is interpreted to mean all modules contained in this DII. After this timeout the download ID is invalid for this DII. Each module is given an ID, version and size. Extra space is provided for higher level protocols to attach relevant information to each module. Extra space is also provided for higher level protocols to attach information to the DII. Several of the other fields are not used and are given default values.
[0048] DownloadDataBlock (DDB) 306 , as shown in FIG. 22 , encapsulates a fragment of a data module. The directory and attached information for the DDBs is given via a DII. The header starts with a dsmccDownloadDataHeader 308 that contains a download ID and a method for differentiating between DDBs and DIIs. The download ID matches the download ID of a DII describing this module. This DDB 306 also includes a DownloadDataBlockHeader 310 as shown in more detail in FIG. 23 , and is received within the scenario timeout of the DII describing it to be valid.
[0049] The dsmccMessageHeader 312 and dsmccDownloadDataHeader 314 shown in FIGS. 24 and 25 , respectively. These headers describe what kind of message follows through the message ID field. A length of the following information is also given in the message Length field. The difference between the dsmccMessageHeader 312 and the dsmccDownloadDataHeader 314 is that the transaction ID in the former becomes a downloadID in the latter.
[0050] The primary use of this transport protocol is as a carousel, which implies that the same data is transmitted several times with little or no modification. If a module is updated the module version field is advanced for that particular module. This allows receivers who may have gotten apart of a previous cycle to flush their buffers to start again, and also stops modules being received again if no modification has been made (power savings).
[0051] A set of modules (one or more) is being prepared for transmission a DII is typically generated first. This will include a download ID unique to this transaction ID for at least the timeout of the scenario. For each module there is generated a module ID unique within the download ID. Also for each module a version is given, size and any attached data from a higher level protocol is appended. A block size is determined for all modules and given in this header. Attached data from a higher level protocol is appended to the DII, and the DII is sent first.
[0052] As the DII has been sent, all DDB for that DII follow (not necessarily in the correct order nor alone). Each DDB has the same downloadID as specified in the DII, all DDBs are numbered within a module and carry a moduleID. All DDBs are received within the scenario timeout to be valid.
[0053] In addition, a simple file transfer is an extremely low overhead way of moving files over DSM CC. The files are transmitted in DDB, without any error checking (e.g., UDP checksums should guarantee error detection). The file is fragmented into the data field of DDBs, with the correct block size. A DII is generated for all files to be transferred, moduleIDs verified against the DDBs. The DII contains the file size and in the module Info field the full, absolute pathname is given. In this example, the field is limited to 256 characters, but can be any suitable number.
[0054] Turning back to FIG. 7 , the DSM-CC header of each packet is decrypted by the decryption module 148 , and the packet is then passed on to the content parser 150 . The content parser 150 extracts content from the DSM-CC encoded packets and thus gives meaning to the packet payload in the context of DSM-CC. That is, packets are arranged in the correct order and each module is flushed to the cache 152 when completed. Once a complete download has taken place, the content handler 134 responds with the content originally requested to the request handler 132 . The content access controller 154 manages the download process discussed above, and provides the request handler 132 with a “virtual” carousel interface as discussed in more detail below. The cache 152 stores data from the broadcast carousel. If the storage space is limited, the cache 152 prioritizes the available space according to request statistics and, possibly, user-specified rules. In addition, as can be appreciated by one skilled in the art, the content handler 134 can communicate with the download handler 136 via function calls, and can communicate with the request handler 132 either via function calls or over a specific type of communication link (e.g. Bluetooth, IP, USB).
[0055] As shown in FIG. 8 , the download handler 136 serves the content handler 134 with a stream of requested data packets. The content handler 134 specifies the IP address/MPLS label for which the download handler 136 should listen to receive. The download handler 138 can interface with the receiver equipment 138 via IP (e.g., UDP), which makes it independent of the particular bearer system and receiver hardware/software being used. The download handler 136 can be embodied in a single component, and also can access information from the content handler 134 via function calls or in any other suitable manner.
[0056] FIG. 9 illustrates an example of the components of the request handler 132 , which provides user applications with a network interface to the services of the core 102 . As indicated, the request handler includes a request listener 156 and a request mediator 158 . The request listener 156 listens for and parses incoming requests, communicates with the core 102 via the request mediator 158 and forwards request information to the content handler 134 . The request mediator 158 in this example communications with the core 102 in accordance with the UCP protocol.
[0057] For each client request, the request handler 132 determines whether the requested content is contained within the content handler 134 or if the request should be forwarded to the core 102 . In the latter case, the core 102 responds with information that is used to identify the content on the broadcast channel. The request handler 132 passes this information on to the content handler 134 . Once the content handler 134 contains the content, either from a previous download or a download that was triggered by the current request, the request handler 132 opens a data stream from the content handler 134 and writes the data out to the client 124 . The request handler 132 can communicate with the core 102 via IP or any other suitable protocol, and can communicate with the content handler 134 via either process calls (e.g., to the internal receiver module 128 ) or over a specific type of communication link (e.g., Bluetooth, IP, USB and so on).
[0058] As shown in FIG. 10 , the monitor and management system 130 includes a local properties module 160 and a control and management module 162 . The monitor and management system 130 configures and fetches information from other subsystems. This functionality is exposed through an interface to an external management program 146 . The local properties module 160 provides access to persistent properties, and the monitor and control management module 162 logs selected system variables and the control of other subsystems. The monitor and management system 130 in this example can communicate with the content handler 134 either through function calls or over a specific type of communication link (e.g., Bluetooth, IP, USB and so on), and can communicate with the download handler 136 either through function calls or over a specific type of communication link. Also, the monitor and management system 130 can communicate with the request handler 132 via, for example, function calls.
[0059] FIG. 11 illustrates further details of the subsystems of the client 124 as discussed above, as well as an example of communications between client subsystems, and between the client 124 and the core 102 . The interfaces are designated as RH-Core which is between the request handler (RH) 132 and the core 102 , RH-CH which is between the request handler (RH) 132 and the content handler (CH) 134 , MMS-CH which is between the monitor and management system (MMS) 130 and the content handler (CH) 134 , MMS-DH which is between the monitor and management system (MMS) 130 and the download handler (DH) 136 , and MMS-RH which is between the monitor and management system (MMS) 130 and the request handler (RH) 132 . It should be noted that all of the interfaces described above are possibly between remote entities.
[0060] The RH-Core interface can include a UCP (Uplink Communication Protocol), and enables a client 102 to request content from the core 102 . An example of UCP will now be described.
[0061] The UCP can be used in communication between the client 124 and the core request system 166 (see FIG. 12 ). As can be appreciated by one skilled in the art, UCP is a session protocol that provides a structure for “conversation” between two parties. UCP follows a binary packet-based client/server request-response model, which is quite compact and requires a small amount of code to implement.
[0062] UCP is the basic structure of conversation between the client 124 and the core request system 166 . UCP includes a format for the conversation between devices and a set of opcodes that define specific actions. UCP follows a client/server request-response paradigm for the conversation format. The terms client and server refer to the originator (client) and receiver (core) of the UCP connection. In UCP, all sessions are initiated by the client.
[0063] Each UCP request includes an epode, a request length, and one or more headers. A header entirely fits within a packet and is not be split over multiple packets. FIG. 26 illustrates an example of the UCP request format 320 . The op-code 322 is one byte and the packet length 324 is represented by two bytes (maximum packet length is therefore 64K-1 bytes), with the most significant byte first. The packet length equals the number of bytes that should be read after the first three bytes, that is the data section 326 .
[0064] The op-code specifies the operation that the client wants to perform. Table 1 lists an example of the op-codes that are defined in UCP and specifies which headers are mandatory for each code. Also listed in the Table 1 are optional headers for each op-code, within brackets, that have special meaning within the context of the corresponding op-code. It is assumed, although not necessary, that the headers are in the order which is presented in the table, when a request is made.
[0000]
TABLE 1
Op-
code
Value
Headers in order
Description
GET
0x01
NAME
Request for a specific resource. A
[USER_NAME]
GET request is followed by a
[PASSWORD]
NAME header that specifies the
name of the requested resource. If
the system expects the user to
authenticate before each request, the
user name and password is included
next. Other headers may appear in
any order thereafter.
[0065] A UCP response includes a response code, a number that denotes the packet length and, optionally, one or more headers. FIG. 27 illustrates an example of the format of a response 330 . The response code 332 is one byte and packet length is represented with a two byte number 334 , in the same manner as for requests. The response 330 further includes a data section 336 .
[0066] The response code 332 indicates the status of the request previously issued by the client. Table 2 below lists an example of the response codes defined for UCP using the same setup as used for Table 1.
[0000]
TABLE 2
Op-code
Value
Headers in order
Description
SUCCESS
0x20
TRANSACTION_ID
This request was handled
ENCRYPTION_KEY
without problems. A SUCCESS
IP_ADDRESS
code is followed by a
[LENGTH]
TRANSACTION_ID header,
[NAME]
which stores the identifier for the
broadcast stream containing the
requested resource. Next there
should be an
ENCRYPTION_KEY header,
containing the key used for
decryption, followed by an
IP_ADDRESS header, which
specifies the IP address that the
client should listen for. The
server can also include the size
of the resource, in bytes, by
sending a LENGTH header. The
server can also indicate to the
client that the name resource that
was requested should hereafter
be referred to with a new name.
This can happen, for example, if
the client requests a general
content category, such “/news”,
instead of a specific file within
that category. To rename the
resource in this manner, the
server attaches a NAME with the
new name included.
BAD_REQUEST
0X40
The request was not formatted
according to UCP.
UNAUTHORIZED
0x41
The client does not have
permission to perform the
operation it requested. This
usually happens when either the
client requested a resource it
does not have access to or if the
necessary credentials were
missing from the request.
NOT_FOUND
0x43
A named resource was not
located with the server.
[0067] As discussed above, the UCP header 340 , as shown in FIG. 28 , contains data that provide certain information when put into perspective with the operation in question. The same type of header can have different meaning when used with different operations. For example, a NAME header that follows a GET operation contains the name of a requested resource, while a NAME header that follows a SUCCESS response means that a named resource should be referred to with new name value.
[0068] HI, the header ID 342 , is an unsigned one-byte quantity that identifies what the header contains and how it is formatted. HV 344 includes one or more bytes in the format and meaning specified by HI. All headers are optional, depending on the nature of the transaction, one may use all of the headers, some, or none at all. IDs make headers parseable and order independent, and allow unrecognized headers to be skipped easily. Unrecognized headers should be skipped by the receiving device.
[0069] The low order 6 bits of the header identifier are used to indicate the meaning of the header, while the upper 2 bits are used to indicate the header encoding. This encoding provides a way to interpret unrecognized headers just well enough to discard them cleanly. The length prefixed header encodings send the length in network byte order, and the length includes the 3 bytes of the identifier and length.
[0070] An example of the 2 high order bits of HI are illustrated in Table 3 below.
[0000]
TABLE 3
Bits 8 and 7 of HI
Interpretation
00
Unicode (UTF-16) text (each character is two bytes),
length prefixed with 2 byte unsigned integer
01
Byte sequence, length prefixed with 2 byte unsigned
integer.
10
One byte quantity.
11
Four byte quantity, transmitted in network byte
order (high byte first).
[0071] As stated, Table 3 lists the headers that are defined for UCP. The table includes the coding of each header in both binary and octal form. The header identifiers are numbered in order, starting with zero. The high order bits which specify the encoding obscure this linear sequence of header numbering. In this example, all 8 bits of each header are needed for identification, that is, two headers that use different encoding could have the same value of the 6 least significant bits.
[0072] Table 4 below also lists examples of the header identifiers.
[0000]
TABLE 4
Identifier (HI)
Hex
Binary
Name
Description
0x01
00 000001
NAME
Name of the resource (often
a file name).
0x05
00 000101
USER_NAME
User name, used for
authentication
0x06
00 000110
PASSWORD
Password matching the user
name, used for authentication.
0xC1
11 000001
IP_ADDRESS
IP address to listen for.
0xC2
11 000010
LENGTH
The size of the resource in
bytes.
0xC3
11 000011
TRANSACTION_ID
Identifier of the
broadcast containing the
requested resource.
0x44
01 00100
ENCRYPTION_KEY
Key to encrypted content.
[0073] Further details of an example of communication between the core 102 and client 124 will now be described. The client 124 can issue a request for a particular content, including a fully-qualified path name of the requested content, that is, a URI within a specified context, and user credentials (e.g., login name and password). The core 102 can determine whether the request is valid by, for example, checking if the requested content exists and if the user has the credentials to access that content. If not, the core 102 responds with an appropriate error message. Otherwise, the core 102 responds with a valid content identifier and a key for decryption. A return value that indicates the status of the request (e.g., successful, rejected, etc.). If the request is successful, the core 102 also responds with a content identifier (e.g., IP address that the Client should listen to) and a key that should be used to decrypt the downloaded data.
[0074] The RH-CH interface can enable the request handler 132 to request content from the content handler 134 . That is, the request handler 132 issues a request for a fully-qualified path name for a particular content. The content handler 134 determines whether or not the content exists. A return value that indicates whether or not the requested content exists, and the content handler 134 returns an open data stream to the content if the request is successful. If the content handler 134 does not contain requested content, the request handler 132 should be able to start a new download. To do this, the request handler 132 issues a request for a download by specifying the name of the content requested from the download, a download identifier (e.g. IP address), and a key for decrypting incoming packages. The content handler 134 can then start a new download. In particular, a return value that indicates whether or not the download succeeded. Following a successful download, the content handler 134 returns a data stream to the requested content.
[0075] The MMS-CH interface enables a user to specify the size and location of the content cache. For example, the user can specify the cache parameters (e.g., through the user interface of the external management program 146 ). The content handler 134 sets up the cache according to the specified parameters. The monitor and management system 130 listens for information on the status of the content handler 134 . That information includes, for example, an amount of cache currently in use. The monitor and management system 130 requests information from the content handler 134 at regular intervals, and the content handler 130 gathers and outputs the requested information if available. The content handler 130 also alerts the monitor and management system 130 with an alarm if an exception occurs. Possible exceptions include an I/O exception indicating that a problem occurs when writing to the cache. If an exception occurs, the content handler 134 sends a corresponding message to the monitor and management system 134 , which notes the exception and sets appropriate status flags (e.g., notification to the external management program 146 ).
[0076] The MMS-DH interface enables the monitor and management system 130 to listen for information on the status of the download handler 136 . The information provided can include, for example, mean throughput rate of input stream. The monitor and management system 130 requests information from the download handler 136 at regular intervals. The download handler 136 gathers and outputs the requested information if available. The download handler 136 also alerts the monitor and management system 130 if an exception occurs, which can be a network exception where the download handler 136 is unable to bind to a specified network address. If an exception occurs, the download handler 136 sends a corresponding message to the monitor and management system 130 , which notes the exception and sets appropriate status flags (e.g., notification to the external management program 146 ).
[0077] Details of the core 102 will now be discussed with regard to FIGS. 12-19 . As discussed above, the core 102 operates to fully utilize the available bandwidth for the broadcast of content and to provide clients 124 with access to that content. As illustrated in FIG. 12 , the core 102 according to an embodiment of the present invention includes a broadcast pipeline 164 (fed, for example, via the carousel), a request system 166 (also referred to as an access system 166 in FIG. 13 ) and a monitor and management system 168 . The broadcast pipeline is then further divided into a content system 170 and delivery system 172 as shown in FIG. 13 .
[0078] In this example, the content system 170 fetches data from a content server 174 in the content network 104 (see FIG. 1 ) and prepares data which is offered to the users. Regular updates of the content are governed by configuration files. Data for transmission is generated according to a schedule. The content system 170 also handles encryption of data.
[0079] The delivery system 172 delivers data to the broadcast equipment 176 which can be included in the broadcast network 112 (see FIG. 1 ). The request (access) system 166 responds to requests for access to the system after consulting, for example, an external AAA system 116 (see FIGS. 1 and 14 ), and also communicates with a terminal 178 in FIG. 13 . Information for access to the systems is stored locally in this request system 166 to facilitate scalability.
[0080] Monitoring and management system 168 fetches key variables provided by the other sub-systems, exposing them to external management software (e.g., operational management software), and also provides an interface to control messages for external management software (e.g., operational management and the editorial system). The monitor and management system 168 can also communicate with a user 180 .
[0081] In this example, a core system external management interface can provide remote, external software with an interface to control and monitor the MC2E Platform. The external management software in this example has two sets of functionality which may be implemented in separate programs: namely, an editorial system and an operations management.
[0082] The editorial system generates schedules for the MC2E Platform and sends them to the platform. This software should help the content provider to maintain an optimal carousel with respect to download time, latency and content. The carousel (discussed below) can be a hierarchical collection of categories, which may be of different sizes and have different transmission intervals. The editorial system can also show to the user estimated size of each category, along with worst case and typical case latency and download time.
[0083] The operations management system can be used by the platform operator to maintain a working system. All alarms generated are displayed here in a clear and non-ambiguous way. Controls of the various subsystems can be exposed to the platform operator here, except for, for example, the schedule updates which are handled by the editorial system. The interface can be a graphical visualization of the platform on which alarms are visible, status of subsystems is obvious as well as various measurement variables (throughput and load operations).
[0084] The configuration of the core 102 discussed above separates the subsystems as much as possible and reduce intersystem traffic to make the system scalable. In this way, different subsystems may be separated as well as spread across different servers. FIG. 14 illustrates an example of subsystem interfaces. The subsystem interfaces are configured to maintain low traffic densities between subsystems, with high traffic links being in single subsystems, except in the broadcast pipeline, which by definition is a sequence of subsystems connected by heavy traffic links. The subsystem interfaces also provide for scaling, and each subsystem may be separated onto its own server, or distributed onto several servers (e.g., the request system 166 and delivery system 172 can be distributed onto several servers).
[0085] Further details of the content system 170 are shown in FIG. 15 . As indicated, the content system 170 includes a cache 182 that fetches and stores content data from the content network, a content preparation module 184 that prepares the content data for transmission in line with DSM-CC, an encryption module 186 that handles encryption of the DSM-CC headers, and a carousel module 188 that handles mixing of categories with the correct frequency into an output stream.
[0086] The encryption module 186 operates to achieve access control, to enable authorized users to access content on the platform while rendering all communications useless to non-authorized users. The encryption module 186 encrypts the DSM-CC header of packets that pass through it using an encryption algorithm and encryption keys. Each key is mapped to the content category from where the data in the packet comes. The header of each packet is encrypted by that key. The encryption module also generates the encryption keys and changes them periodically.
[0087] The encryption module 186 in this example has two tables, a table of content categories and a table of encryption keys, with fixed correspondence between the positions in these tables. The key table is changed periodically but the correspondence between positions in the two tables does not change. These two tables are referred to jointly as the key-category table. The key-category table is known to the request system 166 . When a request comes from a client's terminal for a given content category, the key corresponding to the subject category requested is enclosed in the response message. The request message travels from the request system 166 down the request channel to the terminal and becomes the access key (decryption key) for the client 124 .
[0088] The valid category table (a listing of the content categories in the carousel) is known at any given time. Statistically independent keys are generated and the two tables are fused into a key-category table, which is loaded into the module on initialization. Packets arrive in the encryption module along with information about the content category to which they belong. Matching that information in each case with the corresponding category in the key-category table, the packet header is encrypted with the corresponding key and the encryption function. The packets are then forwarded to the carousel scheduler. All request handlers (which can be many and remote) serving the broadcast pipeline are kept informed of the current key-category table at all times.
[0089] New keys can be generated locally in the encryption module; simply by XOR-ing bitwise an existing key with a random “seed” number of the same bit length. The keys are random numbers (e.g., 144 bits long). This can be done “inplace” without any extra register of storage requirements. That is, the outcome bit of XOR-ing each key-bit with a seed-bit replaces the key-bit in its place. The new keys are as statistically independent as the old ones. The seed number is needed with every new key change (arbitrarily taken every 10 minutes in this example). Rather than generating a key with some congruent algorithm it can be generated with a “pseudo random number generator” (PRNG) run, for example, every 10 minutes. This light-weight encryption mechanism is easily distributable and does not require disseminating any keys or secret information. Rather, the parameter settings of the PRNG are safeguarded.
[0090] At initialization, the key-category table can be loaded onto these subsystems like in the case of the encryption module 186 , and then, at least in the case of distributed remote request handlers, the new keys can be generated in each one locally with the same seed and XOR algorithm as was used in the encryption module. Then periodically when the encryption module changes the key table, it notifies the request handlers of the change by simply transmitting a trigger pulse. The key-table and the seed number need not be set to the same PRNG and parameter setting in each of the remote subsystems. In case of a MC2E platform which is scaled up to many request handlers and which are remote from the broadcast pipeline, it is not necessary to send the whole key-category table or even the new seed number. This not only reduces the communication traffic on the interface between the content system 170 and request system 166 down to a single trigger pulse, but also increases security by not having to send the new access codes over insecure communication lines. In the case of a small platform with one request handler residing on the same server as the broadcast pipeline, the upgraded key table can be sent from the encryption module 186 to the request handle; nothing stands in the way of doing that in simple cases. But in general, the above technique of distributed key generation serves scalability and security greatly in the platform.
[0091] The timing of the change of keys can be critical. The access system may not provide old keys after the new ones take effect. Otherwise the client receiving such a key will never find a “down-load” it can decrypt. This is prevented by a small guard interval from the moment of the trigger to the time the actual change takes place. At or about the time that the access system receives the trigger it will provide all requests with the new keys, but the encryption module 186 will delay using them until the guard interval has passed.
[0092] The periods can be chosen so that the following timing applies:
[0093] Guard interval 100 ms, configurable in the range 10 ms-5000 ms; and
[0094] Key change every 10 minutes, configurable in the range 1 minute-1440 minutes.
[0095] In addition, two types of DSM-CC messages can be used, DDB and DII. The header of the DDB (which is prepended to the actual data) is 18 bytes in length in this example. The DII is contained by itself in a packet which may be 64 Kbytes in length but will typically be less than 4K bytes.
[0096] The DII signals that one or more named content files will follow. The name and a download ID are contained in the DII. A stream of DDB packets will follow which contain fragments of the file, the DDB headers are used to assemble the file from the stream. The DDBs comes after the DII, but may be intermixed with other streams, and in any order.
[0097] By encrypting the DII message and DDB headers, as well as guaranteeing the mixing of the stream (both in order and among other streams), assembling the streams becomes extremely difficult.
[0098] To encrypt, a simple bitwise XOR mechanism is used. The key has a length of at least 18 bytes (144 bits) to provides efficient scrambling of the DDB headers. The key is simply XOR'ed with the plain text to produce the cipher text. If the plain text is longer than the key, the key is reused until the end of the plain text is reached.
[0099] This light-weight encryption system is suitable for streaming the data, and provides a sufficient level of protection against casual unauthorized access attempts. The encryption function (and algorithm in particular) can be substituted with a different algorithm if needed.
[0100] The content system 170 further maintains a schedule of content made available through the network 100 . The schedule describes the whereabouts of the contents in the content network 104 , how to access such content and the frequency of updates.
[0101] For example, as can be appreciated by one skilled in the art, the content system 170 can employ a schedule that links content files to categories, along with meta-data. First, all files and categories are defined. Schedule files can have the following properties:
[0102] Carousel content name: What should the name of the content be in the carousel 188 . These are unique within the carousel 188 .
[0103] Content type: Is the content local fetched over a network connection.
[0104] Content protocol: How should the content be accessed (file, http, ftp, etc.).
[0105] Protocol content name: What is the name of the content, an URL for http, directory path for local files.
[0106] Refresh interval: How often should this content be refreshed (checked for updates) in milliseconds.
[0107] Categories can have the following properties:
[0108] Category name: Name of the category, which is unique within the carousel.
[0109] Transmission interval: Repetition rate of the category. This is the inverse of the frequency. If a category should be transmitted every carousel cycle the interval is 1, if every other cycle is the requirement then the interval is 2.
[0110] The last set of entries in the schedule is the linking of content files to the categories. This is the carousel content name for the content files and category name for the categories. An example of the format of the schedule file is as follows:
[0111] file some content .wmv file some content .wmv 86400000
[0112] category entertainment 1
[0113] categoryfile entertainment matrix.wmv
[0114] The first line above defines a content file, the second a category while the third one links the category. Alternatively, a format having the same functionality but using XML can be used.
[0115] When the schedule changes the revised schedule is sent to the request system 166 along with necessary access parameters such as encryption keys. The content system 170 also stores all content described in the schedule in the cache 182 in a broadcast ready form, i.e. DSM-CC packets. The output stream can be encrypted to provide access control, keys to unlock specific categories is provided to the Request System. A stream of data is provided to the Delivery System, comprised of all the categories with correct frequency.
[0116] The content system 170 interfaces with the content network 104 through IP (e.g., HTTP, FTP and local files) or any other suitable protocol, and interfaces with the monitor and management system 168 through function calls from the content system 170 . The content system 170 also interfaces with the delivery system 172 through function calls from the content system 170 , and with the request system 166 through function calls from the request system 166 . The content system 170 further can provide messages including, for example, information pertaining to the output stream throughput (e.g., via carousel 188 ), the time since last key update, the time left of current key set (e.g., encryption time), and the size of categories (e.g., content preparation), to name a few. The content system 170 can also provide alarms indicating, for example, an indication that the carousel 188 is muted, the request system not responding (e.g., an encryption problem), a category is not complete, a failure to fetch content from cache (e.g., a content preparation problem), and an indication that the content is not accessible (e.g., a content size mismatch in the cache 182 has occurred). The content system 170 can also schedule updates, mute the carousel 188 , force cache reload, and start/stop/restart providing content.
[0117] Further details of the delivery system 172 are shown in FIG. 16 . These components enable the delivery system to fetch data to be output from the content system 170 , and to buffer this stream to provide a constant or substantially constant throughput to the broadcast network 112 (see FIG. 1 ). Specifically, the deliver system 172 includes an inflow controller 190 that fetches data from the content system 170 , a packet buffer 192 that stores the output data, and an outflow controller 194 that sends the data to the broadcast network with a fixed throughput.
[0118] The delivery system 172 interfaces with the broadcast network 112 through IP (UDP) or any other suitable protocol, interfaces with the content system 170 through function calls from the content system 170 , and interfaces with the monitor and management system 168 through function calls from the delivery system 172 . The delivery system also can send messages including information pertaining to the bandwidth of output stream (e.g., outflow control), bandwidth of input stream (e.g., inflow control), and the level of buffer and number of starvations (e.g., packet buffer information). The delivery system 172 also can send alarms indicating, for example, muted outflow control, an output/input bandwidth mismatch (outflow/inflow control), and buffer underflow in the packet buffer 192 , to name a few. The deliver system 172 can also accept control messages pertaining to muting, flush buffer, and start/stop/restart operations
[0119] Further details of the request system 166 are shown in FIG. 17 . Specifically, the request system 166 can include, for example, a request listener 196 that listens for incoming requests, and a request handler 198 that responds to requests. Accordingly, the request system 166 is able to listen for requests for access to the network 100 . When a request arrives, the request system 166 consults an external AAA server 116 (see FIGS. 1 and 14 ). If access is granted, all necessary broadcast information can be sent in the response. Broadcast information can be stored locally in the request system 166 , being updated by the content system 170 when changes occur. The consultation with the AAA system 116 includes the category request to facilitate variable tariffs between categories.
[0120] The request system 166 can interface with the content system 170 through function calls from the request system 166 , and can interface with the AAA server 116 through IP such as RADIUS or any other suitable protocol. The request system 166 can also provide messages including information pertaining to the load (e.g., number of requests served in specific time intervals), and can provide alarms indicating, for example, that the AAA server 116 not responding or that content has been paused. The request system 166 can accept control messages indicating a pause in content, as well as a start/stop/restart operations.
[0121] Further details of the monitor and management system 168 are shown in FIG. 18 . The monitor and management system 168 includes, for example, a local properties module 200 that provides access to persistent properties, a schedule refresh module 202 that checks for schedule updates and pushes them to the subsystems, and a monitor and control logging module (e.g., control and management module 204 ) for monitoring and logging of select system variables and sending of control messages. Accordingly, the monitor and management system 168 fetches information from other subsystems and sends control messages to them. This functionality can be provided through an interface to an external software system. The external system monitors the information, sends schedule updates, and control messages if required. Regulation, if any, can be placed in this subsystem (i.e., automatic triggering of control messages in response to information from the other subsystems).
[0122] The monitor and management system 168 interfaces with the content system 170 through function calls from the content system, interfaces with the delivery system 172 through function calls from the delivery system 172 , and interfaces with the request system 166 through function calls in the request system 166 . Furthermore, the monitor and management system 168 can receive messages from the content system 170 including information pertaining to, for example, bandwidth of output stream (e.g., from the carousel 188 ), time since last key update, time left of current key set (e.g., encryption), and size of categories (e.g., content preparation). The monitor and management system 168 can also receive alarms indicating, for example that the AAA server 116 not responding, or that content has been paused, to name a few.
[0123] The monitor and management system 168 can further request and receive messages from the delivery system 172 including, for example, information indicating the bandwidth of output stream (e.g., outflow control), bandwidth of input stream (e.g., inflow control), and a level of buffer and number of starvations (e.g., packet buffer conditions), to name a few. The monitor and management system can also 168 receive alarms indicating, for example that the outflow control is muted, there is an output/input bandwidth mismatch (outflow/inflow Control), and buffer underflow in the packet buffer, to name a few. In addition, the monitory and management system 168 can receive from the request system 166 load information pertaining to the number of requests served in specific time intervals, as well as alarms indicating, for example that the AAA server 116 is not responding and that outflow control is muted.
[0124] The monitor and management system 168 can also send control messages to other subsystems. For example, the monitor and management system 168 can send to the content system 170 messages pertaining to schedule updates, muting, force cache reload, and start/stop/restart operations. The monitor and management system 168 can send to the delivery system 172 messages pertaining to muting, flush buffer, and start/stop/restart operations, and can send to the request system 166 pause and start/stop/restart messages, to name a few.
[0125] FIG. 19 illustrates and example of subsystem interfaces between the core 102 subsystems on one hand and between a client 124 and the core 102 . As indicated, an MS-AAA interface exists between the management system 168 and the AAA server 116 , an MS-CS interface exists between the management system 168 and the content system 170 , and an MS-DS interface exists between the management system 168 and the delivery system 172 . Also, an MS-RS interface exists between the management system 168 and the request system 166 , an RS-AAA interface exists between the request system 166 and the AAA server 116 , and an RS-CS interface exists between the request system 166 and the content system 170 .
[0126] The RS-CS interface allows for encryption key updates. In this example, the content system 170 is responsible for generating a table of keys that are used to encrypt specific portions of the content that is transmitted over the broadcast channel. To minimize communications between the request system 166 and the content system 170 , a local copy of the key table is stored in the request system 166 . The content system 170 thus implements a standard method of updating the key table stored locally in the request system 166 , which happens when both the application is initially started and also when new keys are generated by the content system 170 .
[0127] In addition, a table of encryption keys are sent to the request system 166 , and the content system 170 contacts the request system 166 and specifies the contents of the new key table. In addition, each request issued by a client 124 is mapped to a specific resource locator, e.g., DSM-CC header ID, IP address and port, MPLS label, etc. The content server 170 is aware of all the resources that the application provides. A mapping structure can be a tree or a table that links arbitrary requests to specific resources. The content server 170 maintains a mapping between resources and locators, based on information provided by the monitor and management system 168 . This mapping is initially sent to the request system 166 when the application is initialized. Updates are sent each time when the mapping is changed, either because resource locators are changed or the schedule is changed.
[0128] The MS-RS interface enables the request system 166 to be able to be manually started, stopped and restarted. The MS-RS interface allows for inputting of a start/stop/restart command, and the request system 166 can thus perform the start/stop/restart operations. The monitor and management system 168 should gather statistics on the number and nature of requests made to the request system 166 . This information has practical value to the system operators (e.g., by identifying which content is most popular), but can also be used to adapt the carousel schedule according to user demands.
[0129] The monitor and management system 168 further can poll the request system 166 for request statistics at regular intervals, and the request system 166 can gather information on all requests that have been made since the last poll. Output information on each request is returned to the monitor and management system 168 . In addition, the request system 166 can alert the monitor and management system 168 if an exception occurs. Possible exceptions include a network error (e.g., the request system 166 is unable to bind sockets, etc.), overload (e.g., the request system 166 is unable to handle all requests), and AAA communication error (e.g., the AAA server 116 is not responding, etc.). To ensure that the request system 166 is functioning correctly, even if no exceptions have been reported, the monitor and management system 168 should regularly poll the request system 166 for its runtime status. If the request system 166 does not respond, the monitor and management system 168 may assume that either the request system 166 is not running or that there is something preventing communication between the two systems. If an exception occurs, the request system 166 can send a corresponding message to the monitor and management system 168 . The monitor and management system 168 can also poll the request system 166 for status indication at regular intervals (configurable through the monitor and management system 168 ). If an exception is reported or if the monitor and management system 168 does not respond to polling messages, the monitor and management system 168 should alert the system administrator (e.g., by sending an e-mail message).
[0130] The MS-CS interface makes it possible to update the carousel schedule at runtime. Such updates are either initiated directly by a system administrator (e.g., when there is need to define a new content category) or by the management system itself, based on request statistics or a pre-scheduled change (e.g., separate schedules for daytime and evenings).
[0131] A system administrator either directly alters the schedule (e.g., through the user interface of the management system 168 ) or the monitor and management system 168 triggers an update based on request statistics it has collected from the request system 166 (e.g. if a category with a low priority suddenly becomes more popular than a category with high priority, the monitor and management system 168 might decide to switch the priority of the two categories). The content system 170 updates its local content schedule, and the monitor and management system 168 sends information on the new schedule to the content server 168 .
[0132] A force cache reload can also occur via this interface, which makes it possible to manually reload the content system 170 cache at runtime. For example, a command for cache reload can be received, upon which the content system 170 clears and then reloads the cache. The interface also enables the content system 170 to be manually started/stopped/restarted when a start/stop/restart command is received by the content system 170 starts/stops/restarts. The monitor and management system 168 can also listen for information on the status of the content system 170 . The information provided includes bandwidth of output stream (carousel 188 ), time since last key update, time left of current key set (encryption information), and size of categories (content preparation information).
[0133] The monitor and management system 168 can request the information from the content system 170 at regular intervals. The content system 170 gathers the requested information, and outputs the requested information. The content system 170 can also alert the monitor and management system 168 if an exception occurs. Possible exceptions include missing content such that the content system 170 is unable to locate some of the content on the schedule, inaccessible content which is content that has been located is inaccessible, and a conflict that occurs when content size is suddenly changed, for example.
[0134] To ensure that the content system 170 is functioning correctly, even if no exceptions have been reported, the content system 170 can regularly report to the monitor and management system 168 with a status indication. If the content system 170 has not reported within a certain interval, the monitor and management system 168 may assume that either the content system 170 is not running or that there is something preventing communication between the two systems. In either case, the monitor and management system 168 can report the error to the system administrator.
[0135] If an exception occurs, the content system 170 sends a corresponding message to the monitor and management system 168 . The content system 170 also sends a status indicator at regular intervals (configurable through the monitor and management system 168 ) to the monitor and management system 168 . If an exception is reported or if the content system 170 has not reported within a certain interval, the monitor and management system 168 should alert the system administrator (e.g., by sending an e-mail message).
[0136] The MS-DS interface allows for manual start/stop/restart of the delivery system 172 . When a start/stop/restart command is received, the delivery system 172 starts/stops/restarts as appropriate. Also, the delivery system 172 buffer can be manually flushed at runtime when a command for buffer flushing is received. The monitor and management system 168 should listen for information on the status of the delivery system 172 . Information provided can include bandwidth of output stream (outflow control), bandwidth of input stream (inflow control), and level of buffer and number of starvations (packet buffer).
[0137] The monitor and management system 168 requests information from the DS at regular intervals. The delivery system 172 gathers and outputs the requested information. The delivery system 172 should alert the monitor and management system 168 if an exception occurs. Possible exceptions include muting (outflow control), output/input bandwidth mismatch (outflow/inflow control) and buffer underflow (packet buffer).
[0138] To ensure that the delivery system 172 is functioning correctly, even if no exceptions have been reported, the delivery system 172 should regularly report to the monitor and management system 168 with a status indication, as described for the request system 166 . If an exception occurs, the delivery system 172 can send a corresponding message to the monitor and management system 168 . The delivery system 172 also can send a status indicator at regular intervals (configurable through the monitor and management system 168 ) to the monitor and management system 168 . If an exception is reported or if the delivery system 172 has not reported within a certain interval, the monitor and management system 168 should alert the system administrator (e.g., by sending an e-mail message).
[0139] The RS-AAA interface enables each client 124 that issues a request to the request system 166 to be authenticated. Moreover, every request has to be authorized, since different users may have different access privileges. The request system 166 sends the user name and password of the client 124 , along with the ID of the content category requested, to the AAA server 116 which attempts to authenticate the user and determine whether the request is authorized. The AAA server 116 outputs a message indicating whether the user is authenticated and whether the requested access is authorized.
[0140] The MS-AAA interface enables billin tgf6g rules to be implemented. For example, the AAA server 116 needs to bill the client 124 for the content that the client 124 receives. The monitor and management system 168 therefore provides the AAA server 116 with information on how different requests should be billed (e.g., different content categories maybe charged differently). The interface can receive mapping of arbitrary requests to billing/price categories. The mapping function may be implemented as a tree search, hash function, table lookup, and so on. The AAA server 116 can thus store the new mapping function/structure.
[0141] Although only a few exemplary embodiments of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims.
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A system and method for providing content over a network. In particular, the system and method is capable of providing content, such as broadband streaming multimedia and Internet Protocol (IP) data, to network devices, including mobile devices, with interactive functionality. The network employs at least one core and a plurality of clients. The core and clients each comprise a plurality of modules that cooperatively communicate with each other to monitor and control the delivery of content and to allow for interactive functionality by a user.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to energy transmission control and in particular, to an energy transmission control mount designed to reduce transmission of energy such as vibration and sound between components such as for example, building structures.
BACKGROUND OF THE INVENTION
[0002] insulating building structures to inhibit the transmission of vibration and sound from one region to another is common in many environments. For example, vibration dampening pads for use on floors to inhibit vibration from traveling through floor surfaces are well known. Until recently, very little was done however to attempt to inhibit vibration and sound from travelling through walls.
[0003] U.S. Pat. No. 6,267,347 to Ryan et al, discloses an acoustic mount for isolating wall structures. The acoustic mount comprises a mounting clip, a sound absorbing inset and a bush. The mounting clip has an orifice defining a single start thread for engaging the thread on the outer surface of a stub on the sound absorbing insert. The sound absorbing insert has an insert for receiving the bush. The sounding absorbing insert is formed of soft rubber and has dimples thereon. The bush when received by the sound absorbing insert is isolated from the mounting clip.
[0004] In use, the mounting clip is placed either directly or indirectly in contact with a thin wall or plaster board, while the bush is placed indirectly in contact with a block wall. The sound absorbing insert, which isolates the bush from the mounting clip, dampens the transmission of low frequency noise between the block wall and the thin wall or plaster board.
[0005] Another mount to isolate walls and ceilings is manufactured by Kinetics Noise Control Inc. of Dublin, Ohio and is sold under the name IsoMax. The IsoMax mount is in the form of a resilient sound isolation clip designed to attach to ceiling joists, wall studs or masonry. Layers of gypsum or plaster board are hung onto furring channels defined by the isolation clip.
[0006] Although the above mounts help to inhibit the transmission of vibration and sound between structures, they are costly to manufacture, complex and expensive to consumers, It is therefore an object of the present invention to provide a novel energy transmission control mount.
SUMMARY OF THE INVENTION
[0007] Accordingly, in one aspect there is provided an energy transmission control mount comprising:
[0008] a carrier having a first major surface, an opposite second major surface and an aperture provided therein;
[0009] channels adjacent opposite ends of said first surface; and
[0010] vibration dampening material on said carrier, said vibration dampening material substantially lining said channels and said aperture and extending over at least a portion of said second surface.
[0011] In one embodiment, the vibration dampening material substantially lining the channels is isolated from the vibration dampening material substantially lining the aperture and extending over at least a portion of the second surface. The vibration dampening material substantially lining the aperture and extending over at least a portion of the second surface also extends over a portion of the first surface.
[0012] On the second surface, the vibration dampening material is configured to define a series of spaced ribs. The ribs are parallel and are generally equally spaced. On the first surface, the vibration dampening material is configured to define a disc. A washer is disposed on the disc. The vibration dampening material substantially lines the aperture of the washer and terminates at a flange overlying a portion of the washer to retain the washer to the disc.
[0013] In one embodiment, the ends of the carrier are folded back over the first surface of the carrier to define the channels and are sized to receive flanges of a furring channel.
[0014] According to another aspect there is provided an energy transmission control mount assembly to reduce transmission of energy between a first budding structure and a second budding structure, comprising:
[0015] a channel-like member adapted to be secured to the first building structure;
[0016] a carrier receiving and retaining said channel-like member, said carrier being adapted to be structurally secured to said second building structure; and
[0017] vibration dampening material acting between at least one of said channel-like member and carrier, and said carrier and second building structure.
[0018] In one embodiment, the vibration dampening material acts between both the channel and carrier and the carrier and second building structure. The vibration dampening material is permanently bonded to the carrier. An aperture is provided in the carrier through which a fastener passes to secure the carrier to the second building structure. Vibration dampening material substantially lines the aperture to isolate the fastener and the carrier.
[0019] According to yet another aspect there is provided an energy transmission control mount to act between a pair of components comprising:
[0020] a carrier having a first major surface and an opposite second major surface and an aperture provided therein:
[0021] vibration dampening material on said carrier, said vibration dampening material substantially lining said aperture and extending over at least, a portion of said second surface, the vibration dampening material extending over said second surface being configured to bear against one of said components; and
[0022] retaining structure on the first surface of said carrier adapted to retain a second of said components.
[0023] The energy transmission control mount is effective, easy to install and inexpensive to manufacture. Its one-piece construction makes the energy transmission control mount simple to use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Embodiments will now be described more fully with reference to the accompanying drawings in which:
[0025] FIG. 1 is a perspective view of an energy transmission control mount;
[0026] FIG. 2 is a rear elevational view of the energy transmission control mount of FIG. 1 ; and
[0027] FIG. 3 is a side cross-sectional view of the energy transmission control mount interposed between a wall stud and drywall and secured to the wall stud via a fastener.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] Turning now to FIGS. 1 and 2 , an energy transmission control mount for isolating components such as for example, building structures is shown and is generally identified by reference numeral 10 . In this particular example, energy transmission control mount 10 acts between a wall stud and a wall structure such as for example drywall, plaster board, gypsum or the like to reduce the transmission of energy between the wall stud and the wall structure. As can be seen, the energy transmission control mount 10 comprises a generally rectangular carrier 12 formed of metal such as for example steel. The top and bottom ends 14 and 16 of the carrier 12 are folded back over the front surface 18 of the carrier 12 to define channels 20 . Vibration dampening material 22 substantially lines each of the channels 20 . A central aperture 26 is also provided through the carrier 12 . Vibration dampening material 30 substantially lines the aperture 26 and extends over a portion of both the front surface 18 and the back surface 32 of the carrier 12 . The vibration dampening material 22 and 30 may be for example polyurethane bonded recycled rubber, polyether urethane foam or other suitable energy absorbing material.
[0029] On the back surface 32 , the vibration dampening material 30 is configured to define a plurality of vertically and generally equally spaced horizontal ribs 34 . On the front surface 18 , the vibration dampening material 30 is configured to define a disc 36 on which a washer 38 is disposed. The vibration dampening material 30 substantially lines the aperture of the washer 38 and forms an annular flange 40 over the washer 38 to retain the washer on the disc 36 . The vibration dampening material 22 substantially lining the channels 20 is isolated from the vibration dampening material 30 substantially lining the aperture 26 and extending over the front surface 18 of the carrier 12 . The vibration dampening material 22 and 30 is permanently bonded to the carrier 12
[0030] Turning now to FIG. 3 , the energy transmission control mount 10 is shown in use interposed between a wall stud 50 and drywall 52 . Energy transmission control mount 10 is designed to increase the sound transmission loss characteristics of the wall stud and drywall assembly. During installation of the energy transmission control mount 10 , a fastener 54 is passed through the aligned apertures of the washer 38 and carrier 12 and engages the wall stud 50 to secure the energy transmission control mount 10 to the wall stud 50 , The head of the fastener 54 rests on the flange 40 to isolate the head of the fastener 54 from the washer 38 . In this position, the ribs 34 bear directly against the wall stud 50 . A standard furring channel 56 , typically formed of steel, is snapped into the front of the carrier 12 by inserting its upper and lower flanges 58 and 60 , respectively, into the lined channels 20 thereby to retain the furring channel. Drywall fasteners (not shown pass through the drywall 52 and engage the furring channel 56 to secure the drywall 52 to the furring channel 56 . In this manner, the energy transmission control mount 10 acts between the drywall 52 and the wall stud 52 to reduce energy from being transmitted therebetween.
[0031] If energy such as vibration or sound is transmitted to the wall stud 50 , the ribs 34 resist transmission of that energy to the carrier 12 . The vibration dampening material 30 substantially lining the apertures of the carrier 12 and the washer 38 resists transmission of energy to the fastener 54 . Energy that is transmitted to the carrier 12 moves to the extremities of the carrier. The vibration dampening material 22 lining the channels 20 resists transmission of this energy to the furring channel 56 , in this manner, the energy transmission control mount 10 reduces the transfer of energy between the wall stud 50 and the furring channel 56 and hence the drywall 52 .
[0032] In the example described above, the energy transmission control mount is shown interposed between a wall stud 50 and drywall 52 . Those of skill in the art will however appreciate that the energy transmission control mount may be used to isolate other building structures such as for example floors and joists, masonry and wall studs, exterior walls and wall studs etc.
[0033] Although the energy transmission control mount is particularly suited to isolate building structures, the energy transmission control mount may be used in other environments to isolate components to inhibit vibration/sound from propagating between components. For example, the energy transmission control mount may be used in automobiles as an engine mount, or as a mount for vehicle body parts.
[0034] Although embodiments have been described, those of skill in the art will appreciate that variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims.
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An energy transmission control mount comprises a carrier having a first major surface, an opposite second major surface and an aperture provided therein. Channels are provided adjacent opposite and of the first surface. Vibration dampening material is provided on the carrier. The vibration dampening material substantially lines the channels and the aperture and extends over at least a portion of the second surface.
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CROSS REFERENCE To RELATED APPLICATION
This application claims the benefit and priority from U.S. provisional application, Ser. No. 60/451,860, filed on Mar. 4, 2003, the contents of which are incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
The present invention relates in general to patient monitoring and drug delivery systems, and more particularly, to methods and apparatus for providing increased practice efficiency throughout medical procedures.
BACKGROUND OF THE INVENTION
Patient monitoring systems are typically used to monitor physiological parameters of patients undergoing diagnostic or surgical procedures. A variety of patient monitoring systems have been employed for the sole purpose of monitoring a patient under the influence of analgesic or amnesic drugs that are administered during painful or anxiety-causing procedures. A monitoring system capable of accurately and reliably monitoring a patient as well as being easy to use is desired.
Unfortunately, known monitoring system suffer from several disadvantages. Monitoring systems in the related art fall generally into two categories: high end, multi-function monitors which collect a multitude of data and are typically used in the procedure, and smaller, limited function monitors which gather only basic physiological data that are typically used in pre-procedure and recovery areas. Inefficiencies occur when the patient must be disconnected from one monitoring system and then, once in the procedure room, connected to a more robust monitoring system that will provide additional critical information during a surgical procedure. The process of connecting and disconnecting multiple physiological data acquisition probes from the patient causes practice inefficiencies by adding time consuming activities, resulting in an overall lengthier medical or surgical procedure.
A patient care system that increases practice efficiency is needed in many patient care facilities. A patient care facility desires to maximize efficiency and perform as many cases as safely possible in a given day. Many patient care facilities find the largest obstacle to increasing practice efficiency relates to minimizing the amount of clinician time that is required in the procedure room. The number of cases a doctor may perform in a given day is limited in part to the amount of time the patient is in the procedure room. The amount of time required to complete a particular procedure is somewhat fixed and based upon the skill and experience level of the clinician. However, much can be done to improve upon clinic practice pre-procedure and post procedure.
Typically in a pre-procedure room, a nurse or technician prepares the patient for the upcoming procedure. This preparation may include connecting monitors to the patient for the purpose of obtaining baseline data to be used in the procedure. Monitors that are commonly used include blood pressure (systolic, diastolic, and mean arterial pressure), and pulse oximetry, which measures a patient's arterial oxygen saturation and heart rate typically via an infrared diffusion sensor. Blood pressure readings are generally taken by a blood pressure cuff. A nurse or technician must secure the cuff around a patients arm and use a bulb type device to pump air into the cuff. Once the reading from the cuff stabilizes, the nurse or technician must manually record the data, usually handwritten on a sheet of paper, and save this information for later reference during the procedure and eventually, for the patient report. For the nurse or technician to take a pulse oximeter reading, he or she must boot up the pulse oximeter module, secure a pulse oximeter probe upon the patient and take a reading of the patient. This reading is also written down on paper to be saved for later use. Once it is determined the patient is ready for the procedure, the nurse or technician must disengage the blood pressure cuff and pulse oximetry probes from the patient, so the patient can be transported from the pre-procedure room to the procedure room.
After the patient enters the procedure room and before the procedure may begin, several tasks are needed to prepare the patient for the procedure. The nurse or technician must reconnect both blood pressure and, pulse oximetry before the procedure can begin. In addition to blood pressure and pulse oximetry other connections such as, for example, capnography, supplemental oxygen, and electrocardiogram are required. A great deal of time is required to connect the physiological monitors to the patient and to connect the physiological monitors to the monitoring system. The nurse or technician must spend time reconnecting physiological monitors that were connected to the patient in the pre-procedure room. The time it takes to make these connections occupies valuable procedure room time, thus decreasing practice efficiency. Clearly a need exists to minimize or eliminate these monitor connections and reconnections while their patient is in the procedure room.
Besides the time delays which may be encountered when adding sensors to the monitors, monitoring systems in the prior art leave much to be desired with respect to cable management. A large number of cables extend between the patient and the monitor. In the past there has been at least one cable for every parameter monitored. This array of cables and hoses interferes with the movement of personnel around the patient's bed. The greater the number of cables and hoses, the greater the risk that someone will accidentally disrupt one of them. In the course of a procedure, many people including nurses, technicians, and physicians must be able to move around the room and access the patient without, having to navigate around cables. This invention addresses cable management, by minimizing the number of cables between patient and monitor.
An additional focus of this invention is the use of fast acting analgesic or amnestic drugs to decrease the length of most procedures and the time needed to recover from procedures, thus increasing practice efficiency. Current solutions for providing patient relief from pain and anxiety require the use of drugs that require a relatively long time to take peak effect and, take a relatively long time for the effect to pass from patient. Physicians must wait for drugs to take full effect for the procedure to begin. The time spent waiting for the drug to take affect is wasted time that hinders practice efficiency. This invention provides means for safely and reliably delivering fast acting drugs in an effort to increase practice efficiency.
An additional focus of this invention is to automate several functions currently performed by clinicians to increase practice efficiency. In current practice, prior to IV drug delivery, nurses must manually purge the IV line of any air that may be trapped in the line before connecting the line to a patient. Failure to do so will result in harmful effect on the patient from air entering the patient's blood stream. The process of purging this line takes a significant amount of time and hinders practice efficiency. This invention provides means for automating the line purging process.
DESCRIPTION OF THE DRAWING
Other objects and many of the intended advantages of the invention will be readily appreciated as they become better understood by reference to the following detailed description of embodiments of the invention considered in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of a one embodiment of a care system apparatus constructed in accordance with this invention, depicting a bedside or patient unit and a procedure unit.
FIG. 2 is a perspective view of an embodiment of a care system apparatus constructed in accordance with this invention depicting a mobile patient unit.
FIG. 3 is a perspective view of an embodiment of a care system apparatus constructed in accordance with this invention depicting the patient unit connected with various patient sensors, and other patient interfaces.
FIG. 3-A is a perspective view of an alternate embodiment of a patient unit.
FIG. 3-B is a perspective view of the patient unit of FIG. 3-A connected to a procedure unit.
FIG. 3-C is an exploded view of the patient unit of FIG. 3-A .
FIG. 3-D is a perspective view of the patient unit of FIG. 3-A illustrating the cable connection and bedside connection.
FIG. 3-E is exploded view of an alternate embodiment of the patient unit of FIG. 3-A .
FIG. 4 is a perspective view of the procedure unit.
FIG. 4-A is a flow diagram depicting the auto priming aspect of the invention.
FIG. 4-B is a partial cut-away view of a drug cassette for use with the procedure unit.
FIG. 4-C is a perspective view of an alternate embodiment of a drug cassette and pump module for use with the procedure unit.
FIG. 5 is a cross-sectional view of the communication cable.
FIG. 6 is a block diagram overview of the invention.
FIG. 7 is an overview data-flow diagram depicting the pre-medical procedure aspect of the invention.
FIG. 8 is an overview data-flow diagram depicting the medical procedure aspect of the invention.
FIG. 9 is an overview data-flow diagram depicting the post-medical procedure aspect of the invention.
SUMMARY OF THE INVENTION
The invention provides apparatuses and methods to efficiently deliver a pharmaceutical drug, for example and not limited to, a sedative, analgesic or amnestic drug, to a patient during a medical procedure as exemplarily described in U.S. patent publications US2002/0017296, US2002/0017300 and US2002/0188259.
The functionality of the invention allows for, but is not limited to, enabling many time consuming and laborious activities to be minimized or moved to a part in the procedure where time is not as critical. To these ends, the invention is capable of physically separating through system architecture and design into two separate monitoring units which, when used as described herein, will increase practice efficiency in patient care facilities.
In general, the invention is a micro-processor based patient monitoring system and drug delivery system having a patient unit that receives input signals from patient monitoring connections. The patient unit outputs patient parameters to a procedure unit and also includes a display screen for displaying patient parameters. The procedure unit is operational during the medical procedure and receives patient parameters from the patient unit. The procedure unit controls the delivery of drugs to the patient.
An additional aspect of this invention is directed to the facilitation of creating a patient record of the procedure. Current techniques for creating a patient record involve manual note taking by a nurse during the course of a patients stay. This technique is time consuming and may lead to errors in record keeping. This invention provides mean for monitoring patient parameters throughout a procedure, electronically capturing data and giving the nurse or technician the option of printing a copy of this data for the purpose of record keeping.
A further aspect of this invention is a method for monitoring a patient and delivering at least one drug during a medical procedure that comprises the steps of connecting to the patient at least one sensor for monitoring at least one physiological parameter of the patient; providing a microprocessor-based patient unit having at least one first connection point and receiving input signals from the at least one sensor through the at least one first connection point and at least one second connection point for outputting patient physiological parameters; inputting to the patient unit physical attributes of the patient; and creating a patient record.
A further expression of the method for monitoring a patient and delivering at least one drug during a medical procedure includes connecting the at least one second connection point to a micro processor-based procedure unit; connecting a drug cassette containing a drug vial to an infusion pump; delivering the drug to the patient and performing a medical procedure; and disconnecting the at least one second connection point from the procedure unit.
A still further expression of the method includes monitoring the at least one physiological condition of the patient; disconnecting the input signals from the at least one sensor from the at least one first connection point; and terminating the creation of the patient record.
Other focuses of the invention are apparent from the below detailed description of preferred embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the present invention in detail, it should be noted that the invention is not limited in its application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative embodiments of the invention may be implemented or incorporated in other embodiments, variations and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative embodiments of the present invention for the convenience of the reader and are not for the purpose of limiting the invention.
It is further understood that any one or more of the following-described embodiments, expressions of embodiments, examples, methods, etc. can be combined with any one or more of the other following-described embodiments, expressions of embodiments, examples, methods, etc.
The system block diagram of FIG. 6 depicts the system architecture of one embodiment of the invention. This diagram illustrates the relationships between the components of a patient care system 5 , which are described in more detail below. Procedure unit 12 has several integrated components including ECG module 36 , cannula module 38 , battery 82 and peristaltic infusion pump 72 . External oxygen 16 and external power 78 are not integrated into procedure unit 12 however; they do have connections to procedure unit 12 . Peristaltic infusion pump 72 interfaces with drug cassette 64 to pump analgesic or sedative drugs. These analgesic or sedative drugs are then pumped through IV tubing 76 and into the patient. In addition to the displays incorporated into bedside unit 10 and procedure unit 12 , an optional display 20 is available for use by the clinician, and could display information such as, for example, patient physiological parameters and, warning alarms. Procedure unit 12 may use a wireless transmitter device such as, for example, “Blue Tooth” to send signals to a wireless receiver device located on optional display 20 . Communication cable 14 serves as a data link between procedure unit 12 and bedside unit 10 . Bedside unit 10 has a plurality of integrated devices including, NIBP module 34 , pulse oximeter module 26 , ART modules 30 , 32 , and bedside unit battery 24 . Bedside unit 10 allows for several connections between bedside unit 10 and the patient being monitored including but not limited to oral nasal cannula 48 , ECG pads 50 , NIBP cuff 58 , pulse oximeter probe 60 , ART earpiece 55 , and ART handpiece 57 . Bedside unit 10 is designed to function independent of, or connected to procedure unit 12 .
As shown in FIG. 1 , patient care system 5 comprises two monitoring units; a bedside unit 10 and a procedure unit 12 . One exemplary use of patient care system 5 is to monitor patient parameters and deliver sedative, analgesic and/or amnestic drugs to a conscious, non-intubated, spontaneously-ventilating patient undergoing a diagnostic or surgical procedure by a physician. This use is not exhaustive of all of the potential uses of the invention but will be used to describe the invention.
Bedside unit 10 and procedure unit 12 are connected via communication cable 14 . Communication cable 14 provides means for transmitting electronic data as well as various hydraulic signals and gases between beside unit 10 and procedure unit 12 . Communication cable 14 may be removed from both bedside unit 10 and procedure unit 12 to facilitate practice efficiency and user convenience. Bedside unit 10 and procedure unit 12 are free to move independently of each other if communication cable 14 is not in place. This allows for mobility of each unit independent of the other; this feature is especially important in hospitals that have a great deal of medical procedures and there is little time to connect patients to monitors. Bedside unit 10 and procedure unit 12 preferably accommodate an external oxygen source that is intended to provide supplemental oxygen to the patient during the course of a surgical procedure if the clinician so desires. An IV tube set 76 is shown connected to procedure unit 12 and delivers sedative or amnestic drugs to a patient during a surgical procedure.
As shown in FIG. 2 , beside unit 10 is compact and portable so it requires little effort to move from one room to another. In the one embodiment, bedside unit 10 could mount upon either an IV pole or a bedrail; this would free the clinician from the burden of carrying the unit wherever the patient needs to be transported. Bedside unit 10 is small and light enough to be held in the hand of a nurse or technician. Bedside unit 10 allows the user to input information via the bedside touch screen assembly or a simple keypad 22 . Bedside touch screen assembly 22 is a display device that is integrated into one surface of bedside unit 10 , and displays patient and system parameters, and operational status of the apparatus. An exemplary bedside touch screen assembly 22 is a 5.25″ resistive touch screen manufactured by MicroTech mounted upon a 5.25″ color LCD manufactured by Samsung. An attending nurse or physician may enter patient information such as, for example, patient weight and a drug dose profile into bedside unit 10 by means of bedside touch screen assembly 22 . Bedside unit battery 24 is fixedly attached to the bedside unit 10 and is a standard rechargeable battery such as, for example, Panasonic model no. LC-T122PU, that is capable of supplying sufficient power to run bedside unit 10 for an extended period of time. In one embodiment, bedside unit battery 24 can be recharged while bedside unit 10 is connected to procedure unit 12 via communication cable 14 or can be charged directly from an independent power source.
As shown in FIG. 3 bedside unit 10 may be connected to a plurality of patient sensors and peripherals used to monitor patient vital signs and deliver supplemental oxygen to the patient. One aspect of the invention integrates drug delivery with one or more basic patient monitoring systems. These systems interface with the patient and obtain electronic feedback information regarding the patient's physiological condition. Oral nasal cannula 48 delivers oxygen from an external oxygen source and collects samples of exhaled gas. Oral nasal cannula 48 is removably attached to cable pass-through connection 15 . Cable pass-through connection 15 sends the signal obtained by oral nasal cannula 48 directly to a capnometer (e.g., a CardioPulmonary Technologies CO2WFA OEM) in procedure unit 12 and preferably via communication cable 14 ( FIG. 1 ). The capnometer measures the carbon dioxide levels in a patient's inhalation/exhalation stream via a carbon dioxide-sensor as well as measuring respiration rate. Also attached to the cable pass-through connection 15 is a standard electrocardiogram (ECG) 50 , which monitors the electrical activity in a patient's cardiac cycle. The ECG signals are sent to the procedure unit 12 where the signals are processed.
Also connect to bedside unit 10 is a pulse oximeter probe 60 (e.g., Dolphin Medical) and a non-invasive blood pressure (NIBP) cuff 58 . Pulse oximeter probe 60 measures a patient's arterial saturation and heart rate via an infrared diffusion sensor. The data retrieved by pulse oximeter probe 60 is relayed to pulse oximeter module 26 (e.g., Dolphin Medical) by means of Pulse Oximeter Cable 61 . The non-invasive blood pressure (NIBP) cuff 58 (e.g., a SunTech Medical Instruments PN 92-0011-00) measures a patient's systolic, diastolic and mean arterial blood pressure by means of an inflatable cuff and air pump (e.g., SunTech Medical), also incorporated as needed. NIBP cuff 58 is removably attached to NIBP module 34 located on bedside unit 10 .
A patient's level of consciousness is detected by means of an Automated Response Tester System (ART). An exemplary ART system is disclosed in U.S. patent application, Ser. No. 10/674,160 and filed on Sep. 29, 2003, which is incorporated by reference herein. The ART system comprises a query initiate device and a query response device. The ART system operates by obtaining the patient's attention with the query initiate device and commanding the patient to activate the query response device. The query initiate device may be any type of stimulus such as a speaker via an earpiece 55 , which provides an auditory command to a patient to activate the query response device. The query response device is a handpiece 57 that can take the form of, for example, a toggle or rocker switch or a depressible button or other moveable member hand held or otherwise accessible to the patient so that the member can be moved or depressed by the patient upon the patient's receiving the auditory or other instruction to respond. Alternatively, a vibrating mechanism may be incorporated into the handpiece 57 that cues the patient to activate the query response device. In one embodiment, the query initiate device is a cylindrical handheld device 57 , containing a small 12V dc bidirectional motor enabling the handheld device to vibrate the patient's hand to solicit a response.
After the query is initiated, the ART system generates signals to reflect the amount of time it took for the patient to activate the query response device in response to the query initiate device. These signals are processed by the main logic board located inside bedside unit 10 and are displayed upon either bedside touch screen assembly 22 , procedure touch screen assembly 62 ( FIG. 4 ) or an optional monitor 20 ( FIG. 6 ). The amount of time needed for the patient to respond to the query gives the clinician an idea as to the sedation level of the patient. The ART System has two modules, the query response module 32 and the query initiate module 30 , collectively referred to as the ART system modules 30 , 32 . ART system modules 30 , 32 have all the necessary hardware to operate and connect the query response device 57 and the query initiate device 55 to bedside unit 10 .
In one embodiment monitoring modules 26 , 30 , 32 , and 34 are easily replaceable with other monitoring modules in the event of malfunction or technological advancement. These modules include all the necessary hardware to operate their respective peripherals. The above-mentioned patient modules are connected to a microprocessor-based electronic controller or computer (sometimes also referred to herein as main logic board, MLB) located within each of the procedure unit 12 and bedside unit 10 . The electronic controller or main logic board comprises a combination of available programmable-type microprocessors and other “chips,” memory devices and logic devices on various board(s) such as, for example, those manufactured by Texas Instruments (e.g., XK21E) and National Semiconductor (e.g., HKL72), among others.
Once bedside unit 10 and procedure unit 12 are connected via communication cable 14 , ECG and capnography will be monitored, and supplemental oxygen will be delivered to the patient. Preferably, however, these connections are made in the pre-procedure room to increase practice efficiency. By making these connections in the pre-procedure room, less time is required in the procedure room connecting capnography, ECG and supplemental oxygen to procedure unit 12 . Oral nasal cannula 48 and ECG leads 51 are connected directly to cable pass-through connection 15 . Cable pass-through connection 15 , located on bedside unit 10 , is essentially an extension of communication cable 14 , which allows the signals from ECG leads 51 and oral nasal cannula 48 to bypass bedside unit 10 and be transferred directly to procedure unit 12 . It will be evident to those skilled in the art, however, that the bedside unit 10 could be configured to accept the ECG 50 and oral/nasal cannula 48 signals and process the signals accordingly to provide the information on screen 22 and supplemental oxygen to the patient in the pre-procedure room. As more features are added to the bedside unit 10 , however, the portability may be limited.
Referring now to FIG. 3-A there is shown a console assembly 410 of the present invention in connection with procedure unit 12 . In this embodiment, console assembly is a simpler version of the bedside unit 10 . As used herein, the term “proximal” refers to a location on the console assembly 410 closest to the device using the console assembly 410 and thus furthest from the patient connected to the console assembly 410 . The term “distal” refers to a location farthest from the device using the console assembly 410 and closest to the patient.
As illustrated in FIGS. 3A-D , console assembly 410 comprises mounting 412 , console box 420 , and console connector cable 450 . Mounting 412 allows console assembly 410 to easily mount horizontally or vertically on, for example a patient's bed rail or IV pole, and is preferably made of a rigid thermoplastic such as, for example, polycarbonate. Mounting 412 is attached to the proximal end of Console Box 420 and includes mounting posts 414 thereon. Mounting posts 414 help secure mounting 412 on a patient's bed rail or IV pole.
Console box 420 , with an outer casing preferably made of a rigid thermoplastic such as, for example, polycarbonate, includes faceplate 419 and hub 421 . Faceplate 419 can be fixedly attached to hub 421 using any attachment means including, but not limited to, glue, mechanical fasteners, screws, and ultrasonic welding. Console box 420 further includes receptacles 432 therein. Receptacles 432 include, but are not limited to, pulse oximeter port 434 , ECG monitor port 436 , NIBP monitor port 438 , ART earpiece jack 440 , ART handpiece port 442 , and oral nasal cannula port 444 that includes supplemental oxygen delivery. Receptacles 432 can be standard medical device connections, well known in the medical art, or custom device connections for use with medical devices custom designed to connect to console box 420 . Console box 420 further includes a plurality of electrical wires 422 , air lines 424 and oxygen delivery tubes 426 therein which connect from the respective receptacle 432 through console box 420 and to corresponding wires 452 , tubes 454 and power lines 456 in connector cable 450 .
As shown in FIG. 3-A , Console assembly 410 further includes a plurality of cables 430 . Cables 430 , which connect to receptacles 432 , attach to any number of devices during a surgical procedure to monitor a patient, among other things. These devices can include, but are not limited to, an oral nasal cannula, a blood pressure cuff, ECG leads and a pulse oximeter monitor, among others.
Connector cable 450 , which is covered with insulation, such as, for example mil-ene or silicon, includes a plurality of wires 452 , tubes 454 and power lines 456 that supply electrical signals, hydraulic signals, and oxygen delivery integrated into one cable and allow console box 420 to be hardwired to procedure unit 12 . Connector cable 450 further includes strain relief 451 at its distal end. Strain reliefs are well known in the art and play an important role in helping to prevent flexing, which causes wires to break after prolonged use, at the connection between connector cable 450 and console box 420 .
As shown in FIG. 3-E , Console box 420 further includes circuit board 459 , microprocessor 460 , removable flash memory reader 461 , removable flash memory 462 , battery 464 , and at least one computer interface 466 . Circuit board 459 can be a multi-layered printed circuit board. Copper circuit paths called traces that resemble a complicated roadmap carry signals and voltages across circuit board 459 . Layered fabrication techniques can be used so that some layers of circuit board 459 can carry data for microprocessor 460 and removable flash memory 462 while other layers carry voltages and ground returns without the paths short-circuiting at intersections. The insulated layers can be manufactured into one complete, complex sandwich. Chips and sockets can be soldered onto circuit board 459 . Mounted to circuit board 459 is microprocessor 460 . Microprocessor 460 is the computational engine of the data received by console box 420 from the external monitors. Microprocessors are well known in the computer field and one of many suitable microprocessors such as, for example, a Pentium, a K6, a PowerPC, a Sparc, a Motorola Dragonball™, among others, may be used for microprocessor 460 . Microprocessor 460 can be run by a software application. The software application can be written in one of many formal programming languages, which can include, but is not limited to Java, C++, Visual Basic, and Fortran. The software application and microprocessor 460 together create a data log of all the physiological parameters gathered from the patient via console box 420 and procedure unit 12 . Circuit board 459 also has removable flash memory reader 461 electrically attached thereto. Removable flash memory reader 461 , which includes a slot in the outer casing of console box 420 , more specifically hub 421 , allows removable flash memory 462 to be inserted and removed from circuit board 459 . When removable flash memory 462 is inserted in removable flash memory reader 461 , removable flash memory 462 is in digital communication with microprocessor 460 , circuit board 459 , and computer interface 466 . Removable flash memory 462 is a solid-state storage device used for easy and fast information storage of the data log generated by microprocessor 460 running its corresponding software application. Removable flash memory 462 is well known in the computer field and one of the many suitable flash memory cards such as, for example, a SmartMedia Card, a MultiMedia Card, or a CompactFlash Card along with others may be used for removable flash memory 462 . The data is stored so that it may be retrieved from removable flash memory 462 at a later time.
When console assembly 410 is removed from procedure unit 12 or another external monitor, battery 464 , which can be comprise lithium ion, supplies power to the components in console box 420 including microprocessor 460 . Microprocessor 460 along with its software application and removable flash memory 462 can digitally communicate its data through computer interface 466 . Computer interface 466 can include, but is not limited to, a standard serial port, a USB port, an IEEE1394 port, a RS232 port, or an Ethernet port. Computer interface 466 sends data formatted by the software application to be printed as a patient report. In addition, removable flash memory 462 can be removed from console box 420 and inserted in one of many compatible flash memory card readers so that the data may be downloaded on a personal computer or handheld device.
During a surgical procedure using console assembly 410 of the present invention, the patient is first admitted and prepped for the procedure. During this stage, a health care clinician or surgeon connects various vital monitors such as, for example, a pulse oximeter monitor on the patient. Cables 430 associated with these monitors are connected to the respective receptacle 432 on console box 420 . A patient record is then initiated through microprocessor 460 and its software application in flash memory 462 and data from the patient such as vitals from cables 430 can now be stored in flash memory 462 . Next, the patient is moved to the procedure room and console assembly 410 connects to procedure unit 12 or other medical monitoring devices. Flash memory 462 continues to collect data for the patient record gathering information via microprocessor 460 from cable 430 and procedure unit 12 including, but not limited to, vital signs, drugs delivered, and other physiological parameters. After the procedure is complete console box 420 is disconnected from procedure unit 12 , and the patient is moved to a recovery and discharge stage. During this stage, flash memory 462 continues to gather data from cable 430 including, but not limited to vitals and post-op drugs. When the patient is ready for discharge, flash memory 462 stops taking data and closes the patient record.
Referring now to FIG. 4 , procedure unit 12 allows a physician to safely deliver drugs, such as a sedative or analgesic drug to a patient and monitor the patient during the medical procedure. Procedure touch screen assembly 62 is a display device that is integrated into the surface of procedure unit 12 , which displays patient and system parameters, and operation status of the apparatus. In one embodiment, procedure touch screen assembly 62 consists of a 15″ resistive touch screen manufactured by MicroTech mounted upon a 15″ color LCD manufactured by Samsung. It should be noted that procedure touch screen assembly 62 is the primary display and input means, and is significantly larger than the bedside touch screen assembly 22 and capable of displaying more detailed information. In addition to procedure touch screen assembly 62 , the user may input information into procedure unit 12 by means of drug delivery controls 80 . Drug delivery controls 80 , such as bottons or dials, are located on one side of procedure unit 12 and preferably, allow the clinician to change various system parameters and bypass procedure touch screen assembly 62 . Printer 70 is integrally attached to the top of procedure unit 12 . Printer 70 allows the clinician to print a patient report that includes patient data for pre-op and the procedure itself. The combination of printing a patient report and the automatic data logging features decrease the amount of time and effort a nurse or technician must spend regarding patient condition during the course of a procedure. Printer 70 receives data signals from a printer interface (e.g., Parallel Systems CK205HS), which is located on the main logic board. Printer 70 may be a thermal printer (e.g., Advanced Printing Systems (APS) ELM 205HS).
Memory card reader 85 , which includes a slot in the outer casing of procedure unit 12 , allows flash memory card 84 to be inserted and removed from procedure unit 12 . Flash memory card 84 is a solid-state storage device used for easy and fast information storage of the data log generated by procedure unit 12 . Flash memory card 84 is well known in the computer field and one of the many suitable removable flash memory cards as for example, a SmartMedia Card, a MultiMedia Card, or a CompactFlash Card, may be used with memory card reader 85 . The data is stored so that it may be retrieved from flash memory card 84 at a later time. In one embodiment, memory card reader 85 accepts flash memory card 84 containing software to upgrade the functionality of patient care system 5 . Data port 88 can include, but is not limited to, a standard serial port, a USB port, a RS232 port, or an Ethernet port. Data port 88 is useful to link procedure unit 12 to an external printer to print a patient report or to transfer electronic files to a personal computer or mainframe. In an alternate embodiment, data port 88 can be a wireless transmitter interacting with a wireless receiver connected to a printer or an external computer or mainframe.
Referring also to FIGS. 4-B and 4 -C, procedure unit 12 delivers fluid to a patient via an infusion pump, such as a peristaltic infusion pump 72 (e.g., B-Braun McGaw). Peristaltic infusion pump 72 is integrally attached to procedure unit 12 . A peristaltic infusion pump uses peristaltic fingers to create a wavelike motion to induce fluid flow inside a flexible tube connected to a fluid reservoir. Drug cassette 64 is a generally rectangular shaped structure that is placed adjacent to peristaltic infusion pump 72 . Drug cassette 64 is preferably made of a rigid thermoplastic such as, for example, polycarbonate. Drug cassette 64 has an internal cavity that houses IV tubing 76 , preferably made of a flexible thermoplastic such as, for example, polypropylene (e.g., Kelcourt). Drug cassette 64 accurately and reliably positions exposed IV tubing 76 in contact with the peristaltic fingers of peristaltic infusion pump 72 . IV tube set 76 attaches to fluid vial 68 , and the majority of the length of IV tube set 76 is contained within drug cassette 64 . A small portion of IV tube set 76 lies external to drug cassette 64 to facilitate the interaction with peristaltic pump 72 . IV tubing 76 is coiled within drug cassette 64 and has a length to reach a patient removed from the procedure unit 12 . Mounted upon one inner wall of drug cassette 64 is fluid detection sensor 302 . Fluid detection sensor 302 may be any one of known fluid sensors, such as the MTI-2000 Fotonic Sensor, or the Microtrak-II CCD Laser Triangulation Sensor both by MTI Instruments Inc. Fluid detection sensor 302 can be fixedly attached to drug cassette 64 using an attachment means including, but not limited to, glue, mechanical fasteners, screws, and ultrasonic welding. Preferably, IV tube set 76 runs through fluid detection sensor 302 before exiting drug cassette 64 .
In one embodiment of a method of operation, procedure unit 12 in combination with drug cassette 64 and peristaltic infusion pump 72 “auto prime” IV tubing 76 so the clinician does not have to take the time to manually prime IV tubing 76 . Drug cassette 64 provides interlocks during the “auto prime” process to prevent the clinician from accessing the IV tubing 76 and inadvertently connect IV tubing 76 to the patient. After the auto prime feature is complete, however, the interlock is disabled and the user is able to access the IV tubing 76 , through, for example an access door, which during the auto prime feature is locked in a closed position.
Referring also to FIG. 4-A , a nurse or clinician initiates the auto priming system by pressing a button on either bedside touch screen assembly 22 or procedure touch screen assembly 62 , step 350 . Upon receiving the command to initiate the auto priming system, peristaltic pump 72 activates and begins a new pump cycle, step 352 . Peristaltic pump 72 displaces fluid from fluid vial 68 through the length of IV tube set 76 , step 354 . Fluid detection sensor 302 monitors the extreme end of the IV tube set 76 for the presence of fluids, step 356 .
Fluid detection sensor 302 continuously monitors for the presence of fluid within IV tube set 76 , step 356 . If no fluid is detected, the nurse or technician is notified by either auditory or visual alert indicating that the auto priming process is not complete, step 358 . After the alert stating that priming is not complete is given, the main logic board commands peristaltic infusion pump 72 to continue operating, step 352 . This process continues through steps 352 - 356 until fluid detection sensor 302 detects the presence of fluid and the main logic board commands peristaltic infusion pump 72 to stop until further notice, step 360 . After the pump cycle ceases, the nurse or technician is notified by either a visual alert on either bedside unit 10 or procedure unit 12 , or by an auditory alert indicating the auto priming system has successfully primed the pump, step 362 .
FIG. 4-C shows an alternate embodiment of the automatic priming system. Fluid detection sensor 302 is integrated with peristaltic pump 72 or another stable structure adjacent to drug cassette 64 . In this embodiment, drug cassette 64 contains two exposed portions of IV tube set 76 , a first portion 320 , and a second portion 322 . First portion 320 allows peristaltic pump 72 to manipulate IV tube set 76 in order to pump fluid through the line. Second portion 322 is placed adjacent to fluid detection sensor 302 . Upon detection of fluid in second portion 322 , peristaltic pump 72 continues to operate for a short time to ensure that no air remains in IV tube set 76 . This time is determined by the main logic board located inside procedure unit 12 calculating the length of IV tube set 76 downstream second portion 322 and the speed at which peristaltic pump 72 is operating. Upon the allotted time has expired, peristaltic pump 72 will cease the pump cycle and IV tube set will be fully primed.
Referring now to FIG. 5 , communication cable 14 contains a plurality of centralized pneumatic tubes surrounded by a plurality of electrical wires. Oxygen conduit 100 is a pneumatic tube that delivers oxygen traveling from an external oxygen source through procedure unit 12 to bedside unit 10 . Oxygen conduit 100 runs the length of communication cable 14 and terminates at oral nasal cannula 48 . Exhaled gas conduit 102 is also a pneumatic tube that transports a patient's exhaled respiratory gases from oral nasal cannula 48 through cable pass-through connection 15 and terminates in procedure unit 12 . ECG conduit 104 contains a plurality of electrical wires known as ECG leads 51 . ECG leads 51 receive electrical signals from ECG pads 50 that are communicated to procedure unit 12 for data processing. NIBP conductor 106 transmits processed information of a patient's blood pressure from bedside unit 10 to procedure unit 12 . Pulse oximeter conductor 108 transmits processed information of a patient's oxygen saturation level from bedside unit 10 to procedure unit 12 . ART response conductor 110 transmits processed information regarding a patient's response to ART stimuli from bedside unit 10 to procedure unit 12 .
As shown in FIG. 7 , a data flow diagram outlines the typical process of the pre-procedure room. As shown, the patient arrives in the pre-procedure room, step 200 . A nurse or technician mounts bedside unit 10 to either the bedrail or IV pole, step 201 . Bedside unit 10 is equipped with an IV pole clamp or a quick connect to quickly and easily mount the unit on either the bedrail or IV pole. Once bedside unit 10 is in place, the nurse or clinician may connect NIBP cuff 58 and pulse oximeter probe 60 to the patient, step 202 . These connections are made between the patient and bedside unit 10 . Bedside unit 10 will automatically begin monitoring parameters such as, for example, diastolic and systolic blood pressure, mean arterial pressure, pulse rate, oxygenation plethysmogram, and oximetry value, steps 203 , 204 . The readings taken by bedside unit 10 will be displayed for the nurse or technician on bedside touch screen assembly 22 . While patient parameters are being monitored, the nurse or technician is free to perform other tasks. As is customary with current practice, the nurse or technician may need to complete a pre-procedure assessment, step 206 . The pre-procedure assessment may include recording patient vital signs, determining any known allergies, and determining patient's previous medical history. Once the nurse or technician has completed the pre-procedure assessment, step 206 , the nurse or technician may start the peripheral IV by placing a catheter in the patient's arm, step 207 . The IV catheter is connected to the primary IV drip device such as, for example, a 500 mL bag of saline fluid. Upon completion of the above activities, the nurse or technician begins to attach ECG pads 50 , ART handpiece 57 , ART earpiece 55 and oral nasal cannula 48 to the patient, step 208 . Preferably, patient care system 5 has the capability to automatically detect and recognize the proper connection of the monitors when they are connected from the patient to bedside unit 10 .
Once the patient is connected to the above-mentioned items, the nurse or technician may explain ART system 52 to the patient. This explanation may involve the nurse or technician instructing the patient to respond to auditory stimulation from ART earpiece 55 and/or tactile stimulation from ART handpiece 57 by squeezing ART handpiece 57 . If the patient fails to respond to either auditory or tactile stimulation, the intensity of the stimulation will increase until the patient responds successfully. At this point, the nurse may initiate an automated ART training, step 209 . Automated ART training is a program run by bedside unit 10 that teaches the patient how to detect an ART stimulus and how to respond to that stimulus and sets a baseline patient response to the stimulus as disclosed in the previously referenced U.S. patent application Ser. No. 10/674,160. The nurse or technician is free to perform other patient related tasks while the patient is participating in the automated ART training. Bedside unit 10 will display the automated ART training status so the nurse or technician can quickly determine if the patient is participating in the automated training. The patient must successfully complete the automated ART training to proceed, step 210 ; if the patient fails to complete the training a nurse or other clinician must intervene and determine if the patient may continue, step 210 -A. If the clinician decides the user may proceed, then the patient will proceed to step 211 ; if the clinician decides the patient is unable to continue, then the procedure will be canceled, step 213 . The user may customize the automated ART training to automatically repeat at specified intervals (i.e. 10 minutes) if the patient is required to wait to enter the procedure room. This will help to instill the newly learned response.
In addition to successfully completing automated ART training, the patients parameters must be in an acceptable range, step 205 . The clinician may decide upon what an acceptable range is by inputting this information into bedside unit 10 by means of bedside touch screen assembly 22 . If any one of the parameters being monitored falls outside a given range, the patient will not be permitted to undergo a procedure until a nurse or other clinician examines the patient to determine whether or not the patient may continue, step 205 -A. If the clinician decides the patient is able to continue, the patient will proceed to step 211 , if the clinician decides the patient is unable to continue, then the procedure will be cancelled, step 213 . Just prior to leaving the pre-procedure room for the procedure room, the nurse administers a predetermined low dose of an analgesic drug, step 211 such as, for example, a 1.5 mcg/kg of Fentanyl. After the injection of the analgesic drug, the patient is ready to be moved to the procedure room, step 212 .
FIG. 8 is a flow chart illustrating the implementation of the invention while the patient is in the procedure room. As shown, the patient and bedside unit 10 are moved into the procedure room, step 220 and is received by the physician and procedure nurse. Bedside unit 10 may be connected to procedure unit 12 upon the patient entering the procedure room, step 221 . Upon connection, the NIBP, pulse and oximetery history from the patient will automatically up-load to procedure unit 12 displaying patient history for the last period of monitoring. In addition to NIBP and pulse oximeter history, a record verifying the patient has completed ART training will also be uploaded. Upon connection of bedside unit 10 to procedure unit 12 , the small display on bedside unit 10 changes immediately from a monitoring screen to a remote entry screen for procedure unit 12 . Display information form bedside unit 10 is automatically transferred to procedure unit 12 .
At this point, the procedure nurse may secure oral nasal cannula 48 to the patient's face, step 222 . Procedure unit 12 may begin monitoring patient parameters such as, for example, ART, ECG, and capnography now that all connections between the patient and procedure unit 12 are complete, step 223 . Procedure unit 12 will continue monitoring patient parameters such as, for example, NIBP, pulse, and oximetery, step 224 . Next the procedure nurse may place and spike a standard drug vial, step 225 onto drug cassette 64 . Drug cassette 64 has an integrated drug vial spike that serves to puncture the rubber vial stopper as well as to allow fluid from the drug vial to enter drug cassette 64 . Next the procedure nurse needs to place drug cassette 64 adjacent to peristaltic infusion pump 72 making sure that the exposed portion of IV tubing 76 lines up with the peristaltic fingers, step 226 . Once the fluid vial and drug cassette 64 are loaded correctly, the nurse may autoprime IV tubing 76 . In one embodiment, the procedure nurse would press a button located upon procedure unit 12 to initiate the autopriming, step 227 . Autopriming is the automatic purging of air from IV tubing 76 , procedure unit 12 continuously monitors the autopriming process to determine the overall success of the autopriming. If procedure unit 12 fails to properly purge IV tubing 76 , a warning notification is made to the user so that the procedure nurse may repeat the autopriming sequence until IV tubing 76 is successfully purged, step 227 .
Upon successful completion of the autopriming sequence, the procedure nurse may enter the patient weight in pounds while the physician may enter the initial drug maintenance dose rate as well as dose method; normal or rapid infusion, step 229 . After the patient weight and dose rate have been inputted, the physician or procedure nurse may initiate drug infusion, step 230 . While the drug is taking effect upon the patient, the physician may perform standard procedure related activities such as, for example, test the scope, and apply any topical anesthetic. Once the drug has taken the desired effect upon the patient, the physician and procedure nurse are free to conduct the procedure, step 231 . Upon completion of the procedure, the clinician may disconnect the drug delivery cassette from the catheter, step 232 and disconnect the bedside unit from the procedure unit, step 233 . If the clinician so desires, procedure unit 12 may print a record of the patient's physiological parameters from printer 70 at this time, step 234 . Included on the print out of the procedure record are patient monitoring data such as, for example, NIPB, pulse oximetery, capnography, respiration rate, and heart rate. Other system events included in the print out are, ART competency, ART responsiveness during the procedure, oxygen delivery history, drug dose, monitoring intervals, drug bolus amount and time, and total drug volume delivered during the procedure. The printout includes a section where the procedure nurse may enter in notes of her own, such as, for example, additional narcotic delivered, topical spray used, Ramsey Sedation Scale, procedure start and finish time, cautery unit and settings used, cautery grounding site, dilation equipment type and size, and Aldrete Score. After printing the patient record, the patient may then be moved to the recovery room, step 235 .
As shown in FIG. 9 , a flow chart illustrating the implementation of the invention while the patient is in the recovery room. As shown, the patient arrives in the recovery room 240 still attached to bedside unit 10 after leaving the procedure room. At this point, bedside unit 10 may be operating on either battery or AC power. Upon entering the room, the attending clinician may remove the ECG pads, ECG lead wires, ART handpiece, and ART earpiece from the patient 241 . Depending upon clinician preference and status of the patient, the patient may require supplemental oxygen while in the recovery room 242 . If the patient does require supplemental oxygen, oral nasal cannula 48 is left on the patients face and oxygen is accessed from an external source such as, for example, a headwall or tank. The nurse or technician would disconnect oral nasal Cannula 48 from bedside unit 10 , plug it directly into a standard oxygen delivery extension set, and set the desired oxygen flow rate, step 243 . If no supplemental oxygen is required in the recovery room, the nurse or technician may remove oral nasal cannula 48 from the patient 244 .
The nurse or technician may now organize ECG leads 51 and ART handpiece 57 and place near bedside unit 10 to be used on the next patient 245 . The nurse or technician may need to fill out additional information on the patient record 246 . The nurse or technician will most likely write notes describing the patient's condition during recovery and record NIBP, pulse rate and oximetery values of the patient during recovery. ECG pads 50 and oral nasal cannula 48 may be discarded at this point into a standard waste container located in the recovery room 247 . It is important to note that bedside unit 10 is still collecting data related to NIBP, pulse rate, and pulse oximetery 248 . The nurse or technician must determine if the patient is ready to be discharged 249 . Criteria for discharge vary among patient care facilities, however an Alderate score of 10 is common for discharge. Other measures of discharge criteria include skin color, pain assessment, IV site intact, NIBP, pulse, respiration rate, and oximetery values all must be close to the measurement taken in pre-procedure. If the patient does not meet any of these criteria, it is recommended that the patient receive additional monitoring 248 . Once a patient is cleared for discharge, the nurse or technician disconnects NIBP cuff 58 , pulse oximeter Probe 60 , and if not done so already, oral nasal cannula 48 from the patient 250 . Once all the above is completed, the patient may be discharged from the care facility 251 .
The foregoing description of several expressions of embodiments and methods of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise forms and procedures disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto.
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Disclosed is a patient monitoring and drug delivery system and associated methods for use during diagnostic, surgical or other medical procedures. The functionality of the invention enables many time consuming and laborious activities to be minimized or moved to a part in the procedure where time is not as critical. The invention is capable of increasing practice efficiency in patient care facilities through system architecture and design into two separate units. A patient unit receives input signals from patient monitoring connections and outputs the signals to a procedure unit. The procedure unit is operational during the medical procedure and controls the delivery of drugs to the patient.
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[0001] This is a continuation-in-part application of U.S. patent application Ser. No. 10/335,314 filed on Dec. 31, 2002, the contents of which are incorporated herewith for reference. The present invention relates to a method for reducing production of slime and a mixture making the same, and more particularly to a method and mixture for reducing production of slime by utilizing a dispersing agent and a benefit microorganism having an inhibition/sterilization ability.
FIELD OF THE INVENTION
Background of the Invention
[0002] During a papermaking process, the waste pulp is always recycled. However, because a starch and a coating in the waste paper provide an excellent nutrition source, it believed that they are the main contaminating source for the microorganisms including bacteria and fungus. Otherwise, for reducing consumption of the water, the papermaking factory usually adopts an airtight water cycle system. However, this condition also provides favorable growth conditions for every kind of microorganism, e.g., temperature, pH, and nutrition. Consequently, a multiplicity and growth of the microorganism will be more intensified so as to cause a problem of an excess of microorganism. The formation of slime at the wet end of the papermaking process is a very serious problem in the papermaking factory.
[0003] A slime produced at the wet end during the papermaking process will cause the problems of foul smell, paper break and holey, and foxing. All these problems will seriously influence the paper quality and then cause a business trouble which will not only increase the cost owing to the indemnity, but also destroy the reputation.
[0004] For preventing the production of the slime, most papermaking factories mainly utilize an organic biocide to reduce the amount of the slime producing microorganisms in the papermaking process and further reduce the slime production so as to solve the problems caused by the slime, e.g., holes in the paper and paper break. However, because the chemical synthesized biocides all are potentially or immediately poisonous to the environment, human beings, and animals, and also because of environmental consciousness, the standards for how to use and dispose the harmful chemicals have become increasingly strict. Consequently, looking for a non-poisonous and unharmful natural prevention method is an important challenge, and research into a mixture which utilizes a local screened antagonist is one topic thereof.
SUMMARY OF THE INVENTION
[0005] It is therefore an object of the present invention to reduce the slime production during the papermaking process so as to solve the problems caused by slime.
[0006] It is a further object of the present invention to add a benefit microorganism, which does not cause the slime, into a system including white water and substances for preventing or reducing the production of slime.
[0007] It is an additional object of the present invention to add a dispersing agent which has an ability of inhibiting the adhesion between the microorganism and the additives during the papermaking process so as to achieve the purpose of inhibiting or reducing a production of slime.
[0008] In accordance with one aspect of the present invention, a method for reducing a production of build-up slime of a papermaking material consisting essentially of a white water and a waste paper pulp in a papermaking process is provided. The method includes steps of: adding a dispersing agent into the papermaking material to obtain a first mixture; mixing and culturing the mixture; adding an antagonist into the first mixture to obtain a second mixture; mixing and culturing the second mixture for reducing the slime; and re-adding the antagonist into the mixed and cultured second mixture after a specific time period for further reducing the slime, wherein the antagonist is a microorganism being Streptomyces bikiniensis.
[0009] Preferably, the antagonist is in an amount of 10 7 /L after being cultivated for 24 hrs.
[0010] Preferably, the dispersing agent is selected from a group consisting of Lignosulfonate, Di-alkyl sulfosuccinate, and Nonionic surfactants).
[0011] Preferably, the specific time period is seven days.
[0012] In accordance with another aspect of the present invention, a method for reducing a production of build-up slime of a papermaking material consisting essentially of a white water and a leaf bleached kraft pulp in a papermaking process is provided. The method includes steps of: adding a dispersing agent into the papermaking material to obtain a first mixture; mixing and culturing the first mixture; adding an antagonist into the first mixture to obtain a second mixture; and mixing and culturing the second mixture for reducing the slime, wherein the antagonist is a microorganism being Streptomyces bikiniensis.
[0013] Preferably, the antagonist is in an amount of 10 7 /mL after being cultivated for 24 hrs.
[0014] Preferably, the dispersing agent is selected from a group consisting of Lignosulfonate, Di-alkyl sulfosuccinate, and Nonionic surfactants.
[0015] In accordance with another aspect of the present invention, a mixture for reducing a production of build-up slime in a papermaking process is provided. The mixture includes a papermaking material consisting essentially of a white water and a leaf bleached kraft pulp, a dispersing agent, and an antagonist being microorganism Streptomyces bikiniensis.
[0016] Preferably, the antagonist is in an amount of 10 7 /mL after being cultivated for 24 hrs.
[0017] Preferably, the dispersing agent is selected from a group consisting of Lignosulfonate, Di-alkyl sulfosuccinate, and Nonionic surfactants.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed.
EXAMPLE 1
The Effect of the Antagonist and the Dispersing Agent on the Formation of the Deposit
[0019] The experimental steps are described as follows:
[0020] Cultures which are isolated from the slime are cultivated in a NB cultivation liquid for 21-24 hours. Then, 1 mL culture liquids of the isolated cultures are centrifuged in 15000 rpm for 1 min and the supernatants thereof are removed. All the isolated cultures are re-suspended by adding 1 mL sterile water, and then each re-suspended culture is inoculated into a flask which already contains sterile white water 100 mL and 3 g LBKP pulp. Later, different dispersing agents are added into different flasks of each kind of culture to obtain different mixtures. The mixtures are cultivated in an incubate shaker at 40° C., 70 rpm. After being mixture cultivated for 3 hours, 3 mL antagonist C5 ( Streptomyces bikiniensis ) which has been amounted to 10 7 /mL after being cultivated for 24 hours is added thereinto to obtain another mixture. The mixture are cultivated in the incubate shaker again at 40° C., 70 rpm. After 7 days, the production of the deposit is recorded.
[0021] The whole experiment is separated into six groups.
[0022] There are two contrast groups:
[0023] 1: Only incubate the antagonist C5 without incubating the culture isolated from the slime; and
[0024] 2: Do not incubate any culture.
[0025] There are four experimental group:
[0026] 3: Only incubate the culture isolated from the slime without incubating the antagonist C5;
[0027] 4: Incubate both the culture isolated from the slime and the antagonist C5;
[0028] 5: Incubate the culture isolated from the slime and the dispersing agent; and
[0029] 6: Incubate the culture isolated from the slime, the dispersing agent, and the antagonist C5.
[0030] The groups described above are double checked and all experiments are repeated at least once. Deposit % is calculated by the formula as follows:
Deposit % = Deposit dry weight of experimental group Deposit dry weight of the culture isolated from slime × 100 %
[0031] Results:
[0032] The experimental results of “The effect of the antagonist and the dispersing agent on the formation of the deposit” are shown in Table 1.
TABLE 1 The result of the effect of adding antagonist and disperaing agent on the slime formation. Deposit (%) Process method of the slime Culture isolated from slime 100.0 Isolated culture + dispersing agent B100 113.0 Isolated culture + dispersing agent S100 53.0 Isolated culture + dispersing agent H40 126.0 Isolated culture + dispersing agent P100 112.0 Isolated culture + dispersing agent Bu200 211.0 Isolated culture + Antagonist C5 53.0 Isolated culture + dispersing agent B100 + 74.6 Antagonist C5 Isolated culture + dispersing agent S100 + 49.0 Antagonist C5 Isolated culture + dispersing agent H40 + 46.0 Antagonist C5 Isolated culture + dispersing agent P100 + 105.0 Antagonist C5 Isolated culture + dispersing agent Bu200 + 66.4 Antagonist C5 Antagonist C5 24.7 The contrast group without any additives 12.0
[0033] Please refer to Table 1 which shows the experimental results of Example 1. Firstly, let's focus on the groups which are only added dispersing agent. Obviously, in the result of adding dispersing agent S100 (Di-alkyl sulfosuccinate), the deposit amount is reduced to 53%. Compared to the contrast group (100%) which is only added the culture isolated from the slime, the deposit amount is significantly different, namely, the dispersing agent (S100) has a good dispersing ability for the formation of the slime.
[0034] Moreover, in the groups which additionally add antagonist C5 after adding the dispersing agent, the deposit amount is 74.6% when the dispersing agent is B100 (Lignosulfonate), the deposit amount is 49% when the dispersing agent is S100, the deposit amount is 46% when the dispersing agent is H40 (Nonionic surfactants), the deposit amount is 105% when the dispersing agent is P100 (Polyethylene glycol), and the deposit amount is 66.4% when the dispersing agent is Bu200 (Nonionic surfactants). As shown above, these five groups show obvious reductions when compared to the contrast deposit 100%. According to the result, the addition of the antagonist C5 is positive to inhibit/reduce the slime formation. Furthermore, no matter which dispersing agent is added with the antagonist C5, after adding the antagonist C5, the deposit amount can be further reduced actually. Thus, this experiment improves that the antagonist owns the ability to reduce the slime production.
EXAMPLE 2
The Track Experiment of Periodically Adding the Antagonist
[0035] The experimental steps are described as follows:
[0036] Cultures which are isolated from the slime are cultivated in a NB cultivation liquid for 21-24 hours. Then, 1 mL culture liquids of the isolated cultures are centrifuged in 15000 rpm for 1 min and the supernatants thereof are removed. All the isolated cultures are re-suspended by adding 1 mL sterile water, and then each re-suspended culture is inoculated into a flask which already contains sterile white water 100 mL and 3 g LBKP pulp. Later, different dispersing agents are added into different flasks of each kind of culture to obtain different mixtures. The mixtures are cultivated in an incubate shaker at 40° C., 70 rpm. After being mixture cultivated for 3 hours, 3 mL antagonist C5 ( Streptomyces bikiniensis ) which has been amounted to 10 7 /mL after being cultivated for 24 hours is added thereinto to obtain another mixture. The mixture are cultivated in the incubate shaker again at 40° C., 70 rpm. After 7 days, the production of the deposit is recorded and simultaneously the antagonist C5 is re-added thereinto. Then, the final deposit amount after another 7 days (total 14 days) is also recorded.
[0037] The whole experiment is separated into four groups.
[0038] There are two contrast groups:
[0039] 1: Only incubate the antagonist C5 without incubating the culture isolated from the slime; and
[0040] 2: Do not incubate any culture.
[0041] There are four experimental group:
[0042] 3: Only incubate the culture isolated from the slime without incubating the antagonist C5; and
[0043] 4: Incubate both the culture isolated from the slime and the antagonist C5.
[0044] The groups described above are double checked and all experiments are repeated at least once. Deposit % is calculated by the formula as follows:
Deposit % = Deposit dry weight of experimental group Deposit dry weight of the culture isolated from slime × 100 %
[0045] Results:
[0046] The experimental results of “The track experiment of periodically adding the antagonist” are shown in Table 2.
TABLE 2 The result of the track experiment of periodically adding the antagonist Deposit % Deposit % Process method (Day 7) (Day 14) Culture isolated from slime 100.0 100.0 Culture isolated from slime + 29.0 87.0 Antagonist C5 Culture isolated from slime + 28.0 Antagonist C5 (Day 7) + Antagonist C5 Antagonist C5 31.0 35.0 Contrast group without any additives 27.0 24.0
[0047] Please refer to Table 2. In the group which contains the culture isolated from the slime, the deposit amount is 29% after adding the antagonist C5 and cultivating for 7 days. Compared to the contrast deposit 100% which is only added the culture isolated from slime, the difference is strictly obvious. However, the difference will be gradually reduced corresponding to the increase of the cultivation time (the deposit amount is 87% when Day 14). But, if another antagonist C5 is added at Day 7, the deposition at Day 14 (after another 7 days) will be still remained as 28% which is obviously different from the contrast deposit 100%. According to the result, the periodical addition (7 days) of the antagonist C5 is positive to inhibit/reduce the adhesion of the deposit. Consequently, if it can utilize this method of adding the antagonist C5 periodically to easily control the production of the slime, this will be a convenient and fast way for the industry. Furthermore, if take 7 days as a period, it will not be a highly concentrated time period, so that it will not consume too much labor and is really a practicable method.
[0048] In view of the aforesaid, through the proving of the experiments, the mixture of the dispersing agent and the local antagonist and the method utilizing the same according to the present invention can actually and efficiently reduce the production of the slime during the papermaking process, solve the problems caused by the slime, such as paper holes, and paper break, and further improve the quality of the paper. Moreover, the method for reducing the slime production and the mixture making the same according to the present invention can substitute for the organic biocide and will not endanger the natural environment, so that it conforms to the standard of the environmental protection and the environmental consciousness. More importantly, the present invention can easily improve the slime problem in the original papermaking process without increasing the production costs. Consequently, this is really an invention with creativity and industrial value.
[0049] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements 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. Therefore, the above description and illustration should not be taken as limiting the scope of the present invention which is defined by the appended claims.
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A method for reducing a production of a build-up slime in a papermaking process is provided. The method includes steps of adding a dispersing agent into the papermaking material to obtain a first mixture, mixing and culturing the first mixture, adding an antagonist into the first mixture to obtain a second mixture, mixing and culturing the second mixture for reducing the production of the slime, and re-adding the antagonist into the mixed and cultured second mixture after a specific time period for further reducing the production of the slime.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 10 2011 018 159.8, filed Apr. 19, 2011, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The technical field generally relates to a device and method for assisting a driver of a motor vehicle when changing between lanes of a multilane road.
BACKGROUND
A driver assistance device for a motor vehicle that monitors a lane adjacent to the lane traveled by the motor vehicle for the presence of other vehicles and outputs a warning signal to the driver of the motor vehicle if a change to this adjacent lane would result in a conflict with a vehicle already located on the lane is known, e.g., from DE 199 21 449 C1. This known driver assistance device monitors a so-called blind spot section, i.e., a region located laterally behind the vehicle carrying the driver assistance device. This blind spot section typically can only be monitored with difficulty by the driver of the vehicle by means of rearview mirrors and vehicles approaching from the rear can easily be overlooked.
This typical driver assistance device cannot respond to a vehicle that moves in parallel to the vehicle carrying the driver assistance device to the lane adjacent to the neighboring lane, because otherwise the driver would also refrain from a change to the closest adjacent lane when this lane is actually free.
A hazardous situation that typical lane change driver assistance devices are not capable of catching occurs if two vehicles attempt to merge from different directions onto a lane located between them. Such a situation can occur in particular if, as schematically shown in FIG. 1 , a first motor vehicle 1 on a passing lane 4 of a freeway passes a motor vehicle 2 moving on the right lane 5 at the level of an entry 6 and simultaneously a third motor vehicle 3 attempts to reach the right lane 5 from the entry 6 . In particular if the second vehicle 2 is a truck, the driver of the motor vehicle 1 generally cannot see the traffic on the entry 6 while he passes the truck 2 , and the driver of the vehicle 3 also has no possibility of seeing the vehicle 1 before it has passed the truck 2 . Therefore, if both other vehicles only pay attention to the truck 2 while merging, an accident can easily occur.
It is at least one object to provide means that help the driver of a motor vehicle to avoid such a hazardous situation. In addition, other objects, desirable features and characteristics will become apparent from the subsequent summary and detailed description, and the appended claims, taken in conjunction with the accompanying drawings and this background.
SUMMARY
A driver assistance device for a motor vehicle is provided. The driver assistance device has an environmental sensor for monitoring a monitoring space extending laterally from the motor vehicle for the presence of an object therein. The driver assistance device also includes an analysis unit receiving a detection signal of the environmental sensor for estimating a possible endangerment of the motor vehicle by an object present in the monitoring space and for delivering at least one result signal representative of the endangerment. The analysis unit is configured to judge on the basis of the detection signal whether an object present in the monitoring space is approaching a lane adjacent to the lane traveled by the motor vehicle and to signal the result of the judgment in a result signal.
According to a first embodiment, the environmental sensor can comprise a receiver for a signal, which is emitted from a foreign vehicle present in the observation space and indicates an imminent or occurring lane change of the foreign vehicle. Such a signal can be a radio signal, for example, which is emitted from the foreign vehicle when the driver of the foreign vehicle actuates a turn signal on the side of the foreign vehicle facing toward the adjacent lane, or it can be automatically generated by the foreign vehicle if a lane departure warning signal of the foreign vehicle registers an approach of the foreign vehicle on the adjacent lane or a beginning change to this lane. Alternatively or additionally, the receiver of the environmental sensor can also comprise an optical sensor which responds directly to the light of the turn signal of the foreign vehicle.
Furthermore, the environmental sensor can alternatively or additionally also comprise a transmitter which emits a scanning signal into the monitoring space and a receiver for receiving an echo of the scanning signal reflected from an object in the monitoring space. Such a transceiver arrangement allows the recognition of an approach of a foreign vehicle on the adjacent lane in particular if the foreign vehicle neither provides a radio signal nor indicates his lane change intention by actuating a turn signal.
Furthermore, the environmental sensor is expediently to be configured to detect a delimitation of the adjacent lane. If the environmental sensor comprises a camera for this purpose, this camera can also be used to detect a turn signal of a foreign vehicle as explained above.
Based on the detection of the lane delimitation, the analysis unit can compare the distance of the motor vehicle, measured transversely to the longitudinal direction of the motor vehicle, from the object to the distance of the motor vehicle from the delimitation and indicate in the result signal if the distance of the motor vehicle from the object decreases more rapidly than the distance of the motor vehicle from the delimitation. If this is the case, this indicates that the object or foreign vehicle is on the point of advancing onto the adjacent lane and therefore the danger of contact exists.
However, the detection of the lane delimitation can also be used for the purpose of automatically detecting the intention of the driver of the motor vehicle to change to the adjacent lane. As long as the motor vehicle does not approach the delimitation, there is no danger of a collision with a foreign vehicle possibly advancing on the adjacent lane, so that the driver also does not need to be irritated by a warning about the foreign vehicle. However, if the intention of the driver to change lanes may be recognized from the monitoring of the distance from the delimitation, then the judgment result is to be signaled, in order to possibly also notify the driver of an endangerment by the foreign vehicle.
In a similar way, the driver assistance device according to an embodiment can recognize the intention of the driver to change lanes as a function of whether or not he has set a turn signal in the direction of the monitoring space. If the turn signal is not set and also no other suggestion of a lane change intention of the driver is recognizable, the result of the judgment does not need to be signaled; however, if the turn signal is set, the result is to be signaled.
Estimating a speed component of the motor vehicle transversely to its longitudinal direction and displaying it in the result signal if the distance of the motor vehicle from the object measured transversely to the longitudinal direction decreases more rapidly than is to be expected on the basis of the estimated speed component comes into consideration as an alternative or supplementary approach for recognizing a possible endangerment. In this way, it can be decided without reference to a lane marking whether an approach between the motor vehicle and the object is caused solely by the movement of the motor vehicle, or whether an intrinsic movement of the object contributes thereto. In an embodiment, the speed component oriented transversely to the longitudinal direction of the motor vehicle can be estimated in particular on the basis of a steering angle set on the motor vehicle.
Furthermore, in another embodiment, the analysis unit is configured to derive the curvature of one of the lanes based on map data, which can be provided by a vehicle navigation system, for example. The analysis unit rectifies the estimated speed component by a curve-related fraction, taking into consideration in this manner that when the object detected in the monitoring space is a foreign vehicle, it will follow the curvature of its lane, even if it is not changing lanes.
The result signal is preferably used to activate a signal generator perceptible to the driver, which is preferably optical, acoustic, or haptic; under certain circumstances, it can also be used for an automatic engagement in the steering of the motor vehicle. Optic or acoustic signal generators are preferably each provided in pairs, each in spatial assignment to monitoring spaces on different sides of the motor vehicle. The haptic signal generator, for example, an actuator, uses a counterforce and opposes a steering movement of the driver toward the side of a monitoring space in which an endangerment was established.
In another embodiment, a method for assisting a driver of a motor vehicle is provided. The method includes monitoring a monitoring space located laterally to the motor vehicle for the presence of an object, judging whether an object present in the monitoring space is approaching a lane adjacent to a lane traveled by the motor vehicle, and signaling the result of the judgment in a detection signal.
In a further embodiment, a computer program product having program code means, which make a computer capable of operating as an analysis unit in a driver assistance device as described above or of executing the above-described method, is provided. Such a computer program product can be provided in a form stored on a computer-readable data carrier or also in a form not bound to a data carrier.
BRIEF DESCRIPTION OF THE DRAWINGS
The present embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
FIG. 1 illustrates a potentially hazardous situation in which two motor vehicles attempt to pass a truck; and
FIG. 2 is a block diagram of driver assistance devices using a method for assisting a driver of a motor vehicle when changing between lanes of a multilane road in accordance with an exemplary embodiment.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the application and uses contemplated herein. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
Referring again to FIG. 1 , the motor vehicle 1 is equipped with a driver assistance device according to an exemplary embodiment. Ambient sensors of the driver assistance device are arranged on both sides of the motor vehicle 1 , for example, on its outside mirrors, to monitor monitoring spaces 7 on the left and right of the vehicle 1 . The boundaries of each monitoring space 7 can be defined, e.g., if the ambient sensor is a camera or a receiver of other than optical rays, in particular radio waves, by the spatial angles from which the sensor can receive radiation. In FIG. 1 , the boundaries of the monitoring spaces 7 are defined by dot-dash lines incident on one another at the location of the outside mirrors. In addition a restriction of the monitoring space to a predefined distance from the vehicle 1 , as symbolized by shaded surfaces, can be performed based on triangulation or runtime measurements, for example.
In the traffic situation shown in FIG. 1 , the right monitoring space 7 in relation to the travel direction of the motor vehicle 1 is completely blocked by the truck 2 . The truck is too close to be detected as an object in the monitoring space 7 because it is located on the lane 5 directly adjacent to the lane 4 of the motor vehicle 1 . Monitoring space 7 is essentially restricted to the lane 6 next to the closest lane—however, the truck prevents the detection of the foreign vehicle 3 actually located in the monitoring space 7 . The path is free so that the driver assistance device of the motor vehicle 1 can perceive the foreign motor vehicle 3 only when the truck 2 has fallen back in relation to the vehicles 1 , 3 farther than shown in the figure.
FIG. 2 shows a block diagram of an embodiment of the driver assistance device. Of the manifold components of this assistance device, all do contribute to the utility of the driver assistance device; however, many of them can be left out without putting the functionality of the driver assistance device into question.
The core component of the driver assistance device is a microcomputer 10 . This microcomputer 10 can exclusively be used to implement the driver assistance device; however it can also be a microcomputer having a part of its computing capacity used for other control and monitoring tasks in the motor vehicle 1 , which is made capable by a suitable program stored in its operating memory 11 of operating as an analysis unit in the scope of the driver assistance device. In particular, a computer readable medium of the microcomputer ma embodying a computer program product, the computer program product including a driver assistance program configured to assist a driver of a motor vehicle as contemplated herein.
The microcomputer 10 is connected in the illustration of FIG. 2 to a plurality of ambient or environmental sensors such as a radar or lidar transceiver 12 , a camera 13 , and a radio transceiver 14 . Alternative embodiments can have one or two of these types of environmental sensors and also other types of environmental sensors
Transceiver 12 and camera 13 are each provided in pairs, one for each monitoring space 7 , on the vehicle 1 . Because the monitoring of both monitoring spaces 7 functions identically, only one of these environmental sensors is discussed in each case in the following description.
The transceiver 12 emits a radio or light (in particular, infrared (IR)) scanning signal in the direction of the assigned monitoring space 7 and collects reflected echoes of this scanning signal. Through triangulation, runtime analysis, or the like, echoes of objects whose distance from the motor vehicle 1 transversely to its longitudinal direction is less than one or significantly more than two lanes can remain unconsidered, and the monitoring space 7 can thus be effectively restricted to the shaded area 7 in FIG. 1 .
The camera 13 can also be positioned on one of the outside mirrors and can be aligned therefrom on the monitoring space 7 . The estimation of the distance to a foreign vehicle 3 in the monitoring space 7 can be performed in that the microcomputer 10 recognizes the image of a foreign vehicle in the images delivered by the camera 13 and relates the size of the image to a reference. Of course, a stereoscopic camera can also be used as the camera 13 , or signals of the camera 13 and of the transceiver 12 can be linked in the microcomputer 10 in order to arrive at a distance estimation.
Lane delimitation markings 8 , 9 , which mark the boundaries between the lanes 4 , 5 , 6 or the edge of the drivable surface, are also in the field of vision of the camera 13 —if they are not concealed by foreign vehicles or other objects. The images of the camera 13 are therefore supplied to a lane departure warning system 15 known per se, which monitors on the basis of the figures the distance of the motor vehicle 1 to the closest-adjacent lane delimitation marking 8 and delivers a warning signal to a loudspeaker 16 , in order to warn the driver of the vehicle 1 if this distance becomes critically small or the motor vehicle 1 traverses the marking 8 . The lane departure warning system 15 is shown as a unit separate from the microcomputer 10 in FIG. 2 , however, it is typically implemented in practice in the form of software on the microcomputer 10 itself, so that at least partially identical image processing routines can be used to identify lane delimitation markings 8 and foreign vehicles 3 in the images of the camera 13 .
A warning signal generated by the lane departure warning system 15 is supplied not only to a loudspeaker 16 , but rather also to a radio transceiver 14 , in order to broadcast a corresponding warning to adjacent vehicles 2 , 3 . The radio transceiver 14 or other ambient sensors has a directional antenna 17 . This can be used to broadcast the lane change warning message undirected or, preferably, only to broadcast it on the side of the lane which the vehicle 1 has critically approached. Vice versa, the directional antenna 17 is also used to receive corresponding lane change warning messages of other vehicles, the directional characteristic of the antenna 17 being able to be used here to restrict the reception of such warning messages to foreign vehicles in the monitoring space 7 , i.e., to vehicles which are not well perceivable by the driver because they are located behind the motor vehicle 1 .
A lane change warning message received from a foreign vehicle 3 in the monitoring space 7 is relayed from the radio transceiver 14 directly to the microcomputer 10 . If the microcomputer 10 receives such a lane change warning message of a third vehicle from the transceiver 14 together with a warning signal of the lane departure warning system 15 , this means that the motor vehicle 1 and the foreign vehicle 3 are simultaneously at the point of changing to the same lane 5 , and therefore the danger of a collision exists. The microcomputer 10 reacts by activating a warning signal generator 19 , e.g., a loudspeaker or an illuminated display, which is arranged in the passenger compartment of the motor vehicle 1 on the side of the lane 5 to which the motor vehicle 1 is at the point of changing. Alternatively or additionally, an actuator engaging on the steering wheel of the motor vehicle 1 can also be provided as the signal generator 19 , which opposes a rotation of the steering wheel in the direction of the lane 5 with a counterforce clearly perceptible by the driver.
The microcomputer 10 and the lane departure warning system 15 are both connected to a turn signal switch 18 , which the driver uses to set a turn signal on the motor vehicle body to visibly indicate his lane change intention for the drivers of other vehicles. If the signal of the turn signal switch 18 indicates that the turn signal is set on the side of the lane 5 , this has the result that a critical approach of the motor vehicle 1 to the lane 5 detected by the lane departure warning system 15 is judged to be intended by the driver and does not result in the output of a warning signal via the loudspeaker 16 . However, a corresponding warning message is nonetheless broadcast to the surrounding traffic via the radio transceiver 14 . The microcomputer 10 reacts to the signal of the turn signal switch 18 precisely as to a lane change warning of the lane departure warning system 15 . If a lane change warning of a foreign vehicle 3 received by the radio transceiver 14 is coincident with a signal of a turn signal switch 18 which indicates a turn signal set toward the side of the foreign vehicle 3 , the microcomputer 10 then outputs the warning signal to the signal generator 19 .
With the aid of the radio transceiver 14 , only those foreign vehicles 3 are detected and taken into consideration which broadcast the same lane change warning messages as described above. In order to avoid a collision with the foreign vehicle 3 even if the latter does not broadcast lane change warning messages, it is necessary to estimate and monitor the distance between the motor vehicle 1 and the foreign vehicle 3 transversely to the longitudinal direction of the motor vehicle 1 . For such an estimation, as already mentioned above, measuring signals of the transceiver 12 and/or the camera 13 can be analyzed by the microcomputer 10 . Multiple analysis strategies can be used alternatively or cumulatively based on such a distance estimation.
A first such strategy is based on the other above-mentioned possibility of also monitoring the distance of the motor vehicle 1 from one of the lane delimitation markings 8 with the aid of the camera 13 . If the distance D to the foreign vehicle 3 measured transversely to the longitudinal direction of the motor vehicle 1 decreases more rapidly than the distance d of the motor vehicle 1 from the marking 8 , this means that the vehicles 1 and 3 are moving from different sides toward the lane 5 located between them. The danger of a collision exists, and the microcomputer 10 outputs the warning signal to the signal generator 19 .
A second strategy requires the microcomputer 10 to also receive measuring data from a steering angle sensor 20 and a speedometer 21 of the vehicle 1 . Based on the data of these two sensors 20 , 21 , the microcomputer 10 is capable of estimating a speed component of the vehicle 1 transversely to its longitudinal direction even without reference to an external reference object such as the lane delimitation marking 8 . If the distance D to the foreign vehicle 3 decreases more rapidly than would be expected based on this lateral speed component, there is also a collision danger, and the microcomputer 10 delivers a warning signal to the signal generator 19 .
In the simplest case, if the road on which the vehicles 1 , 3 are moving extends straight ahead, then any nonzero steering wheel angle should have the result that the motor vehicle 1 approaches an adjacent lane at a lateral speed proportional to the steering wheel angle. Therefore, according to a simple embodiment, the rate dD/dt at which the distance D to the foreign vehicle 3 should change, if it remains on its lane, can be assumed to be equal to the lateral speed.
However, this assumption does not apply if the roadway describes a curve. Both vehicles 1 , 3 must follow this curve, so that in this case the microcomputer 10 does calculate a non-negligible lateral speed of the motor vehicle 1 from the measured values of the steering angle sensor 20 and the speedometer 21 , but the distance D between the vehicles 1 , 3 can nonetheless remain equal. In contrast, if both vehicles 1 , 3 simultaneously move toward a lane located between them, the decrease |dD/dt| of the distance D can be less than the lateral speed of the motor vehicle 1 . Therefore, when establishing which rate of change of the distance D is to be expected if the motor vehicle 1 changes its lane, but the foreign vehicle 3 maintains its lane, the radius of curvature of the lane must accordingly be taken into consideration when cornering. In order to be able to estimate this radius of curvature r, the camera 13 can be used if its field of vision is large enough; however, a further camera 22 oriented in the vehicle longitudinal direction is preferably provided for this purpose. In that this camera 22 records images of the parts of the lane 4 located in front of or behind the motor vehicle 1 , the microcomputer 10 can estimate on the basis of the course of the lane delimitation markings 8 visible in these images the radius of curvature r of the lane 4 and calculate the lateral speed which the motor vehicle 1 must have so that it does not change its distance from the edges of the lane 4 traveled thereby in the course of its movement. The difference between this speed and the lateral speed calculated on the basis of the data of the steering angle sensor 20 and the speedometer 21 is the speed at which the distance D should decrease if the foreign vehicle 3 does not change its lane. If the decrease of the distance D is significantly more rapid, this means that both vehicles 1 , 3 are moving toward the same lane and a danger of collision exists.
To determine the radius of curvature r of the lanes, instead of camera images as described above, in another embodiment, data on the course of the road traveled by the motor vehicle 1 can also be used, which are provided by a vehicle navigation system 23 known per se. These data can be coordinates of the currently traveled road, for example, on the basis of which the microcomputer 10 calculates the radius of curvature of the road at the location of the motor vehicle 1 , or the navigation system 23 can be configured to deliver such radii of curvature directly to the microcomputer 10 .
The calculation of an expected rate of change of the distance D based on this radius of curvature r can be performed in the same way as described above for the radius of curvature r estimated from the camera image data.
The navigation system 23 can have a further utility for the driver assistance device according to an embodiment if it not only delivers data about the course of the traveled road to the microcomputer 10 , but rather also about the locations at which lanes of this road end. Foreign vehicles which are underway on such a lane must leave it before its end and are forced to change to an adjacent lane. The microcomputer 10 can use specifications of the navigation system 23 about the imminent end, e.g., of the lane 6 of FIG. 1 , in that a warning signal is already output to the signal generator 19 in the traffic situation shown in FIG. 1 to stop the driver of the motor vehicle 1 from a possible change to the lane 5 , although (or particularly because) the truck 2 prevents the assistance device from detecting possible foreign vehicles on the entry 6 .
In another embodiment, decision thresholds which must be exceeded as a requirement for outputting a warning signal to the signal generator 19 are reduced sometime before the end of the lane 6 to temporarily increase the readiness of the device to assume merging of a foreign vehicle from the lane 6 onto the lane 5 .
In a further embodiment, within a predefined distance before the end of the lane 6 , the microcomputer assumes the intention to change to the lane 5 of every foreign vehicle moving on this lane, even if no movement of the foreign vehicle 3 transversely to its lane yet indicates this. In other words, at a predefined distance before the end of the lane 6 , merely the presence of a foreign vehicle 3 on this lane is sufficient so that the microcomputer 10 delivers a warning signal to the signal generator 19 .
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents.
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A driver assistance device for a motor vehicle is provided. The driver assistance device includes an environmental sensor configured for monitoring a monitoring space located laterally to the motor vehicle for the presence of an object. An analysis unit is configured to receive a detection signal from the environmental sensor for estimating a possible endangerment of the motor vehicle by the object present in the monitoring space and to deliver a result signal representative of the endangerment. The analysis unit is configured to judge on the basis of the detection signal whether the object present in the monitoring space is approaching a lane adjacent to a lane traveled by the motor vehicle and to signal a result of a judgment in the result signal.
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FIELD OF THE INVENTION
[0001] This invention relates to a machine for shaping box blanks using cardboard cutouts and in particular “American box”—type cutouts, with or without flaps.
DESCRIPTION OF THE PRIOR ART
[0002] The preparation of a box blank involves a series of operations that are linked together on the shaping machine: —an operation of extracting the cutout that is stored in a storage site, —an operation of erecting the cutout in the form of a box blank, then—an operation of transferring and removing said blank.
[0003] The machine therefore comprises a plurality of juxtaposed stations, and in particular: —a storage station, or storage site, of the “fifo” type, where the cardboard cutouts are housed, —a forming station, and—a removal station with, in addition, depending on the case, a filling station that can be combined with the forming station, and a box finishing station or, for special wrappings, one or more stations for operations that consist of adjoining a base and/or a lid.
[0004] This type of machine is used in boxing installations, for example, for preparing box blanks that enable diverse and varied products, such as flasks, bottles and the like, to be wrapped and packaged.
[0005] In consideration of the wide variety of products to be wrapped, the boxing machines are increasingly versatile, i.e. they are capable of handling cutouts with a wide variety of formats in order to prepare boxes suitable for the products to be packaged.
[0006] However, this versatility has a tendency to result in relatively complex and especially bulky machines because they are designed in consideration of the largest format of cutout to be shaped in the form of boxes.
[0007] The space available for integrating this type of machine at existing sites is sometimes limited, and this integration can cause, for the operators, working conditions that are not necessarily ideal, in particular with regard to ergonomics.
[0008] The operators must indeed be capable of moving around the machine if only to supply it with cardboard cutouts. They must also be capable of moving around the machine to perform adjustments when the cutout formats are changed, or during maintenance, and they must be capable of intervening under good conditions in the event of any incident.
[0009] The development of these machines is therefore becoming increasingly complex while the delivery times for these machines are decreasing.
SUMMARY OF THE INVENTION
[0010] The invention is intended to overcome the disadvantages of the current machines by proposing an original concept that enables, first, the user requirements to be satisfied more easily, whether concerning time periods, the bulk of the machine, and so on.
[0011] It is also intended to improve the general ergonomics of the machine and the working conditions of the operators, and in particular the working conditions of the operator responsible for positioning the cutouts in the storage site.
[0012] It also enables the interventions on the machine in order to perform the necessary adjustments when changing formats to be minimized.
[0013] The original design of the machine also enables high box blank preparation speeds to be reached, and therefore enables the speed over the entire boxing line to be substantially increased.
[0014] The machine for shaping cardboard box blanks according to the invention includes, combined on a single chassis: —a storage station, or storage site, of the “fifo” type, in which the cutouts are deposited, —arm-type means with suction cups for picking up said cutouts one by one in said storage site, —arm-type means also for erecting each cutout, and—a downstream conveyor device for taking over and removing the box blanks,
[0015] which pick-up and erecting means are combined on the frame of a forming bench that is placed, as a module, between said cutout storage site and said downstream conveyor device,
[0016] which bench includes:
[0017] a ramp, such as said frame, inclined upward at an angle between 30° and 60°, approximately 45°, with respect to the horizontal, which ramp acts as a guide passage for the cutouts, and it consists of two corners arranged laterally with an adjustable spacing that corresponds to the width of the cutouts, which corners form both the soleplate and the lateral walls for said cutouts, guiding them during the trajectory between the bottom point and the top point of said ramp, in which said ramp is divided into two portions: a lower portion with a soleplate that is stationary and an upper portion, at the level of the forming station, with a soleplate that is retractable so as to enable the passage of the blank across said ramp between the lateral walls in order to be transferred to said removal conveyor device;
[0018] a transverse shaft located at the lower portion of the ramp and the frame, serving as a pivot for the extractor arms, which pick up the cutouts in the storage site, which extractor arms pivot under the effect of suitable actuator-type means;
[0019] a repository of which the reference point is located in the lower portion of said ramp, opposite the edge of the storage site outlet, in order to receive and hold the cutouts brought by said extractor arms;
[0020] a second repository of which the reference point is located at mid-height on said ramp, at the level of the inlet of the forming station, in order to wedge the cutouts before and during the forming thereof;
[0021] an inclined conveying system, which extends over the lower half of the length of said ramp in order to move said cutouts from one repository to the other, given that the distance between the two repositories is substantially greater than the largest cutout format dimension;
[0022] a device for forming each cutout, consisting of at least one forming arm, of the type with suction cups, which is pivotably connected to a transverse shaft and maneuvered by suitable actuator-type means, which transverse shaft coincides, within the cardboard thickness range, with the angle of the dihedral of the upper repository located at the level of said forming station;
[0023] a transfer device, also in the form of an arm with suction cups, pivotably connected to a transverse shaft and maneuvered by suitable means, which transfer arm participates in the forming of the cutout before bringing it, when it has become a box blank, to the downstream conveyor device.
[0024] This bench for assembly of the cutout in the form of a box blank enables, due to its inclination, the space between the storage site and the downstream portion of the machine to be reduced, and enables a constant space to be provided regardless of the formats of the cutouts to be processed with said machine.
[0025] According to another arrangement of the invention, the ramp of the forming bench comprises, in its lower portion, on its lateral corners, safety stops that are stationary, which stops also act as a repository for the cutout, and they are located on an arc of circle of which the center corresponds to the pivot shaft of the extractor arm, which arc of circle passes through the edge of the storage site outlet.
[0026] This structural arrangement enables the ergonomics of the machine to be improved. Indeed, having stationary stops that determine a stationary reference point regardless of the cutout formats enables the storage site to have a soleplate that is also stationary. With a stationary storage site soleplate, the operator performs the loading operations, with cutout packets, always at the same height, for example between 55 and 100 cm, and preferably approximately 85 cm.
[0027] Also according to the invention, the system for conveying cutouts on the forming bench consists of an endless belt of which the active side is located in the plane of the soleplate of the ramp of said bench, which belt is centered between the two extractor arms and extends between a lower pulley located upstream of the lower repository and an upper pulley located at the level of the upper repository, upstream of the inlet of the forming station, which belt comprises at least one L-shaped cleat of which the active surface, in the form of a heel, serves as a push member for the cutout, which heel acts as a positioning stop for said cutout at the level of the top reference point, at the inlet of said forming station, and it is located clearly downstream of the anchoring point of said L-shaped cleat on said belt so as to avoid any interference between said conveying system and the box blank when the latter is taken over by the transfer arms in order to be brought to the downstream conveyor device.
[0028] According to another arrangement of the invention, the belt of the conveying system comprises two diametrally-opposed cleats that push the cutouts in turns, and said two cleats serve, also in turns, as a positioning stop and a repository for said cutouts, at the level of the forming station.
[0029] Also according to the invention, the means for maneuvering the arms that transfer the blanks between the forming station and the downstream conveyor device consist of a servomotor and a connecting rod-crankshaft system inserted between the latter and said arms.
[0030] The invention also relates to the process for shaping “American box”—type cutouts by means of the machine described above, which process consists of:
[0031] picking up a cutout in the storage site by means of extractor arms;
[0032] depositing said cutout in the lower repository, which is arranged on the inclined ramp of the forming bench;
[0033] moving said cutout upward in order to bring it to the level of the forming station, in the upper repository;
[0034] erecting said cutout by means of the transfer and forming arms;
[0035] moving the box blank thus formed by means of said transfer arms, between said bench and the downstream conveyor device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Also according to the invention, the process for assembling the cutout by means of transfer and forming arms consists of:
[0037] placing the transfer arms in the active position for gripping the lower panel of the cutout;
[0038] placing the forming arm(s) in the active position for taking over the upper adjacent panel of said cutout, in which said cutout is sandwiched between said transfer and forming arms;
[0039] pivoting the forming arm by one-quarter of a circle in order to erect said cutout in the form of a sheath constituting the box blank;
[0040] releasing said upper adjacent panel, i.e. said blank, with respect to said forming arm;
[0041] retracting the upper portion of the soleplate of the ramp, at the level of the forming station;
[0042] bringing said box blank by means of said transfer arms in order to deposit it onto the downstream conveyor device, by crossing said ramp;
[0043] returning said upper portion of the soleplate to the active position in order to continue with a new cycle.
[0044] The invention will be further detailed in the following description and appended drawings, provided for indicative purposes, in which:
[0045] FIG. 1 shows, in the form of a functional diagram, seen from the side, the elements forming the machine according to the invention;
[0046] FIG. 2 is a diagrammatic plan view of the downstream conveyor device also showing the two arms that perform, in particular, the transfer and deposition of the blank on said downstream conveyor device;
[0047] FIG. 3 is a diagrammatic plan view of the bench for forming cutouts with, laterally, to the right of the diagrammatic plan, cross-section figures: FIGS. 3 a and 3 b;
[0048] FIG. 4 is a graphic and chronological representation of the movements of the various elements that contribute to the assembly of the cutouts on the forming bench;
[0049] FIGS. 5 to 9 show, in relation to FIG. 4, certain steps involved in forming the cutouts, which steps are indicated in the graphic representation of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0050] The machine, diagrammed in FIG. 1, enables “American box”—type cardboard cutouts 1 to be formed.
[0051] A cutout 1 is shown at the left of the figure, partially assembled; it comprises sides L′ and L″, which can be large or small, and sides l′ and l″, which, conversely, can be small or large. In the figure, the flaps are shown from a single side; the cutout can include them on both sides or be without flaps, in the form of a simple sheath.
[0052] These cutouts 1 are prepared in advance and, before being introduced into the machine, they are flat, and delivered in a packet on a pallet, for example.
[0053] The forming of these cutouts consists in fact of opening them up in order to create a sheath that constitutes a box blank. The actual box is then made at a so-called pressing station where the flaps are, for example, coated with glue and folded after, depending on the case, an operation of filling the blank with products to be packaged.
[0054] This forming machine includes, arranged and assembled on a chassis 2; —a storage site 3 of the “fifo” type for storing cutouts 1, —a module M or bench 4 that comprises all of the elements necessary for the actual forming of said cutouts 1 and—a conveying device 5 arranged downstream in order to take over the box blanks 6 and move them or take them away to other stations or destinations not shown.
[0055] The store 3 can comprise, as shown in the figure, a conveyor 13 that moves the cutouts 1 toward the bench 4. The cutouts are inclined toward the outlet; the alignment of their upper edge is downstream of the edge 14 that is arranged at the outlet of the storage site 3.
[0056] The upper side of the conveyor 13 acts as a soleplate 15 for the cutouts 1 and this soleplate comprises, beyond the downstream end of said conveyor 13, an extension in the form of a stationary shelf 16 that ends with the edge 14 of the storage site outlet.
[0057] The forming of a cutout 1 involves a series of operations that are linked together on the bench 4 by means of a plurality of specific elements detailed below; these different forming elements are all arranged on the same frame 20, which is itself secured to the chassis 2 of the machine. This frame 20 is inclined upward, by an angle of between 30° and 60°, on the order of 45°.
[0058] The first operation consists of picking up a cutout 1 in the storage site 3. This operation is performed by means of a pick-up device consisting of two aims 21 called extractor arms; these extractor arms 21 are pivotably connected around a shaft 22 that is located at the lower portion of the frame 20; they are maneuvered by means of an actuator 23, which is anchored on said frame 20.
[0059] The cutout 1 is deposited, by the arms 21, in an inclined passage, such as the frame 20, which forms a sort of ramp 24, which will be described in detail below in reference to FIG. 3; this cutout 1 is in fact wedged in a repository provided at the bottom portion of said ramp 24 and in particular at the level of the reference point B.
[0060] The next operation consists of bringing the cutout 1 to the forming station 30. This forming is carried out, on said machine according to the invention, at a high point, i.e. at a level that, in a manner unconventional in machines of this type, is located well above the level of the soleplate of the storage site 3, at the level of the downstream conveyor 5.
[0061] The movement of the cutout 1, between point B of the lower repository and point H of the upper repository at the level of the forming station 30, is performed by means of a conveying system 32.
[0062] Point B is a reference point that is formed by a positioning stop, as described below, in reference to FIG. 3. Point H is a virtual reference point of which the existence is dependent on elements that are associated with the conveying system 32, and of which the placement is carried out according to a cycle associated with the general cutout 1 forming cycle.
[0063] This conveying system 32 includes an endless-type belt 34, which extends between pulleys 35, 36, of which one is powered by means of a servomotor, not shown. The pulley 35 is located at the lower portion of the ramp 24, clearly upstream of point B.
[0064] This conveying system 32 is also inclined, like the ramp 24 and the frame 20, according to an angle of between 30° and 60°, and preferably approximately 45°.
[0065] The cutout 1 is taken over and brought, to the level of point B, by a cleat 37 that is secured to the belt 34. This cleat 37 has a specific L-shape, as shown to the side in FIG. 1. It is noted that the large branch 38 of the cleat 37 is attached to the belt 34 so that the heel 39 of said cleat 37 can advance beyond the downstream end of the conveyor system 32, i.e. beyond the upper pulley 36. In fact, the heel 39 of said cleat 37 serves as a stop for the cutout 1 and it acts as a reference for positioning said cutout 1 at the level of the forming station 30; it establishes the virtual point H of the upper repository.
[0066] The belt 34 preferably comprises two cleats 37 that are diametrally opposed and that act, in turns, as repositories.
[0067] The pulley 35 of the belt 34 is located at the lower portion of the ramp 24, sufficiently upstream of point B in order to enable the cleat 37, and in particular the heel 39, to be positioned so as to take over the cutout 1 that is waiting, wedged at the level of the reference point B. The pulley 36 is located at mid-height on the ramp 24, upstream of the inlet of the forming station 30, i.e. upstream of point H at the level of which the cutout 1 is wedged by the heel 39 of the cleat 37 when it is in the active position.
[0068] This position of the pulley 36, slightly retracted with respect to point H, enables any interference between the latter and the box blank 6 to be avoided during the transfer of said blank 6 to the downstream conveyor device 5.
[0069] Point H of the upper repository is located at a distance from point B of the lower repository, which is at least equal to the dimension of the largest cutout 1 format capable of being handled by the machine. This space between the two reference points enables all cutout 1 formats to be handled without having to perform longitudinal adjustments.
[0070] The actual forming operation is performed by means of two devices consisting of arms of the type with suction cups: the arm 40 called the forming arm and the arm 41, which, in this case, has a plurality of functions since it also acts as a transfer arm.
[0071] The forming arm 40 and the transfer arm 41 are generally, like the extraction arm 21, arranged in pairs in order to secure the operation of taking over and sensing the panels of the cutout 1. In the remainder of the text, the singular or plural will be used indifferently to designate all of these arms since, in certain figures, only one arm can be seen.
[0072] The transfer arm 41 is primarily intended in this forming operation to keep the L′ side of the cutout 1 in the plane of the repository of station 30. The actual forming is performed by the forming arm 40. This arm 40, as described in detail below, is arranged above the plane of circulation of the cutout 1; its pivot shaft 42 coincides with point H of the repository and it is maneuvered by means of an actuator 43, which is anchored on the frame 20, as shown to the side in FIG. 1.
[0073] When it arrives at the station 30, the cutout 1 is sandwiched between the transfer arm 41 and the forming arm 40. The latter pivots around its shaft 42, with an amplitude on the order of a quarter of a circle, bringing side l′ of the cutout 1, while the arm 41 remains stationary, holding side L′.
[0074] Once the cutout 1 has been formed, the arm 40 is detached from side l′ and the arm 41 is moved so as to transfer the blank 6 to the conveyor device 5, which takes it over for other operations.
[0075] The transfer arm 41 is pivotably connected to a shaft 44, which is located at the level of the conveyor device 5. It is maneuvered by means of a drive member, of the servomotor type; this servomotor actuates the arm 41 by means, for example, of a connecting rod-crankshaft-type system, not shown, which ensures smooth operation.
[0076] One will note a guide 46 above the conveyor device 5. This guide 46 is intended to hold the blank 6 in the shape that it was given at the erecting station 30, first during its transfer to the conveyor device 5, and then when it is moved by the latter.
[0077] This guide 46 forms the inlet and the opening of an arch 47, which can be seen in FIGS. 8 and 9, which forms, with the conveyor device 5, a guide passage for the blank 6; to enable its adjustment, this guide 46 is secured to the chassis 2 by means of a slide system 48.
[0078] This guide 46 is moreover capable of moving longitudinally in the upstream direction, by means of an actuator 49, which is shown in FIGS. 8 and 9, in order to be positioned on the blank 6 when it is placed on the conveyor device 5 and when it is released by the transfer arms 41.
[0079] The downstream conveyor device 5 is diagrammatically shown in FIG. 2, from a top view. It consists in particular of two chains 50, 51 of the endless chain type, which are equipped with cleats 52, 54, respectively, for gripping the blank 6. One of the chains, chain 50, comprises upstream cleats 52 that push the blank 6; the other chain, chain 51, comprises cleats 53 that are arranged on the downstream face of said blank 6. The two chains 50, 51 are mounted separately and can be offset from one another in order to adjust the spacing between the cleats 52 and 53 according to the formats of the blanks 6.
[0080] In this FIG. 2, one will also note the presence of transfer arms 41, which are arranged on each side of the conveyor device 5; these arms 41 are arranged to pass above the shaft 54, which bears the pulleys 55, 56 driving the chains 50, 51, respectively.
[0081] FIG. 3 is a sort of diagrammatic plan view that shows, with the cross-sections of FIGS. 3 a and 3 b , the detail of the bench 4 for forming cutouts 1.
[0082] All of the elements shown in FIGS. 3, 3 a and 3 b are arranged directly or indirectly on the frame 20, which frame 20 is secured to the general chassis 2 of the machine, as specified earlier.
[0083] These FIGS. 3, 3 a and 3 b show:
[0084] the conveying system 32 that extends over the lower half of the ramp 24, which conveying system 32 moves the cutouts 1 between points B and H of the lower and upper repositories, respectively.
[0085] the extractor arms 21, which are arranged on each side of said conveying system 32,
[0086] the arms 41, which have a dual function: to ensure that the cutout 1 is held during its forming and to ensure its transfer after it has been transformed into a blank 6, to the downstream conveyor device 5,
[0087] the forming arm 40, which is single or double, shown in FIG. 3 b , in the inactive position and in FIG. 3 with phantom lines, in the active position for taking over side l′ of the cutout 1, as explained earlier,
[0088] and, in greater detail than in FIG. 1, the guide passage for the cutout 1, in the form of a ramp 24.
[0089] This ramp 24 consists, in particular in FIG. 3 a , of two corners 60 arranged laterally to form the guide passage of the cutouts 1.
[0090] These corners 60 are arranged on each side of the arms 21 and 41 and they form both the soleplate 61 and the lateral walls 62 for guiding the cutouts 1; they are mounted adjustably with respect to the frame 20 in order to adjust to the various formats of the cutouts 1.
[0091] The level of the soleplates 61 is the same as that of the upper active side of the belt 34 of the conveying system 32.
[0092] In the lower portion of the ramp 24, the corners 60 are arranged to act as a repository and ensure the wedging of each cutout 1, when deposited by the extractor arms 21. This arrangement is shown to the side at the bottom of FIG. 3; it consists of a stop 63 shaped in the form of a fold, at the end of the soleplate 61, on the corner 60, which stop 63 constitutes the reference point B of the lower repository; it enables the cutout 1 to be held in the waiting position, until said cutout 1 is taken over by the cleat 37 of the conveying system 32 in order to be brought to the forming station 30. This arrangement is performed on each side of the ramp 24, at the lower end of the corners 60.
[0093] The reference point B is therefore stationary; it is constant and common for the cutouts 1 regardless of their formats. This point B is located on an arc of circle that passes through the edge 14 of the outlet of the storage site 3, which arc of circle is centered on the shaft 22 of the extractor arms 21. This arrangement enables a storage site 3 to be provided, of which the soleplate 15 is at a constant level with respect to the ground, between 55 and 100 cm, and approximately 85 cm, for example.
[0094] The ramp 24, which forms the guide passage of the cutouts 1 comprises two portions: —a bottom portion with corners 60 of which the soleplate 61 is stationary and—a top portion with corners 60 of which the soleplate 61′ is retractable. This top portion is in fact located at the level of the station 30 for forming the cutout 1. Indeed, when the operation for forming the cutout 1 is terminated, it is necessary to open the cutout guide passage in order to transfer the blank 6 to the downstream conveyor device 5 because said blank 6 passes between the walls 62 of said ramp passage 24.
[0095] As shown diagrammatically in FIG. 3 b , the soleplates 61 40 are longitudinally pivotably connected around shafts 64 in order to pivot under the effect of suitable actuator-type means, not shown, and in order to be retracted, thus freeing the passage to enable the transfer of the blank 6, which is moved by means of the arms 41 also shown in the figure.
[0096] According to an alternative embodiment, not shown, the soleplates 61′ can also be retracted like drawers, laterally, in order to free the passage between the walls 62.
[0097] This FIG. 3 b also shows the foaming arm 40. This arm 40 is arranged as a cantilever or, as shown in the figure, it is arranged on a sort of portal frame 70 that passes over the ramp 24 and the guide passage for the cutouts 1. This portal frame 70 is maneuvered by means of the actuator 43, which is shown to the side in FIG. 1, and it pivots around the shaft 42 arranged transversally, which shaft 42 coincides, within the cardboard thickness range, with the point H of the upper repository, i.e. with the angle of the dihedral formed by the soleplate 61′ and the heel 39 of the cleat 37 when the latter is in the top active position, at the inlet of the forming station 30.
[0098] FIG. 4 shows, in the form of a chronological diagram, the movements and positions of the various elements of the bench 4 that are involved in forming the cutouts 1. This diagram is associated with FIGS. 5 to 9, which diagrammatically show some of the phases of the process for forming cutouts 1. In this FIG. 4, the conveying system 32 comprises, over a cycle, a period 80 in which it is in movement and a period 81 in which it is at rest; during this rest period, the heel 39 of the cleat 37, which is in the top position, serves as a reference point H.
[0099] The cycle of the extractor arms 21 comprises a rest period 82, which corresponds substantially to the time necessary for moving the cutout 1 between the two reference points B and H, by means of the conveying system 32. The arms 21 pivot in order to go pick up a cutout 1 in the storage site 3, and the period 83 for picking up and extracting the cutout in the storage site 3 is substantially based on the middle of the rest period of the conveying system 32; then, the period 84 of said arms 21 corresponds to the transfer of the cutout 1 in the lower repository, which cutout 1 is wedged at the level of point B, where it will be taken over by the next cleat 37 of said system 32.
[0100] The cycle of the transfer arms 41 is practically based on that of the extractor arms 21. It comprises a rest period 85 after the box blank 6 has been deposited on the downstream conveyor device 5, the time for the latter to remove said box blank 6, and a period 86 of taking over the cutout 1 at the level of the forming station 30; at the end of the forming, the arm 41 transfers the box blank to the downstream conveyor device 5, which corresponds to period 87 in the diagram.
[0101] The actual forming of the cutout 1 is performed by means of the forming arm 40. The cycle of said arm 40 is similar to that of the other arms; there is first a period 88 of taking over side l′ of the cutout 1, then the actual forming period 89, at the end of which the rest period 90, which is relatively long, begins.
[0102] FIG. 5 shows a cutout 1 that is on course between point B of the lower repository and point H of the upper repository, pushed by the heel 39 of the cleat 37 of the conveying system 32. The extractor arms 21 and the transfer arms 41 are at rest, at the end of their rest periods 82 and 84, respectively. The foaming arm 40 begins to pivot in order to take over side l′ of the cutout 1, which is arriving at the fanning station 30.
[0103] When the cutout 1 is positioned at the forming station 30, wedged at point H of the upper repository, the forming arm 40 presses said cutout 1 on the soleplates 61′ and holds this cutout 1 in the repository so as to enable the arms 41 to be positioned.
[0104] Then, as shown in FIG. 6, the forming arm 40 pivots around its shaft 42, bringing with it side l′ of the cutout 1, while the arms 41 hold side L′ in the upper repository. It is noted that the shaft 42 of the forming arm 40 coincides with the edge common to sides l′ and L′ of the cutout 1 and with point H of the upper repository.
[0105] During this operation of assembling the cutout 1 in the form of a box blank 6, as shown in FIGS. 6 and 7, the extractor arms 21 pivot in order to go pick up another cutout 1 at the outlet of the storage site 3, actuated by the maneuvering actuator 23.
[0106] When the assembly is complete, as shown in FIG. 7, the forming arm 40 releases side l′ by releasing the vacuum in its suction cups while the arms 41 hold side L′ in order to be capable of bringing the blank 6 to the downstream conveyor device 5. To be capable of moving the blank 6, the upper portion of the ramp 24 opens, by means of the retraction of the soleplates 61′, as shown in FIG. 8, and the transfer arms 41 pivot in order to bring the blank 6 down and deposit it onto the conveyor device 5. During this time, the extractor arms 21 have completed their course and have deposited the new cutout 1 in the lower repository, wedged at the level of point B, waiting to be taken over by the second cleat 37 of the conveying system 32.
[0107] During its transfer between the framing station 30 and the conveyor device 5, the blank 6 slides over the guide 46, this prevents it from being deformed. At the end of the course (FIG. 9), the blank 6 is deposited on the downstream conveyor device 5 by the transfer arms 41. Before being released by the aims 41, the guide 46 moves in the upstream direction, onto the blank 6, under the effect of its maneuvering actuator 49, in order to hold said blank, which is then brought by the cleats 51, 52 of the conveyor device 5 to the appropriate destination.
[0108] Once the passage is freed on the conveyor device 5, the transfer arms 41 return to the forming station 30 in order to hold the new cutout 1, which has just arrived in the upper repository, and the cycle continues.
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The machine according to the invention comprises a store containing the blanks; an extractor arm; means for shaping the blanks; and an upstream transport device for receiving and distributing the blanks of the boxes. The extractor aim and the shaping means are provided on the frame of a bench, which is inserted, as in a module, between the store and the upstream transport device. Said bench comprises: a ramp which is upwardly inclined at an angle of 45° in relation to the horizontal and acts as a guiding channel; a sole having an upper part, in the region of the shaping station, which can be retracted to enable the blank to pass via the ramp; a transport system for moving the blanks from the lower point to the upper point; a forming arm carried by a framework which extends above the ramp; and a transfer arm which participates in the shaping of the blank before moving it, once it has become a box blank on the downstream transport device.
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FIELD OF THE INVENTION
[0001] This invention relates to the heat treatment of magnesium alloys that can be strengthened by precipitation hardening, known also as ageing or age hardening. This invention particularly relates to a low temperature ageing process for strengthening precipitation-hardenable magnesium alloys.
BACKGROUND TO THE INVENTION
[0002] Alloys in which the solubility of at least one of the alloying elements decrease with decreasing temperature can be strengthened by age hardening. Age hardening is common to a number of alloying systems including magnesium alloys. The age hardening process in general involves three stages:
[0003] 1) Solution heat treatment—in this stage an alloy is held at a very high temperature (close to the alloy solidus temperature) in order to obtain a single phase solid solution and to dissolve the alloying elements in the magnesium matrix.
[0004] 2) Quenching—rapid cooling from the temperature of solution heat treatment using a quenching medium (such as cold water) in order to retain alloying elements in the solid solution and obtain a supersaturated solid solution.
[0005] 3) Holding the as-quenched alloy at an intermediate temperature (artificial ageing) in order to promote the decomposition of the highly unstable supersaturated solid solution in which the alloying elements, often including the magnesium atoms, form precipitates throughout grains.
[0006] The strengthening during ageing generally occurs as a result of the formation of a fine dispersion of precipitates that reinforce the magnesium matrix and represent obstacles to movement of dislocations, thus increasing the alloy's ability to resist the deformation leading to failure. Generally, optimal strengthening is achieved in the presence of a high density of uniformly distributed and very closely spaced precipitates that cannot be easily bypassed by gliding dislocations.
[0007] Many cast and wrought magnesium alloys are age-hardenable. The most common are those based on the systems Mg—Zn(—Zr) (ZK series), Mg—Zn—Cu (ZC series), Mg—Zn-RE (ZE and EZ series; where RE means rare earth elements), Mg—Zn—Mn(—Al) (ZM series), Mg—Al—Zn(—Mn) (AZ and AM series), Mg—Y-RE(—Zr) (WE series), Mg—Ag-RE(—Zr) (QE and EQ series), Mg—Sn(—Zn, Al, Si) based alloys etc. In each system, magnesium typically comprises more than 85 weight %. Magnesium alloys containing Zn as the major alloying element are precipitation hardenable and comprise a great proportion of currently used magnesium alloys.
[0008] While the following description will focus on Mg—Zn alloys, it is to be understood that the invention is not limited to those alloy compostions and is applicable to all precipitation hardenable magnesium based alloys.
[0009] Heat treatable magnesium alloys are generally subjected to an elevated temperature heat treatment (commonly referred to in the art as “T6”) wherein the stage of artificial ageing (stage (3) of the age hardening process above) is conducted typically at a temperature between 150° C. and 350° C.
[0010] In the case of Mg—Zn alloys, the precipitation sequence above ˜110° C. has been reported to be:
[0000] SSSS →(pre-β′)→β′ 1 rods ⊥{0001}Mg (possibly MgZn 2 )→β′ 2 discs ∥{0001}Mg (MgZn 2 )→β equilibrium phase (MgZn or Mg 2 Zn 3 )
[0011] The structure, composition and the stability of some of these phases have not yet been fully investigated and determined, however a number of reports agree that the maximal hardening due to the precipitation in Mg—Zn based alloys subjected to a conventional T6 heat treatment is associated with the formation of the rod-shaped transition β′ 1 phase. This phase forms perpendicular to the basal plane of Mg, possibly via another transition phase denoted pre-β′. On overageing, β′ 1 is replaced by a coarse β′ 2 phase in the form of a plate parallel to the Mg basal plane. The equilibrium β phase, MgZn or Mg 2 Zn 3 , may form upon high overageing. Precipitation at reduced temperatures (˜<110° C.) has not been clearly observed by transmission electron microscopy (TEM). While it is believed that GP zones may possibly form at reduced temperatures, the formation, structure, thermal stability and the sequence of the formation of GP zones have not yet been clarified.
[0012] Although many magnesium alloys undergo precipitation hardening, currently the most effective methods of increasing their mechanical properties preferably still include solid solution hardening, dispersion hardening and grain refinement. Even then, the tensile properties of most heat treatable magnesium alloys are limited compared to those of the currently used aluminum alloys, which is one of the main limitations for the wider application of magnesium alloys. Age hardening of magnesium alloys is generally not considered as being as effective in improving tensile properties as it is in the case of aluminum alloys. This is believed to be primarily because the number density of the precipitates formed during the conventional T6 ageing in magnesium alloys is several orders of magnitude lower than in the aged aluminum alloys. Therefore widely spaced precipitates that form in the T6 condition of magnesium alloys are easily bypassed by gliding dislocations and such alloys display reduced resistance to deformation.
[0013] Strengthening of magnesium alloys through age hardening would become more effective in the case of the formation of higher density of finely dispersed precipitates throughout the microstructure.
[0014] It would accordingly be desirable to make precipitation hardening more effective in increasing strength. This can then be used alone or in the combination with work hardening and grain refinement to increase the upper limit of the mechanical properties that can be achieved in magnesium alloys, thereby enabling wider and more competitive use of these light weight alloys. It would be particularly desirable to make precipitation strengthened magnesium alloys more ductile.
[0015] It would also be desirable to improve those properties using an ageing process able to be conducted at lower temperatures than those of the conventional T6 ageing.
[0016] The present invention is based upon the surprising discovery by the inventor that age hardening of magnesium based alloys can be effected at significantly lower temperatures than are typically used during conventional T6 ageing, such as at ambient temperature. Moreover, the ageing response achievable using the invention can be comparable to or in some cases exceed, that achieved using conventional T6 ageing.
[0017] Age hardening at ambient temperature of any notable magnitude has never previously been observed in age-hardenable magnesium alloys, including the Mg—Zn based alloys, and it has been assumed that magnesium alloys therefore do not show any significant precipitation hardening response when held at reduced temperatures such as close to ambient temperature after quenching from the solution heat treatment temperature.
SUMMARY OF THE INVENTION
[0018] According to the present invention, there is provided a method for the low temperature heat treatment of an age-hardenable magnesium-based alloy, including the steps:
[0019] (a) providing a solution heat-treated and quenched age-hardenable magnesium based alloy; and
[0020] (b) subjecting said alloy to low temperature ageing below 120° C. for a period of time sufficient to develop an enhanced ageing response.
[0021] The present invention also provides a method for producing an age-hardenable magnesium-based alloy, including the steps:
[0022] (a) solution treating, within a suitable elevated temperature range or ranges, an age-hardenable magnesium based alloy for a time or times sufficient to allow the elements active in the precipitation reaction to be dissolved into solid solution;
[0023] (b) quenching the solution treated alloy from the temperature cycle for step (a) whereby the dissolved elements are retained in a supersaturated solid solution; and
[0024] (c) subjecting the quenched alloy from step (b) to low temperature ageing below 120° C. for a period of time sufficient to develop an enhanced ageing response.
[0025] The enhanced ageing response may comprise one of enhanced peak hardness, enhanced yield strength, enhanced ductility, enhanced tensile strength, enhanced fracture toughness, or a combination of two or more of the above properties.
[0026] The enhanced ageing response is preferably comparable to or exceeding that of an alloy of the same composition subjected to a T6 ageing stage.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The inventive heat treatment is applicable to any precipitation-hardenable magnesium-based alloy and to both casting and wrought magnesium based alloys. It is particularly applicable to magnesium alloys containing zinc as one of the major alloying elements, such as the ZK, ZM and ZC series, and alloys containing rare earth elements or tin.
[0028] The inventive heat treatment is very effective for both casting and wrought Mg—Zn based alloys that contain ageing accelerants, ie alloying elements that aid nucleation of precipitates and increase the nucleation rate. These alloying elements assist to increase the number density of precipitates and accelerate the rate of ageing at low temperatures, especially at ambient temperatures.
[0029] An example of an alloying element that accelerates age hardening at reduced temperatures, in particular at ambient temperatures, in magnesium alloys containing Zn as the major alloying element is Cu (the ZC series of magnesium alloys). Addition of Cu in the amount as low as 0.1 atomic % will significantly accelerate age hardening even at ambient temperature. Addition of further alloying elements in addition to Cu, that affect the precipitation processes and generally promote nucleation of precipitates will also accelerate age hardening at reduced temperature.
[0030] Examples of other accelerants instead of copper or in addition to copper are manganese, aluminium and particularly titanium, also vanadium, chromium and barium as a moderate accelerant.
[0031] As a result of the alloying additions, the low temperature heat treatment can be accelerated, resulting in improved mechanical properties, such as ductility, strength and hardness levels, comparable to or better than those in the T6 condition. Fracture toughness of alloys can be also significantly improved, using the process of the invention.
[0032] Without wishing to be restricted to a particular mechanism, it is believed that the modified mechanical properties of the alloys aged at reduced temperature according to the invention are produced due to the precipitation of a very high density of closely spaced Guinier-Preston (GP) zone type precipitates of 3 to 30 nm in size, instead of the coarser and considerably more widely spaced precipitates typically formed during the T6 heat treatment. Accordingly, the inventor has found that low temperature ageing should occur at temperatures significantly less than those conventionally used during T6 (150° C.-350° C.). The density of the precipitates in the low temperature aged condition is significantly higher than what is commonly observed in the T6 condition of magnesium alloys (˜10 18 -10 20 precipitates/m 3 ) and is often of the order of precipitate density in a typical heat treated aluminum alloy, ie 10 23 -10 24 precipitates/m 3 . The fraction of each of the three types of GP zones can be controlled by the alloy composition, in particular the amount of the alloying additions other than Zn, and also by the ageing temperature. At temperatures close to ambient temperatures, strengthening is produced mainly by the formation of GP1 zones (planar precipitates perpendicular to the basal plane of magnesium), and prismatic precipitates perpendicular to the basal plane of magnesium, hereinafter designated as GP2 zones. Increase in the heat treatment temperature above ˜70° C. leads to the formation of the additional and thermally more stable GP zone type phase, hereinafter designated as GP3 zones (discs/plates parallel to basal plane of magnesium). When the alloying additions other than Zn are added in a larger amount (more than about 1 weight %), formation of GP1 zones is more favorable than the formation of GP2 zones during ambient temperature ageing, while GP2 zones are the more dominant type of precipitate in the absence of any alloying elements other than Zn and when these additions are very small.
[0033] The low temperature heat treatment is conducted after a typical solution heat treatment at a typical solution heat treatment temperature for a chosen alloy, optimally 5°-20° C. below the alloy solidus temperature for at least 1 hour. Preferably, the solution heat treatment temperature should be chosen closer to the upper limit in order to ensure maximum solubility of the alloying elements as well as vacancies in solid solution, so that a high supersaturation of alloying elements and vacancies is achieved in the as-quenched condition. Age hardening response during heat treatment described in the present application, especially the ambient temperature hardening, can be sensitive to the solution heat treatment temperature and the rate of quenching from this temperature.
[0034] After solution heat treatment, alloys should be rapidly quenched, ie, not simply cooled, in an appropriate quenching medium (such as cold water or other medium). After quenching, the alloy is typically immediately transferred to the ageing temperature, or left at ambient temperature in the case of an ambient temperature heat treatment.
[0035] The low temperature ageing is typically conducted between ambient temperature and 110° C.±10° C. Where the selected temperature is ambient temperature, the ageing process advantageously does not require energy consumption for heating. In one embodiment, the ageing is conducted at higher than ambient temperature in order to reduce the ageing time. In another embodiment, low temperature ageing is conducted at less than 100° C. In another embodiment, low temperature ageing is conducted at less than or equal to 95° C.
[0036] Typically, the low temperature ageing is conducted for at least 24 hours. The length of the ageing treatment is dependent on the temperature of ageing. At ambient temperature, ageing is usually conducted for a minimum of 2 to 16 weeks. The length of ageing depends on the temperature of ageing and whether any accelerants are present in the alloy. In some embodiments, ageing is conducted for at least 4 weeks. In other embodiments, ageing is conducted for a minimum of 8 weeks. In yet further embodiments, ageing is conducted for a minimum of 12 weeks. For low temperature ageing conducted at higher than ambient temperature, or where the alloy composition includes one or more accelerants, the length of ageing typically decreases. In yet further embodiment, ageing at reduced temperature is conducted for a time sufficient to obtain a favorable combination of tensile properties such as appreciably high yield strength (and hardness) and enhanced ductility when compared to T6 condition. Once the optimal mechanical properties are attained, they remain stable at ambient temperature and there is little likelihood of over-ageing.
[0037] The use of temperatures higher than ambient temperatures typically requires heating in a furnace or in an oil bath. For alloys aged at higher than ambient temperature, the optimal mechanical properties are reached after a significantly shorter heat treatment time. For ageing at temperatures below ˜75° C., mechanical properties comparable to those in the T6 condition can be achieved after a minimum of about 110 hours of ageing and exceeded after prolonged ageing. For ageing at temperatures above 95° C., optimal mechanical properties are typically achieved after ageing for at least 100 hours.
[0038] Alloys subjected to ambient temperature ageing for 4 to 16 weeks or longer if needed, in comparison to the T6 condition exhibit high hardness, improved ductility and fracture toughness, combined with a reasonable tensile strength. An increase in the heat treatment temperature and the change of the GP zone type, size, morphology and density in general results in the increase in the tensile strength and hardness while the ductility and fracture toughness remain improved compared to the T6 condition.
DESCRIPTION OF THE DRAWINGS
[0039] In order that the invention may be more readily understood, description now is directed to the accompanying drawings, in which:
[0040] FIG. 1 . Temperature vs time graphs comparing the respective heat treatments wherein the alloys are aged at reduced temperatures after a typical solution heat treatment as opposed to the T6 heat treatment that is typically conducted at considerably higher temperatures.
[0041] FIG. 2 . Hardness (VHN) vs Time (hours, log scale) plots showing: (a) a comparison of the hardness curves for ageing at 160° C. (T6) and ˜22° C. of alloys Mg-6Zn-3Cu-0.1Mn and Mg-7Zn; (b) a comparison of the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. for alloy Mg-6Zn-3Cu-0.1Mn.
[0042] FIG. 3 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. for alloy Mg-7Zn.
[0043] FIG. 4 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves for ageing at 160° C. (T6) and ˜22° C. for alloys: (a) Mg-6Zn-0.8Cu-0.1Mn and Mg-7Zn; (b) Mg-4.6Zn-0.4Cu and Mg-7Zn.
[0044] FIG. 5 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. for a large scale casting of alloy Mg-6Zn-1.8Cu-0.1Mn.
[0045] FIG. 6 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. for alloy Mg-6Zn-0.8Ti.
[0046] FIG. 7 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. for alloys: (a) Mg-6Zn-0.2Cr and Mg-7Zn; (b) Mg-7Zn-0.3V and Mg-7Zn.
[0047] FIG. 8 . Hardness (VHN) vs Time (hours) plots showing a comparison of the hardness curves between alloy Mg-7Zn-1.2Ba for ageing at 160° C. (T6), 70° C. and ˜22° C., and alloy Mg-7Zn for ageing at 160° C. and ˜22° C.
[0048] FIG. 9 . Transmission electron microscopy (TEM) images of microstructures aged at 160° C. (all images on the left) and those aged at ˜22° C. (all images on the right) for alloys: Mg-7Zn (a, b), Mg-6Zn-3Cu-0.1Mn (c, d) and Mg-6Zn-0.8Cu-0.1Mn (e, f).
[0049] FIG. 10 . TEM (a, b) and HRTEM (c, d) images of microstructure of alloy Mg-6Zn-3Cu-0.1 Mn aged at 70° C. for 4 weeks taken with the electron beam parallel to <2 1 1 0> Mg direction (a, c) and also parallel to <0001> Mg direction (b, d).
[0050] FIG. 11 . Models of microstructures believed to be produced during ageing at 160° C., 70° C. and ˜22° C. based on TEM observations.
[0051] FIG. 1 compares the respective temperature-time regimes for solution heat treatment, conventional T6 ageing, and the low temperature ageing process of the present invention. The low temperature ageing of the present invention occurs at a lower temperature, but often for a longer time, than that of T6.
[0052] In FIGS. 2 to 8 , the ageing response for a number of different solution heat treated and quenched Mg alloys are compared. The alloy compositions and the conditions of solution heat treatment followed by quenching in cold water are as follows:
[0053] Mg-7Zn: solution heat treated at 340° C. for 5 hours.
[0054] Mg-6Zn-3Cu-0.1Mn: solution heat treated at 440° C. for 5 hours.
[0055] Mg-6Zn-0.8Cu-0.1Mn: solution heat treated at 390° C. for 5 hours.
[0056] Mg-4.6Zn-0.4Cu: solution heat treated at 435° C. for 5 hours.
[0057] Mg-6Zn-1.8Cu-0.1Mn: solution heat treated at 460° C. for 5 hours.
[0058] Mg-6Zn-0.8Ti: solution heat treated at 340° C. for 4 hours.
[0059] Mg-6Zn-0.2Cr: solution heat treated at 360° C. for 5 hours.
[0060] Mg-7Zn-0.3V: solution heat treated at 360° C. for 5 hours.
[0061] Mg-7Zn-1.2Ba: solution heat treated at 430° C. for 5 hours.
[0062] FIG. 2( a ) compares the hardness curves for two casting magnesium based alloys: Mg-7Zn and Mg-6Zn-3Cu-0.1Mn which have been each aged at 160° C. (ie under the T6 condition) and at ambient temperature, (˜22° C.) respectively. For both alloys hardness achieved during ambient temperature ageing (104 VHN and 89 VHN for Mg-6Zn-3Cu-0.1Mn and Mg-7Zn alloys respectively) almost equals that achieved by ageing in the T6 condition (109 VHN and 87 VHN for Mg-6Zn-3Cu-0.1Mn and Mg-7Zn alloys respectively). In the case of the Mg-7Zn alloy ageing time required for this is nearly 8 months (86 VHN after 5208 hours). However in the ZC type alloy hardness in the ambient temperature aged condition almost equals that in the T6 condition after ageing for more than 4 weeks. The ageing response (in terms of hardness) to ambient temperature ageing is significantly improved and accelerated in the presence of Cu and the addition of Mn in alloy Mg-6Zn-3Cu-0.1Mn. FIG. 2( b ) compares the hardness curves for ageing alloy composition Mg-6Zn-3Cu-0.1 Mn at 160° C. (T6), 95° C., 70° C. and ˜22° C., respectively. It can be seen that reduced temperature ageing, in particular at the temperatures above the ambient temperature significantly improves the age hardening response of alloy compared to the T6 heat treatment.
[0063] FIG. 3 compares the hardness curves for ageing alloy composition Mg-7Zn at 160° C. (T6) 95° C., 70° C. and ˜22° C. Although ageing at ambient temperature requires a long time for hardness to equal that in the T6 condition (nearly 8 months), ageing at 95° C. and 70° C. significantly improves age hardening response and a remarkable improvement in the alloy hardness can be achieved after ageing for a relatively short length of time (typically after 250 hours of ageing).
[0064] FIG. 4( a ) compares the hardness curves for ageing alloy compositions Mg-6Zn-0.8Cu-0.1Mn, and Mg-7Zn, at ageing temperatures of 160° C. (T6) and ˜22° C. This figure shows that the accelerated age hardening at ambient temperature and hardness level comparable to that in the T6 condition can be achieved even when the content of the alloying element stimulating the accelerated age hardening is reduced. Likewise, for ageing alloy composition Mg-4.6Zn-0.4Cu after only 4 weeks of ambient temperature ageing, hardness equals that of an alloy aged in the T6 condition. This is shown in FIG. 4( b ) and compared with alloy Mg-7Zn for at ageing temperatures of 160° C. (T6) and ˜22° C. This result indicate that an addition of even a trace amount of alloying elements that stimulate nucleation of precipitates, such as Cu, will significantly accelerate and improve the age hardening response to reduced temperature ageing even in the absence of other alloying elements commonly added to improve tensile properties, corrosion resistance, grain refinement etc. (Mn, Al, Zr, etc.). FIGS. 4(a) and (b) also indicate that the reduced temperature heat treatment is applicable to alloys with lower levels of alloying elements i.e., wrought Mg—Zn based alloys.
[0065] FIG. 5 compares the hardness curves for ageing a large scale casting of an alloy composition Mg-6Zn-1.8Cu-0.1Mn. As can be seen, the peak hardness achieved for alloys aged at 95° C. and 70° C. exceed that of the T6 condition, while hardness achieved for ageing at 22° C. nearly equals that in the T6 condition after about 5.5 months of ageing. The reduced response to ambient temperature ageing compared to a smaller size casting of alloy of a similar composition is due to a reduced rate of quenching of larger metal pieces.
[0066] Table 1 shows hardness and tensile properties of the alloy Mg-6Zn-1.8Cu-0.1Mn aged at 160° C. for 16 hours (circled on the hardness curve in FIG. 5 ) and at ˜22° C. for 2180 hours (˜13 weeks, also circled on the hardness curve). A significant improvement in the ductility (three times the T6 value) was achieved in the naturally aged condition combined with 72% of the T6 0.2% proof stress, 86.5% of the T6 peak hardness, and significantly improved tensile strength (UTS).
[0000]
TABLE 1
Peak
hardness
0.2% Proof
UTS
Elongation
Heat treatment
(VHN)
Stress (MPa)
(MPa)
(%)
Peak aged at
89
168
220
2.8
160° C. (T6)
Aged at ~22° C.
77
121
253
8.6
[0067] FIG. 6 shows that titanium represents another very effective accelerant of reduced temperature ageing and hardness in the naturally aged condition nearly equaled that in the T6 after 7 weeks. The peak hardness achieved for ageing at 95° C. and 70° C. exceed that of the T6 condition of the same alloy. This element also improves the magnitude and kinetics of artificial ageing when compared to alloy Mg-7Zn.
[0068] FIG. 7 compares the hardness curves for ageing at 160° C. (T6), 95° C., 70° C. and ˜22° C. of alloys (a) Mg-6Zn-0.2Cr and (b) Mg-7Zn-0.3V with hardness curves for ageing at 160° C. (T6) and ˜22° C. for alloy Mg-7Zn. As can be seen, chromium and particularly vanadium act as accelerants of reduced temperature ageing, in addition to notably enhancing the T6 ageing response when compared to Mg-7Zn alloy. The peak hardness achieved for ageing at 95° C. and 70° C. for both alloys containing the accelerants exceed that of the T6 conditions of the same alloys.
[0069] FIG. 8 shows that barium represents a moderate accelerant of reduced temperature ageing, in addition to significantly enhancing the T6 ageing response when compared to Mg-7Zn alloy. It is also shown that the peak hardness achieved by ageing at 70° C. exceed that of the T6 condition of the same alloy.
[0070] FIG. 9 shows TEM images of alloy microstructures aged at 160° C. (a, c, e) and those aged at ˜22° C. (b, d, f) for the alloy compositions Mg-7Mn (a, b), Mg-6Zn-3Cu-0.1Mn (c, d) and Mg-6Zn-0.8Cu-0.1 Mn (e, f). Precipitates seen in the T6 condition of the alloys are those referred to as the β′ 1 rods which from perpendicular to {0001} Mg planes (parallel to <0001> Mg direction). These TEM images are taken with the electron beam parallel to <2 1 1 0> Mg direction so that the rod-like precipitates are seen edge on. The density of these precipitates is increased in the T6 condition of the Cu containing alloys proportionally to the content of Cu.
[0071] In alloy Mg-7Zn aged at ambient temperature for 11 weeks (b) a relatively low density of sparsely distributed prismatic precipitates formed perpendicular to { 0001 } Mg planes, believed to be GP2 zones, are observed with the electron beam parallel to <0001> Mg direction (inset image show a high resolution TEM-HRTEM, image of these precipitates). A smaller fraction of planar GP1 zones (formed perpendicular to {0001} Mg planes) were also occasionally observed in this condition.
[0072] In alloy Mg-6Zn-3Cu-0.1Mn aged at ambient temperature for 11 weeks (d) a very high density of homogeneously distributed precipitates was observed with the electron beam parallel to <0001> Mg direction. The majority of these precipitates were planar GP1 zones (shown in inset HRTEM image). A smaller fraction of very fine GP2 zones was also observed in this condition. The number density of the precipitates in this condition was determined to be of the order of 10 24 precipitates/m 3 which is significantly higher than what is commonly observed in the T6 condition of magnesium alloys (˜10′ 18 -10 20 precipitates/m 3 ).
[0073] Also, in alloy Mg-6Zn-0.8Cu-0.1Mn aged at ambient temperature for 12 weeks (f) a very high density of homogeneously distributed precipitates was observed with the electron beam parallel to <0001> Mg direction. A significant proportion of these precipitates were fine GP2 zones combined with fine GP1 zones (both are shown in inset HRTEM image). This image shows the change in the morphology/type of GP zones with the change in the content of the alloying element/s that promote precipitate nucleation for unchanged Zn content. The formation of the prismatic GP2 zones is more favorable than the formation of the planar GP1 zones when the content if Cu is reduced.
[0074] FIG. 10 shows TEM (a, b) and HRTEM (c, d) images of the microstructure of an alloy having the composition Mg-6Zn-3Cu-0.1Mn, which has been aged at 70° C. for 4 weeks. An extremely high density of very fine GP zone type precipitates distributed homogeneously is observed in this condition. HRTEM images show that these precipitates are mainly prismatic GP2 zones formed perpendicular to {0001} Mg planes and planar GP3 zones formed parallel to {0001} Mg planes. Some GP1 zones were also occasionally observed in this condition.
[0075] FIG. 11 presents proposed models of the alloy microstructures, based on the TEM observations believed to be produced during ageing at 160° C. (a), 70° C. (b) and ˜22° C. (c). Microstructures aged at reduced temperatures (b and c) exhibit a significantly higher density of finer precipitates than the microstructure aged to T6 condition (a), which is comparable to that normally observed in age-hardened aluminum alloys (˜10 23 -10 24 precipitates/m 3 ). This kind of microstructure offers a favorable combination of improved ductility, hardness, ultimate tensile strength and (anticipated) fracture toughness combined with the reasonable (in the case of ambient temperature ageing) or comparable and even improved tensile strength (in the case of the ageing at temperatures above the ambient temperature but considerably lower than the T6 ageing temperature) when compared to that produced during the conventional T6 heat treatment.
[0076] Finally, it is to be understood that various alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the spirit or ambit of the invention.
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A method for the low temperature heat treatment of an age-hardenable magnesium based alloy, including following steps:
(a) providing a solution heat-treated and quenched age-hardenable magnesium based alloy; and (b) subjecting said alloy to low temperature ageing below 120° C. for a period of time sufficient to develop an enhanced ageing response.
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[0001] This application is a division of U.S application Ser. No. 09/234,481 filed Jan. 21, 1999.
FIELD OF INVENTION
[0002] This invention relates to the synthesis and isomerization of 1,2-bis(indenyl)ethanes (EBI). BACKGROUND OF THE INVENTION
[0003] In this specification, the expression 1,2-bis(indenyl)ethane or EBI means collectively all isomers of Formula I:
[0004] in which the symbol “(” indicates a 1,2-bis(indenyl-1)ethane which has a 1,2, 1,2′double bond (thermodynamic EBI, BRN No. 3055002, CAS RN No. 18657-57-3) or a 2,3 2′, 3′double bond (kinetic EBI, BRN No. 3083835, CAS RN Nos. 15721-07-0, 18686-04-9, 18686-05-0). The two unnumbered fusion C atoms are asymmetric. The 1,1° C. atoms are asymmetric in kinetic EBI compounds. The 3,3° C. atoms are asymmetric when substituted.
[0005] Each of the ring substituents may be hydrogen or any one to ten carbon atom hydrocarbyl group. Each ring substituent may be the same as or different from any other ring substituent. One to ten carbon atom alkyl groups are preferred. 2,2′methyl and 4,7, 4′7′dimethyl EBIs are representative.
[0006] The EBI 3,3′substituents may be any hydrocarbyl group or hydrocarbyl silyl group, preferably having one to ten carbon atoms. Useful alkyl silyl 3,3′substituents have the formula (R) 3 -Si, in which R is a one to ten carbon atom hydrocarbyl group, typically an alkyl group. The methyl group is preferred. Each R may be the same as or different from each of the other two R groups. Chiral TMS-EBI is preferred.
[0007] Meso and rac (racemic) forms of kinetic EBI and thermal isomerization of kinetic to thermodynamic EBI are known phenomena. Marechal, et al, Bulletin de la Societe Chimicue de France (1967) 8:2954-2961.
[0008] Kinetic and thermodynamic EBI are interchangeably useful separately and in mixtures as ligands for metallocene olefin polymerization catalysts. However, the large-scale production of kinetic EBI is constrained because the thermodynamic isomer is produced at temperatures below about −70° C.; whereas, at higher temperatures low yields of kinetic EBI consequent from Spiro indene and vinylidene impurities may result. See, e.g., Yang, et al., SYNLETT (1996) 147 and Collins, et al., J. Organometallic Chem. (1988) 342:21 (thermodynamic EBI synthesized at −78° C. stirred overnight and warmed to room temperature). See also , Ewen, J., et al., J. Am. Chem. Soc. (1987) 109:6544-6545 and Grossman, R., et al., Organometallics (1991) 10:1501-1505 (50% to 80% arecrystallized yields of thermodynamic isomer because of the formation of spiroindene by-product).
[0009] 3,3′C substitution imparts chirality to some Formula I compounds with consequent achiral meso and chiral racemic forms. Metallocene isotactic polypropylene catalysts may require substantially pure rac EBI ligands; for example, rac 1,2-bis(3,3′trimethylsilyl indenyl-1)ethane (hereinafter rac TMS-EBI). Typically, TMS-EBI may be produced by reaction of EBI with two equivalents of BuLi to produce dilithio EBI. Dilithio EBI is treated with two equivalents of TMSCl to produce 3,3′-bis TMS-EBI. Synthesis of substituted EBI compounds, including TMS-EBI, typically yields a mixture of meso and rac forms. Separation of the rac form from such mixtures may not be practical for industrial applications.
SUMMARY OF THE INVENTION
[0010] The invention may comprise a method for producing EBI from an indene in good yield at moderate temperatures.
[0011] Pursuant to one aspect of the invention, a method is provided for the moderate temperature synthesis of kinetic EBI substantially free of by-product impurities.
[0012] Important embodiments of the invention include isomerization agents effective to convert kinetic EBI to thermodynamic EBI and also to convert meso 3,3′substituted EBI to a meso/rac mixture. The invention may include isomerization protocols implemented by these reagents.
[0013] The invention may include a series of moderate temperature steps to produce a reaction mixture from which solid kinetic EBI which may be substantially free of spiro indene impurities is separated from a mother liquor. The solid kinetic EBI may be separated in a single increment or in a plurality of increments, each of said increments being separated from the mother liquor of the preceding increment. Each mother liquor may comprise a solution of additional kinetic EBI which may be isomerized to thermodynamic EBI, preferably in solution in its mother liquor which is cooled induce precipitation of solid thermodynamic EBI. The solid kinetic and thermodynamic EBI products are useful separately or in combination as metallocene catalyst ligands. This procedure for synthesizing thermodynamic EBI, which includes an isomerization step, is practiced and scalable, and is an improvement over the lower yielding preparation of thermodynamic EBI which requires starting the reactions at temperatures below −70° C. reported in the cited references.
[0014] The invention may include isomerization of a meso 3,3′substituted EBI, such as TMS-EBI to yield a meso and rac mixture. Treatment of an existing mixture of meso and rac 3,3′substituted EBI with the isomerization agent yields a product mixture enriched in the rac isomer. The stereospecific transformation of racemic TMS-EBI to racemic metallocene is known. See, e.g., Nifant′ev, I. A., et al. (1997) Organometallics 16:713-715. However, racemic TMS-EBI was isolated in only 34% crystallized yield from the reaction of dilithio EBI and a trimethyl silicon chloride. The isomerization of meso to meso-rac TMS pursuant to this invention is an improvement over the prior art because racemic TMS-EBI is used to synthesize racemic metallocene. Iteration of the isomerization reaction with rac enrichment of the product mixture at each iteration may yield an ultimate substantially pure, e.g., 96% pure, rac product useful as a stereospecific metallocene olefin polymerization catalyst ligand.
DETAILED DESCRIPTION OF THE INVENTION
1. Synthesis of EBI
[0015] Formula I EBIs produced by any of the several known methods may be used in any one or more of the embodiments of the invention.
2. The Isomerization Agents
[0016] The isomerization agents useful in this invention are solutions of alkali metal alkoxides having the formula MOR, wherein M is any alkali metal and R is as defined. In the preferred isomerization agents, R is t-butyl.
[0017] Useful isomerization agents are alkali metal alkoxide solutions in a non-interfering, preferably ether, solvent. Suitable solvents include tetrahydrofuran, 2-methyl tetrahydrofuran, dioxane, and 1,2-dimethoxyethane. The isomerization agent solution may contain any functional concentration, e.g., from 10 mol percent to 20 mol percent, of alkali metal alkoxide. The preferred isomerization agent is a 10 to 20 mol percent solution of potassium tertiary butoxide in tetrahydrofuran.
3. The Isomerization Reactions
[0018] The isomerization reagents convert kinetic EBI to thermodynamic EBI. They also convert meso 3,3′-substituted chiral EBI to a mixture of the meso and rac forms.
[0019] In general, the isomerization reaction is accomplished by treatment of a kinetic EBI or meso 3,3′-substituted EBI with the isomerization reagent under conditions and for a time effective to accomplish the desired reaction. Selection of the appropriate conditions for a particular isomerization is determined by the skilled man as a function of the particular isomerization involved and of the degree of conversion desired. It is known that by going from sodium methoxide to potassium t-butoxide, a substantial increase in basic strength as well as more favorable solubility in ether is achieved. See, Gilman (1953) Organic Chemistry Vol. III, pp. 4-5, citing Gould, Jr., et al. (1935) J. Am. Chem. Soc. 57:340, and Renfrow (1944) J. Am. Chem. Soc. 66:144.
[0020] Each type of isomerization may be accomplished to some degree by treatment of the particular EBI isomer with an isomerization reagent at a temperature of from about 20° C. to reflux for a time period of 30 minutes to 12 hours. The kinetic to thermodynamic EBI isomerization appears to be facilitated by a higher temperature and a longer time than the 3,3′-bis TMS-EBI meso to meso:rac mixture isomerization. For example, 100% conversion of kinetic to thermodynamic EBI may be accomplished by overnight reflux in the reagent solvent such as THF. Less than 100% isomerization occurs at lower temperatures or in a shorter reflux time. In contrast, 100% meso TMS-EBI is converted in 30 minutes at room temperature (20° C.) by a similar isomerization agent to a 50/50 rac-meso mixture.
4. Work-UP of Kinetic EBI Reaction Mixture
[0021] This aspect of the invention relates to the recovery of kinetic EBI from a synthesis reaction mixture. An important step entails exchange of any non-hydrocarbon reaction mixture solvent for a hydrocarbon solvent from which kinetic EBI may be precipitated, e.g., by cooling with consequent crystallization. Appropriate hydrocarbon solvents are five to eight carbon atom alkanes. Hexane and commercially available mixtures of hexanes preferred. Aromatic hydrocarbon solvents including benzene, toluene, and xylene may be used having due regard to conditions requisite to crystallization from a particular solvent.
[0022] The hydrocarbon solution of kinetic EBI is cooled to cause precipitation of at least a portion of solute. The quantity of kinetic EBI precipitated is a function of the conditions imposed. The solid kinetic EBI is separated, typically by filtration, from the mother liquor solution of additional kinetic EBI. The separated solid kinetic EBI is dried. A yield of 20% to 50% from indene is typical.
5. Work-Up of Kinetic EBI Mother Liquor
[0023] This mother liquor or filtrate from the separation of solid kinetic EBI is treated with an isomerization agent as described in Sections 4 and 5, wherein the kinetic EBI solute is converted to the thermodynamic isomer. The isomerization reaction mixture is cooled or otherwise treated to induce precipitation of thermodynamic EBI. The precipitate is recovered. The combined yield of solid kinetic and thermodynamic EBI from indene may exceed 60%.
6. Conversion of EBI to a Metallocene
[0024] Either the separated kinetic EBI product of step 5, or the separated thermodynamic product of step 6, or a mixture thereof may be used in subsequent procedures to yield other products. An important aspect of this invention is the substantial combined yield of both EBI isomers from indene at relatively low reaction temperatures. The EBI product mixture is used in known manner to produce, inter alia, metallocene olefin polymerization catalysts having the formula
A 2 ZX 2
[0025] in which A is a mixture of kinetic and thermodynamic EBI, Z is Zr, Ti or Hf, and X is a halogen. Z is typically Zr and X is typically chlorine. (EBI) 2 ZrCl 2 is a typical catalyst. Typically, such metallocenes are produced by the reaction of a ligand lithenide with a Group IV tetrahalide. See, generally, Spaleck (1994) Organometallics 13:954-963, Journal of Organometallic Chem. 288 (1985) 63-67, and various Spaleck patents, including U.S. Pat. Nos. 5,145,819 and 5,278,264.
EXEMPLIFICATION OF THE INVENTION
EXAMPLE I (Laboratory)
[0026] Indene in diethyl ether (1.25 equivalents) was treated with BuLi in ethyl ether at −20° C. to provide reaction mixture containing lithium indenide pursuant to Equation 1,
[0027] The lithium indenide containing reaction mixture was warmed to room temperature, was stirred for one hour, and then treated 0.5 mol of with dibromoethane. Ten minutes later tetrahydrofuran (THF) (0.25 equiv.) was added. The temperature of the reaction slowly warmed to 40° C.
[0028] The 1 H NMR of the product mixture showed >95% yield from indene of the kinetic isomer of EBI. No Spiro product was observed. See Equation 2.
[0029] Water was added and the mixture separated into an aqueous phase and an organic phase. The organic phase was separated and dried with sodium sulfate.
[0030] The organic phase solvent (i.e., THF and hexanes) was exchanged with hexanes in an amount such that the final volume was concentrated to about 40 weight % of Kinetic EBI. The solution was cooled to −20° C. and filtered. The solid was dried to give a 35% yield of the kinetic isomer of EBI.
EXAMPLE I(a) (Laboratory)
[0031] The Example I filtrate, a hexane solution of kinetic EBI, was treated with 20 mol % potassium tertiary butoxide in THF and refluxed overnight. 1 H NMR of the reaction mixture showed 100% conversion of the kinetic EBI content to thermodynamic EBI. The isomerization is illustrated by Equation 3:
[0032] The resulting hexane solution of thermodynamic EBI was cooled to −20°. The solid thermodynamic EBI precipitated and was removed by filtration. The solid was dried to give an additional 50% of thermodynamic EBI. Total yield of from indene was 85%.
EXAMPLE II
Meso to Rac Isomerization of TMS-EBI
[0033] 1.0 mol pure meso bis-1,2(3,3′TMS-EBI)ethane was dissolved in THF (403 g) and 0.2 mol potassium tertiary butoxide (KOtbu) was added in one portion to provide a THF solution containing 20 mol percent of KOtbu. The solution changed color immediately from yellow to green. The reaction mixture was stirred for 30 minutes. 1 H NMR of the crude mixture showed rac/meso in a 50:50 ratio.
[0034] Upon addition of 3% aqueous NaCl, the reaction product separated into an organic layer and an aqueous layer. The organic layer was separated and washed with water; the THF solvent was exchanged with heptane under conditions such that a heptane solution containing about 35% bis-1,2(3,3′TMS-EBI-1) was obtained. The heptane solution was cooled to −20° C. and the meso isomer crystallized. The solid meso was separated (198 g) by filtration. The filtrate that contained rac was distilled, leaving behind a sticky semi- solid that contained 200 g of 90% diastereomerically pure rac.
EXAMPLE II(a)
[0035] The solid meso collected in Example II was converted to a 50 meso/50 rac mixture from which the rac was separated by reiteration of the Example I work-up.
EXAMPLE III
[0036] Example II is repeated using 2,2T methyl substituted TMS-EBI. An isomerization reaction mixture having a 65:35 meso:rac ratio was produced:
EXAMPLE IV (Laboratory)
[0037] Example II is repeated using 4,4′:7,7′methyl substituted TMS-EBI. An isomerization reaction mixture having an 80:20 meso:rac ratio was produced:
EXAMPLE V (Batch Record)
Synthesis of Rac-1,2-Ethylenebis (3-trimethylsilyl-l-indenyl)ethane
Process Description
[0038] 1,2-Bis(indenyl)ethane, BSC-395 and THF are charged to a reaction vessel. Butyllithium in hexanes is then added slowly. This mixture is then slowly heated to room temperature and agitated. THF and TMSC1 (trimethylsilyl chloride) are added to the vessel, and the lithiated EBI is fed in cold. THF and unreacted TMSC1 are distilled to the vessel. Heptane is added. The slurry is filtered through a sparkler filter, collecting lithium salts. The filtrate is cooled, and the meso product is collected on a filter. The meso ligand is treated with potassium t-butoxide to isomerize to a rac-:meso- mixture. The isomer mixture is separated.
Reaction 3
[0039] Meso product of reaction 2 is treated with potassium t-butoxide in THF. Product of Reaction 3-50/50 rac and meso 1,2-ethylenebis(3-trimethylsilyl-1-indenyl) ethane.
(i) Exemplification of Reaction 1
[0040] A nitrogen purged first reactor [190-241] was charged with 9.1 kgs of 1,2-bis(indenyl) ethane. 90.7 kgs of THF is charged to the first reactor vessel. Thereafter, the pot temperature of the first reactor vessel is reduced to the range of −25° C. to −20° C. under 2-5 psig regulated nitrogen. 29.9 kgs of 1.6 molar n-butyl lithium in hexane is fed to first reactor vessel at a rate effective to maintain the pot temperature in the range of −25° C. to −15° C. Upon completion of n-butyl lithium addition, the pot temperature of the first reactor is raised to a temperature of 20° C. to 25° C. over a time period of 16 hours. The pot temperature is then raised to about 30° C. to dissolve the reactor product slurry and the contents of the first reactor vessel are transferred from the first reactor vessel to a dry, glass holding receiver [“receiver”]. The first reactor is maintained wet with THF after the transfer of its contents to the receiver.
(ii) Exerplification of Reaction 2
[0041] 11.5 kgs of trimethylsilyl chloride are charged to the THF wet first reactor vessel. The pot temperature of the first reactor vessel is lowered to the range of −20° C. to −10° C. The contents of the glass holding receiver are added to the first reactor vessel over a 30 minute time period while the pot temperature is maintained in the range of −20° C. to −10° C. The resulting reaction mixture is agitated under 2-5 psig regulated nitrogen as the pot temperature is slowly raised to 20° C. to 25° C. over a period of three hours. Thereafter, the contents of the first reactor are stripped to a paste by distillation of THF and TMSC1 to a temperature of 95° C.
(iii) Exemplification of Reaction 3
[0042] The neutralized distillate which comprises a solution of meso TMS is transferred to a second reactor [115-254]. 5.5 kgs of heptane is added to the second reactor at a temperature of 20° C. to 25° C. THF content of the second reactor is reduced to less than 2% by distillation of heptane/THF.
[0043] The temperature of the second reactor contents is adjusted, if necessary, to 78° C. to 82° C., and that reactor is emptied by filtration to remove lithium salts. The filtrate, a solution of meso solids, is transferred to a nitrogen purged drum. The second reactor is rinsed twice with heptane at 78° C. to 82° C. in an amount sufficient to provide a 35% solution of meso solids when combined with the filtrate form the second reactor contents.
[0044] The combined rinse heptane and the filtrate from the second reactor are transferred to the first reactor at a temperature of −30° C. to −20° C. The resulting meso solids precipitate is removed by filtration and dried.
[0045] The dry meso solids are transferred to a third reactor [95-252] which is charged with 13 kgs. of THF. 135 grams of potassium t-butoxide are added by sprinkling to the contents of the third reactor with agitation for 30 minutes. A 50:50 meso:rac mixture is produced.
[0046] The third reactor is charged with 11.3 liters of water, followed by 1.3 kgs. of sodium chloride which, in turn, is followed by 5.4 kgs. of ethyl ether. The reaction mixture is agitated for 15 minutes, and settled for 15 minutes. A lower aqueous and an upper organic layer form. The lower aqueous layer is removed. Pot temperature of the third reactor is adjusted to less than 20° C. 2 kgs. of sodium sulfate is added with agitation for two hours. The agitated mixture is allowed to settle for 20 minutes, and filtered to a dry second reactor. Solvents are distilled, the contents of the second reactor are cooled to 20° C. to −20° C., and charged with heptane in an amount sufficient to provide a 35% solution of 50:50 rac:meso solids. THF content is adjusted, if necessary, to less than 2%.
[0047] The first reactor [109-241] is cooled to −30° C. to −20° C. The resulting solids are removed by filtration and dried. The filtrate is retained for further processing.
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A method for producing 1,2-bis(indenyl)ethanes in good yield is described. An agent and its application for isomerizing kinetic EBI to thermodynamic EBI and for isomerizing meso TMS-EBI to rac TMS-EBI are exemplified.
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BACKGROUND OF THE INVENTION
The present invention is directed to a method for manufacturing a buried region of increased refractive index in a glass member by an ion exchange. The method comprises the steps of providing a mask of titanium on a surface of a glass member or substrate, raising the refractive index of exposed portions of the glass surface by penetrating the exposed surface with an iontype raising the refractive index of the glass, then removing the titanium mask and then burying the raised refractive index portions in the glass member or substrate by conducting a second ion exchange with another type of ion, which will not raise the refractive index but causes an inward migration of the ions that raise the refractive index.
It is known to raise the refractive index of glass in a method wherein Cs + ions from a CsNO 3 /KNO 3 melt in a first fieldpromoted ion exchange are used. Thus, the Cs + ions penetrate into the glass only where the region of raised refractive index, for example, a strip waveguide or a structure composed of such waveguides, is to occur. To control this, a mask of titanium is employed, and the titanium will block the penetration of the Cs + ions into the glass on those portions of the surface covered by the titanium mask. The regions of raised refractive index will be produced in those regions not covered by the layer of titanium material or, in other words, the spaces between the layers or portions of titanium material. A similar method is known from an article in Appl. Optics Vol. 23, No. 11 (1984), pp. 1745.
An additional field-assisted ion exchange for burying the region is then undertaken. For example, the additional ion exchange uses a salt melt which contains an alkali ion of the glass, generally Na + or/and K + ions. In this exchange, the region of raised refractive index produced by the first ion exchange will migrate into the interior of the glass member and is, thus, buried.
Problems occur in the removal of the roughly 200-500 nm thick mask of titanium from the surface of the glass member or substrate. One problem is to find an etchant, which will etch the titanium away without damaging the glass surface or damaging the region of the raised refractive index, for example, the strip waveguide or the strip waveguide structure.
Due to chemical reactions in the hot salt melt, the mask of the titanium is significantly more resistant to a hydrofluoric acid than in the case of a fresh layer of titanium. A mechanical erosion, for example by grinding of the titanium, is also a problem, because the glass member may have warped due to the treatment with the hot salt melt, and an adequately planar surface generally no longer exists. Therefore, problems occur with being able to grind or polish the mask away without damaging or destroying the region of the raised refractive index.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a method for raising the refractive index of a glass substrate to form waveguides or waveguide structures in which a titanium mask can be removed without problems and can be removed without risk to the region of the raised refractive index.
This object is achieved by an improvement in a process or method for producing a buried region of raised refractive index in a glass member by ion exchange, said method comprising providing a glass member having a mask of a layer of titanium with portions of the surface free of the layer of titanium, raising the refractive index of the exposed portions of the surface of the glass member with a first field-assisted ion exchange having an ion type for raising the refractive index of the glass coming from the salt melt contacting the glass member, subsequently removing the mask by etching the titanium away and then treating the regions of raised refractive index by a second field-assisted ion exchange at the surface of the glass member, which contains the regions of raised refractive index, said second field-assisted ion exchange utilizing another type of ion which does not raise the refractive index of the glass to cause migration of the raised refractive index into the interior of the glass member. The improvements are that the titanium, which is exposed to the hot salt melt during the first ion exchange is etched away with an EDTA disodium etching solution, and this etching step is followed by a slight material erosion, which does not substantially deteriorate the region of the raised refractive index on the glass surface, which is now free of the titanium before the step of the second field-assisted ion exchange.
This solution is based on a new perception that the titanium can, in fact, be etched off by an EDTA etching solution without damage to the glass surface, but that, subsequently, the glass surface freed of the titanium acts like an ion barrier, which will prevent the penetration of the ions into the glass during the second ion exchange process, and that the ion blocking effect can be eliminated by a slight material erosion of this surface which does not deteriorate the region of the raised refractive index.
An EDTA disodium solution, which has proven itself, is a solution which contains 200 ml of H 2 O, and at least 0.1 g of ethylene dinitrilo tetraacetic acid disodium salt, which is sold by the Merck Company under the Trademark "TITRIPLEX III". Another EDTA disodium etching solution is one which includes, in addition to the Titriplex III, contains either NH 3 or H 2 O 2 and NH 3 . For example, an etching solution which is composed of 0.1 g-25 g of the Titriplex III, 0 g-80 g of H 2 O 2 and 0 g-80 g of NH 3 , with 200 ml of H 2 O is preferably employed.
It should be pointed out that the employment of EDTA disodium etching solutions for gently etching a titanium layer is already known from Electron. Lett., Vol. 20, No. 19 (1984), pp. 760. The titanium layer therein, however, is not situated on glass but on a LiNb0 3 , and the method described therein does not relate to an ion exchange process.
The slight material erosion is preferably generated by polishing, however, it can also be produced by etching.
Other objects and advantages of the present invention will be readily apparent from the following exemplary embodiment of the invention, which is set forth in the following description with reference to the Figures and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view through a traditional apparatus for the implementation of the first ion exchange;
FIG. 2 is a cross sectional view through an apparatus for the implementation of the etching step for removing the titanium in accordance with the present invention;
FIG. 3 is a cross sectional view of a glass member containing two strip waveguides on the surface of the member obtained after the etching step in the apparatus of FIG. 2;
FIG. 4 is a cross sectional view through a traditional apparatus for the implementation of the second ion exchange; and
FIG. 5 is an end view of the glass member having the two buried strip waveguides produced by the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The principles of the present invention are particularly useful for producing a glass member 3 (FIG. 5), which has buried strip waveguides 33 and 34.
In the first step of the method of producing, the glass member 3 with the buried strip waveguides 33 and 34 of FIG. 5, comprises providing a vessel 1 (FIG. 1) for a CsNO 3 /KNO 3 melt and a tube 2 for a KNO 3 melt, on whose lower end a glass member or substrate 3' is held by suction. The two buried strip waveguides are to be produced in this glass member 3'. Such an apparatus is known, for example, from an article in Electron. Lett., Vol. 18, No. 8 (1982) pp. 344. The KNO 3 melt cathodically contacts the member or substrate 3' on an upper surface 30, whereas the underside or bottom surface 35 is anodically contacted by the CsNO 3 /KNO 3 melt. A mask of titanium has been applied to the under surface 35, and this will block the penetration of the Cs + ions into the glass, except in the strip areas 41 and 42, which are free of the titanium layer 4, to expose portions of the surface 35.
During the field-assisted ion exchange carried out at about 400° C., the Cs + ions penetrate into the glass in the region of the strips 41 and 42 and raise the refractive index of the glass in this region so that the strip waveguides 31 and 32 arise at the surface of the underside 35 to produce a processed glass member 3".
The glass member 3", which has the strip waveguides 31 and 32 and the mask 4 of titanium, is then removed from the apparatus 1 of FIG. 1. After removal, the member 3" is placed in an EDTA disodium etching solution in a vessel 5 (FIG. 2), in which the titanium layer of the mask 4 is etched away without deterioration of the glass surface. EDTA disodium stands for ethylene dinitrilo tetraacetic acid disodium salt (Dihydrate), which has a chemical formula of C 10 H 14 N 2 Na 2 O 8 .2H 2 O.
The EDTA disodium can, for example, have the following composition 5 g Titriplex III; 200 ml H 2 O; 20 ml 30% H 2 O 2 solution; and 20 ml 25% NH 3 solution. As noted hereinabove, Titriplex III is a trademark for the ethylene dinitrilo tetraacetic acid disodium salt (Dihydrate), which has a formula of C 10 H 14 N 2 Na 2 0 8 .H 2 O.
After the titanium has been etched off, the glass member 3" (shown in FIG. 3) will have two strip waveguides 31 and 32 on the undersurface 35. The undersurface 35, which is freed of the titanium, i.e., the region of the undersurface 35 that was covered by the titanium acts as an ion barrier so that a second ion exchange including the whole surface cannot be carried out. When etching the titanium off, a thin ion-blocking layer may remain. This layer, however, can be polished off without problems and without deteriorating the strip waveguides 31 and 32. An etching treatment is also suitable to remove the layer and it can be either a wet-etching or a dry-etching method. Care must merely be exercised to see that the etching process is selected to be so short that the strip waveguides 31 and 32 are not deteriorated, but long enough so that the blocking effect of the underside or surface 35 has been eliminated. As in the case of polishing, this can be easily determined with a few trials.
The second ion exchange is undertaken on the polished member for burying the strip waveguides 31 and 32. An apparatus similar to the apparatus of FIG. 1 is provided for this purpose and this differs from that apparatus only in that the vessel 6 of the second ion exchange process has a KNO 3 melt instead of the melt of CsNO 3 /KNO 3 . The vessel 6 is anodically contacting the underside 35, which has the waveguides 31 and 32 of the glass member 3". After the implementation of this ion exchange at a temperature of about 400°C., the strip waveguides 31 and 32 will have migrated from the polished under surface 35 in an upward direction into the interior of the glass member so that the final glass member 3, which has the buried strip waveguides 33 and 34, shown in FIG. 5, will be obtained.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art.
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An improvement for a method of producing buried regions of raised refractive index in a glass member by ion exchange characterized by removing a titanium mask from the glass member after a first ion exchange to raise the refractive index of exposed portions of the glass member with an EDTA disodium etching solution followed by a slight material erosion of the glass after removal of the titanium mask prior to an implementation of a second field-assisted ion exchange.
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BACKGROUND OF INVENTION
This disclosure relates generally to a turbine part and more particularly to performing an electronic triage of a turbine part such as a blade or bucket.
The market for long-term contractual agreements has grown at high rates over recent years for many of today's power systems businesses. As the power systems businesses establish long-term contractual agreements with their customers, it becomes important to provide a variety of service solutions for each of their products. One area where adequate service solutions are lacking is with the repair of turbine parts, in particular buckets. For example, buckets for a gas turbine are currently repaired using a manual process that is slow and fails to take into account historical information that could be useful in making repair decisions. In particular, when a set of buckets is brought into a service center, they are logged as one single job. The individual buckets are visually inspected to determine whether to repair or scrap them. Information on individual buckets is captured as verbose text that is not searchable for future use. Therefore, each decision to repair or not to repair a bucket is made without regard to historical information of other buckets that may have exhibited similar symptoms. Without adequate information available to make a repair decision, some buckets may be subjected to repair when it is not necessary and some buckets may not undergo repair when it is necessary. The buckets that do not undergo repair that need it will eventually have to receive repair. This is not a very efficient approach to servicing a bucket.
In order to avoid the problems associated with the above repair process, there is a need for an approach that uses historical information to quickly and accurately facilitate the decision process in determining whether to repair the buckets or to scrap them.
SUMMARY OF INVENTION
In one embodiment of this disclosure, there is a system and method that facilitates the repair of a turbine part. In this embodiment there is a triage storage unit that stores a plurality of repair information. A repair triage application facilitates the repair of the part in accordance with the plurality of repair information stored in the triage storage unit. A computing unit is configured to execute the repair triage application.
In a second embodiment of this disclosure, there is a system and method that facilitates the repair of a turbine part. In this embodiment there is a triage storage unit that stores a plurality of repair information. A repair triage application facilitates the repair of the part in accordance with the plurality of repair information stored in the triage storage unit. A first computing unit is configured to execute the repair triage application. A second computing unit is configured to serve the triage storage unit and the repair triage application to the first computing unit over a network.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic of a general-purpose computer system in which a system that facilitates the repair of a turbine part operates on;
FIG. 2 shows a schematic diagram of the turbine part repair system that operates on the computer system shown in FIG. 1;
FIG. 3 shows a system architecture diagram for implementing the system shown in FIG. 2;
FIG. 4 shows a flow chart describing the acts performed during the parts tracking module shown in FIG. 2;
FIG. 5 shows an example of a screen view of job information details presented to a user and filled in by the user while running the parts tracking module;
FIG. 6 shows another example of a screen view taken from the parts tracking module;
FIG. 7 shows an additional example of a screen view taken from the parts tracking module;
FIG. 8 shows an example of a screen view of an inspection planning schedule that may be presented to a user while running the parts tracking module;
FIG. 9 shows an example of a screen view that may be presented to a user that provides inspection results for a particular part while running the parts tracking module;
FIG. 10 shows a flow chart describing the acts performed during the decision support module shown in FIG. 2; and
FIG. 11 shows a flow chart describing the acts performed during the customer tracking module shown in FIG. 2 .
DETAILED DESCRIPTION
FIG. 1 shows a schematic of a general-purpose computer system 10 in which a system for facilitating the repair of a turbine part such as a blade or bucket operates on. The computer system 10 generally comprises at least one processor 12 , memory 14 , input/output devices, and data pathways (e.g., buses) 16 connecting the processor, memory and input/output devices. The processor 12 accepts instructions and data from the memory 14 and performs various calculations. The processor 12 includes an arithmetic logic unit (ALU) that performs arithmetic and logical operations and a control unit that extracts instructions from memory 14 and decodes and executes them, calling on the ALU when necessary. The memory 14 generally includes a random-access memory (RAM) and a read-only memory (ROM), however, there may be other types of memory such as programmable read-only memory (PROM), erasable programmable read-only memory (EPROM) and electrically erasable programmable read-only memory (EEPROM). Also, the memory 14 preferably contains an operating system, which executes on the processor 12 . The operating system performs basic tasks that include recognizing input, sending output to output devices, keeping track of files and directories and controlling various peripheral devices.
The input/output devices may comprise a keyboard 18 and a mouse 20 that enter data and instructions into the computer system 10 . A display 22 allows a user to see what the computer has accomplished. Other output devices could include a printer, plotter, synthesizer and speakers. A communication device 24 such as a telephone or cable modem or a network card such as an Ethernet adapter, local area network (LAN) adapter, integrated services digital network (ISDN) adapter, or Digital Subscriber Line (DSL) adapter, that enables the computer system 10 to access other computers and resources on a network such as a LAN or a wide area network (WAN). A mass storage device 26 allows the computer system 10 to permanently retain large amounts of data. The mass storage device may include all types of disk drives such as floppy disks, hard disks and optical disks, as well as tape drives that can read and write data onto a tape that could include digital audio tapes (DAT), digital linear tapes (DLT), or other magnetically coded media. The above-described computer system 10 can take the form of a hand-held digital computer, personal digital assistant computer, personal computer, workstation, mini-computer, mainframe computer or supercomputer.
FIG. 2 shows a top-level component architecture diagram of a system 28 for facilitating the repair of a turbine part that operates on the computer system 10 shown in FIG. 1 . In FIG. 2 there is a triage storage unit 30 that contains information that users of the system 28 access. The triage storage unit 30 comprises a variety of information such as part pedigree information, component design criteria, operational parameters, repair history, repair statistics and repair analytics for a plurality of turbines. The part pedigree information comprises the life history of a plurality of turbine parts for the turbines. Each life history of a part includes the turbines on which the part was placed, the conditions under which the turbines were run and the part repair history of the part. The component design criteria comprise information such as engineering drawings for the various turbine parts of the turbines. The operational parameters comprise the conditions under which the turbines were operated. Examples of some operational parameters are load, type of start and ambient temperature and type of fuel used and the number of trips. The repair history comprises information on the type of repairs made to the turbines. The repair statistics comprise information gathered during repairs of any of the turbines. Examples of repair statistics are inspection tests performed, the results of the tests, the repairs made, the time taken to perform the repairs, cost of the repairs and the number of repairs performed on any of the parts in the turbines. Repair analytics comprise information (e.g., trends in the part condition, prediction of remaining life) on repairs made to any of the parts of the turbines. These examples are illustrative of only a few items of information that may be stored in the triage storage unit 30 and one of ordinary skill in the art will recognize that other items of information can be stored therein.
A user information database 32 contains identity and security information for users of the system 28 . Specifically, the user database 32 contains general information such as phone numbers, addresses, the type of user (e.g., customers, engineers, administrators, etc.), e-mail addresses, passwords, login identification, etc. This information enables the system 28 to authenticate all on-line users accessing the system and have an access control mechanism for different users such as shop personnel, design engineers and customers. The user information database 32 can take the form of a lightweight directory access protocol (LDAP) database, however, other types of databases can be used.
A repair triage application 34 facilitates the repair of the turbine part in accordance with the plurality of repair information stored in the triage storage unit 30 . The repair triage application 34 comprises a parts tracking module 36 that tracks parts of the turbine during repair and inspection such as buckets, nozzles, rotors, shafts, etc. The parts tracking module 36 comprises a job module that assigns a job number for the part and provides job information for the part during inspection and repair. The job information comprises an inspection schedule for the part and any inspection results for the part and a repair schedule and any repair results. In addition, the parts tracking module comprises an inspection schedule module that plans the inspection for the part. Also, the parts tracking module 36 comprises a repair schedule module that plans the repair of the part.
The repair triage application 34 also comprises a decision support module 38 that determines whether a part needs to be repaired or should be scrapped. The decision support module comprises a search module that searches the triage storage unit 30 for other parts that have experienced conditions similar to the bucket undergoing examination. In addition, the decision support module comprises a cost benefit analysis module that determines the costs and benefits associated with repairing the part or scrapping the part.
Another module associated with the repair triage application 34 is the customer tracking module 40 . This module enables a customer to track the progress of a job being performed for them without having to call a service engineer. In this module, a customer enters the assigned job number on a screen and the system will display the status of the job. In addition, the customer tracking module 40 shows the customer the steps that are planned, those that are completed, those that the part has passed and those that the part has failed. Also, the customer tracking module 40 informs the customer of the expected date that the job will be finished.
In addition to the above modules, the repair triage application 34 may comprise other modules that run utilities for performing special tasks. For example, there can be utilities for administering and performing maintenance functions. Other utilities that may be used are utilities for creating, modifying and deleting user profiles.
FIG. 3 shows a system 42 architecture diagram for implementing the system shown in FIG. 2 . FIG. 3 shows that there are several ways of accessing the system 28 . A computing unit 44 allows shop personnel, design engineers, decision makers, administrators, etc. to access the system 28 . Also, customers access the system 28 through a computing unit 44 . The computing unit 44 can take the form of a hand-held digital computer, personal digital assistant computer, personal computer or workstation. The shop personnel, design engineers, decision makers, administrators, customers and any other users use a web browser 46 such as Microsoft INTERNET EXPLORER or Netscape NAVIGATOR to locate and display the system 28 on the computing unit 44 . A communication network connects the computing unit 44 to the system 28 . FIG. 3 shows that the computing units 44 may connect to the system 28 through a private network 48 such as an extranet or intranet or a global network 48 such as a WAN (e.g., Internet). For example, shop personnel, design engineers, decision makers and administrators can access the system 28 via an extranet or intranet, while other users such as customers could access it through an extranet or the Internet. The system 28 resides in a triage server 50 , which comprises a web server 52 that serves the repair triage application 34 , triage storage unit 30 and the user information database 32 .
FIG. 4 shows a flow chart describing the acts performed during the parts tracking module shown in FIG. 2 . At block 54 , a user such as a design engineer, service personnel, turbine operator, administrator or customer signs into the system 28 . The sign-in act can include entering identity and security information (e.g., a valid username and password). As previously mentioned, the user information database 32 contains identity and security information for users of the system 28 . Furthermore, the user information database 32 may have an access control mechanism that allows users (e.g., design engineers, service personnel, turbine operators, administrators or customers) to have different roles in accessing the system 28 . For example, the parts tracking module and the decision support module can be made accessible only to design engineers, service personnel, turbine operators, or administrators and off limits to other users. Similar restrictions can be made for the customer tracking module 40 .
A user continues with the parts tracking module once access control and authentication has been completed. Initially, the user enters job information for a part at 56 . Entering the job information comprises information such as the assigned job number, the number of parts in the job, the number assigned to the turbine which the part belongs to, etc. If the parts tracking module is unable to find the job in the triage storage unit 30 that matches the entered criteria, then a message is displayed to the user instructing him or her to enter the details of the job. FIG. 5 shows an example of a screen view of job information details that is presented to the user and filled in by the user. Details of the job as the user enters them are displayed in a screen view similar to the one shown in FIG. 6 .
Referring back to FIG. 4, in addition to the job information, the user enters customer information at 58 for the particular job. The customer information comprises information such as the customer name, location and address of the customer, customer contact, phone number of the customer contact, etc. FIG. 7 shows a screen view that prompts a user to enter job information, customer information and other miscellaneous information while running the parts tracking module. One skilled in the art will recognize that other information can be entered into the system upon initiating the parts tracking module.
Referring again to FIG. 4, at 60 , the user enters the inspection planning schedule of the job. The inspection planning schedule comprises a series of steps to be performed on the parts in the job. In an exemplary embodiment, each part of the turbine has a template of steps that have to be followed to complete the inspection phase. For instance, there is an inspection planning schedule for the various parts of a turbine such as a bucket, nozzle, rotor, shaft, etc. FIG. 8 shows a screen view of an inspection planning schedule that may be presented to a user while running the parts tracking module. Note that this screen view does not show a particular template; however, one skilled in the art will know of various steps that have to be performed when inspecting parts of a turbine and will be able to generate an appropriate schedule. For example, an inspection schedule could comprise performing steps such as a manual inspection, photo inspection, water flow test of cooling holes, a heat treatment, etc. These inspection steps are illustrative of only a few steps that can be performed and are not exhaustive of other possibilities.
In FIG. 4, a user enters the inspection results at 62 . The inspection results may comprise information such as the condition of the part at each of the various steps of the inspection schedule. In addition, the inspection results may indicate whether the part has passed or failed each of the steps of the inspection schedule. One skilled in the art will recognize that other information can be captured for the inspection results. FIG. 9 shows an example of a screen view that may be presented to a user that provides inspection results for a particular part. If the inspection results are not clear as determined at 64 then the inspection schedule is revised and the part or parts of the job are inspected again and the results are reviewed.
Upon receipt of the inspection results, the user then enters a repair schedule at 66 . The repair schedule comprises a series of steps to be performed on the parts in the job to make it operate in a satisfactory manner. Like the inspection schedule, the repair schedule for each part of the turbine has a template of steps that have to be followed to complete the repair phase. For instance, there is a repair schedule for the various parts of a turbine such as a bucket, nozzle, rotor, shaft, etc. For example, a repair schedule could comprise performing some of the following repairs: a blend repair of an airfoil, a blend repair of a cooling hole, a touchup of buckets, a weld repair, a wire check of cooling holes, etc. These repairs are illustrative of only a few types that can be performed and are not exhaustive of other possibilities.
The user enters the repair results at 68 after the repair schedule has been run. The repair results may comprise information such as the person that performed the repairs, the start time of the repairs, the end time of the repairs, a description of the repairs performed, the amount of material used to make the repairs, the equipment used to make the repairs, whether the repairs were a success or failure, etc. One skilled in the art will recognize that other information can be captured for the results. If the repair has to be repeated as determined at 70 then the part or parts of the job are subjected to the repair schedule again. If the repair results are okay as determined at 70 then the part or parts are considered repaired at 72 . Alternatively, if the repair results are not okay as determined at 70 then the part or parts of the job are considered scrap at 74 .
FIG. 10 shows a flow chart describing the acts performed during the decision support module shown in FIG. 2 . At block 76 , a user signs in and selects the decision support module. Afterwards, the user obtains the conditions of the part of the turbine undergoing a repair decision at 78 . Specifically, the user obtains the conditions by entering the job number that has been assigned to the part. Next, the user searches the triage storage unit for parts having similar conditions as the part undergoing review at 80 . More specifically, the user selects the data from the information received that best describes the condition of the part. Based on that data the system 28 searches the triage storage unit 30 for parts that had similar conditions when undergoing previous repair decisions. This search also provides other information such as the repair process of those similar parts and the costs to repair. The system 28 then uses the search results to perform a history and cost benefit analysis at 82 . The history of the parts shows the part pedigree, the conditions under which the turbine operated and the repair statistics. The cost benefit analysis provides the historical cost of repair for a similar part versus the remaining life of the part. The cost benefit analysis also shows the difference in cost between repair and a replacement part. Note that the replacement part could be new or refurbished.
Referring again to FIG. 10, the system 28 recommends a repair solution for the subject part at 84 in accordance with the history and cost benefit analysis. Generally, the repair solution will entail fixing the part or scrapping it. If the part is to be fixed, the repair solution corresponds to the repair solutions of the parts that most closely relate to the subject part. All of the search results and the repair solution are displayed to the user at 86 . If there are any more parts that have to be reviewed for a repair decision as determined at 88 , then blocks 78 - 86 are repeated until there are no more parts.
FIG. 11 shows a flow chart describing the acts performed during the customer tracking module shown in FIG. 2 . As mentioned above, this module enables a customer to track the progress of a job being performed for them without having to call a service engineer. At block 90 , a customer signs in and selects the customer tracking module. After signing in, the customer enters the job number assigned to the customer at 92 . Upon entering the job number, the customer tracking module generates the status of the job at 94 and displays the results to the customer at 96 . The status information comprises information such as the planned inspection schedule, those inspection steps that have been completed, the inspection results, the repair schedule, the results of any completed repair steps and the time that the job is expected to be completed. If the customer wants to track the status of another job as determined at 98 , then blocks 92 - 96 are repeated until there are no more jobs to be tracked. Alternatively, if there are no more jobs then the customer tracking module ends.
The foregoing flow charts of this disclosure show the functionality and operation of a possible implementation of the system and method for performing electronic triage of a turbine part. In this regard, each block represents a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that in some alternative implementations, the functions noted in the blocks may occur out of the order noted in the figures, or for example, may in fact be executed substantially concurrently or in the reverse order, depending upon the functionality involved. Furthermore, the functions can be implemented in programming languages such as C++ or JAVA, however, other languages such as Visual Basic can be used.
The above-described system and method for performing electronic triage of a turbine part comprises an ordered listing of executable instructions for implementing logical functions. The ordered listing can be embodied in any computer-readable medium for use by or in connection with a computer-based system that can retrieve the instructions and execute them. In the context of this application, the computer-readable medium can be any means that can contain, store, communicate, propagate, transmit or transport the instructions. The computer readable medium can be an electronic, a magnetic, an optical, an electromagnetic, or an infrared system, apparatus, or device. An illustrative, but non-exhaustive list of computer-readable mediums can include an electrical connection (electronic) having one or more wires, a portable computer diskette (magnetic), a random access memory (RAM) (magnetic), a read-only memory (ROM) (magnetic), an erasable programmable read-only memory (EPROM or Flash memory) (magnetic), an optical fiber (optical), and a portable compact disc read-only memory (CDROM) (optical). It is even possible to use paper or another suitable medium upon which the instructions are printed. For instance, the instructions can be electronically captured via optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.
It is apparent that there has been provided in accordance with this disclosure, a system, method, and computer product for performing electronic triage of a turbine part. While the invention has been particularly shown and described in conjunction with a preferred embodiment thereof, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.
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A system and method for performing electronic triage of a turbine part. A triage storage unit stores a variety of repair information. A repair triage application facilitates the repair of the turbine part in accordance with the repair information stored in the triage storage unit. A computing unit is configured to execute the repair triage application. A second computing unit is configured to serve the triage storage unit and the repair triage application to the first computing unit over a network.
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COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] N/A
FIELD OF THE INVENTION
[0003] This invention relates generally to stairway construction and specifically to tread supports for stairways.
STATEMENT REGARDING FEDERALLY FUNDED RESEARCH
[0004] This invention was not made under contract with an agency of the US Government, nor by any agency of the US Government.
BACKGROUND OF THE INVENTION
[0005] Construction of wooden stairs for residential use is a surprisingly painful process for the builder.
[0006] The stairs must obviously traverse a vertical height from one end to the other, however, in most instances, the horizontal run of the stairs is pre-set by an architect while the vertical height may or may not be set: outdoor patio steps, for example, will depend upon the distance from the top of the patio to the ground or landing at the lower end. Thus the builder must construct the steps within an entirely defined boundary.
[0007] Since local building codes, the Americans with Disabilities Act and other regulations and rules require that steps be of even height, that is, each step being the same height as the steps above and below it, the builder must then divide the height change into a number of even increments. For example, a height change of 8′ 3½″ (99.5 inches) would not allow 10 steps of 10 inches each, as one step would be ½ inch short. Rather, the builder would have to calculate some reasonable number of inches per step and number of steps which “works” for the given height and is possible to do. In the given example, cutting 10 steps of 9.95 inches each is probably not possible as most construction measuring devices are denominated in units of ⅛ inch, 1/16 inch, and so on, but not 1/20 (0.05) of an inch. Rounding to the nearest ⅛ inch unit would result in the ½″ deviance mentioned previously, cutting long pieces of wood on-site to within 1/16 of an inch tolerance is difficult at best and would still leave some small deviation. In this case the builder might, after some math headaches, conclude that 8 rather tall steps of 12 7/16″ (12.4375″), would be difficult but at least would be even. However, under the Uniform Building Code at the present time in the US steps must be no more than 8″ in height, thus sending the builder back to the math.
[0008] Obviously, this example is constructed to be very annoying to the builder, but the problem is a real one even with simpler numerical requirements.
[0009] Once the math problem has been accomplished the builder's problems are NOT over. The builder must then obtain a comparatively expensive piece of wood for the “stringer”, that is, the main support beam of the stairway which runs at a diagonal from lower end to upper end, holding up all of the stairs.
[0010] A stringer is a single strong piece of wood, usually a 2×12 or the like, which under many codes must be solid wood, not composite material such as plywood or the like as composites are generally deemed unsafe for the extreme loads placed on the stairway. The stringer length much be calculated—a relatively easy issue—and normally two or more long, solid, wide, pieces of wood are bought. Depending on the stair width and length, the expense of purchasing stringers is not great but is not insignificant. Then the stringers must be cut on site.
[0011] Each step is cut individually in triangular cuts removed from the stringers, and since the treads and risers of the staircase have thickness, the previous calculations of the height of each step are now adjusted to compensate in the cutting for the treads and risers which will be part of the step.
[0012] Obviously, numerous precise cuts on an expensive piece of wood are less than desirable for the builder. The possibility of a single cut passing entirely through the stringer and thus ruining it is present, as is the possibility of a single cut which is of proper depth but misplaced so badly that the wood cannot be recut correctly and with a safe strength, requiring the reinforcement or even replacement of the stringer.
[0013] Once the stringer is cut, the stairs risers and treads may finally be fastened to it. The strength of the stringer is dramatically reduced by the cutting: after the expense and difficulty of using a 2×12 piece of wood as the stringer, that 2×12 may well have only a 2×6 thickness remaining at its narrowest and thus weakest points—where the stairs are cut the deepest into the stringers.
[0014] It is worth considering that pre-made stairs which might be nailed or otherwise fastened to an uncut stringer would only be usable in circumstances in which the height to be traversed measures EXACTLY a multiple of the stair height. For example, pre-made steps of exactly 8 inches each would be allowable for sets of stairs which cover a rise of exactly 16 inches, 24 inches, 32 inches and so on, but would NOT be allowable for stairs which need to cover a rise of 17 inches, 23 inches, 25 inches, and so on.
[0015] It would obviously be preferable to provide a device which allows the stringer to remain whole and uncut.
[0016] It would obviously be preferable to provide a device which allows the stringer to remain whole and uncut and thus stronger.
[0017] It would obviously be preferable to provide a device which allows the stringer to remain whole and uncut and thus allow the use of narrower and thus less expensive stringers.
[0018] It would obviously be preferable to provide a device which allows the builder to avoid the exasperating mathematics necessary to bridge a given rise and run with a set of equal stairs which meet all regulatory requirements.
[0019] These and many other issues are addressed by the present invention, whose advantages, aspects, objectives and embodiments are disclosed below.
SUMMARY OF THE INVENTION
General Summary
[0020] The present invention teaches a mathematically pre-calculated tread support which is mounted upon the top edge of a stringer, the device having numerous possible riser heights available to the builder in the form of numerous choices of fastener placement. The device allows the stringer to retain full strength without being cut into and thus provides a stronger stringer of for example lumber such as 2×4, 2×6, 2×8, 2×10, 2×12, etc.
[0021] It further teaches that the tread support may have an alignment guide so that a builder, knowing the number of steps and the height to be traversed and having simply divided one by the other to obtain a stair rise, may then adjust the device to the correct rise, spot by eyeball the correct fastener placement to use, and then build the staircase without further need for calculation.
[0022] The present invention further teaches that the tread support of the bottom-most stair in a set will need to provide the proper rise, but will not have the same amount of stringer available underneath for support, and therefore the tread support must have a second configuration which can be placed in a smaller vertical space of stringer and yet be fully supported at the proper height.
[0023] The present invention further teaches that the tread support will require left-handed and right-handed embodiments, for use on the opposite ends of stair treads.
[0024] In detail, the device of the invention teaches a two part tread support having a generally triangular profile. The lower part will conform to the top and side of a diagonal stringer, regardless of the angle of the slope of the stringer, and has holes therethrough for fasteners such as screws, bolts and the like (or other fasteners as they become available) to be used to hold the support to the stringer. A fin of the lower part extends upward.
[0025] The lower part and the upper part are connected at a pivot allowing them to assume a range of angles in relation to one another. The pivot is disposed at one corner of the device, the corner where the stringer and the tread meet (and for stairs having risers, the same place where the riser bottom meets as well).
[0026] The upper part will conform to the bottom of the tread, and may have means for fastening to the tread. The fin of the lower part is coplaner and overlapping with the upper part.
[0027] The upper and lower parts each have upon them respective pluralities of holes. The groups of holes are both disposed centered at approximately the same distance from the pivot. Thus at the proper angles, various different pairs of holes of the two different groups will overlap. A fastener may be place through the holes to fix the two parts together at the chosen angle, which results in fixing the two parts together with the desired riser height.
[0028] The exact placement of the holes may be pre-calculated so that the holes will, in their various combinations of overlapping, provide numerous different heights.
[0029] In the best mode now contemplated and presently preferred embodiment, the holes will cover a span of inches with every possible adjustment from a minimum to maximum height in increments of a mere ⅛ inch. It has been determined that a group of approximately 13 to 14 holes on one part of the support, overlapping with a group of approximately 5 holes on the other part will provide this wide range. In practice, a range of over two inches may be accommodated and wider ranges are possible as well. Other increments may be used, however, ⅛ inch is a common increment of carpentry and is thus presently preferred.
[0030] An important advantage of the present invention is that an alignment guide is provided. This alignment guide allows a builder to pivot the two pieces relative to one another until the alignment guide indicates the riser height which the builder desires. At that point, the precision of the alignment guide and hole placement is such that the builder can visually see which pair of holes (one from the fin of the lower part and one from the upper part) are precisely overlapping, after which the builder may simply insert the fastener through the desired pair of holes, fastening the tread support in the proper configuration. A rivet is presently preferred for the fastener, due to strength, but any fastener now known or later developed may of course be used if issues of strength, durability and regulations may be addressed.
[0031] For additional strength, each unit has thereon not two but five groups of holes, so that with one unit at each end of a tread, the tread is supported by seven fasteners at one end and the pivot point (also preferably a rivet) at the other end, making a total of eight fasteners holding up the end of the step or tread. Obviously additional fastening groups may be provided for even more support.
Summary in Reference to Claims
[0032] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device for use on a stringer of a set of stairs, the stringer having a top and a side, the tread support device for use supporting a level tread, the tread support device comprising:
[0033] a pivot point;
[0034] a first lower part, the lower part having a vertical fin;
[0035] a second upper part, the upper part and the lower part pivoting relative to one another about the pivot point;
[0036] a first riser height H measured at a first edge of the device distal from the pivot point, the riser height H having a plurality of values;
[0037] a first plurality of holes passing through the fin of the lower part, the first plurality of holes centered at a first distance from the pivot point;
[0038] a second plurality of holes passing through the upper part, the second plurality of holes also centered at the first distance from the pivot point;
[0039] a first pair of holes including a first hole of the first plurality of holes and a second hole of the second plurality of holes which are overlapping when the riser height H is a first riser height H 1 ;
[0040] the first and second plurality of holes arranged so that as the riser height H increases by a first increment X from H 1 to a riser height H 2 , the first pair of holes are no longer overlapping and a second pair of holes including a third hole of the first plurality of holes and a fourth hole of the second plurality of holes do overlap;
[0041] a fastener dimensioned and configured to pass through the overlapping pairs of holes and disposed within an overlapping pair of holes.
[0042] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a set of stairs including the tread support device of claim 1 , the set of stairs further comprising:
[0043] an uncut stringer, the stringer supported at a first end and at a second end, the first end higher than the second end, the stringer having a top surface disposed at an angle due to the first end being supported higher than the second end;
[0044] the tread support device disposed upon the top surface, the first lower part fastened to the stringer, the fastener disposed through the first pair of holes such that the riser height H has the value H 1 ;
[0045] a tread, the tread disposed upon the second upper part of the tread support device, the tread fastened to the second upper part.
[0046] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the increment X is ⅛ inch (3 mm).
[0047] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device further comprising:
[0048] a second tread support device, the second tread support device having a second tread support device pivot point;
[0049] a second tread support device lower part, the second tread support device lower part having a second tread support device vertical fin;
[0050] a second tread support device upper part, the second tread support device upper part and the second tread support device lower part pivoting relative to one another about the second tread support device pivot point;
[0051] a second tread support device first riser height H measured at a second tread support device second edge distal from the second tread support device pivot point, the second tread support device riser height H having a plurality of values;
[0052] a second tread support device first plurality of holes passing through the second tread support device fin of the second tread support device lower part, the second tread support device first plurality of holes centered at a second tread support device first distance from the second tread support device pivot point;
[0053] a second tread support device second plurality of holes passing through the second tread support device upper part, the second tread support device second plurality of holes also centered at the first distance from the second tread support device pivot point;
[0054] a third pair of holes including a fifth hole of the second tread support device first plurality of holes and a sixth hole of the second tread support device second plurality of holes which are overlapping when the second tread support device riser height H is the first riser height H 1 ;
[0055] the second tread support device first and second plurality of holes arranged so that as the second tread support device riser height H increases by the first increment X from H 1 to the riser height H 2 , the third pair of holes are no longer overlapping and a fourth pair of holes including a seventh hole of the second tread support device first plurality of holes and an eighth hole of the second tread support device second plurality of holes do overlap;
[0056] a second fastener dimensioned and configured to pass through the overlapping pairs of holes of the second tread support device and disposed within an overlapping pair of holes;
[0057] the second tread support device further comprising:
[0058] a height adjustment mechanism separate from the pluralities of holes, the height adjustment mechanism providing a second independent adjustment to the riser height H of the second tread support device, the height adjustment mechanism located on the second tread support device second edge;
[0059] the second edge being shorter than the first edge.
[0060] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the height adjustment mechanism further comprises:
[0061] a bolt, secured to the second tread support device second edge with the bolt parallel to the second edge, whereby a bottom step is additionally supported.
[0062] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the bolt is secured to the second edge by passing through a bracket attached to the second tread support device lower part, the bolt passing through a bracket nut attached to the bracket and further passing through a jam nut.
[0063] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the second plurality of holes on the upper part are arranged in a first pivot line, the first pivot line passing through the pivot point, while the first plurality of holes on the lower part are arranged in a group, the group deviating from the first pivot line.
[0064] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the pivot point further comprises: a rivet.
[0065] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the fastener further comprises: a rivet.
[0066] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the first edge further comprises:
[0067] an alignment guide, the alignment guide having a series of markings, the series of markings bearing indicia indicating the value of the riser heights H 1 and H 2 , measured to the nearest increment X.
[0068] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the alignment guide is sufficient accurate that when riser height H 1 is indicated, the overlap of the first and second holes is visible and the first and second holes overlap, and when riser height H 2 is indicated, the overlap of the third and fourth holes is visible and the third and fourth holes overlap;
[0069] whereby the overlap is sufficiently accurate that the fastener may pass through the visibly overlapping holes.
[0070] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the lower part further comprises a flat-to-stringer-support portion, the flat-to-stringer-support portion disposed upon such stringer top.
[0071] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the lower part further comprises a side-of-stringer-support portion, the side-to-stringer-support portion disposed upon such stringer side.
[0072] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the flat-to-stringer-support portion further comprises: a fastening hole allowing fastening of the tread support device to such stringer.
[0073] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a stairway tread support device wherein the upper portion further comprises a tread support part, the tread support part having such tread disposed thereon and fastened thereto.
[0074] It is therefore another aspect, advantage, objective and embodiment of the invention, in addition to those discussed previously, to provide a system for fastening treads to stringers and supporting the treads, the system comprising:
[0075] a first tread support device of claim 1 having a left-handed orientation;
[0076] a second tread support device of claim 1 having a right-handed orientation;
[0077] a third tread support device of claim 6 having a left-handed orientation;
[0078] a fourth tread support device of claim 6 having a right-handed orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0079] FIG. 1 is an elevational oblique view of a first and a second embodiment of the device in use on a set of stairs.
[0080] FIG. 2 is a transparent side view diagram of a first and second embodiment of the device, in use on a set of stairs.
[0081] FIG. 3 is a front view of the device in use on a set of stairs.
[0082] FIG. 4 is a front view of the device in use on a set of stairs, showing additional details of the bottom step.
[0083] FIG. 5 is an oblique view of a first embodiment of the invention, in a right-handed sub-embodiment.
[0084] FIG. 6 is an oblique view of a first embodiment of the invention, in a left-handed embodiment.
[0085] FIG. 7 is a transparent view of the first embodiment of the device in a right-handed embodiment.
[0086] FIG. 8 is a transparent view of the first embodiment of the device in a left-handed embodiment.
[0087] FIG. 9 is a transparent side view of the lower portion of the device's first embodiment.
[0088] FIG. 10 is a side view of the upper portion of the device's first embodiment.
[0089] FIG. 11 is an oblique view of the second embodiment in a left-handed sub-embodiment for the bottom step.
[0090] FIG. 12 is an oblique view of the second embodiment in a right-handed sub-embodiment for the bottom step.
[0091] FIG. 13 is a side view of the second embodiment of the invention, left-handed.
[0092] FIG. 14 is a side view of the second embodiment of the invention, right-handed.
[0093] FIG. 15 is a front view of the second embodiment of the invention, left-handed.
[0094] FIG. 16 is a side view of the second embodiment of the invention, right-handed.
[0095] FIG. 17 is an oblique view of the bottom bolt assembly of the invention.
[0096] FIG. 18 is a transparent side view of the bottom bolt assembly of the invention.
INDEX TO REFERENCE NUMERALS
[0000]
Stairs 100
Stringer 102
Tread 104
Tread support device 106
Bottom tread support 108
Bottom bolt 110
Stairs 200
Stringer 202
Tread 204
Tread support 206
Bottom tread support 208
Bottom bolt 210
Tread support upper portion 212
Tread support lower portion 214
Adjustable height device 216
Stairs 300
Tread 304
Tread support 306
Bottom tread support 308
Bottom bolt 310
Bottom bolt 410
Bottom bolt bracket 420
Bracket nut 422
Jam nut 424
Tread support (right) 506
Tread support upper portion 530
Tread support lower portion 532
Flat to stringer support 534
Side of stringer support 536
Fin 538
Flat to tread support 540
Fin holes group 1 (on lower portion) 542
Fin holes group 2 (on lower portion) 544
Pivot 546
Pivot hole 1 (w/ rivet) 546 a
Pivot hole 2 (w/ rivet) 546 b
Upper portion holes group 1 548
Upper portion holes group 2 550
Fastener (rivet) 552
Fastener (rivet) 554
Alignment scale 556
Fastening point 572
Tread support (bottom step) 1208
Bottom bolt 1210
Bottom bolt bracket 1220
Bracket nut (square) 1222
Jam nut 1224
Tread support upper portion 1230
Tread support lower portion 1232
Flat to stringer support 1234
Side of stringer support 1236
Flat to tread support 1240
Fin holes group 1 (lower portion holes) 1242
Pivot (w/ rivet) 1246
Pivot hole 1 (w/ rivet) 1246 a
Upper portion holes group 1 1248
Upper portion holes group 2 1250
Fastener (rivet) 1252
Fastener (rivet) 1270
Fastener hole 1 1270 a
Fastening point 1272
Partially occluded hole 1274
DETAILED DESCRIPTION
[0159] In the presently preferred embodiment and best mode now contemplated for carrying out the invention, the invention is a generally triangular tread support which has overlapping upper and lower portions which may pivot in relation to one another. By pivoting the halves, the value of the riser height may be adjusted up and down, by reference to an alignment guide the correct pair of holes among two pluralities of overlapping holes, one group on each part, may be chosen and secured together to maintain the desired riser height. The device of the invention in a presently preferred embodiment and best mode now contemplated may change height from 6.5″ to 8″ inches (16.5 cm to 20.32 cm) in height in accordance with the ADA and Uniform Building Code. However, it is not so limited, for example in jurisdictions which have different laws, or should US standards change, the device may adjust to virtually any range of heights by recalculation of hole locations.
[0160] FIG. 1 is an elevational oblique view of a first and a second embodiment of the device in use on a set of stairs. Stairs 100 have stringer 102 (one of two such), which is a sturdy diagonal member of wood or the like and which serves as the main support of the stairs. Tread 104 may be seen, while the risers have been omitted from the diagrams for the sake of clarity.
[0161] Tread support device 106 is seen mounted on the top edge of a stringer, one of six in use: four are similar and are triangular, while bottom tread support 108 and it's matching companion are only approximately triangular, since they must provide space (one corner is clipped off) to make up for the fact that the stringer 102 does not extend all the way to the end of the bottom-most tread. To make up for the lack of support, bottom bolt 110 is provided.
[0162] It will be immediately seen that both of the types have two sub-types: left and right handed. One type goes onto the left stringer and one type goes onto the right. Note that the actual designation as to which is “left” or “right” is made looking from the bottom of the stairs to determine the left and right, however one type must fit on a left stringer and one type fits onto a right stringer.
[0163] FIG. 2 is a transparent side view diagram of a first and second embodiment of the device, in use on a set of stairs. Stairs 200 have stringer 202 visible.
[0164] It will be immediately noted that stringer 202 , like stringer 102 , is not cut.
[0165] An uncut stringer is stronger than a stringer made of the same size of wood but cut: the cuts narrow a stringer and weaken it. Thus, the uncut stringer is one important feature and advantage of the present invention. Tread 204 may be seen. It may be made of materials such as TREX® brand material, wood, polymers, composites and the like.
[0166] Tread support 206 is seen in transparency, with the tread support lower portion 214 behind the tread support upper portion 212 and the stringer 202 . The upper and lower portions 212 / 214 are not identical, nor are they strictly overlapping, rather they are angled a bit in relationship to one another. As they are installed, they are fixed into angular relationship and are no longer free to pivot.
[0167] Bottom tread support 208 may be seen to have the clipped corner (not actually clipped during manufacture, the expression is used to describe the fact that one corner of the triangle is not manufactured), which is necessary as it will be seen that stringer 202 runs under the full length of the stairs higher up but only under part of the length of the lowest stair, in addition to the lowest stair having no depth of a riser below it. Thus, the bottom unit must be able to cope with different conditions from all the other units and yet provide the same rise, and thus adjustable bottom bolt 210 is provided.
[0168] Adjustable height device 216 (which is different from the overall unit) is seen but is clearer in later diagrams: this part of the tread support allows the overall adjustment of heights on all the steps, not just on the bottommost step. This part of the invention, the adjustment device, 216 , is seen to comprise two sets of holes on two different portions of the device, the holes overlapping in a number of configurations which allow different heights to be maintained, and a fastener which may pass through the selected pair of holes. One unit of the invention may have a plurality of such height adjustment devices 216 thereon: in the presently preferred embodiments the number is four, however, more may be used for extra support or fewer may be used if it may be safely accomplished, all within the scope of the present invention.
[0169] FIG. 3 is a front view of the device in use on a set of stairs. The stringer cannot be seen, but stairs 300 have tread 304 which is held in place by tread support 306 .
[0170] Again, bottom tread support 308 has bottom bolt 310 , and will be explained in greater detail in the next diagram. FIG. 4 is a front view of the device in use on a set of stairs.
[0171] Bottom bolt 410 passes twice through bottom bolt bracket 420 having bracket nut 422 . It may then be tightened into place by means of jam nut 424 .
[0172] FIG. 5 is an oblique view of a first embodiment of the invention, in a right-handed sub-embodiment.
[0173] Tread support 506 , the unit, has two major portions: tread support upper portion 530 and tread support lower portion 532 .
[0174] Flat-to-stringer-support 534 is a flat area dimensioned and configured to engage flatly to the sloping top surface of a stringer, by which means weight of the stairs and weight on the stairs may be efficiently transferred to the stringer.
[0175] Side-of-stringer-support 536 is dimensioned and configured to engage flatly to the vertical side face of the stringer, and by means of numerous fastening points 572 (in this case, holes which allow screws, bolts or the like to be driven into or through the wooden stringer) allows for efficient fastening. Other fasteners may be used if they are safe and meet code, whether fasteners now known (rivets, nails) or later devised, however, in the present embodiment, certain fasteners are strongly preferred. Note that additional fastening points may be provided on other surfaces, such as flat-to-stringer-support surface 534 , the flat-to-tread-support 540 , etc.
[0176] Fin 538 protrudes above the rest of the lower part 532 and lays, coplaner, against matching parts of the upper part 530 . The fin 538 has two groups of holes on it: fin holes group 1 , 542 , and also fin holes group 2 , reference number 544 . While one group is sufficient, a plurality of groups may optionally provide greater strength. The positioning of these holes is calculated and manufactured very precisely.
[0177] With one group, the weight on the tread, pressing down through upper part 530 , is transmitted to lower part 532 and the stringer by way of one pivot 546 (preferably a rivet) and one fastener through the holes (preferably another rivet). A second group of holes ( 544 ) allows the addition of a third fastener for additional strength, conveniently located close to the riser end of the tread where maximum strength is usually needed.
[0178] Pivot 546 may seen in parts in later diagrams ( FIG. 6 , FIG. 9 , FIG. 10 ) and comprises not just a rivet as an axle, but also pivot hole 1 ( 546 a ) and pivot hole 2 ( 546 b ), through the lower and upper parts of the device.
[0179] Upper portion holes group 1 ( 548 ) and upper portion holes group 2 ( 550 ) are very precisely precalculated and positioned. This is for the functioning of the invention. In particular, these holes must match very precisely with the matching hole groups 542 and 544 of the fin.
[0180] In usage, as the two parts of the invention are slowly pivoted relative to one another, the value of the rise height (the shape of the triangle) will change, increasing and decreasing, and the carefully positioned holes will have different pairs (one hole on the upper piece and one hole on the lower piece) come into a complete overlap at different times equating to different rise heights. By careful calculation and placement, these holes will provide a useful set of alignments, preferably every ⅛ inch, very precisely and yet without the need to do more than rotate the two parts to the correct amount.
[0181] After the correct riser height is achieved, the device is locked permanently into that shape. FIG. 6 is an oblique view of a first embodiment of the invention, in a left-handed embodiment, showing fastener (rivet) 552 and fastener (rivet) 554 passing through a pair of overlapping holes in this way. While the groups on the other part are arranged in several rows and in arcs, the groups 552 / 554 are on straight lines, which lines if extended will pass through the pivot 546 .
[0182] This can be seen in transparency in FIG. 7 , which is a transparent view of the first embodiment of the device in a right-handed embodiment. It will immediately be seen that rivets 552 and 554 are holding a pair of holes in alignment. Careful study of the diagram reveals that in transparency all four sets of holes are seen. Thus, at the top of group 544 of the fin, group 550 (a line) may be seen. Similarly, atop group 542 of the lower part, group 548 (another straight line) may be seen.
[0183] Alignment scale 556 is also clearly visible. An alignment scale such as 556 may be located at any convenient location on the device. Alignment scale 556 may align to an edge, a corner of one piece, a guide mark on the device, a notch on the device, etc.
[0184] This alignment scale greatly eases the use of the device. In particular, the indicia of the scale (lines as depicted, letters, numbers, holes, marks, painted or printed indicia, etc) may tell the builder/user exactly what value of riser height is set in when a given indicia or alignment mark matches some external object, such as the top of the stringer, the top of the riser below, a matching pointer on the other half, etc. Thus a user desiring a 7½″ inch step would simply slide the device to 7½″ indicator of the alignment guide. At that point, one pair of holes would be clearly overlapping and in alignment, rather than blocked or partially occluded. That aligned pair of holes would be visible to the user, who would then slide the fastener (a rivet, bolt, or other device now known or later developed) through and then secure it, for example by popping the rivet in or tightening a nut onto a bolt.
[0185] At the present time rivets are the preferred embodiment rather than bolts or the like, for the purpose of securing the holes in the desired configuration, while screws and bolts are preferred for fastening to the stringer.
[0186] FIG. 8 is a transparent view of the first embodiment of the device in a left-handed embodiment. This diagram at first sight appears identical to FIG. 7 , but in fact it is a view of the matching device having the opposite handedness.
[0187] FIG. 9 is a transparent side view of the lower portion of the device's first embodiment. This is shown without the upper portion for additional clarity, while FIG. 10 is a side view of the upper portion of the device's first embodiment, shown without the lower portion for additional clarity.
[0188] FIG. 11 is an oblique view of the second embodiment in a left-handed sub-embodiment, while FIG. 12 is an oblique view of the second embodiment in a right-handed sub-embodiment.
[0189] FIG. 13 is a side view of the second embodiment of the invention, left-handed, while FIG. 14 is a side view of the second embodiment of the invention, right-handed.
[0190] As discussed previously, this second embodiment is useful or necessary for the bottom-most step in a set of stairs. Adverting back to FIG. 1 , it is obvious that the stringer physically cannot extend as far under the lowest step as it does for other steps higher up: the ground intervenes. This situation is very common in real building situations. Thus the second embodiment tread support 1208 is necessary in order to create a complete system of stairs.
[0191] Bottom bolt 1210 passes through bottom bolt bracket 1220 which is physically secured to the bottom part 1232 . Bracket nut 1222 and jam nut 1224 serve to lock the bolt 1210 in place and prevent it from rotating during use.
[0192] Note that the single square nut is advantageous for diverse reasons, including fit to the bracket, ease of use and so on.
[0193] Tread support upper portion 1230 and tread support lower portion 1232 do however have most of the same configurations as in the previously discussed embodiment.
[0194] Flat-to-stringer-support 1234 effectively transfers weight to the stringer while side-of-stringer-support 1236 provides efficient location of fasteners, such as at fastening point 1272 .
[0195] Flat-to-tread support 1240 provides a flat surface for the tread to rest upon, fin holes group 1 ( 1242 ) match with upper portion holes group 1 ( 1248 ).
[0196] Pivot 1246 and pivot hole 1 1246 a may be seen, as may fastener (rivet) 1252 and fastener (rivet) 1270 . Fastener 1270 and fastener hole 1 ( 1270 a ) actually serve to secure the bolt bracket to the device as a whole.
[0197] Partially occluded hole 1274 ( FIG. 13 ) is provided to illustrate how the device is used and how it appears in use. The hole having the fastener 1252 may be seen through, unoccluded. Other holes are blocked, or in the case of hole 1274 , partially eclipsed. Thus a builder has a quite easy time once they have lined up the alignment guide, in deciding which hole is proper for their needed elevation change. While the alignment guide is not shown on this embodiment, alternative alignment guides may be used. In practical terms, alignment for the bottom step may be accomplished by matching the same holes used for other steps supports (which do have guides). In even more practical terms, the bottom step has the bottom bolt 1210 which is adjustable, so at final installation the builder will simply adjust the bolt properly in any case.
[0198] FIG. 15 is a front view of the second embodiment of the invention, left-handed, FIG. 16 is a side view of the second embodiment of the invention, right-handed. Bolt 1210 , bracket 1220 , the upper and lower parts 1230 / 1240 and so on may be seen. FIG. 17 is an oblique view of the bottom bolt assembly of the invention, while FIG. 18 is a transparent side view of the bottom bolt assembly of the invention. Again, the locking nut 1224 (jam nut) and bracket nut 1222 obviously cooperate to easily secure bolt 1210 . Fastener hole 1270 a is more clearly visible.
[0199] The disclosure is provided to allow practice of the invention by those skilled in the art without undue experimentation, including the best mode presently contemplated and the presently preferred embodiment. Nothing in this disclosure is to be taken to limit the scope of the invention, which is susceptible to numerous alterations, equivalents and substitutions without departing from the scope and spirit of the invention. The scope of the invention is to be understood from the appended claims.
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A tread support device for stairways is generally triangular with two parts which pivot in relationship to one another to allow selection of any desired riser height. Precalculated groups of holes on each of the two parts overlap, with different sets of holes overlapping at different riser heights separated by different increments of ⅛ inch. An alignment guide allows easy selection of the desired riser height, after which the holes which are aligned and overlapping are fastened together to keep the device whole. A complete system consists of left-handed and right-handed tread support units, along with right and left handed units designed to meet the base of the steps with adjustable bolts. A stairway may be built using uncut stringers by use of the invention.
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[0001] This is continuation is part of application Ser. No. 09/696,004, filed Oct. 26, 2000, now U.S. patent No.
FIELD OF THE INVENTION
[0002] The present invention relates to flexible coupling devices for shafts to permit and facilitate transmission of torque between a drive and a driven shaft while accommodating misalignment between the shafts. More particularly, the present invention relates to spool type flexible couplings, where the spool will permit a relatively large variation of the distance between the shafts to be coupled and a greater degree of accommodation of distance variation between the shafts. The flexible elements of the coupling will include outer rings usually of metal to allow secure attachment to hubs provided on each of the shafts to be coupled and a central connecting tubular piece between the flexible elements. Various types of elastomeric type flexible elements are disclosed with particular emphasis on optimal construction for maximum bond strength and durability.
BACKGROUND OF THE INVENTION
[0003] In the field of elastomer or plastic flexible elements couplings, a number of considerations affecting the design of a flexible coupling exist. Among these are the degree of misalignment tolerated, the anticipated torque loads and design constraints relating to the installation allowed. In some arrangements, only a limited type of elastomeric material could be employed in a coupling to accommodate the torque loads desired. In other arrangements, the cost of the coupling has been increased, as a result of the complicated design of the flexible elements of the coupling. The assembly means of the flexible elements to the other coupling components has been the typical deficiency of prior art couplings. This is an essential factor in the coupling design, affecting both cost and performance capabilities.
[0004] One such prior art coupling is shown in FIG. 2 of a French Patent No. 984,089 of Jul. 2, 1951. The assembly method of the element, detailed in FIG. 1 , shows a complicated arrangement of several typically heavy metal parts, which clamp the upper and lower extremities of the flexible element, to allow torque transmission. The main problem of clamping elastomer parts is that they do not generally retain their original shape under load and acquire a permanent set. This reduces the initial clamping force, and loss of torque capacity. The clamped areas at the upper and lower extremities of this element are also highly stressed and subject to failures in operation. The number of auxiliary parts is also increasing the fabrication cost.
[0005] Another coupling construction and element assembly method is described in U.S. Pat. No. 4,411,634 to Hammelmann. The materials for the flexible elements, described as diaphragm-style in common coupling terminology, and the central spacer shaft are plastic. They are not described as having elastomer ic properties, but to a lesser extent, they exhibit similar properties in terms of stress-deformation set. The inner diaphragm connection is achieved by a press fit among several convoluted shaped parts. For this reason, the low material modulus requires a considerable thickness and weight for the center tube to allow a reasonable torque capacity and avoid compression set. Additional complications of the design are required, such as the steel sleeves pressed inside and outside the tube, as well as the convoluted steel reinforcement part mounted at the inside diameter of the diaphragm hub, fitted over the convoluted sleeve mounted over the shaft ( FIGS. 1 and 2 ). The outside flexible element connection is achieved through bolting. The thicker rim of the element is provided with holes and is clamped between two metal members. The compression stresses developed when the fasteners are tightened have a negative effect on the performance of the coupling, acting as stress concentration areas, and failures are likely to occur in this upper extremity of the plastic flexible diaphragm member.
SUMMARY OF THE INVENTION
[0006] The present invention avoids the complications of the prior art devices yet provides a flexible coupling, which, in its basic form, accommodates a much broader range of distances between the shafts to be coupled, from relatively large to very close shafts separations, yet reliably transmits torque over a satisfactory range and through an increased degree of tolerance for misalignment.
[0007] In one form of the invention for close spaced shafts, the coupling spool is split longitudinally and reinforced during assembly by a rigid ring which may be bolted in place during installation. The rigid ring serves as reinforcement for the split spool. In addition, flexible elastomeric annular diaphragms are employed as the flexing members of the coupling and are also split and attached by bonding on the respective halves of the split spool and to the outer split attachment rings prior to installation in the coupling. This allows assembly and disassembly for closely spaced shafts, without moving the hubs installed on the shafts, or the two connected machines.
[0008] In another form, the present invention provides a permanently assembled coupling spool piece, consisting of two axially spaced elastomer flexible diaphragms, bonded at their inner periphery to a tubular piece, and also bonded at their outer periphery to a pair of similarly axially spaced rings, each such ring member having attachment bores for securing it to the respective flanges or hubs of the shafts to be coupled. The tube, rings and flexible elements thus form a unitary spacer assembly which is easy to install and remove.
[0009] In another form, the present invention provides a coupling spool on which are initially movably mounted two coupling sleeves at opposite ends thereof. Each coupling sleeve is provided with a flexible diaphragm in the form of an elastomeric element bonded to an outer ring preferably of metal, which can be coupled directly to a flange of a coupling hub, which in turn is mounted on a drive or a driven shaft. The flexible elements are spaced apart a distance that is typically more substantial than in the prior art arrangements. Minor manufacturing changes will enable the coupling of this form of the present invention to accommodate a broad range of distances between the shafts to be coupled. The coupling tube combinations will be such that these members can be readily assembled together by adhesive bonding, riveting or the like. As noted above, the flexible elements incorporated in the coupling are preferably made from a flexible elastomeric material that is shaped to accommodate the degree of flexibility needed for a particular application without experiencing stresses leading to failures in normal use. In one form, the flexible elements are formed with a curve so that the outer end of the elements will be axially spaced from the center of the base of the element. With the flexible element preferably manufactured in an annular shape, a taper is provided where the element narrows as one moves radially outwardly from the inner periphery of the element to adjacent the outer rim which is narrower in axial extent. The actual cross-sectional shape and taper are designed for the application requirements. The element may be manufactured using various common elastomer processing methods, such as compression, gravity casting or injection molding.
[0010] In terms of the flexible element / adjacent parts attachment method used in the present invention, bonding has been chosen for it's simplicity and absence of auxiliary parts. The reliability of elastomer adhesives has evolved over the years, the modern ones exhibiting a much higher strength than in the past. Lord Chemical Corporation is one of the manufacturers of such adhesives.
[0011] With the flexible couplings of the present invention, a user a will be able to transmit high torque loads while accommodating high degrees of misalignment. Further, the coupling is characterized by ease of installation in either narrow or extended spaces between the shafts and by a low number of individual parts for assembly. With even widely spaced apart shafts, the flexible coupling of this invention will provide high-speed capability due to the high radial rigidity of the flexible elements.
[0012] The foregoing and other advantages will become apparent as consideration is given to the following detailed description taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a side view in elevation of one embodiment showing an arrangement of the elements of the present invention using a split spool;
[0014] FIG. 2 is a view along lines 2 - 2 of FIG. 1 ;
[0015] FIG. 3 is a side view in elevation of an alternate arrangement of the elements of the present invention;
[0016] FIG. 4 is a side view in elevation of a further arrangement of the elements of the present invention;
[0017] FIG. 5 is a perspective view in section of a further embodiment of the present invention;
[0018] FIG. 6A is a side view in elevation of the coupling of the present invention; and
[0019] FIG. 6B is a view similar to FIG. 6A but with the telescoping feature shown in a different condition.
[0020] FIGS. 7-9 are respective side views in elevation, partly in section, of several further forms of the invention;
[0021] FIGS. 10 is a detailed view in elevation of the curved flexible ring of FIG. 9 ; and
[0022] FIG. 11 is a side view in elevation of an alternate arrangement of the elements of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to the drawings, in FIGS. 1 and 2 , there is shown an embodiment of the present invention which is adapted for close-coupled shafts, that is, shafts the ends of which are in close proximity to one another and which cannot be moved away from each other than at an unacceptable cost. In this arrangement, the spool is in the form of a split tube 32 which is reinforced by an inner ring 34 and which is held in place typically by four bolts such as at 36 , which are evenly spaced about the periphery of the split tube 32 . The ring 34 is preferably located at the midpoint of the tube 32 as shown in FIG. 1 . The ring 34 may be integral or provided in two halves, with two bolts provided to retain each half of the ring 34 in place against the inner surface but bridging over the edges as at 41 , 43 of the tube halves which it is reinforcing. As shown in the sectional view of FIG. 2 , the tube 32 is split longitudinally along its entire length to provide two semi cylindrical bodies 32 ′ and 32 ″. Similarly, the flexible elastomeric rings 16 may each be split into two parts 16 ′ and 16 ″. The radially inner peripheral edges of the ring parts 16 ′ and 16 ″ will each be easily secured by a suitable, commercially available adhesive to the radially outer peripheral surface of the split tubes 32 ′ and 32 ″. According to this embodiment, the diameter of the split tube 32 is made large enough to accommodate the hubs 26 as shown in FIG. 1 . This will allow a substantially more compact configuration for the elements when achieving coupling between two closely located shaft ends 28 and 30 and yet will provide a coupling with adequate flexibility and tolerance for axial misalignment. The radially extending flanges 22 of hubs 26 are continuous to provide adequate torque transfer through the split rings 16 ′ and 16 ″. The axial extent of the hubs 26 allows it to be easily secured as by welding to the outer surfaces of their respective shafts 28 and 30 . Since the spool is provided in two parts 32 ′ and 32 ″, the coupling will be easily reassembled whenever it is necessary to repair or replace elements such as the flexible rings 16 ′ and 16 ″.
[0024] The assembly of the elements of the coupling of FIGS. 1 and 2 is important to obtain the full benefit of the invention. To avoid distortions of the split elements under torque, the presence of the reinforcing ring is mandatory. In the case of a split ring it is preferable to offset the split edges 41 , 43 of the spool halves 32 ′ and 32 ″ by ninety degrees to the edges 47 , 48 of the split ring 34 as shown in FIG. 2 , so that the rigidity of the assembly is not affected.
[0025] In FIGS. 6A, 6B , and 11 , illustrate invention forms designed for extra-long or adjustable length spools for wide shaft spacing. The telescoping form of the inventions 10 , 10 a are shown, where a spool 12 and 12 a is interposed between two relatively larger diameter sleeves 14 . Each of the sleeves 14 and 14 a is identically configured so that a description of only the right hand sleeve will be provided.
[0026] The sleeves 14 and 14 a and spool 12 and 12 a are preferably made of a material such as steel or fiberglass that is easily bonded together with a conventional adhesive such as an epoxy or connected mechanically such as by rivets. Additionally, annular ring members 16 and 16 a are readily bonded about their respective inner openings to the outer peripheral surface of each sleeve 14 and 14 a as shown with conventionally available adhesives such as epoxies. The flexible element member 16 , 16 a is bonded at its outer periphery to the inner surface of a ring member 19 , 19 a which has equally spaced about its body bores 18 , 18 a in which locking bolts 20 are located. A connection hub 26 , 26 a is provided with an annular flange 22 , 22 a , which is provided with openings for receiving the bolts 20 , 20 a . Locking nuts 25 are employed to effect the attachment of the coupling flange 26 , 26 a to the flexible element member's 16 , 16 a as shown in these Figures.
[0027] The flexible coupling 10 as described above is particularly adapted to accommodate spaced apart annular flexible rings 16 , 16 a for a range of distances “I” to “L” between the coupling flanges 22 . In FIG. 11 , the corresponding elements are denoted with the suffix “a” with the general designation 10 a corresponding to the tube or spool 10 in FIGS. 6 a and 6 b . In this construction, the intermediate sleeves are inserted into the open ends of each sleeve 14 a and preferably bonded to intermediate connecting bushings 13 a by an adhesive although riveting or bolting may suffice in some applications. Thus, by simply selecting spools 12 and 12 a of a desired length, a user can accommodate a broad range of coupling distances between shafts.
[0028] As will be apparent from FIG. 3 , where a telescoping facility is not used, the spool 12 may be employed alone as shown in FIG. 3 to provide a flexible coupling employing spaced apart flexible, elastomeric rings 16 which are securely bonded to the outer periphery of the spool 12 adjacent the ends of the spool 12 . This form of the invention is used for fixed lengths, such as 3, 5 and 7 inches, typical for industry-established standards. The use of a suitable elastomeric material such as polyurethane elastomer for the diaphragm elements 16 makes it particularly easy to install. In this and the other forms using a hub flange 22 , an outer lip 23 may be provided to stabilize the parts during assembly as well as use.
[0029] A modification of the coupling of FIG. 1 is shown in FIG. 4 where a spool member 40 surrounds the coupling elements including two hubs or sleeves 42 and 44 . The flexible, elastomeric ring members 16 are bonded at their interior periphery directly to the outer periphery of each of the hub members 42 and 44 . The outer periphery of each of the members 16 are similarly bonded to the inner periphery of the reinforcing rings 46 and 48 . The spool 40 may be either bonded or riveted as through holes 50 to the outer periphery surface of the rings 46 and 48 . The shafts to be coupled will be inserted into the interior of a hub 42 to an extent to allow the second shaft to be inserted as through end 51 into hub 44 . The shafts will then be fixed to their respective hubs 42 , 44 by welding, bolting, riveting, or the like. The spool 40 may be split parallel to its longitudinal axis to facilitate installation where the shafts are too closely placed together at the site to allow easy installation.
[0030] Referring to FIG. 5 , there is shown a perspective, sectional view of a further modification of the invention where a split spool 50 is employed in a configuration similar to that of FIG. 4 but with the hubs projecting externally of the ends of the spool 50 . Again, the elastomeric elements 16 are bonded to the inner periphery of reinforcing rings 56 , 58 and to the outer periphery of the shaft mounting hubs 52 and 54 . Again, the use of a split spool facilitates installation without sacrificing the integrity of the coupling or its torque transmission ability. In addition, the rings 56 , 58 may be positioned at positions located axially inwardly of the outer edges 60 of the spool 50 sections by the provision of alternate fastener bores 62 located, as shown, inwardly of the edges and the outermost holes in which the screws, two of which are indicated at 64 , are positioned. A plurality of sets of bores 62 may be provided to expand the range of adjustability.
[0031] The use of spaced apart flexible rings as described in the foregoing embodiments increases the misalignment tolerated by the couplings while allowing significant latitude in installation. Moreover, the couplings described above will provide high torque transmission while retaining the advantages of lightweight installations.
[0032] With respect to the embodiments shown in FIGS. 7-10 , these forms use a modified flexible ring element, which is characterized by the provision of an extended base or pedestal and/or a curvature along the radial extent of the ring element.
[0033] In FIG. 7 , there is shown a coupling similar to that shown in FIG. 3 but one where the flexible elements 70 are shaped to include a larger surface area for the base 72 to improve the bonding strength and durability for the elements 70 to the surface of the spool 12 c.
[0034] This form of the invention is based on the construction of the spacer coupling component in FIG. 7 and presented in its most general form: a single piece assembly comprising five permanently assembled parts: two outer rings 19 c , which may be metal, two axially spaced, annular elastomer flexible elements 70 and one central tubular piece 12 c . The assembly is affected by bonding the peripheral areas at the inside and outside interfaces of the flexible elements 70 with the tube 12 c and rings 19 c , respectively. The rings and the tube are significantly more rigid than the elastomer flex elements material, which is preferably a polyurethane formulation and which features better properties for torque transmission than other elastomer classes. The tube 12 c can be made of metal and composite materials such as fiberglass can also be used. The interface bond is formed by using one of many commercially available adhesives, formulated specifically for the attachment of urethane to metal or fiberglass parts. Their strength, resistance to temperature and chemical agents is constantly improving.
[0035] Referring again to FIG. 7 , it will be appreciated that each of the elastomer elements 70 , which are substantially annular shaped extend a radial distance H from the outer radius of the tube 12 c to the inner radius of the ring 19 c . Each element 70 comprises two main portions: a thicker and more rigid radially inner base 74 , which provides bond reinforcement, of radial height “a” and a flexible portion profiled and tapered according to the application requirements, the profile having a neutral axis 72 (defined as the curve or line equally spaced from the two sides of the profile), its radial extent being “H-a”. A large degree of flexibility for a given profile is associated with a high “(H-a)/H” ratio. The base portion 74 is typically the thickest at the inner periphery, and the thinnest area of the profile “t” is generally situated towards the outer periphery. The height and thickness H and a may be theoretically and empirically determined relative to the torque load and rotational speed of the coupling. It has been found that, for the widest range of loads and rotational speeds, the flexible elements 70 should be curved at least on one side as shown in FIGS. 1 and 7 and preferably two sides as well as shown in FIG. 8 . The thickness of the base 74 portion may also be increased to control the flexibility of the elements 70 as shown in FIG. 8 and the axial width may also be increased as shown in FIG. 9 . These modifications result in a stronger and therefore longer lasting bond between the base 74 of the flexible elements 70 and the supporting spool 12 c.
[0036] As shown in detail in FIG. 10 , the flexible coupling elements of this invention are preferably curved outwardly, that is, away from each other, as shown in FIG. 9 . As noted above, each flexible element will have a neutral axis 72 and the range of curvature may vary depending on the specific application including torque load and rotational speed.
[0037] A general range of the curvature amount can be defined by the included angles between lines: 76 , 84 and 88 shown in FIG. 10 . As shown in FIG. 10 , the curvature on the right side of the vertical radial line 84 may be represented as the included angle φ, defined by a line 76 which extends from the inner end 80 of the neutral axis to the outer end 82 of this axis and a radial line 84 extending from the inner end 80 of the neutral axis of the flexible element 70 . The angle may range from 0° to about 20°. Additionally, the total curvature amplitude may be represented as the included angle “A” formed by line 76 and line 88 which extends from the inner end 80 of the neutral axis to the point on the neutral axis marked “t/2”, corresponding to the location of the minimum thickness “t”. Angle “A” may vary typically between 15° to about 25°.
[0038] As shown in FIG. 10 , the curvature is formed by smoothly arcuate portions, forming the curved shaped neutral axis, resembling an elongated letter “c”. Additionally, the neutral axis 72 , and the vertical axis 84 , starting from the same inner base point 80 , further intersect each other only once, towards the outer periphery of the element. It will be understood that a specific application may require greater or lesser amounts of curvature for the flexible elements 70 .
[0039] A flexible portion profiled and tapered according to the application requirements will have a profile having its neutral axis 72 (defined as the curve or line equally spaced from the two faces or sides of the profile), its radial extent being “H-a” where the neutral axis curve is shaped as shown. This curvature results in a reduction in the bond stresses, typically highest at the joint between the bond reinforcement area 74 and tube 12 c.
[0040] The outer end of the element is preferably provided with an axially extending, annular extension 78 and radially extending face 80 defining a ledge in which the metal reinforcing ring 82 is adhesively bonded. This structure facilitates assembly and imparts additional stability to the coupling. The ring 82 is provided with the conventional bores 84 for receiving bolts to attach the ring 82 to hubs 26 . Preferably, the bores 84 are threaded and blind so as not to interfere with the adhesive bond or the material of the outer end of the flexible element 70 with the metal ring 82 . Lip 86 will act like a protective shroud, providing a coverage area against impact, mishandling, or ingress of chemicals in the bonded zone, which may affect its integrity. Each respective reinforcing ring has surfaces complimentary to the radially extending and the axially extending surfaces of the outer periphery, as shown in FIG. 10 , with said axially extending surface being positioned radially inwardly of said radially extending surface.
[0041] The bond stresses need to be minimized under torque loading, which are typically the highest at the center of the inner bond of the base portion 74 of the tube or spool 12 c . For any given profile shape, the stresses on the bond can be reduced by being redistributed away from the critical center, and averaged over a wider portion. The addition of the bond reinforcement area achieves this purpose. Its width “w” of the base portion also contributes to the bond strength, but past a certain magnitude, it does not become proportionately effective. Thus, the bond strength and the degree of flexibility are related at least empirically. Where the torque load to be imposed on a coupling is low, the flexible elements 70 may have an enhanced degree of flexibility but where the torque load is relatively higher, only moderate flexibility can be had.
[0042] The preferred ratios for the conditions noted above are “H/a” ratio in the range of 4 to 16 and with the “w/t” ratio in the range of 2 to 4 for a high degree to flexibility where “t” is the thickness of the flexible element at its narrowest part as shown in FIGS. 10 a and 10 b FIG. 10 . For more moderate flexibility “H/a” should be in the range of 4 to 8 with the ratio w/t in the range of 4 to 8 also.
[0043] The shape of the flexible element, and the general orientation of the neutral axis are additional means of reducing the bond stresses. For example, the two forms of the invention shown in FIGS. 7 and 8 , designed for lower torque and higher flexibility, exhibit higher bond stresses than the invention in FIGS. 9 and 10 , described above. For example, the flexible element shown in FIG. 7 has one flat side and a curved side, for ease of manufacturing through gravity molding. The neutral axis is slightly curved but slanted at the top towards the center of the spool. Additionally, as opposed to the invention in FIG. 10 , the neutral axis and the vertical centerline starting from a common point close to the inner periphery, do not have another point of intersection towards the outer periphery.
[0044] The element in FIG. 8 has both sides symmetrically profiled, hence the neutral axis and the vertical centerline coincide. The bond stresses are better averaged than in the case of FIG. 7 , but the direct vertical path of torque leads to higher bond stresses than in the case of the “c” shaped neutral axis element.
[0045] Having described the inventions, it will be understood that various modifications are possible without departing from the spirit and scope of the invention as defined in the appended claims.
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A coupling between a driving and a driven shaft includes a rigid tube to which are attached by bonding, in axially spaced apart relation at least two flexible annular elements of elastomeric material, the annular elements being of various shapes; the outer periphery of each ring is bonded to an attachment ring which is attachable to a flange of a connecting hub with each hub mounted or connected to one the shafts; in one form the tube is split axially and is adjustably attachable to the periphery of the rings.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to the creation of conventional sewage disposal systems and, in particular to an apparatus and method for laying drain field pipe, aggregate, and geotextile fabric into a drain field trench.
[0002] Conventional sewage disposal systems are created in conjunction with residential and commercial buildings for the disposal of human waste. These sewage disposal systems are built in rural areas where municipal sewage utilities are not available. A typical installation of said sewage system consists of a concrete septic tank that is set a determined depth into the ground. An outlet of the septic tank is generally a few inches from the top of the tank. The level of the outlet determines the level of a drain pipe exiting from the septic tank into the drain field. The drain pipe is corrugated to leech waste passing through the pipe, and the corrugated drain pipe is laid on a level plane in a trench that is dug to comprise the drain field. The drain field trench may be about three feet wide and two to three feet in depth. The drain pipe rests in the trench on a bed of aggregate fill material, such as gravel. The gravel surrounds the drain pipe holding the pipe level and centered within the bed of gravel. Once the drain field material and drain pipe is laid, a special geotextile fabric paper is layered on top of the drain field and is covered by backfilling of soil and landscaping.
[0003] The process described for creating a convention sewage disposal system by placing the pipe, fill material, and paper into a trench is quite labor intensive. Typically, the process is undertaken using shovels and rakes to fill the trench uniformly and level the fill material for placing the drain pipe requires the labor of more than one person. Furthermore, leveling the drain field material by eye is difficult and requires even more workman time. Thus, the cost of manual labor contributes significantly to the cost of installing a sewage disposal system and a need exists to decrease the labor required. Wasted material while installing a sewage system is yet another concern that is fostered by the use of manual labor that causes waste of gravel during transfer by shoveling and the scattering of gravel on the ground where it may be a future nuisance. Therefore, a further need exists to decrease the amount of wasted fill material and cleanup during installation of a sewage system.
SUMMARY OF THE INVENTION
[0004] A method and apparatus are disclosed in the present invention for installing a drain field in a sewage disposal system. A drain field trench is dug on 45 degree angles and a drain pipe is laid in the trench. An apparatus of the present invention having a bin full of aggregate fill material such as gravel is set into the trench at a point of beginning. The pipe laid downstream from the apparatus is fed through a guide cylinder of the apparatus. The apparatus includes an outlet for the fill material, and entrance of the pipe into the guide cylinder is at about the center of the outlet. The apparatus moves downstream in the trench with the pipe feeding through the guide cylinder. As the apparatus moves, fill material exits the outlet by force of gravity. The fill material is supplied beneath the pipe such that the pipe rests on a uniformly deep bed of material. Further, fill material exits the outlet above the pipe such that a uniformly deep bed of material covers the drain pipe. A paper roller is attached to the apparatus above the outlet, and geotextile fabric paper is installed on the roller. The loose end of the paper is attached to the drain pipe such that as the apparatus is propelled downstream in the trench the paper will be applied to the top of the fill material. The dimensions of the outlet and the apparatus are in accordance with the required width and depth of the drain field to be installed and may vary according to specifications for sewage disposal systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a perspective view of the apparatus of the present invention showing the bin and outlet features of the invention as well as the roller and guide.
[0006] [0006]FIG. 2 is a top plan view of the same apparatus.
[0007] [0007]FIG. 3 is a side view of the apparatus of the present invention showing the installation of drain field gravel, drain pipe, and paper into a trench.
[0008] [0008]FIG. 4 is a front view of the same apparatus installing a drain field and being propelled forward by towing the apparatus by chain.
[0009] [0009]FIG. 5 is a rear view of the same apparatus installing a drain field.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Referring to the drawings, the drain field apparatus of the present invention is exemplified by the embodiment shown in FIG. 1. The main body of the apparatus comprises a bin 2 having an intermediate pass through section 4 , and an outlet 6 for distributing an aggregate fill material 8 into a trench 10 . The bin 2 , also referred to as a hopper or gravel bin, receives the fill material 8 for drain field installation. Any fill material 8 having desirable properties for sewage disposal drain fields could be used with the present apparatus. Common fill materials 8 include gravel and rubber. The apparatus described herein is especially efficient when used with gravel like fill material 8 because the gravel flows well and evenly from the apparatus during distribution in a drain field trench 10 . The fill material 8 will be referred to as gravel material 8 herein without intending to limit the fill materials 8 that are included within the scope of the invention.
[0011] As shown in the figures, the bin 2 includes four downwardly sloping wall panels 12 , 14 , 16 , 18 consisting of a pair of side panels 12 , 14 , a front panel 16 , and a rear panel 18 . A vertically oriented rim 20 extends from the top of the wall panels to form the top opening of the bin 2 where fill material 8 is added to the bin 2 . The intermediate pass through section 4 or pass through box 4 includes vertically oriented rear 22 and side walls 24 , 26 and a front wall 28 having a portion 30 thereof that slopes downwardly toward the rear 32 of the apparatus. The front wall 28 of the pass through box 4 directs the gravel 8 into the outlet 6 such that the pass through box 4 functions as a means for feeding gravel 8 to the outlet 6 for effective distribution into the trench 10 .
[0012] As the gravel 8 is fed by force of gravity into the outlet 6 at the bottom 34 of the apparatus, it passes through an opening that forms the outlet 6 at the rear 32 of the apparatus. The size of the opening for the outlet 6 is determined by the depth and width of the gravel bed 36 to be applied in the drain field 38 . For instance, in the case of a drain field 38 having a depth of one foot and a width of three feet, the outlet 6 opening will measure about 15 inches tall and about 34 inches wide. Further, as illustrated in the drawings, the outlet 6 opens to the floor 40 of the trench 10 to further promote the release of gravel material 8 into the trench 10 .
[0013] A guide 42 is attached within the pass through box 4 of the apparatus for receiving a corrugated drain field pipe 44 . The guide 42 may consist of a guide tube 42 of tubular steel as shown, but is not limited thereto. The guide 42 provides a means for positioning the drain pipe 44 as needed for installation of a drain field. In the illustrations, the guide tube 42 runs from the front 46 of the apparatus to the rear 32 of the apparatus such that the inserted drain pipe 44 passes through the apparatus. The drain pipe 44 is first set out downstream of a point of beginning for the apparatus. The guide tube 42 receives the drain pipe 44 at a first end 48 at the front 46 of the apparatus, and the drain pipe 44 exits the guide tube 42 at a second end 50 of the guide tube 42 at the rear 32 of the apparatus and connects to a septic tank outlet. The guide tube 42 is oriented within the pass through box 4 such that the exiting drain pipe 44 that is fed through the guide tube 42 is positioned in the center of the gravel bed 36 laid by the apparatus. Thus, the second end 50 of the guide tube 42 terminates at about the center of the gravel outlet's 6 vertical opening.
[0014] A roller 52 is attached to the rear 32 of the apparatus on the bin 2 or on the pass through box 4 . As shown in FIG. 1, the roller 52 is attached to the bin 2 and includes a bracket 54 and roll bar 56 that hold a roll of paper or fabric 58 . A special water absorbent paper or geotextile fabric material 58 is used in sewage drain fields atop the gravel bed 36 . The roller 52 allows the paper 58 to be attached to the drain pipe 44 and installed at the same time as the distribution of gravel material 8 and centering of the drain pipe 44 .
[0015] A support bar 60 as shown in FIG. 2 may be attached at the top of the bin 2 for reinforcement and a lift tab 62 may be attached to each side 12 , 14 of the bin 2 for lifting the apparatus and removing the apparatus from a trench 10 .
[0016] Movement of the apparatus in the trench 10 is facilitated by a pair of wheels 64 that are mounted on an axle 66 or spindles at the front 46 of the apparatus. The wheels 64 may consist of standard automobile tires 68 and rims 70 . Further, the axle 66 or spindles may be vertically adjustable to permit adjustment of the level of the front 46 of the apparatus in the trench 10 and allow the wheels 64 to gauge the trim of the apparatus in the trench 10 . The bottom edges 72 of the pass through box 4 flare slightly downward toward the rear 32 of the apparatus. The downward flare of the edges 72 promotes movement of the apparatus in the trench 10 by allowing some space between the floor surface 40 of the trench 10 and the bottom edges 72 of the pass through box 4 except at the very rear edge 74 of the apparatus.
[0017] When installing a drain field 38 for a sewage disposal system using the described apparatus, a drain field trench 10 of about ten to twelve feet in length is dug with a backhoe. In the present invention, the trench 10 is preferably dug on 45 degree angles such that the apparatus in FIG. 1 does not have to navigate comers in which the apparatus must be turned more than 45 degrees. The apparatus of FIG. 1 is able to negotiate 45 degree turns successfully.
[0018] To begin using the apparatus, it is set in the trench 10 beginning near a septic tank previously placed in the ground. Corrugated drain pipe 44 is rolled out downstream from the septic tank. One end of the drain pipe 44 is installed through the guide tube 42 such that the drain pipe 44 enters the front 46 of the apparatus and exits the rear 32 of the apparatus. A paper roll 58 is installed on the roller 52 of the apparatus and attached to the drain pipe 44 exiting the rear 32 of the apparatus. The bin 2 is filled with gravel 8 that is gravity fed through the bin 2 and exits through the outlet 6 . The apparatus is propelled forward in the trench 10 about eight feet with a backhoe. The apparatus may be self-propelled or may be pulled through the trench 10 as illustrated by the chain 76 attached to the apparatus in FIGS. 2 - 4 . The movement of the drain pipe 44 through the guide tube 42 stimulates the uniform and efficient application of gravel material 8 from the outlet 6 into the trench 10 .
[0019] The apparatus moves downstream in the trench 10 with the pipe 44 feeding through the guide 42 . As the apparatus moves, the fill material 8 or gravel exits the outlet 6 by force of gravity. The fill material 8 is supplied beneath the pipe 44 such that the pipe 44 rests on a uniformly deep bed 36 of material 8 . Further, fill material 8 exits the outlet 6 above the pipe 44 such that a uniformly deep bed 36 of material 8 covers the drain pipe 44 . The paper 58 attached above the outlet 6 is applied to cover the fill material 8 as the apparatus is propelled downstream in the trench 10 .
[0020] Once the trench 10 is filled with drain field material 8 , then the process is repeated as needed. An additional trench 10 is dug using the backhoe on an angle of 45 degrees or more. The drain pipe 44 is laid downstream. The bin 2 is refilled with gravel 8 . The apparatus is propelled forward in the trench 10 , and the drain field 38 of gravel material 8 , drain pipe 44 , and drain field paper 58 is laid. Once completed, the apparatus is removed from the trench 10 , and the backhoe is used to backfill with soil before landscaping.
[0021] From the foregoing description of the illustrative embodiments of the invention, it will be apparent that many modifications may be made. The embodiments described exemplify the invention, and the invention is not limited thereto. Therefore, it is intended that the claims are to cover all such modifications that fall within the true spirit and scope of the invention.
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An apparatus and method are disclosed for the installation of a drain field using a bin that receives an aggregate fill material and has an outlet for releasing the fill material into a trench to create a layer of the aggregate. A guide within the bin receives a corrugated drain field pipe and positions the pipe into the center of the fill material. The apparatus is propelled forward on a pair of gauge wheels using a backhoe or motorized means and causes the fill material to be released and the pipe laid therein. A roller on the rear of the bin places a layer of water absorbent geotextile material atop the aggregate as the apparatus moves forward.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of U.S. patent application Ser. No. 10/889,241, filed Jul. 12, 2004, which is a continuation application of International Application No. PCT/US03/00980 filed Jan. 14, 2003, and claims benefit of U.S. provisional patent application Ser. No. 60/349,009, filed Jan. 14, 2002, the teachings of which applications are incorporated herein by reference.
FIELD OF INVENTION
This invention relates to plastic and metal paint tray assemblies and paint kits, more particularly to a paint tray assembly that has a sealable lid and a paint kit with a sealable lid and paint applicator such as a roller assembly.
BACKGROUND
This invention relates generally to sealable paint tray assemblies and paint kits, more specifically to a combination wet architectural coating and wet coating applicator storage container, dry storage container, and dry package assembly for sealable paint tray assemblies or paint kits. For convenience of description, reference will hereafter be made to “paint” as representative generally of architectural coatings. References will hereafter be made to “paint kit” as representative generally of a paint tray, lid and paint applicator such as a roller assembly.
Conventional roller painting equipment used by consumers or professionals almost invariably consists essentially of a roller assembly and a paint tray. A batch of paint from a one gallon or other convenient sized container of paint is poured into a tray which usually has a storage capacity considerably less than the volume of the paint container, and the roller sleeve is dipped into the tray as the work progresses until the batch is exhausted, at which time another batch is poured into the tray. It is always hoped that the paint in the tray will be exhausted at the same time as the person applying the paint quits for the day or leaves the job for an extended period of time so that a skin will not form on the paint left in the tray and the paint applicator will not harden due to solvent evaporation, but quite often this does not happen. As a consequence the user has the option of throwing out or cleaning the roller sleeve and pouring the unused paint back into the original container, which is invariably a messy and time consuming process with the potential for spillage on a floor or carpeted surface, or leaving the roller assembly and unused paint in the tray until the user can return to finish the job. If the paint is left in the tray, removing the skin that forms over the paint reservoir is an even messier task than pouring out the unused paint with all the above described disadvantages. In addition, due to solvent evaporation, the now skin free paint will often be thicker than when it was poured from the original container and, as a consequence, the surface cover ability and quality may consequently be lowered. Items like roller sleeves are often replaced once painting is resumed. This becomes expensive to replace the roller sleeves at every new starting point but is often a popular choice rather than the long, messy, and often aggravating process of washing a roller sleeve at any point when the tray and paint accessories are not in use.
Attempts have been made to address the above disadvantages but none to our knowledge has been sufficiently successful. For example, a number of proposals have been made involving a mating lid for a tray but many, and possibly a majority, of said proposed structures attempt to make a provision to also contain paint accessories such as roller assemblies, brushes and pads in the closed space formed by the tray and associated lid. An assembly of items such as a tray, lid and a paint applicator can be referred to as a paint kit. Such past construction has however had inherent disadvantages when used as wet storage units in that all, or nearly all, trays include an inclined ramp near the front thereof for the purpose of “rolling out” or distributing a fresh roller sleeve load of paint after dipping into the paint reservoir so that the paint is evenly distributed on the roller sleeve prior to application to a receiving surface. The surface of the inclined ramp becomes coated with wet and sticky paint when in use and hence if an applicator handle is laid thereon preparatory to closing the lid on the tray, the handle becomes sticky and unusable thereby requiring cleaning prior to recommencing use.
Further attempts have been made to address the above disadvantages and in focusing on this particular disadvantage, created other problems. For example, some proposals have included additional structure to hold the handles of both the brush and roller assembly away from the wet ramp by extending the handles outside of the tray when the lid is closed. This of course lends itself to accidental tripping on and kicking of the tray assembly and it also uses as much as twice the space necessary to store the tray assembly with protruding applicator handles while not in use.
In some instances it is a requirement of a commercially practical tray assembly that the assembly function as a package so as to provide the option to the ultimate consumer of combining the tray assembly with an appropriate paint applicator such as a roller assembly, mini roller assembly and pads so that a paint kit is formed. There is accordingly a need for a tray assembly having a paint receptacle and a lid which provides a liquid tight, and virtually air tight, container when holding paint between active uses of the tray assembly and yet is easily assembled when the tray assembly is intended to function as a wet storage unit, and easily disassembled when the tray assembly is opened for active use. There is also a need for a paint kit consisting of at least a paint applicator and a tray assembly as above described, which displays the paint applicator and the tray assembly in a visually appealing manner when presented to potential purchasers in a retail outlet.
In addition to the foregoing requirements a tray assembly consisting of a tray and lid only, must occupy a minimal cubic space for manufacturing, shipping and displaying purposes. In effect, the trays should be nestable, the lids should be nestable, and a plurality of lids should add only a minute fraction of bulk to an equal number of trays so that manufacturing, shipping and displaying steps may be carried out at the lowest possible cost and least inconvenience. In this connection the lid should have surfaces to accommodate labels and other externally applied point of purchase marketing aids which assist in the selling potential of the tray assembly and roller assembly. If the lid is made from a clear plastic material a label on the underside of the lid will present the product for sale and, by turning over the lid, will provide use instructions.
SUMMARY OF INVENTION
A tray assembly including of a paint tray and a matching lid which, when assembled, forms a sealed container effective to maintain paint or other coating material and a paint applicator in a stable condition; that is, for an extended period of time without a skin forming on the paint or allowing the paint applicator to harden while not in use. In addition, the sealed tray assembly may dramatically reduce the volatile organic compound emissions inherent in paint from entering the atmosphere. The seal feature may be formed by a means for locking the lid to the tray by mating projecting flanges on the underside of the lid and the top edge of the tray.
The tray assembly may include a paint tray having the features above described in combination with an internal applicator rest for maintaining a supplemental applicator, such as a roller assembly, out of contact with the paint in the paint reservoir portion of the tray. The tray may also feature a recess or concave shape at the top of the incline ramp where the roller sleeve portion rests once the end of the roller assembly handle is placed in the internal applicator rest. This concave shape allows the user to fix the roller assembly's sleeve portion within it when the tray is in use and tow the tray around the work area without having to bend down to manually pick up the tray and risk injury to the user and to avoid accidental spillage. To assist the tray tow feature, the front area opposite the paint reservoir or the front legs of the tray, may be formed in an inward or outward curve to enable smooth transport. To further assist the tray tow feature, the back of the tray opposite the front legs and directly under the paint reservoir may include a second pair of legs that are rounded to assist in the smooth transport of the tray across the work area. Further more, the tray's bottom, directly under the paint reservoir may be elevated off the floor to minimize the friction and resistance against the tray assembly when pulled or towed across the floor.
The lid of the invention could be manufactured by a thermoforming process whereby; minimal material and forming costs are incurred in the manufacturing process. But most likely, the same manufacturing process will be used for forming both the tray and lid which would be an injection molding process to insure a proper fit and seal which would produce a better quality product. In addition, the lid and tray could be constructed so that like parts nest within one another to thereby realize maximum savings in shipping and handling costs when not sold as a kit. When the lid is sealed, the lid's surface just over the paint reservoir portion of the tray may be concaved inward in two halves stopping at a point just above the maximum paint fill line located on the tray in the paint reservoir portion. These two half portion of the lid may be separated by the location of the roller assembly handle when placed in the internal applicator rest. When the lid is sealed on the tray with the roller assembly in its proper location within the tray, the front portion of the lid's surface just over the roller sleeve portion of the roller assembly is convex in shape and forms closely around the roller sleeve portion. When the lid is properly sealed on the tray, and the roller assembly is properly located in the internal applicator rest, the above described lid closely mirrors the internal paint reservoir, and inclined ramp of the tray and the inclusive paint roller assembly. The purpose of this is to displace as much air within the sealed tray assembly to maximize and extend the period of time without a skin forming on the paint and the hardening of the paint roller sleeve portion of the roller assembly.
When the lid is opened and the tray assembly is in use, the inside of the above described lid may double as an additional paint applicator workstation. Popular paint applicators other than the standard nine-inch roller assembly are brushes, mini roller assemblies and pad applicators. In conventional paint trays and paint kits with or without lids, there is simply no place for these additional paint applicators to rest when not being used. These items are typically placed on paint cans, drop cloths, or are balanced on the corners of the conventional paint tray. Accidents in this regard occur far too often and add aggravation to an already difficult task.
Other advantageous features of the invention will become apparent from the following description of the invention.
BRIEF DESCRIPTION OF THE DRAWING
Advantages of the present invention will be apparent from the following detailed description of exemplary embodiments thereof, which description should be considered in conjunction with the accompanying drawings, in which:
FIG. 1 is an exploded perspective view of a paint kit consistent with the invention, the paint kit including, a sealable tray assembly consisting of a separate lid which may be assembled and disassembled from the tray body and a paint applicator such as a roller assembly;
FIG. 2 is a perspective side view of the sealable tray assembly showing the lid in sealing engagement with the tray body;
FIG. 3 is a perspective left end view of the tray body as shown in FIG. 1 ;
FIG. 4 is a top plan view of the interior features of the tray body and a roller assembly properly placed in the internal applicator rest and concaved section of inclined ramp;
FIG. 5 is a section through the tray body taken at a position, which illustrates the roller assembly in side elevation;
FIG. 6 is a perspective of the inverse view of lid as seen in FIG. 1 ;
FIG. 7 is a perspective of the inverse view of lid as seen in FIG. 1 with additional paint applicators;
FIG. 8 is a perspective of the tray body at a position, which illustrates the roller assembly towing the tray body;
FIG. 9 is a perspective view of a tray body according to another embodiment of the present invention having a pitched tray body; and
FIG. 10 is a perspective view of the tray body embodiment of FIG. 9 illustrating a plurality of ribs of varying height on the pitched tray body.
DESCRIPTION OF THE INVENTION
In the following description of a specific embodiment like reference numerals will be used to refer to like or similar parts from Figure to Figure in the drawing.
Referring first to FIG. 1 , the paint kit of this invention is illustrated generally at 10 in an exploded, disassembled condition. The paint kit 10 includes a tray assembly indicated generally at 11 , the tray assembly consisting of a lid indicated generally at 12 and a tray body indicated generally at 13 . The kit 10 , in addition to the tray assembly 11 , also includes a paint applicator indicated generally at 14 , here a roller assembly. The roller assembly 14 may include a handle 15 and a sleeve portion 16 . In FIG. 1 the lid and tray are shown in an unassembled, exploded condition whereas in FIG. 2 the lid and tray are shown sealed and assembled.
Tray body 13 of tray assembly 11 includes rear wall 17 , left wall 18 , right wall 19 , and bottom wall 20 . The upper peripheral co-planer edges of rear wall 17 , left and right side walls 18 and 19 and front wall 23 , terminate in an outwardly projecting flange 39 . The front end of the tray body 13 may be include several elements including, an incline ramp 21 , which terminates at a down turned plane 22 , best seen in FIG. 4 . A generally vertically disposed portion of the front wall is indicated at 23 , wherein the wall portion 23 desirably flanks a concave section 24 that conforms to roller sleeve portion 16 , of roller assembly 14 . The concave section 24 includes left and right vertical sides 25 , 26 . A tray towing section, indicated generally at 59 , may be located on front wall, as best seen in practice in FIG. 8 , including a continuing concave section 27 blending smoothly into concave section 24 and a top plane 28 , which terminates at front-most wall 23 . The concave section 27 includes left and right vertical sides 29 , 30 . An interior applicator rest 31 , formed generally in a U-shape, or similar upwardly opening protrusion, best seen in FIG. 5 , may be disposed extending inwardly from interior of wall 17 . Roller assembly handle 15 , may rests in applicator rest 31 when roller assembly is not in use. A pair of legs may be formed descending from front-most wall 23 , indicated at 32 , 33 which terminate in an inward and upward curve. A second pair of legs 34 , 35 opposite legs 32 , 33 may be provided to support the rear of the tray body 13 and keep bottom wall 20 sufficiently elevated off any surface for which the paint tray is set. The legs 34 , 35 may be shaped in an open U-shape or curve. The floor of the inclined ramp 21 is preferably provided with a plurality of ribs 36 and a pair of paint draining channels 37 , 38 arranged on either side of the ribs for removing excess paint from the roller sleeve portion 16 in a conventional manner.
Lid 12 includes a flat portion 49 , which surrounds a convex section indicated generally at 50 near the front end of lid. The convex section 50 may be formed as an upwardly and outwardly protruding hemi-cylindrical section that that may be bounded by left and right vertical sides 57 , 58 . Flat portion 49 preferably terminates at a trough indicated generally at 61 near the rear end of lid 12 . The trough 61 may be formed by downwardly and inwardly inclined rear wall 62 , left and right downwardly and inwardly inclined side walls 63 , 64 , respectively, and a front wall indicated generally at 65 . Front wall 65 and rear wall 62 , may be connected by a convex section 66 , that divides the bottom wall into two equal halves indicated at 67 , 68 . The outer peripheral co-planer edges of rear wall 62 , left and right side walls 63 and 64 and flat portion 49 , terminate in an outwardly projecting flange 51 . The outwardly projecting flange 39 of tray body 13 may mate with the outwardly projecting flange 51 of lid 12 to seal the paint kit 10 . The convex section 50 and left and right vertical sides 57 , 58 form an abutment, which mechanically blocks movement of paint applicator 14 in a parallel direction as next described.
As best seen in FIGS. 1 and 4 the tray body 13 is preferably dimensioned to entirely receive the roller assembly 14 within the cavity formed in tray body 13 , such that the roller sleeve portion 16 may be generally received at 59 , and the roller handle 15 generally received in the interior U-shaped applicator rest 31 extending inwardly from the interior wall 17 . The roller assembly 14 preferably remains sufficiently above the surface of the inclined plane 21 to prevent contact therewith, or contamination with any pain thereon. The lid's convex section 50 in conjunction with concave section 24 , that preferably blends smoothly into concave section 27 of tray body 13 and with U-shaped applicator rest 31 fixed on the interior of wall 17 , acts as a stationary abutment to block movement of the roller assembly 14 in a parallel direction as best viewed in FIGS. 1 and 4 . The length of the roller assembly with respect to the distance between front wall 23 and rear wall 17 , may be so dimensioned that the roller assembly 14 is locked into the position with only slight variation, in all angular orientations of the paint kit 10 with respect to the vertical; i.e., from the vertical position of FIGS. 1 and 4 to a position ninety degrees tilted with respect thereto and all angles there between. Thus, whether the paint kit 10 is displayed for purchase in the vertical position or in a horizontal position ninety degrees removed from that position, the paint applicator 14 will generally retain its same relative position with respect to the tray assembly 11 , and hence an orderly, eye pleasing appearance of the paint kit 10 will always be presented to the retail customer. It will be understood of course that the width of any paint applicator, such as the roller assembly 14 used in the above described fashion, may be slightly less than the inside dimension of the two walls 17 , 23 . Such slight clearance is not sufficient however to permit any paint applicator, such as a paint roller assembly 14 to become skewed with respect to the paint tray assembly 11 so that the orderly appearance of the paint kit 10 is maintained at all times.
The inverse, or inside, of lid 12 , as best seen in FIGS. 6 and 7 , illustrates the underside of lid 12 , as it would look when tray assembly 11 is in use and open. The bottom walls 67 , 68 are preferably provided with a plurality of ribs 69 for removing any excess paint from paint pads 70 and the inverse of convex section 66 of the lid 12 is now a concaved section, and may be used, for example, to hold a mini paint roller assembly 71 . Similarly, section 50 of lid 12 can now be used to rest an additional roller assembly if necessary, while the tray assembly is in use.
It should also be noted that paint kit 10 has a separate utility. Thus, since a good seal is desirably formed between the lid 12 and tray body 13 with the two parts may function as a sealed container for holding paint and a paint applicator, such as a roller assembly 14 between uses of the paint kit 10 . Thus, should the user not be able to complete a project and be forced to terminate work before the paint stored in tray body 13 is used, the lid 12 may be snapped onto the tray body 13 and the paint and roller assembly 14 be left overnight or longer with a lessened degree of solvent evaporation and the emissions of volatile organic compounds inherent in paint into the environment, and the consequent formation of a skin on the paint and the hardening of paint on the paint applicator when the paint kit 10 is not in use.
Turning to FIG. 9 , another embodiment of the present invention includes a tray body 13 having a pitched inclined ramp 21 . The inclined ramp 21 includes a first portion 21 a and a second portion 21 b positioned to form an apex 21 c of the ramp 21 . As such, the first portion 21 a and the second portion 21 b are angled downward from the apex 21 c forming a pitched ramp 21 such that excess paint from the sleeve portion 16 of the roller 14 advantageously also runs downward as indicated by the arrow lines on the first portion 21 a and second portion 21 b of the inclined ramp 21 . The excess paint also runs downward off the first portion 21 a and second portion 21 b into associated drain lines 902 and 904 on either side of the outer edges of the tray body 13 . Each drain line 902 , 904 is further sloped downward to the reservoir of the tray having a bottom wall 20 .
Turning to FIG. 10 , the inclined ramp 21 of FIG. 9 may advantageously have a plurality of ribs 906 of varying height. The height of each rib may be varying in order to compliment the slope of the first portion 21 a and second portion 21 b of the inclined ramp 21 such that the top surface of each of the plurality of ribs 906 forms a flat surface for uniformly removing excess paint from the sleeve portion 16 of the roller. Accordingly, the height of the ribs 906 varies depending on the slope of the first portion 21 a and second portion 21 b of the ramp 21 . An exemplary rib 906 - 1 therefore has its maximum height h 1 at the outer edge of the inclined ramp 21 closest to the drain lines 902 , 904 and its minimum height at the apex 21 c of the ramp 21 . Advantageously, additional excess paint is allowed to disperse from the sleeve portion 16 of the roller 14 while maintaining a flat surface for uniform displacement of excess paint across the sleeve portion 16 of the roller 14 .
Thus there has been disclosed a paint kit consisting of a lid, tray and accompanying paint applicator, such as a paint roller assembly which has utility in the presence of paint as a wet paint storage unit and a paint kit consisting of a lid, tray and applicator which, when assembled, presents a neat compact eye pleasing appearance in all positions of display and a paint tray assembly consisting of a lid and tray if it is decided to sell the two items as a single item or as separate items.
Although a specific embodiment of the invention has been illustrated and described it will be appreciated from the foregoing description that modifications may be made without departing from the spirit and scope of the invention. Accordingly it is intended that the scope of the invention be limited solely by the scope of the hereafter appended claims when interpreted in light of the relevant prior art, and not by limitations set out in the foregoing specification.
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A paint tray system including a paint tray and a lid that may be sealed to the paint tray in a generally airtight manner. The shape of the lid corresponds to the interior of the paint tray so that the volume of air sealed in the paint try by the lid is minimized. The underside of the lid may also include a recess that may receive a paint applicator between the paint tray and the lid. The paint tray may also include an applicator rest for holding a paint roller in the paint tray while keeping the handle out of a paint reservoir.
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STATUS OF RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No. 13/430,908, filed Mar. 27, 2012, now pending, which is a continuation-in-part of U.S. Ser. No. 13/027,314, filed Feb. 15, 2011, now pending, the contents hereby incorporated by reference as if set forth in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to new chemical entities and the incorporation and use of the new chemical entities as fragrance materials.
BACKGROUND OF THE INVENTION
[0003] There is an ongoing need in the fragrance industry to provide new chemicals to give perfumers and other persons the ability to create new fragrances for perfumes, colognes and personal care products. Those with skill in the art appreciate how differences in the chemical structure of the molecule can result in significant differences in the odor, notes and characteristics of a molecule. These variations and the ongoing need to discover and use the new chemicals in the development of new fragrances allow the perfumers to apply the new compounds in creating new fragrances.
SUMMARY OF THE INVENTION
[0004] The present invention provides novel compounds and their unexpected advantageous use in enhancing, improving or modifying the fragrance of perfumes, colognes, toilet water, fabric care products, personal products and the like.
[0005] More specifically, the present invention relates to novel pyrimidine derivatives represented by Formula I set forth below:
[0000]
[0006] wherein m and n are integers that when m is 0, n is 1; when m is 1, n is 0 or 1; or when m is 2, n is 0;
[0007] wherein (CH) m and (CH) n are each independently optionally substituted with a substituent selected from the group consisting of methyl and ethyl;
[0008] wherein X is selected from the group consisting of N, O, and S; and
[0009] wherein R 1 and R 2 each independently represent H or a hydrocarbon group, or R 1 and
[0010] R 2 together represent a fused ring or a ring system, with the proviso that when R 1 is H, R 2 is not H.
[0011] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula II set forth below:
[0000]
[0012] wherein a pyrimidine ring 1 is attached to a proximal ring 2, and wherein the proximal ring 2 is attached to a distal ring 3;
[0013] wherein o is an integer of 0 or 1;
[0014] wherein R 3 represents a substituent in any position of the distal ring 3 and is selected from the group consisting of H, methyl, and ethyl;
[0015] wherein R 4 represents a substituent in any position of the proximal ring 2 and is H or methyl; and
[0016] wherein the broken line represents a single or double bond,
[0017] with the proviso that when R 3 is H, R 4 is not H.
[0018] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula III set forth below:
[0000]
[0019] wherein R 5 and R 6 each independently represent H or a C 1 -C 6 straight or branched, saturated or unsaturated hydrocarbon group; and
[0020] wherein the broken line represents a single or double bond,
[0021] with the proviso that R 5 and R 6 together contain 3-10 carbon atoms.
[0022] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula IV set forth below:
[0000]
[0023] wherein R 7 and R 8 each independently represent H or a C 1 -C 8 straight or branched, saturated or unsaturated hydrocarbon group,
[0024] with the proviso that R 7 and R 8 together contain 4-8 carbon atoms.
[0025] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula V set forth below:
[0000]
[0026] wherein p is an integer selected from the group consisting of 0, 1, and 2; and
[0027] wherein R 9 represents a 5 to 6 membered saturated or unsaturated hydrocarbon ring substituted with a substituent selected from the group consisting of methyl and ethyl.
[0028] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula VI set forth below:
[0000]
[0029] wherein R 10 represents
[0000]
[0030] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula VII set forth below:
[0000]
[0031] wherein a pyrimidine ring 4 is attached to a proximal ring 5, and wherein the proximal ring 5 is attached to a distal ring 6;
[0032] wherein R 9 represents a substituent in any position of the proximal ring 5 and is selected from the group consisting of H, methyl, and ethyl;
[0033] wherein R 10 represents a substituent in any position of the distal ring 6 and is selected from the group consisting of H, methyl, and ethyl; and
[0034] wherein the broken line represents a single or double bond,
[0035] with the proviso that R 9 and R 10 together contain at least two carbon atoms.
[0036] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula VIII set forth below:
[0000]
[0037] wherein R 11 and R 12 taken together represent
[0000]
[0038] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula IX set forth below:
[0000]
[0039] wherein a ring 7 is attached to a proximal ring 8, and wherein the proximal ring 8 is attached to a distal ring 9;
[0040] wherein q and r are each independently integers of 0 or 1 that when q is 0, r is 1; or when q is 1, r is 0 or 1;
[0041] wherein s represents an integer of 0 or 1;
[0042] wherein Y represents O or S;
[0043] wherein R 13 represents a substituent in any position of the distal ring 9 and is selected from the group consisting of H, methyl, and ethyl;
[0044] wherein R 14 represents a substituent in any position of the proximal ring 8 and is H or methyl; and
[0045] wherein the broken line represents a single or double bond, with the proviso that when R 13 is H, R 14 is not H.
[0046] Another embodiment of the present invention relates to a subgenus of pyrimidine derivatives represented by Formula X set forth below:
[0000]
[0047] wherein a pyrazine ring 10 is attached to a proximal ring 11, and wherein the proximal ring 11 is attached to a distal ring 12;
[0048] wherein t represents an integer of 0 or 1;
[0049] wherein R 15 represents a substituent in any position of the distal ring 12 and is selected from the group consisting of H, methyl, and ethyl;
[0050] wherein R 16 represents a substituent in any position of the proximal ring 11 and is H or methyl; and
[0051] wherein the broken line represents a single or double bond,
[0052] with the proviso that when R 15 is H, R 16 is not H.
[0053] Another embodiment of the present invention relates to a fragrance composition comprising the novel compounds provided above.
[0054] Another embodiment of the present invention relates to a fragrance product comprising the compounds provided above.
[0055] Another embodiment of the present invention relates to a method of improving, enhancing or modifying a fragrance formulation through the addition of an olfactory acceptable amount of the novel compounds provided above.
[0056] These and other embodiments of the present invention will be apparent by reading the following specification.
DETAILED DESCRIPTION OF THE INVENTION
[0057] The novel pyrimidine derivatives represented by Formula I of the present invention are illustrated, for example, by following examples.
1,1,2,3,3-Pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
1,1,2,3,3-Pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
1,1,3,3-Tetramethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
1,1,3,3-Tetramethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
1,1,2,3,3,5-Hexamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
1,1,2,3,3,5-Hexamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0000]
7,7,10,10-Tetramethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline:
[0000]
7,7,10,10-Tetramethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline:
[0000]
5,7,7,8,10,10-Hexamethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline:
[0000]
5,7,7,8,10,10-Hexamethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline:
[0000]
7,7,10a-Trimethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline:
[0000]
8-Isopropyl-5,6,7,8-tetrahydro-quinazoline:
[0000]
8-tert-Butyl-5,6,7,8-tetrahydro-quinazoline:
[0000]
5-(1,5-Dimethyl-hex-4-enyl)-pyrimidine:
[0000]
4-tert-Butyl-pyrimidine:
[0000]
4-(2,2-Dimethyl-propyl)-pyrimidine:
[0000]
4,5-Diisopropyl-pyrimidine:
[0000]
4,5-Di-tert-butyl-pyrimidine:
[0000]
5-tert-Butyl-4-(2,2-dimethyl-propyl)-pyrimidine:
[0000]
4-(2,6,6-Trimethyl-cyclohex-3-enyl)-pyrimidine
[0000]
4-(3,3-Dimethyl-cyclohexyl)-pyrimidine:
[0000]
4-[2-(2,6,6-Trimethyl-cyclohex-1-enyl)-ethyl]-pyrimidine:
[0000]
4-[2-(2,5,6,6-Tetramethyl-cyclohex-1-enyl)-ethyl]-pyrimidine:
[0000]
4-(1,1,2,3,3-Pentamethyl-indan-5-yl)-pyrimidine:
[0000]
4-(6-tert-Butyl-1,1-dimethyl-indan-4-yl)-pyrimidine:
[0000]
6,6,9a-Trimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline:
[0000]
5a,10-Dimethyl-5,5a,6,7,8,9-hexahydro-benzo[g]quinazoline:
[0000]
5a,10-Dimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline:
[0000]
6,6,10,10-Tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a,9-methanobenzo[H]quinazoline:
[0000]
5,7,7,10-Tetramethyl-6,7,7a,8,9,10-hexahydro-5H-6,10a-methanoazuleno[5,4-d]pyrimidine:
[0000]
5,6,7,8-Tetrahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole:
[0000]
5,5a,6,7,8,8a-hexahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole:
[0000]
6,6,7,8,8-Pentamethyl-5,6,7,8-tetrahydro-4H-1-oxa-3-aza-as-indacene:
[0000]
6,6,7,8,8-Pentamethyl-5,6,7,8-tetrahydro-4H-indeno[4,5-d]oxazole:
[0000]
6,6,7,8,8-Pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-1-oxa-3-aza-as-indace:
[0000]
6,6,7,8,8-Pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-indeno[4,5-d]oxazole:
[0000]
2,6,6,7,8,8-Hexamethyl-5,6,7,8-tetrahydro-4H-3-thia-1-aza-as-indacene:
[0000]
2,6,6,7,8,8-Hexamethyl-5,5a,6,7,8,8a-hexahydro-4H-3-thia-1-aza-as-indacene:
[0000]
7,7,8,9,9-Pentamethyl-5,7,8,9-tetrahydro-6H-cyclopenta[f]quinoxaline:
[0000]
7,7,8,9,9-Pentamethyl-5,6a,7,8,9,9a-hexahydro-6H-cyclopenta[f]quinoxaline:
[0000]
[0098] Those with skill in the art will recognize that the compounds of the present invention contain chiral centers, thereby providing a number of isomers of the claimed compounds. For example, the compounds of Structure 1 and Structure 2 described in the above contain chiral centers indicated with asterisks (*) in the following:
[0000]
[0099] Thus, the isomeric forms of Structure 1 and Structure 2 may be further represented, respectively, by the following structures:
[0000]
[0100] Structure 1a represents 2S-1,1,2,3,3-pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene;
[0101] Structure 1b represents 2R-1,1,2,3,3-pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene;
[0102] Structure 2a represents diastereomeric mixture cis-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1 H-7,9-diaza-cyclopenta[a]naphthalene; and
[0103] Structure 2b represents diastereomeric mixture trans-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene.
[0104] It is intended herein that the compounds described herein include isomeric mixtures of such compounds, as well as those isomers that may be separated using techniques known to those having skill in the art. Suitable techniques include chromatography such as high performance liquid chromatography, referred to as HPLC, and particularly silica gel chromatography and gas chromatography trapping known as GC trapping. Yet, commercial products are mostly offered as isomeric mixtures.
[0105] The preparation of the compounds of the present invention is detailed in the Examples. Materials were purchased from Aldrich Chemical Company unless noted otherwise.
[0106] The use of the compounds of the present invention is widely applicable in current perfumery products, including the preparation of perfumes and colognes, the perfuming of personal care products such as soaps, shower gels, and hair care products, fabric care products, air fresheners, and cosmetic preparations. The present invention can also be used to perfume cleaning agents, such as, but not limited to detergents, dishwashing materials, scrubbing compositions, window cleaners and the like.
[0107] In these preparations, the compounds of the present invention can be used alone or in combination with other perfuming compositions, solvents, adjuvants and the like. The nature and variety of the other ingredients that can also be employed are known to those with skill in the art. Many types of fragrances can be employed in the present invention, the only limitation being the compatibility with the other components being employed. Suitable fragrances include but are not limited to fruits such as almond, apple, cherry, grape, pear, pineapple, orange, strawberry, raspberry; musk, flower scents such as lavender-like, rose-like, iris-like, carnation-like. Other pleasant scents include herbal and woodland scents derived from pine, spruce and other forest smells. Fragrances may also be derived from various oils, such as essential oils, or from plant materials such as peppermint, spearmint and the like.
[0108] A list of suitable fragrances is provided in U.S. Pat. No. 4,534,891, the contents of which are incorporated by reference as if set forth in its entirety. Another source of suitable fragrances is found in Perfumes, Cosmetics and Soaps , Second Edition, edited by W. A. Poucher, 1959. Among the fragrances provided in this treatise are acacia, cassie, chypre, cyclamen, fern, gardenia, hawthorn, heliotrope, honeysuckle, hyacinth, jasmine, lilac, lily, magnolia, mimosa, narcissus, freshly-cut hay, orange blossom, orchid, reseda, sweet pea, trefle, tuberose, vanilla, violet, wallflower, and the like.
[0109] The compounds of the present invention can be used in combination with a complementary fragrance compound. The term “complementary fragrance compound” as used herein is defined as a fragrance compound selected from the group consisting of 2[(4-methylphenyl)methylene]-heptanal (Acalea), iso-amyl oxyacetic acid allylester (Allyl Amyl Glycolate), (3,3-dimethylcyclohexyl)ethyl ethyl propane-1,3-dioate (Applelide), (E/Z)-1-ethoxy-1-decene (Arctical), 2-ethyl-4-(2,2,3-trimethyl-3-cyclo-penten-1-yl)-2-buten-1-ol (Bacdanol), 2-methyl-3-[(1,7,7-trimethylbicyclo[2.2.1]hept-2-yl)oxy]exo-1-propanol (Bornafix), 1,2,3,5,6,7-hexahydro-1,1,2,3,3-pentamethyl-4H-inden-4-one (Cashmeran), trimethylcyclopentenylmethyloxabicyclooctane (Cassiffix), 1,1-dimethoxy-3,7-dimethyl-2,6-octadiene (Citral DMA), 3,7-dimethyl-6-octen-1-ol (Citronellol), 3A,4,5,6,7,7A-hexahydro-4,7-methano-1H-inden-5/6-yl acetate (Cyclacet), 3A,4,5,6,7,7A-hexahydro-4,7-methano-1H-inden-5/6-yl propinoate (Cyclaprop), 3A,4,5,6,7,7A-hexahydro-4,7-methano-1G-inden-5/6-yl butyrate (Cyclobutanate), 1-(2,6,6-trimethyl-3-cyclohexen-1-yl)-2-buten-1-one (Delta Damascone), 3-(4-ethylphenyl)-2,2-dimethyl propanenitrile (Fleuranil), 3-(O/P-ethylphenyl) 2,2-dimethyl propionaldehyde (Floralozone), tetrahydro-4-methyl-2-(2-methylpropyl)-2H-pyran-4-ol (Floriffol), 1,3,4,6,7,8-hexahydro-4,6,6,7,8,8-hexamethylcyclopenta-gamma-2-benzopyran (Galaxolide), 1-(5,5-dimethyl-1-cyclohexen-1-yl)pent-4-en-1-one (Galbascone), E/Z-3,7-dimethyl-2,6-octadien-1-yl acetate (Geranyl Acetate), α-methyl-1,3-benzodioxole-5-propanal (Helional), 1-(2,6,6-trimethyl-2-cyclohexen-1-yl)-1,6-heptadien-3-one (Hexylon), (Z)-3-hexenyl-2-hydroxybenzoate (Hexenyl Salicylate, CIS-3), 4-(2,6,6-trimethyl-2-cyclohexen-1-yl)-3-buten-2-one (Ionone α), 1-(1,2,3,4,5,6,7,8-octahydro-2,3,8,8-tetramethyl-2-naphthalenyl)-ethan-1-one (Iso E Super), methyl 3-oxo-2-pentylcyclopentaneacetate (Kharismal), 2,2,4-trimethyl-4-phenyl-butanenitrile (Khusinil), 3,4,5,6,6-pentamethylhept-3-en-2-one (Koavone), 3/4-(4-hydroxy-4-methyl-pentyl)cyclohexene-1-carboxaldehyde (Lyral), 3-methyl-4-(2,6,6-trimethyl-2-cyclohexen-1-yl)-3-buten-2-one (Methyl Ionone γ), 1-(2,6,6-trimethyl-2-cyclohexen-1-yl)pent-1-en-3-one (Methyl Ionone α Extra, Methyl Ionone N), 3-methyl-4-phenylbutan-2-ol (Muguesia), cyclopentadec-4-en-1-one (Musk Z4), 3,3,4,5,5-pentamethyl-11,13-dioxatricyclo[7.4.0.0<2,6>]tridec-2(6)-ene (Nebulone), 3,7-dimethyl-2,6-octadien-1-yl acetate (Neryl Acetate), 3,7-dimethyl-1,3,6-octatriene (Ocimene), ortho-tolylethanol (Peomosa), 3-methyl-5-phenylpentanol (Phenoxanol), 1-methyl-4-(4-methyl-3-pentenyl)cyclohex-3-ene-1-carboxaldehyde (Precyclemone B), 4-methyl-8-methylene-2-adamantanol (Prismantol), 2-ethyl-4-(2,2,3-trimethyl-3-cyclopenten-1-yl)-2-buten-1-ol (Sanjinol), 2-methyl-4-(2,2,3-trimethyl-3-cyclopenten-1-yl)-2-buten-1-ol (Santaliff), Terpineol, 2,4-dimethyl-3-cyclohexene-1-carboxaldehyde (Triplal), decahydro-2,6,6,7,8,8-hexamethyl-2H-indeno[4,5-B]furan (Trisamber), 2-tert-butylcyclohexyl acetate (Verdox), 4-tert-butylcyclohexyL acetate (Vertenex), acetyl cedrene (Vertofix), 3,6/4,6-dimethylcyclohex-3-ene-1-carboxaldehyde (Vertoliff), and (3Z)-1-[(2-methyl-2-propenyl)oxy]-3-hexene (Vivaldie).
[0110] The term “hydrocarbon group” means a chemical group that contains only hydrogen and carbon atoms. The hydrocarbon group of the present invention can be a straight, branched and/or cyclic, saturated or unsaturated group.
[0111] The terms “fragrance formulation”, “fragrance composition”, and “perfume composition” mean the same and refer to a consumer composition that is a mixture of compounds including, for example, alcohols, aldehydes, ketones, esters, ethers, lactones, nitriles, natural oils, synthetic oils, and mercaptans, which are admixed so that the combined odors of the individual components produce a pleasant or desired fragrance. The fragrance formulation of the present invention is a consumer composition comprising a compound of the present invention. The fragrance formulation of the present invention comprises a compound of the present invention and further a complementary fragrance compound as defined above.
[0112] The term “fragrance product” means a consumer product that adds a fragrance or masks a malodor. Fragrance products may include, for example, perfumes, colognes, personal care products such as soaps, shower gels, and hair care products, fabric products, air fresheners, cosmetic preparations, and perfume cleaning agents such as detergents, dishwashing materials, scrubbing compositions, and window cleaners. The fragrance product of the present invention is a consumer product that contains a compound of the present invention. The fragrance product of the present invention contains a compound of the present invention and further a complementary fragrance compound as defined above.
[0113] The term “improving” in the phrase “improving, enhancing or modifying a fragrance formulation” is understood to mean raising the fragrance formulation to a more desirable character. The term “enhancing” is understood to mean making the fragrance formulation greater in effectiveness or providing the fragrance formulation with an improved character. The term “modifying” is understood to mean providing the fragrance formulation with a change in character.
[0114] The term “olfactory acceptable amount” is understood to mean the amount of a compound in a fragrance formulation, wherein the compound will contribute its individual olfactory characteristics. However, the olfactory effect of the fragrance formulation will be the sum of effect of each of the fragrance ingredients. Thus, the compound of the present invention can be used to improve or enhance the aroma characteristics of the fragrance formulation, or by modifying the olfactory reaction contributed by other ingredients in the formulation. The olfactory acceptable amount may vary depending on many factors including other ingredients, their relative amounts and the olfactory effect that is desired.
[0115] The amount of the compounds of the present invention employed in a fragrance formulation varies from about 0.005 to about 70 weight percent, preferably from 0.005 to about 50 weight percent, more preferably from about 0.5 to about 25 weight percent, and even more preferably from about 1 to about 10 weight percent. Those with skill in the art will be able to employ the desired amount to provide desired fragrance effect and intensity. In addition to the compounds of the present invention, other materials can also be used in conjunction with the fragrance formulation. Well known materials such as surfactants, emulsifiers, polymers to encapsulate the fragrance can also be employed without departing from the scope of the present invention.
[0116] When used in a fragrance formulation these ingredients provide additional notes to make a fragrance formulation more desirable and noticeable, and add the perception of value. The odor qualities found in these materials assist in beautifying and enhancing the finished accord as well as improving the performance of the other materials in the fragrance.
[0117] The following are provided as specific embodiments of the present invention. Other modifications of this invention will be readily apparent to those skilled in the art. Such modifications are understood to be within the scope of this invention. As used herein all percentages are weight percent unless otherwise noted, ppm is understood to stand for parts per million, L is understood to be liter, mL is understood to be milliliter, Kg is understood to be kilogram, g is understood to be gram, mol is understood to be mole, psi is understood to be pound-force per square inch, and mmHg be millimeters (mm) of mercury (Hg). IFF as used in the examples is understood to mean International Flavors & Fragrances Inc., New York, N.Y., USA.
Example I
[0118]
Preparation of 1,1,3,3-Pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 1)
[0119] A 5 L reaction vessel was charged with Cashmeran™ (412 g, 2.0 mol, commercially available at IFF), formamidine acetate (HN 2 CH═NH/HOOCCH 3 ) (1.03 Kg, 10.0 mol), and butanol (1.2 L). The reaction mixture was heated to 118° C. for 4 hours and then cooled to 25° C. The reaction mixture was washed twice with brine (1 L) and purified by vacuum distillation to afford 1,1,2,3,3-pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (260 g) having a boiling point of 140° C. at a pressure of 1.6 mmHg. Further recrystallization from ethanol afforded a solid with a melting point of 80.0° C.
[0120] 1 H NMR (CDCl 3 , 500 MHz): 8.90 ppm (s, 1H), 8.31 ppm (s, 1H), 2.77-2.82 ppm (m, 2H), 2.35-2.41 ppm (m, 1H), 2.25-2.32 ppm (m, 1H), 1.74 ppm (q, 1H, J=7.37 Hz), 1.38 ppm (s, 3H), 1.23 ppm (s, 3H), 1.11 ppm (s, 3H), 0.95 ppm (d, 3H, J=7.40 Hz), 0.93 ppm (s, 3H).
[0121] Structure 1 was described as having musky, ambery, and powdery notes.
Example II
[0122]
Preparation of 1,1,2,3,3-Pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2)
[0123] Dihydrocashmeran was obtained via the hydrogenation of Cashmeran™. A 3 L reaction vessel was charged with dihydrocashmeran (255 g, 1.2 mol), formamidine acetate (642 g, 6.2 mol), and butanol (1.2 L). The reaction mixture was heated to 118° C. for 4 hours and then cooled to 25° C. The reaction mixture was washed twice with brine (1 L) and purified by vacuum distillation to afford a 40:60 cis/trans mixture of 1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (200 g) having a boiling point of 153° C. at a pressure of 2.0 mmHg. The cis/trans structures were confirmed by NMR analysis by GC trapping.
[0124] Cis-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0125] 1 H NMR (CDCl 3 , 500 MHz): 8.96 ppm (s, 1H), 8.39 ppm (s, 1H), 3.00 ppm (d, J=9.7 Hz, 1H), 2.52-2.79 ppm (m, 2H), 1.25-2.15 ppm (m, 4H), 1.42 ppm (s, 3H), 1.10 ppm (s, 3H), 0.92 ppm (s, 3H), 0.84 ppm (d, J=7.3 Hz, 3H), 0.54 ppm (s, 3H).
[0126] Trans-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene:
[0127] 1 H NMR (CDCl 3 , 500 MHz): 8.92 ppm (s, 1H), 8.37 ppm (s, 1H), 2.75-2.93 ppm (m, 2H), 2.65 ppm (d, J=12.6 Hz, 1H), 1.20-2.10 ppm (m, 4H), 1.32 ppm (s, 3H), 0.99 ppm (s, 3H), 0.95 ppm (s, 3H), 0.84 ppm (d, J=7.5 Hz, 3H), 0.71 ppm (s, 3H).
[0128] Structure 2 was described as having ambery, musky, and woody notes.
Example III
[0129]
Preparation of Cis-1,1,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2a)
[0130] A 500 mL zipper autoclave was charged with 1,1,2,3,3-pentamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (100 g, prepared as above in EXAMPLE I), IPA (100 mL), and palladium on carbon (Pd/C) (1 g). The autoclave was sealed, purged with nitrogen, and then pressurized with hydrogen. The reaction mixture was heated to 180° C. for 4 hours and subsequently cooled to 25° C. The autoclave was vented and purged with nitrogen. The catalyst was removed by filtration through celite. A crude mass containing the major product cis-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (90%) was obtained. The crude mass was evaluated by gas chromatography olfactometry. Cis-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene was described as having a musky character. In addition, the minor product in the crude mass, trans-1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2b) (10%), was also evaluated and described as having an ambery character.
Example IV
[0131]
Preparation of 1,1,3,3-Tetramethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 3)
[0132] A 100 mL reaction flask is charged with 1,1,3,3-tetramethyl-1,2,3,5,6,7-hexahydro-inden-4-one (prepared as described in U.S. Pat. No. 3,927,083) (10 g, 0.05 mol), formamidine acetate (27 g, 0.26 mol), and butanol (C 4 H 9 OH) (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (H 2 SO 4 ) (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 1,1,3,3-tetramethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (˜5 g) is obtained.
Example V
[0133]
Preparation of 1,1,3,3-Tetramethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 4)
[0134] 1,1,3,3-Tetramethyl-octahydro-inden-4-one is first prepared by hydrogenating 1,1,3,3-tetramethyl-1,2,3,5,6,7-hexahydro-inden-4-one (prepared as described in U.S. Pat. No. 3,927,083) with Pd/C in alcohol in a Parr Hydrogenator at 25-60° C. and under 500 psi of hydrogen gas. A 100 mL reaction flask is the charged with 1,1,3,3-tetramethyl-octahydro-inden-4-one (10 g, 0.05 mol), formamidine acetate (27 g, 0.26 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 1,1,3,3-tetramethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (˜5 g) is obtained.
Example VI
[0135]
Preparation of 1,1,2,3,3,5-Hexamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 5)
[0136] A 100 mL reaction flask is charged with 1,1,2,3,3,6-hexamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (prepared as described in U.S. Pat. No. 3,927,083) (10 g, 0.045 mol), formamidine acetate (23 g, 0.22 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 1,1,2,3,3,5-hexamethyl-2,3,4,5-tetrahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (˜5 g) is obtained.
Example VII
[0137]
Preparation of 1,1,2,3,3,5-Hexamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 6)
[0138] 1,1,2,3,3,6-Hexamethyl-octahydro-inden-4-one is first prepared by hydrogenating 1,1,2,3,3,6-hexamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (prepared as described in U.S. Pat. No. 3,927,083) with Pd/C in alcohol in a Parr Hydrogenator at 25-60° C. and under 500 psi of hydrogen gas. A 100 mL reaction flask is the charged with 1,1,2,3,3,6-hexamethyl-octahydro-inden-4-one (10 g, 0.045 mol), formamidine acetate (23 g, 0.22 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 11,1,2,3,3,5-hexamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (˜5 g) is obtained.
Example VIII
[0139]
Preparation of 7,7,10,10-Tetramethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline (Structure 7)
[0140] A 100 mL reaction flask is charged with 5,5,8,8-tetramethyl-3,4,5,6,7,8-hexahydro-2H-naphthalen-1-one (prepared as described in U.S. Pat. Nos. 3,927,083 and 2,912,462) (10 g, 0.048 mol), formamidine acetate (25 g, 0.24 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 7,7,10,10-tetramethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline (˜5 g) is obtained.
Example IX
[0141]
Preparation of 7,7,10,10-Tetramethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline (Structure 8)
[0142] 5,5,8,8-Tetramethyl-octahydro-naphthalen-1-one is first prepared by hydrogenating 5,5,8,8-tetramethyl-3,4,5,6,7,8-hexahydro-2H-naphthalen-1-one (prepared as described in U.S. Pat. Nos. 3,927,083 and 2,912,462) with Pd/C in alcohol in a Parr Hydrogenator at 25-60° C. and under 500 psi of hydrogen gas. A 100 mL reaction flask is the charged with 5,5,8,8-tetramethyl-octahydro-naphthalen-1-one (10 g, 0.048 mol), formamidine acetate (25 g, 0.24 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 7,7,10,10-tetramethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[11]quinazoline (˜5 g) is obtained.
Example X
[0143]
Preparation of 5,7,7,8,10,10-Hexamethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline (Structure 9)
[0144] A 100 mL reaction flask is charged with 3,5,5,6,8,8-hexamethyl-3,4,5,6,7,8-hexahydro-2H-naphthalen-1-one (prepared as described in U.S. Pat. No. 3,927,083) (10 g, 0.042 mol), formamidine acetate (21 g, 0.2 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5,7,7,8,10,10-hexamethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline (˜5 g) is obtained.
Example XI
[0145]
Preparation of 5,7,7,8,10,10-Hexamethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline (Structure 10)
[0146] 3,5,5,6,8,8-Hexamethyl-octahydro-naphthalen-1-one is first prepared by hydrogenating 3,5,5,6,8,8-hexamethyl-3,4,5,6,7,8-hexahydro-2H-naphthalen-1-one (prepared as described in U.S. Pat. No. 3,927,083) with Pd/C in alcohol in a Parr Hydrogenator at 25-60° C. and under 500 psi of hydrogen gas. A 100 mL reaction flask is the charged with 3,5,5,6,8,8-hexamethyl-octahydro-naphthalen-1-one (10 g, 0.042 mol), formamidine acetate (21 g, 0.2 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5,7,7,8,10,10-hexamethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline (˜5 g) is obtained.
Example XII
[0147]
Preparation of 7,7,10a-Trimethyl-5,6,6a,7,8,9,10,10a-octahydro-benzo[h]quinazoline (Structure 11) and 6,6,9a-Trimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline (Structure 26)
[0148] A 100 mL reaction flask is charged with 5,5,8a-trimethyl-octahydro-naphthalen-2-one (prepared as described by Strike in Journal of the American Chemical Society, 1964, 86(10), pages: 2044-2050) (10 g, 0.05 mol), formamidine acetate (27 g, 0.26 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. A mixture of products 5,7,7,8,10,10-hexamethyl-5,6,7,8,9,10-hexahydro-benzo[h]quinazoline and 6,6,9a-Trimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline (˜5 g) is obtained, which may be separated using techniques known to those having skill in the art. Suitable techniques include chromatography such as high performance liquid chromatography, referred to as HPLC, and particularly silica gel chromatography and gas chromatography trapping known as GC trapping.
Example XIII
[0149]
Preparation of 8-Isopropyl-5,6,7,8-tetrahydro-quinazoline (Structure 12)
[0150] A 100 mL reaction flask is charged with 2-isopropyl-cyclohexanone (10 g, 0.07 mol), formamidine acetate (40 g, 0.4 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 8-isopropyl-5,6,7,8-tetrahydro-quinazoline (˜5 g) is obtained.
Example XIV
[0151]
Preparation of 8-tert-Butyl-5,6,7,8-tetrahydro-quinazoline (Structure 13)
[0152] A 100 mL reaction flask is charged with 2-tert-butyl-cyclohexanone (10 g, 0.07 mol), formamidine acetate (40 g, 0.4 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 8-tert-butyl-5,6,7,8-tetrahydro-quinazoline (˜5 g) is obtained.
Example XV
[0153]
Preparation of 5-(1,5-Dimethyl-hex-4-enyl)-pyrimidine (Structure 14)
[0154] A 100 mL reaction flask is charged with 3,7-dimethyl-oct-6-enal (Citronellal®) (Commercially available at IFF) (10 g, 0.06 mol), formamidine acetate (31 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5-(1,5-dimethyl-hex-4-enyl)-pyrimidine (˜5 g) is obtained.
Example XVI
[0155]
Preparation of 4-tert-Butyl-pyrimidine (Structure 16)
[0156] A 100 mL reaction flask is charged with 3,3-dimethyl-butan-2-one (10 g, 0.1 mol), formamidine acetate (57 g, 0.5 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-tert-butyl-pyrimidine (˜5 g) is obtained.
Example XVII
[0157]
Preparation of 4-(2,2-Dimethyl-propyl)-pyrimidine (Structure 16)
[0158] A 100 mL reaction flask is charged with 4,4-dimethyl-pentan-2-one (10 g, 0.1 mol), formamidine acetate (57 g, 0.5 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-(2,2-dimethyl-propyl)-pyrimidine (˜5 g) is obtained.
Example XVIII
[0159]
Preparation of 4,5-Diisopropyl-pyrimidine (Structure 17)
[0160] A 100 mL reaction flask is charged with 2,5-dimethyl-hexan-3-one (10 g, 0.08 mol), formamidine acetate (40 g, 0.4 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4,5-diisopropyl-pyrimidine (˜5 g) is obtained.
Example XIX
[0161]
Preparation of 4,5-Di-tert-butyl-pyrimidine (Structure 18)
[0162] A 100 mL reaction flask is charged with 2,2,5,5-tetramethyl-hexan-3-one (10 g, 0.06 mol), formamidine acetate (33 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4,5-di-tert-butyl-pyrimidine (˜5 g) is obtained.
Example XX
[0163]
Preparation of 5-tert-Butyl-4-(2,2-dimethyl-propyl)-pyrimidine (Structure 19)
[0164] A 100 mL reaction flask is charged with 2,2,6,6-tetramethyl-heptan-4-one (10 g, 0.06 mol), formamidine acetate (33 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5-tert-butyl-4-(2,2-dimethyl-propyl)-pyrimidine (˜5 g) is obtained.
Example XXI
[0165]
Preparation of 4-(2,6,6-Trimethyl-cyclohex-3-enyl)-pyrimidine (Structure 20)
[0166] A 100 mL reaction flask is charged with 1-(2,6,6-trimethyl-cyclohex-3-enyl)-ethanone (10 g, 0.06 mol, commercially available at IFF), formamidine acetate (31 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-(2,6,6-trimethyl-cyclohex-3-enyl)-pyrimidine (˜10 g) is obtained.
Example XXII
[0167]
Preparation of 4-(3,3-Dimethyl-cyclohexyl)-pyrimidine (Structure 21)
[0168] A 100 mL reaction flask is charged with 1-(3,3-dimethyl-cyclohexyl)-ethanone (Herbac®) (10 g, 0.06 mol, commercially available at IFF), formamidine acetate (31 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-(3,3-dimethyl-cyclohexyl)-pyrimidine (˜10 g) is obtained.
Example XXIII
[0169]
Preparation of 4-[2-(2,6,6-Trimethyl-cyclohex-1-enyl)-ethyl]-pyrimidine (Structure 22)
[0170] A 100 mL reaction flask is charged with 4-(2,6,6-trimethyl-cyclohex-1-enyl)-butan-2-one (10 g, 0.05 mol, commercially available at IFF), formamidine acetate (26 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-[2-(2,6,6-trimethyl-cyclohex-1-enyl)-ethyl]-pyrimidine (˜10 g) is obtained.
Example XXIV
[0171]
Preparation of 4-[2-(2,5,6,6-Tetramethyl-cyclohex-1-enyl)-ethyl]-pyrimidine (Structure 23)
[0172] A 100 mL reaction flask is charged with 4-(2,5,6,6-tetramethyl-cyclohex-1-enyl)-butan-2-one (10 g, 0.05 mol, commercially available at IFF), formamidine acetate (26 g, 0.3 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 4-[2-(2,5,6,6-tetramethyl-cyclohex-1-enyl)-ethyl]-pyrimidine (˜10 g) is obtained.
Example XXV
[0173]
Preparation of 4-(1,1,2,3,3-Pentamethyl-indan-5-yl)-pyrimidine (Structure 24)
[0174] A 5 L reaction vessel was charged with 1-(1,1,2,3,3-pentamethyl-indan-5-yl)-ethanone (460 g, 2.0 mol) (commercially available at IFF), formamidine acetate (675 g, 6.4 mol), and butanol (1.0 L). The reaction mixture was heated to 120° C. for 10 hours and then cooled to 25° C. The reaction mixture was washed twice with brine (1 L) and purified by vacuum distillation to afford 4-(1,1,2,3,3-pentamethyl-indan-5-yl)-pyrimidine (200 g) having a boiling point of 153° C. at a pressure of 2.0 mmHg
[0175] 1 H NMR (CDCl 3 , 500 MHz): 9.25 ppm (d, 1H, J=1.28 Hz), 8.71 ppm (d, 1H, J=5.40 Hz), 7.88-7.93 ppm (m, 2H), 7.69 (d, 1H, J=5.40 Hz, of d, J=1.40 Hz), 7.28 ppm (d, 1H, J=7.90 Hz, of d, J=0.40 Hz), 1.92 ppm (q, 1H, J=7.36 Hz), 1.35 ppm (s, 3H), 1.31 ppm (s, 3H), 1.13 ppm (s, 3H), 1.11 ppm (s, 3H), 1.02 ppm (d, 3H, J=7.36 Hz).
[0176] 4-(1,1,2,3,3-Pentamethyl-indan-5-yl)-pyrimidine was described as having weak floral note.
Example XXVI
[0177]
Preparation of 4-(6-tert-Butyl-1,1-dimethyl-indan-4-yl)-pyrimidine (Structure 25)
[0178] A 5 L reaction vessel was charged with 1-(6-tert-butyl-1,1-dimethyl-indan-4-yl)-ethanone (300 g, 1.2 mol) (commercially available at IFF), formamidine acetate (639 g, 6.1 mol), and butanol (1.0 L). The reaction mixture was heated to 125° C. for 10 hours and then cooled to 25° C. The reaction mixture was washed twice with brine (1 L) and purified by vacuum distillation to afford 4-(6-tert-butyl-1,1-dimethyl-indan-4-yl)-pyrimidine (200 g) having a boiling point of 180° C. at a pressure of 0.5 mmHg
[0179] 1 H NMR (CDCl 3 , 500 MHz): 9.28 ppm (d, 1H, J=1.28 Hz), 8.74 ppm (d, 1H, J=5.32 Hz), 7.65 ppm (d, 1H, J=1.84 Hz), 7.57 ppm (d, 1H, J=5.32 Hz, of d, J=1.44 Hz), 7.31 ppm (d, 1H, J=1.80 Hz), 3.11 ppm (t, 2H, J=7.14 Hz), 1.95 ppm (t, 2H, J=7.14 Hz), 1.38 ppm (s, 9H), 1.31 ppm (s, 6H).
[0180] 4-(6-tert-Butyl-1,1-dimethyl-indan-4-yl)-pyrimidine was described as having weak fatty note.
Example XXVII
[0181]
Preparation of 5a,10-Dimethyl-5,5a,6,7,8,9-hexahydro-benzo[g]quinazoline (Structure 27)
[0182] A 100 mL reaction flask is charged with 1,4a-dimethyl-4,4-a,5,6,7,8-hexahydro-3H-naphthalen-2-one (prepared as described by Sjoebers in Acta Chemica Scand., 1990, 44(10), pages: 1036-1041) (10 g, 0.05 mol), formamidine acetate (27 g, 0.26 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5a,10-dimethyl-5,5a,6,7,8,9-hexahydro-benzo[g]quinazoline (˜5 g) is obtained.
Example XXVIII
[0183]
Preparation of 5a,10-Dimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline (Structure 28)
[0184] 1,4a-Dimethyl-octahydro-naphthalen-2-one is first prepared by hydrogenating 1,4a-dimethyl-4,4-a,5,6,7,8-hexahydro-3H-naphthalen-2-one (prepared as described by Sjoebers in Acta Chemica Scand., 1990, 44(10), pages: 1036-1041) with Pd/C in alcohol in a Parr Hydrogenator at 25-60° C. and under 500 psi of hydrogen gas. A 100 mL reaction flask is charged with 1,4a-dimethyl-octahydro-naphthalen-2-one (10 g, 0.05 mol), formamidine acetate (27 g, 0.26 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5a,10-dimethyl-5,5a,6,7,8,9,9a,10-octahydro-benzo[g]quinazoline (˜5 g) is obtained.
Example XXIX
[0185]
Preparation of 6,6,10,10-Tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a,9-methanobenzo[H]quinazoline (Structure IV)
[0186] A 5 L reaction vessel was charged with 1,1,5,5-tetramethyl-hexahydro-2,4-a-methano-naphthalen-8-one (440 g, 2.0 mol) (commercially available at IFF), formamidine acetate (1040 g, 10.0 mol) and butanol (2 L). The reaction mixture was heated to 120° C. for 10 hours and then cooled to 25° C. The reaction mixture was washed twice with brine (1 L) and purified by vacuum distillation to afford crude product 6,6,10,10-tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a,9-methanobenzo[H]quinazoline (430 g) having a boiling point of 159° C. at a pressure of 1.0 mmHg. Further recrystallization from ethanol afforded 6,6,10,10-tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a,9-methanobenzo[H]quinazoline (95% purity) (125 g) with a melting point of 44-45° C.
[0187] 1 H NMR (CDCl 3 , 500 MHz): 8.97 ppm (d, 1H, J=0.60 Hz), 8.34 ppm (s, 1H), 2.81 ppm (d, 1H, J=16.14 Hz), 2.45 ppm (s, 1H), 2.30 ppm (d, 1H, J=16.11 Hz), 1.90-1.97 ppm (m, 1H), 1.76-1.77 ppm (m, 1H), 1.71 ppm (d, 1H, J=3.95 Hz, of t, J=12.22 Hz), 1.61-1.66 ppm (d, 1H, J=9.45 Hz, of m), 1.51-1.58 ppm (m, 1H), 1.39 ppm (s, 3H), 1.28 ppm (d, 1H, J=9.95 Hz, of t, J=1.68 Hz), 1.16-1.23 ppm (m, 1H), 1.09 ppm (s, 3H), 0.74 ppm (s, 3H), 0.67 ppm (s, 3H).
[0188] 6,6,10,10-Tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a,9-methanobenzo[H]quinazoline was described as having musky, woody, and ambery notes.
Example XXX
[0189]
Preparation of 5,7,7,10-Tetramethyl-6,7,7a,8,9,10-hexahydro-5H-6,10a-methanoazuleno[5,4-d]pyrimidine (Structure 30)
[0190] A 100 mL reaction flask is charged with 3,6,8,8-tetramethyl-hexahydro-3a,7-methano-azulen-5-one (prepared as described in U.S. Pat. No. 3,887,622) (10 g, 0.045 mol), formamidine acetate (21 g, 0.2 mol), and butanol (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sulfuric acid (10%, 100 mL) followed by twice with brine (30 mL). Butanol is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 5,7,7,10-tetramethyl-6,7,7a, 8,9,10-hexahydro-5H-6,10a-methanoazuleno[5,4-d]pyrimidine (˜5 g) is obtained.
Example XXXI
[0191]
Preparation of 5,6,7,8-Tetrahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole (Structure 31)
[0192] A 2 L reaction flask was charged with sodium hydride (NaH) (40 g) in dimethoxyethane (DME) (CH 3 OCH 2 CH 2 OCH 3 ) (1.39 Kg) and a mixture of Cashmeran™ (520 g) and ethyl formate (185 g) at room temperature. The mixture was stirred for 8 hours to provide 1,1,2,3,3-pentamethyl-4-oxo-2,3,4,5,6,7-hexahydro-1H-indene-5-carbaldehyde. Dimethylformamide (DMF) (300 mL) and hydroxylamine hydrochloride (NH 2 OH*HC1) (174 g) were then added and the temperature was heated to and maintained at 130° C. for 8 hours. Water was then added and the organic layer was extracted by toluene and washed once with water. Toluene was distilled off using a Rotovap to provide crude product 5,6,7,8-tetrahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole (260 g), which was then recrystallized to afford a pure product with a melting point of 80.96° C.
[0193] 1 H NMR (CDCl 3 , 500 MHz): 8.01 ppm (s, 1H), 2.68-2.73 ppm (m, 2H), 2.28-2.43 ppm (m, 2H), 1.75 ppm (q, 1H, J=7.40 Hz), 1.31 ppm (s, 3H), 1.09 ppm (s, 3H), 1.07 ppm (s, 3H), 0.93 ppm (s, 3H), 0.93 ppm (d, 3H, J=7.40 Hz).
[0194] 5,6,7,8-Tetrahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole was described as having cashmeran, slightly musky, geranium, and hint of ambery notes.
Example XXXII
[0195]
Preparation of 5,5a,6,7,8,8a-Hexahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole (Structure 32)
[0196] A 2 L reaction flask was charged with sodium hydride (24 g) in DME (867 g) and a mixture of dihydrocashmeran (208 g, prepared as above in EXAMPLE II) and ethyl formate (111 g) at room temperature. The mixture was stirred for 8 hours to provide 1,1,2,3,3-pentamethyl-4-oxo-octahydro-indene-5-carbaldehyde. Tetrahydrofuran (THF) (20 mL), ethanol (CH 3 CH 2 OH) (200 mL), hydroxylamine hydrochloride (70 g), and acetic acid (CH 3 COOH) (200 mL) were then added and the temperature was heated to and maintained at 75° C. for 8 hours. Water was then added and the organic layer was extracted by toluene and washed once with water. Toluene was distilled off using a Rotovap to provide crude product 5,5a,6,7,8,8a-hexahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole (186 g), which was then recrystallized to afford a pure product with a melting point of 82.35° C.
[0197] 1 H NMR (CDCl 3 , 400 MHz): 8.03 ppm (s, 1H), 2.57-2.64 ppm (m, 2H), 2.40-2.50 ppm (m, 1H), 1.88-1.94 ppm (m, 1H), 1.61 ppm (d, 1H, J=2.24 Hz, of t, J=12.42 Hz), 1.43 ppm (q, 1H, J=7.53 Hz), 1.30-1.39 ppm (m, 1H), 1.19 ppm (s, 3H), 1.00 ppm (s, 3H), 0.94 ppm (s, 3H), 0.84 ppm (d, 3H, J=7.52 Hz), 0.70 ppm (s, 3H).
[0198] 5,5a,6,7,8,8a-Hexahydro-6,6,7,8,8-pentamethyl-4H-indeno[5,4-D]isoxazole was described as having woody, earthy, green, patchouli, cashmeran, moldy, cucumber, aldehydic, moss and ambery notes.
Example XXXIII
[0199]
Preparation of 6,6,7,8,8-Pentamethyl-5,6,7,8-tetrahydro-4H-1-oxa-3-aza-as-indacene (Structure 33) and 6,6,7,8,8-Pentamethyl-5,6,7,8-tetrahydro-4H-indeno[4,5-d]oxazole (Structure 34)
[0200] 1,1,2,3,3-Pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione is first prepared with 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF) via oxidation with (2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (TEMPO) (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione (10 g, 0.04 mol) and formamide (NH 2 CHO) (50 mL). The reaction mixture is heated to 200° C. and stirred for 24 hours. The crude mass is diluted with toluene (50 mL) and then washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Toluene is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product of a mixture of 6,6,7,8,8-pentamethyl-5,6,7,8-tetrahydro-4H-1-oxa-3-aza-as-indacene and 6,6,7,8,8-pentamethyl-5,6,7,8-tetrahydro-4H-indeno[4,5-d]oxazole (˜10 g) is obtained.
Example XXXIV
[0201]
Preparation of 6,6,7,8,8-Pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-1-oxa-3-aza-as-indacene (Structure 35) and 6,6,7,8,8-Pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-indeno[4,5-d]oxazole (Structure 36)
[0202] 1,1,2,3,3-Pentamethyl-octahydro-inden-4-one is first prepared by the hydrogenation of 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF). 1,1,2,3,3-Pentamethyl-hexahydro-indene-4,5-dione is subsequently prepared with 1,1,2,3,3-pentamethyl-octahydro-inden-4-one (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-hexahydro-indene-4,5-dione (10 g, 0.04 mol) and formamide (50 mL). The reaction mixture is heated to 200° C. and stirred for 24 hours. The crude mass is diluted with toluene (50 mL) and then washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Toluene is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product of a mixture of 6,6,7,8,8-pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-1-oxa-3-aza-as-indacene and 6,6,7,8,8-pentamethyl-5,5a,6,7,8,8a-hexahydro-4H-indeno[4,5-d]oxazole (˜10 g) is obtained.
Example XXXV
[0203]
Preparation of 2,6,6,7,8,8-Hexamethyl-5,6,7,8-tetrahydro-4H-3-thia-1-aza-as-indacene (Structure 37)
[0204] 1,1,2,3,3-Pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione is first prepared with 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF) via oxidation with (2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (TEMPO) (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione (10 g, 0.04 mol), thioacetamide (CH 3 CSNH 2 ) (3.5 g, 0.04 mol), and diglyme (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Diglyme is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 2,6,6,7,8,8-hexamethyl-5,6,7,8-tetrahydro-4H-3-thia-1-aza-as-indacene (˜10 g) is obtained.
Example XXXVI
[0205]
Preparation of 2,6,6,7,8,8-Hexamethyl-5,5a,6,7,8,8a-hexahydro-4H-3-thia-1-aza-as-indacene (Structure 38)
[0206] 1,1,2,3,3-Pentamethyl-octahydro-inden-4-one is first prepared by the hydrogenation of 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF). 1,1,2,3,3-Pentamethyl-hexahydro-indene-4,5-dione is subsequently prepared with 1,1,2,3,3-pentamethyl-octahydro-inden-4-one (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-hexahydro-indene-4,5-dione (10 g, 0.04 mol), thioacetamide (3.5 g, 0.04 mol), and diglyme (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The crude mass is washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Diglyme is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 2,6,6,7,8,8-hexamethyl-5,5a,6,7,8,8a-hexahydro-4H-3-thia-1-aza-as-indacene (˜10 g) is obtained.
Example XXXVII
[0207]
Preparation of 7,7,8,9,9-Pentamethyl-5,7,8,9-tetrahydro-6H-cyclopenta[f]quinoxaline (Structure 39)
[0208] 1,1,2,3,3-Pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione is first prepared with 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF) via oxidation with (2,2,6,6-tetramethylpiperidin-1-yl)oxidanyl (TEMPO) (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-2,3,6,7-tetrahydro-1H-indene-4,5-dione (10 g, 0.04 mol), ethylene diamine (NH 2 CH 2 CH 2 NH 2 ) (2.5 g, 0.04 mol), and diglyme (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The reaction mixture is then cooled to 25° C. and further oxidized with 2,3-dichloro-5,6-dicyano-1,4-benzoquinone (10 g, 0.045 mol) for another 8 hours. The crude mass is washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Diglyme is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 7,7,8,9,9-pentamethyl-5,7,8,9-tetrahydro-6H-cyclopenta[f]quinoxaline (˜10 g) is obtained.
Example XXXVIII
[0209]
Preparation of 7,7,8,9,9-Pentamethyl-5,6a,7,8,9,9a-hexahydro-6H-cyclopenta[f]quinoxaline (Structure 40)
[0210] 1,1,2,3,3-Pentamethyl-octahydro-inden-4-one is first prepared by the hydrogenation of 1,1,2,3,3-pentamethyl-1,2,3,5,6,7-hexahydro-inden-4-one (Cashmeran®) (commercially available at IFF). 1,1,2,3,3-Pentamethyl-hexahydro-indene-4,5-dione is subsequently prepared with 1,1,2,3,3-pentamethyl-octahydro-inden-4-one (prepared as described by Barton in Tetrahedron Letters, 1984, 25(6), pages: 603-606). A 100 mL reaction flask is charged with 1,1,2,3,3-pentamethyl-hexahydro-indene-4,5-dione (10 g, 0.04 mol), ethylene diamine (NH 2 CH 2 CH 2 NH 2 ) (2.5 g, 0.04 mol), and diglyme (50 mL). The reaction mixture is heated to 130° C. and stirred for 24 hours. The reaction mixture is then cooled to 25° C. and further oxidized with 2,3-dichloro-5,6-dicyano-1,4-benzoquinone (10 g, 0.045 mol) for another 8 hours. The crude mass is washed once with aqueous sodium carbonate (10%, 100 mL) followed by twice with brine (30 mL). Diglyme is recovered by roto-evaporation. The crude product is further purified with liquid chromatography (Biotage® system) and then crystallized. Product 7,7,8,9,9-pentamethyl-5,6a,7,8,9,9a-hexahydro-6H-cyclopenta[f]quinoxaline (˜10 g) is obtained.
Example XXXIX
[0211] The fragrance formulas exemplified as follows demonstrated that the addition of 1,1,2,3,3-Pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2) containing a 40:60 cis/trans isomeric mixture provided a musky character to the fragrance formula.
[0000]
Ingredient
Parts (g)
Parts (g)
Kharismal ™
175
175
Ethylene Brassylate
50
50
Dipropylene Glycol
34
34
Iso Gamma Super ™
30
30
Hydroxy Citronellal Pure
15
15
Indasan
10
10
Amberiff 20% IPM
10
10
L-Citronellol
8
8
Beta Ionone Extra
5
5
Linalyl Acetate
5
5
Ambrettolide
3
3
Geraniol 980
3
3
Healingwood ™
1
1
Amber Xtreme ™ 1% DPG
1
1
Structure 2
10
—
DPG
—
10
Total
360
360
[0212] The above fragrance formulas had floral and woody characters. The addition of 1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2) intensified the floral and woody notes and provided a musky undertone.
Example XL
[0213] Fragrance formulation containing 1,1,2,3,3-pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2):
[0000]
Ingredient
Parts (g)
Santaliff ™
24
Phenoxanol ™
32
Coumarin
28
Cyclamal Extra
1
Eth Vanillin
7
Geraniol 980 Pure
1
Hedione ™
60
Amy Cinnamic Aldehyde
60
Heliotropine
17
Hexyl Cinnamic Ald
16
Beta Ionone Extra
6
Iso E Super ™
70
Lyral ™
16
lillial ™
160
Lilianth
20
Methyl Ionone Gamma A
73
Veramoss
2
Peru Balsam Oil India
3
Prenyl Acetate
1
Methyl Cedryl Ketone
40
Methyl Phenyl Acetate
1
Aubepine
4
Benzoin
10
Cedrol Tex
3
Citronellol Extra
3
Geraniol Coeur
4
Methyl Cinnamate
3
Styrax Alva Ess
2
Vanillin ex Lignin
12
Cananga Java Native
5
Structure 2
20
Total
704
[0214] 1,1,2,3,3-Pentamethyl-2,3,3a,4,5,9b-hexahydro-1H-7,9-diaza-cyclopenta[a]naphthalene (Structure 2) imparted diffusive floral and soft powdery characters to a fragrance formula.
Example XLI
[0215] The fragrance formulas exemplified as follows demonstrated that the addition of 6,6,10,10-tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a, 9-methanobenzo[H]quinazoline (Structure 29) provided floral odor character with woody and musky undertones.
[0000]
Ingredient
Parts (g)
Parts (g)
Triplal BHT
20
20
Aldehyde C11 Ulenic
13
13
Aldehyde C12 MNA
10
10
Iso Gamma Super ™
170
170
Hydroxy Citronellal Pure
10
10
Bacdanol ™ BHT
10
10
Benz Acetone
25
25
Benz Salicylate
50
50
Citronellol 950
15
15
Cyclacet
20
20
Cyclaprop
20
20
Damascone delta
2
2
Dihydro myrcenol
60
60
Eugenol Natural
10
10
Galaxolide 50 ™
140
140
Hexyl cinnamic ald
35
35
Hexyl Salicylate
35
35
Iso bornyl acetate
40
40
Iao butyl quinoline
1
1
Methyl ionone gamma
15
15
Peomosa ™
25
25
Rosetone
60
60
Styralyl acetate
1
1
Terpineol alpha
3
3
Gamma undecalactone
6
6
Veramoss
1
1
Verdox
40
40
Yara Yara
1
1
Structure 29
30
—
DPG
—
30
Total
868
868
Example XLII
[0216] The fragrance formula exemplified as follows demonstrated that 6,6,10,10-Tetramethyl-5,7,8,9,10,10a-hexahydro-6H-6a, 9-methanobenzo[H]quinazoline (Structure 29) imparted diffusive floral, soft powdery, and sweet characters.
[0000]
Ingredient
Parts (g)
Santaliff ™
24
Phenoxanol ™
32
Coumarin
28
Cyclamal Extra
1
Eth Vanillin
7
Geraniol 980 Pure
1 s
Hedione ™
60
Amy Cinnamic Aldehyde
60
Heliotropine
17
Hexyl Cinnamic Ald
16
Beta Ionone Extra
6
Iso E Super ™
70
Lyral ™
16
lillial ™
160
Lilianth
20
Methyl Ionone Gamma A
73
Veramoss
2
Peru Balsam Oil India
3
Prenyl Acetate
1
Methyl Cedryl Ketone
40
Methyl Phenyl Acetate
1
Aubepine
4
Benzoin
10
Cedrol Tex
3
Citronellol Extra
3
Geraniol Coeur
4
Methyl Cinnamate
3
Styrax Alva Ess
2
Vanillin ex Lignin
12
Cananga Java Native
5
Structure 29
20
Total
704
|
The present invention relates to novel pyrimidine derivatives and their use in perfume compositions. The novel pyrimidine derivatives of the present invention are represented by the following formula:
wherein m and n are integers that when m is 0, n is 1; when m is 1, n is 0 or 1; or when m is 2, n is 0;
wherein (CH) m and (CH) n are each independently optionally substituted with a substituent selected from the group consisting of methyl and ethyl;
wherein X is selected from the group consisting of N, O, and S; and
wherein R 1 and R 2 each independently represent H or a hydrocarbon group, or R 1 and R 2 together represent a fused ring or a ring system,
with the proviso that when R 1 is H, R 2 is not H.
| 2
|
FIELD OF THE INVENTION
[0001] The invention relates to a cable holder configured to support one or more cables.
BACKGROUND OF THE INVENTION
[0002] The use of transmission line or cable hangers, or clamps, configured to attach a transmission line or cable to a support, such as an antenna tower, have been known for many years. The advent of electronic equipment has caused a few problems related to coupling of a hugely increased number of transmission lines along antenna towers due to a limited space capable of accommodating these lines. Typically, since installation of cables is associated with safety considerations as well as with the time and expense involved with installing these lines, it is highly desirable to minimize both the amount of time and the complexity of the work required for coupling cables to support structures. To address these issues, various structures of cable hangers, designed to rapidly attach cables to support structures, have been recently developed.
[0003] A typical cable holder is illustrated in FIGS. 1 and 2 and includes inner and outer cable hangers 110 coupled to one another so that the outer hanger may be added later to accommodate additional cables without disassembling the previously installed hanger(s). Attachment of the inner hanger 110 to a support 118 as well as coupling the hangers to one another are realized by compressing opposite arms 112 so that locking fingers 114 are first inserted into an opening 116 and then, upon ceasing the compressing force, spread apart to reliably engage the rim of the opening. Support 118 may be horizontally or vertically disposed, and may include a plurality of openings to accommodate multiple hangers 110 .
[0004] Insertion of the cable holder may pose several problems. For example, if the cable holder, as shown in FIGS. 1 and 2 , is assembled before its attachment to the support 118 , the access to the inner hanger may be limited because the outer hanger blocks the inner one, which is, thus, difficult to reach manually. Note that the inner and outer hangers may rotate relative to one about an axis of symmetry S′-S′ upon insertion of the locking fingers 114 into the opening 116 . However, because this rotation occurs about the axis of symmetry common to both hangers, the outer hanger blocks the inner hanger regardless of the relative angular position of the hangers. Thus, this structure necessitates the use of instruments, which are a) inconvenient, since the direct access to the inner hanger is still blocked by the outer hanger, and b) undesirable, because having additional instruments on a tall tower imposes an additional physical and logistical hardship on the serviceman.
[0005] If, however, the cable holder of FIGS. 1 and 2 is deployed by initially attaching only the inner hanger with a respective cable to the support 118 , further installation of the outer hanger in response to the increased demands for additional cables may be associated with difficulties caused by climatic conditions. Indeed, typically, cables are installed on tall towers. As a consequence, low temperatures and strong winds may critically complicate the attachment of the outer hanger to the inner one. Also, gradual installation of subsequent outer hangers may be associated with still another problem stemming from variations of the size of the opening 116 leading to unreliable securing the hangers to one another and to the support 118 . Overall, the above-discussed problems may detrimentally affect the reliability of the installation as well as the safety of the worker.
[0006] Furthermore, the cable holder of FIGS. 1 and 2 is configured to lock a respective cable by compressing the arms of the hangers against this line upon inserting the locking fingers 114 into the opening 116 . Yet, the inherent elasticity of the arms of the hanger may not be sufficient to prevent displacement of the cables along the tower for a variety of reasons. Even those hanger designs that have mechanisms for penetrating or biting into the cable jacket may not prevent longitudinal movement of the cable because the frictional coefficient between the metal hanger and the plastic cable jacket is very low. The polyethylene typically used for cable jackets is a soft material that has an inherent lubricant quality. In addition, the cable jacket can “cold flow” which reduces the holding force of the cable hanger over time, resulting in cable slippage.
[0007] It is therefore desirable to provide a stackable cable holder configured to provide an easy installment of cables as well as reliable securement thereof.
SUMMARY OF THE INVENTION
[0008] The present invention attains these objectives by providing a stackable cable holder including multiple interconnected hangers, which are displaceable relative to one another without being detached. As a consequence, even if, initially, only a single cable, which is secured to an inner hanger, is needed, the installation of subsequent lines does not pose the difficulties associated with the discussed-above prior art, since an outer hanger, configured to receive an additional line, has been already installed.
[0009] In accordance with one aspect of the invention, to facilitate access by the worker to an inner hanger couplable to a support, inner and outer hangers are displaceable relative to one another about an axis offset from a central symmetry axis. As opposed to the structure shown in FIGS. 1 and 2 , displacement of the hangers about the off-center axis leads to a position in which the inner hanger can be conveniently gripped and squeezed by the worker. As a result, displacing the outer hanger relative to the inner one in accordance with the invention creates a sufficient space allowing the worker to manually attach the inner hanger to a support.
[0010] In accordance with another aspect of the invention, the outer hanger is configured to positively lock a cable in the hanger. A locking assembly is characterized by its simplicity and is configured to allow reliable accommodation of differently sized cables.
[0011] It is therefore an object of the invention to provide a cable holder overcoming drawbacks of the known prior art.
[0012] A further object of the invention is to provide a cable holder allowing securement of additional cables in a time- and labor-efficient manner; and
[0013] Still a further object of the invention is to provide a reliable securement of cables to the inventive cable holder.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and other features, objects and advantages will become more readily apparent from the detailed description of the invention accompanied by the following drawings, in which:
[0015] FIG. 1 is an isometric view of detached inner and outer hangers of a stackable cable holder of the known prior art;
[0016] FIG. 2 is an isometric view of the assembled cable holder of FIG. 1 ;
[0017] FIG. 3 is an isometric view of a stackable cable holder configured in accordance with the invention and shown in a deployed position, in which inner and outer hangers each are ready to receive a respective cable;
[0018] FIG. 4 is an isometric view of a stackable cable holder configured in accordance with the invention and shown in an installation position, in which the outer hanger is displaced to allow substantially the unobstructed access to the inner hanger;
[0019] FIG. 5 is an isometric view of the inner hanger of the inventive cable holder illustrating the interior surface of the outer hanger;
[0020] FIG. 6 is an isometric view of the inner hanger of the inventive cable holder illustrating the exterior surface of the inner hanger;
[0021] FIG. 7 is an isometric view of the outer hanger of the inventive cable holder illustrating the exterior surface of the outer hanger; and
[0022] FIG. 8 is an isometric exploded view of the cable holder configured in accordance with another embodiment of the invention.
DETAILED DESCRIPTION
[0023] Referring to FIGS. 3-4 , the inventive cable holder 20 has at least one pair of coupled inner 22 and outer 24 hangers displaceable relative to one another along a direction “A”′ between deployed and installation positions as shown in FIGS. 3 and 4 , respectively. In accordance with one inventive embodiment, the hangers 22 , 24 rotate relative to one another about an axis C-C ( FIG. 4 ), which is offset from an axis of symmetry S-S ( FIG. 4 ) common to both hangers in the deployed position of FIG. 3 . Accordingly, in the deployed position, the axis of symmetry S-S of both hangers 22 , 24 extends substantially perpendicular to a longitudinal axis V-V of an antenna tower (not shown), which complicates access to a body 28 of the inner hanger 22 by a serviceman. To facilitate this access, the outer hanger 24 is designed to move so that the body 28 is conveniently exposed to the serviceman. The serviceman then applies a compressing force to the body 28 , brings the fingers 30 together to insert them into the support, which is not shown, but is similar to the one illustrated in FIG. 2 . Upon ceasing the compressing force, the fingers are biased apart to have inner hook portions 34 ( FIG. 5 ) engage the rim of the opening 116 . To ensure that the inner hanger 22 would not disengage from the support 118 , the fingers 30 are formed with barbs 32 extending laterally outwards from the fingers to urge against the support upon ceasing the compressing force.
[0024] Having installed the inventive cable holder 20 to the support, the outer hanger 24 is rotated to the deployed position of FIG. 3 , in which the inner and outer hangers 22 , 24 extend along longitudinal axis axes A-A and B-B parallel to the tower's longitudinal axis V-V. As a result, in addition to a cable locked in the inner hanger 22 , an additional cable can extend through and be locked in the outer hanger 24 , as will be disclosed below.
[0025] Turning specifically to FIGS. 5 and 6 , the inner hanger 22 is made preferably from a relatively flexible material, such as sheet steel, and includes the body 28 configured to have a substantially “C” shape particularly convenient for gripping by the serviceman. The body 28 extends between a bottom 36 and the recessed inner ends formed with multiple hook portions 34 , each pair of which defines therebetween a respective one of the fingers 30 .
[0026] The bottom 36 of the body 28 is formed with a U-shaped or rectangular indent 37 interrupting an otherwise curved inner surface of the body 28 and extending outwards to support a pair of pins or rivets 42 and 42 ′, which are either fixed to the inner hanger 22 or removably attached thereto. The pin 42 extending through both the inner and outer hangers serves as the axis of rotation C-C of the hangers relative to one another. The other pin 42 ′ functions as an anchor frictionally engaging the outer hanger 24 in the deployed position of the holder 20 , as will be explained below. One of the reasons for forming the indent 37 is to allow the pins 42 and 42 ′ to have a sufficient length without excessively penetrating the space within the interior of the body 28 , which is configured to receive a cable, this preventing inadvertent damage to the cable.
[0027] The outer side of the indent 37 serves as a support surface for the outer hanger 24 and carriers a plate 38 attached to this hanger by the pins 42 and 42 ′. To prevent displacement of the hangers beyond the deployed position of the cable holder 20 , the plate 38 is formed with a hook 40 configured to engage and subsequently stop the outer hanger 24 in the deployed position, as will be explained hereinbelow.
[0028] As illustrated in FIG. 7 , the outer hanger 24 is formed with a body having a pair of arms 26 , which, like the body 28 of the inner hanger, are made from flexible material to conform to variously dimensioned cables locked between the arms 26 . The arms 26 each have a respective outwardly concave region, configured to conform to an opposing segment of cable, and a pair of planar or inwardly convex inner 44 , 48 and axially opposite outer free end regions 50 , 52 . The inner regions 44 , 48 are bridged to form a bottom 64 juxtaposed with the plate 38 and coupled thereto by the pin 42 so that the hangers 22 , 24 , as discussed above, rotate relative to each other. The opposite outer free end regions 50 , 52 are biased away from one another and capable of yielding to a compressing force applied by the serviceman after a respective cable is positioned between the concave portions of the arms 26 .
[0029] In use, when the inner hanger 22 receives a respective cable, the serviceman applies a compressive force to the body 28 engaging thus the fingers 30 with the support. During the attachment of the inner hanger 22 , the outer hanger 24 is displaced to the installation position of FIG. 4 , and, after the inner hanger has been mounted to the support, is rotated towards the deployed position about the pin 42 . As the outer hanger rotates, its bottom 64 engages the pin 42 ′ extending outwards from the plate 38 at a distance sufficient to prevent displacement of the outer hanger towards the deployed position unless a sufficient torque is applied thereto to overcome the pin's resistance. Having overcome this resistance, the bottom 64 of the outer hanger 24 continues to frictionally slide relative to the plate 38 until the pin 42 ′ snaps into an opening 66 ( FIG. 7 ) formed in the bottom 64 , preventing thus further displacement of the hangers. To ensure that the hangers are locked in the deployed position, the hook 40 of the plate 38 extends through and engages recesses 46 ( FIG. 7 ) of the inner end regions 44 , 48 of the outer hanger 24 . Disengagement of the hangers 22 , 24 is realized by initially applying a slight force directed so that the hangers are forced away from another along the axis of symmetry S-S ( FIG. 4 ), and subsequently, by applying a torque force to rotate to the installation position. While the plate 38 has been disclosed as attached to the inner hanger 22 , the inventive holder 20 can be easily modified so that the plate 38 is mounted to the outer hanger 24 .
[0030] Locking of the cable in the outer hanger 24 can be realized by various means, one of which is illustrated in FIGS. 3, 4 and 7 and includes multiple lugs 56 , 58 and a locking member 54 engaging the lugs upon compressing the outer regions 50 , 52 of the outer hanger. Structurally, the locking member 54 can be brought into engagement either with a pair of spaced apart side lugs 56 formed on the terminal portion of the end region 52 or the central lug 58 depending on a diameter of a cable. If this diameter is relatively small, the locking member 54 engages the central lug 58 spaced axially inwards from the side lugs 56 so that the inner surfaces of the concave portions of the arms 26 are compressed relatively close to one another to abut the received cable. However, if the cable to be locked has a relatively large diameter, the locking member will engage the pair of side lugs 56 . As can be seen in FIG. 7 , the locking member 54 is configured as a frame rotatably mounted on the outer end region 50 of the outer hanger 24 . A specific shape and concrete dimensions of the locking member can be modified in response to the locking requirements.
[0031] The hangers 22 and 24 are subject to substantial loads generated by the cables and, thus, should be sufficiently reinforced not to deform as a result of these loads. Accordingly many components of the hangers may be provided with reinforcing ribs, such a rib 60 formed on the arms 26 of the outer hanger 24 , as shown in FIG. 7 .
[0032] Turning to FIG. 8 , a further embodiment of the invention, while utilizing the main concept including displacement of the hangers relative to one another, realizes this in a manner different from the embodiment shown in FIGS. 3-7 . Instead of rotating about the rotation axis C-C ( FIG. 4 ), the cable holder of FIG. 8 is characterized by linear motion of the inner 22 and outer 24 hangers relative to each other. In particular, one of the hangers, for example the inner hanger 22 , may be provided with an outwardly extending bottom portion 62 split in half and forming a recess 70 which is shaped and dimensioned to slidably receive a T-shaped flange 62 ′ configured complementary to the inner surface of the recess. In use, upon inserting the flange 62 ′ into the recess 70 , the hangers can slide relative to one another between the deployed position, in which the hangers coaxially extend along an axis of symmetry S″-S″, and the installation position, in which the outer hanger is displaced so that the body of the inner hanger is substantially unobstructed. The positions of the T-shaped flange 62 ′ and the bottom portion 62 can be reversed.
[0033] It will be understood that various modifications may be made to the embodiments disclosed herein which can find a variety of applications expanding the scope of the invention beyond the disclosed coupling of cables. For example, the inventive holder can be utilized for installing elongated objects, such as pipes or tubes and a variety of transmission lines. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.
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A cable holder for securing multiple elongated objects to a support has a plurality of inner and outer hangers fixedly attached to one another and each configured to receive a respective one of the multiple elongated objects. The inner and outer hangers are displaceable relative to one another so that the outer hanger does not block the inner hanger during attachment of the latter to a support.
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BACKGROUND OF THE INVENTION
The present invention is related to the following Ser. Nos. 11/586,050 & 11/586,087, filed on Oct. 25, 2006, Nov. 5, 2006, respectively.
The present invention relates to airfoils for a rotor blade of a gas turbine. In particular, the invention relates to compressor airfoil profiles for various stages of the compressor. In particular, the invention relates to compressor airfoil profiles for either inlet guide vanes, rotors, or stators at various stages of the compressor.
In a gas turbine, many system requirements should be met at each stage of a gas turbine's flow path section to meet design goals. These design goals include, but are not limited to, overall improved efficiency and airfoil loading capability. For example, and in no way limiting of the invention, a blade of a compressor stator should achieve thermal and mechanical operating requirements for that particular stage. Further, for example, and in no way limiting of the invention, a blade of a compressor rotor should achieve thermal and mechanical operating requirements for that particular stage.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with one exemplary aspect of the instant invention, an article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
In accordance with another exemplary aspect of the instant invention, a compressor comprises a compressor wheel. The compressor wheel has a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an airfoil shape. The airfoil comprises a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
In accordance with yet exemplary another aspect of the instant invention, a compressor comprises a compressor wheel having a plurality of articles of manufacture. Each of the articles of manufacture includes an airfoil having an uncoated nominal airfoil profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in TABLE 1, wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic exemplary representation of a compressor flow path through multiple stages of a gas turbine and illustrates an exemplary airfoil according to an embodiment of the invention;
FIGS. 2 and 3 are respective perspective exemplary views of a rotor blade according to an embodiment of the invention with the rotor blade airfoil illustrated in conjunction with its platform and its substantially or near axial entry dovetail connection;
FIGS. 4 and 5 are side elevational views of the rotor blade of FIG. 2 and associated platform and dovetail connection as viewed in a generally circumferential direction from the pressure and suction sides of the airfoil, respectively;
FIG. 6 is a cross-sectional view of the rotor blade airfoil taken generally about on line 6 - 6 in FIG. 5 ;
FIG. 7 is a perspective views of a rotor blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon; and
FIG. 8 is a perspective view of a stator blade according to an exemplary embodiment of the invention with coordinate system superimposed thereon.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, FIG. 1 illustrates an axial compressor flow path 1 of a gas turbine compressor 2 that includes a plurality of compressor stages. The compressor stages are sequentially numbered in the Figure. The compressor flow path comprises any number of rotor stages and stator stages, such as eighteen. However, the exact number of rotor and stator stages is a choice of engineering design. Any number of rotor and stator stages can be provided in the combustor, as embodied by the invention. The seventeen rotor stages are merely exemplary of one turbine design. The eighteen rotor stages are not intended to limit the invention in any manner.
The compressor rotor blades impart kinetic energy to the airflow and therefore bring about a desired pressure rise across the compressor. Directly following the rotor airfoils is a stage of stator airfoils. Both the rotor and stator airfoils turn the airflow, slow the airflow velocity (in the respective airfoil frame of reference), and yield a rise in the static pressure of the airflow. The configuration of the airfoil (along with its interaction with surrounding airfoils), including its peripheral surface provides for stage airflow efficiency, enhanced aeromechanics, smooth laminar flow from stage to stage, reduced thermal stresses, enhanced interrelation of the stages to effectively pass the airflow from stage to stage, and reduced mechanical stresses, among other desirable aspects of the invention. Typically, multiple rows of rotor/stator stages are stacked in axial flow compressors to achieve a desired discharge to inlet pressure ratio. Rotor and stator airfoils can be secured to rotor wheels or stator case by an appropriate attachment configuration, often known as a “root”, “base” or “dovetail” (see FIGS. 2-5 ).
A stage of the compressor 2 is exemplarily illustrated in FIG. 1 . The stage of the compressor 2 comprises a plurality of circumferentially spaced rotor blades 22 mounted on a rotor wheel 51 and a plurality of circumferentially spaced stator blades 23 attached to a static compressor case 59 . Each of the rotor wheels is attached to aft drive shaft 58 , which is connected to the turbine section of the engine. The rotor blades and stator blades lie in the flow path 1 of the compressor. The direction of airflow through the compressor flow path 1 , as embodied by the invention, is indicated by the arrow 60 ( FIG. 1 ). This stage of the compressor 2 is merely exemplarily of the stages of the compressor 2 within the scope of the invention. The illustrated and described stage of the compressor 2 is not intended to limit the invention in any manner.
The rotor blades 22 are mounted on the rotor wheel 51 forming part of aft drive shaft 58 . Each rotor blade 22 , as illustrated in FIGS. 2-6 , is provided with a platform 61 , and substantially or near axial entry dovetail 62 for connection with a complementary-shaped mating dovetail, not shown, on the rotor wheel 51 . An axial entry dovetail, however, may be provided with the airfoil profile, as embodied by the invention. Each rotor blade 22 comprises a rotor blade airfoil 63 , as illustrated in FIGS. 2-6 . Thus, each of the rotor blades 22 has a rotor blade airfoil profile 66 at any cross-section from the airfoil root 64 at a midpoint of platform 61 to the rotor blade tip 65 in the general shape of an airfoil ( FIG. 6 ).
To define the airfoil shape of the rotor blade airfoil, a unique set or loci of points in space are provided. This unique set or loci of points meet the stage requirements so the stage can be manufactured. This unique loci of points also meets the desired requirements for stage efficiency and reduced thermal and mechanical stresses. The loci of points are arrived at by iteration between aerodynamic and mechanical loadings enabling the compressor to run in an efficient, safe and smooth manner.
The loci, as embodied by the invention, defines the rotor blade airfoil profile and can comprise a set of points relative to the axis of rotation of the engine. For example, a set of points can be provided to define a rotor blade airfoil profile.
A Cartesian coordinate system of X, Y and Z values given in the Table below defines a profile of a rotor blade airfoil at various locations along its length. The airfoil, as embodied by the invention, could find an application as a 4 th stage airfoil variable stator blade. The coordinate values for the X, Y and Z coordinates are set forth in inches, although other units of dimensions may be used when the values are appropriately converted. These values exclude fillet regions of the platform. The Cartesian coordinate system has orthogonally-related X, Y and Z axes. The X axis lies parallel to the compressor blade's dovetail axis, which is at a angle to the engine's centerline, as illustrated in FIG. 7 for a rotor and FIG. 8 for a stator. A positive X coordinate value is axial toward the aft, for example the exhaust end of the compressor. A positive Y coordinate value directed normal to the dovetail axis. A positive Z coordinate value is directed radially outward toward tip of the airfoil, which is towards the static casing of the compressor for rotor blades, and directed radially inward towards the engine centerline of the compressor for stator blades.
For reference purposes only, there is established point- 0 passing through the intersection of the airfoil and the platform along the stacking axis, as illustrated in FIG. 5 . In the exemplary embodiment of the airfoil hereof, the point- 0 is defined as the reference section where the Z coordinate of the table above is at 0.000 inches, which is a set predetermined distance from the engine or rotor centerline.
By defining X and Y coordinate values at selected locations in a Z direction normal to the X, Y plane, the profile section of the rotor blade airfoil, such as, but not limited to the profile section 66 in FIG. 6 , at each Z distance along the length of the airfoil can be ascertained. By connecting the X and Y values with smooth continuing arcs, each profile section 66 at each distance Z can be fixed. The airfoil profiles of the various surface locations between the distances Z are determined by smoothly connecting the adjacent profile sections 66 to one another, thus forming the airfoil profile. These values represent the airfoil profiles at ambient, non-operating or non-hot conditions and are for an uncoated airfoil.
The table values are generated and shown to three decimal places for determining the profile of the airfoil. There are typical manufacturing tolerances as well as coatings, which should be accounted for in the actual profile of the airfoil. Accordingly, the values for the profile given are for a nominal airfoil. It will therefore be appreciated that +/− typical manufacturing tolerances, such as, +/− values, including any coating thicknesses, are additive to the X and Y values. Therefore, a distance of about +/− 0.160 inches in a direction normal to any surface location along the airfoil profile defines an airfoil profile envelope for a rotor blade airfoil design and compressor. In other words, a distance of about +/− 0.160 inches in a direction normal to any surface location along the airfoil profile defines a range of variation between measured points on the actual airfoil surface at nominal cold or room temperature and the ideal position of those points, at the same temperature, as embodied by the invention. The rotor blade airfoil design, as embodied by the invention, is robust to this range of variation without impairment of mechanical and aerodynamic functions.
The coordinate values given in TABLE 1 below provide the nominal profile envelope for an exemplary 4 th stage airfoil variable stator blade.
TABLE 1
X-LOC
Y-LOC
Z-LOC
1.829
−1.808
−0.003
1.828
−1.81
−0.003
1.826
−1.814
−0.003
1.819
−1.82
−0.003
1.807
−1.825
−0.003
1.783
−1.821
−0.003
1.752
−1.81
−0.003
1.71
−1.797
−0.003
1.659
−1.779
−0.003
1.591
−1.756
−0.003
1.514
−1.729
−0.003
1.432
−1.699
−0.003
1.34
−1.665
−0.003
1.238
−1.626
−0.003
1.126
−1.582
−0.003
1.01
−1.534
−0.003
0.889
−1.482
−0.003
0.765
−1.426
−0.003
0.636
−1.366
−0.003
0.504
−1.301
−0.003
0.368
−1.231
−0.003
0.229
−1.155
−0.003
0.087
−1.073
−0.003
−0.053
−0.988
−0.003
−0.19
−0.899
−0.003
−0.325
−0.807
−0.003
−0.457
−0.71
−0.003
−0.586
−0.609
−0.003
−0.712
−0.503
−0.003
−0.834
−0.394
−0.003
−0.952
−0.281
−0.003
−1.067
−0.164
−0.003
−1.177
−0.044
−0.003
−1.284
0.081
−0.003
−1.381
0.205
−0.003
−1.47
0.328
−0.003
−1.551
0.449
−0.003
−1.624
0.569
−0.003
−1.691
0.686
−0.003
−1.75
0.802
−0.003
−1.804
0.914
−0.003
−1.849
1.02
−0.003
−1.886
1.117
−0.003
−1.916
1.205
−0.003
−1.94
1.283
−0.003
−1.957
1.352
−0.003
−1.97
1.41
−0.003
−1.98
1.461
−0.003
−1.986
1.504
−0.003
−1.988
1.539
−0.003
−1.986
1.568
−0.003
−1.983
1.59
−0.003
−1.979
1.605
−0.003
−1.973
1.618
−0.003
−1.966
1.626
−0.003
−1.959
1.631
−0.003
−1.951
1.634
−0.003
−1.941
1.635
−0.003
−1.928
1.633
−0.003
−1.914
1.628
−0.003
−1.895
1.619
−0.003
−1.872
1.605
−0.003
−1.846
1.585
−0.003
−1.815
1.558
−0.003
−1.781
1.524
−0.003
−1.74
1.484
−0.003
−1.694
1.436
−0.003
−1.641
1.38
−0.003
−1.581
1.316
−0.003
−1.515
1.243
−0.003
−1.442
1.163
−0.003
−1.363
1.075
−0.003
−1.28
0.983
−0.003
−1.193
0.888
−0.003
−1.103
0.789
−0.003
−1.008
0.687
−0.003
−0.91
0.581
−0.003
−0.808
0.472
−0.003
−0.702
0.359
−0.003
−0.595
0.248
−0.003
−0.487
0.137
−0.003
−0.378
0.027
−0.003
−0.268
−0.081
−0.003
−0.157
−0.189
−0.003
−0.045
−0.295
−0.003
0.068
−0.401
−0.003
0.182
−0.506
−0.003
0.297
−0.609
−0.003
0.413
−0.711
−0.003
0.53
−0.812
−0.003
0.644
−0.908
−0.003
0.755
−1
−0.003
0.863
−1.088
−0.003
0.969
−1.17
−0.003
1.071
−1.248
−0.003
1.171
−1.322
−0.003
1.266
−1.392
−0.003
1.359
−1.458
−0.003
1.443
−1.517
−0.003
1.52
−1.57
−0.003
1.588
−1.617
−0.003
1.652
−1.659
−0.003
1.708
−1.696
−0.003
1.752
−1.724
−0.003
1.786
−1.747
−0.003
1.812
−1.764
−0.003
1.829
−1.78
−0.003
1.832
−1.792
−0.003
1.832
−1.8
−0.003
1.831
−1.804
−0.003
1.83
−1.806
−0.003
1.829
−1.807
−0.003
1.822
−1.233
1.307
1.821
−1.235
1.307
1.819
−1.239
1.307
1.813
−1.244
1.307
1.802
−1.25
1.307
1.78
−1.248
1.307
1.752
−1.24
1.307
1.714
−1.228
1.307
1.666
−1.215
1.307
1.605
−1.196
1.307
1.534
−1.175
1.307
1.458
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11.784
1.834
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11.784
1.834
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11.784
1.834
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11.784
1.834
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11.784
1.837
−1.795
13.094
1.837
−1.797
13.094
1.835
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13.094
1.831
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13.094
1.82
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13.094
1.799
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13.094
1.771
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13.094
1.734
−1.798
13.094
1.688
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13.094
1.628
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13.094
1.559
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13.094
1.485
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1.403
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13.094
1.312
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13.094
1.212
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13.094
1.108
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13.094
1
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13.094
0.889
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0.774
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0.534
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13.094
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13.094
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13.094
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13.094
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13.094
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13.094
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13.094
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1.349
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1.435
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1.512
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1.647
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1.704
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13.094
1.783
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1.809
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1.828
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13.094
It will also be appreciated that the exemplary airfoil(s) disclosed in the above Table 1 may be scaled up or down geometrically for use in other similar compressor designs. Consequently, the coordinate values set forth in the Table 1 may be scaled upwardly or downwardly such that the airfoil profile shape remains unchanged. A scaled version of the coordinates in Table 1 would be represented by X, Y and Z coordinate values of Table 1 multiplied or divided by a constant.
While various embodiments are described herein, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made by those skilled in the art, and are within the scope of the invention.
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An article of manufacture having a nominal profile substantially in accordance with Cartesian coordinate values of X, Y and Z set forth in a TABLE 1. Wherein X and Y are distances in inches which, when connected by smooth continuing arcs, define airfoil profile sections at each distance Z in inches. The profile sections at the Z distances being joined smoothly with one another to form a complete airfoil shape.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to telemetry data transmission from a missile to a receiving station. More specifically, the present invention relates to a signal converting circuit for converting a missile's telemetry data which is bi-phase-level data to non-return-to-zero-level data for processing by a receiving station.
2. Description of the Prior Art
A missile's telemetry unit transmits data, including guidance, tracking and other information, in a coded waveform format to a receiving station. The receiving station then processes the information to determine the performance of the missile during flight.
One coded waveform for transmitting information from a missile in flight to a receiving station is identified as Bi-Phase-level coded waveform or Split Phase coded waveform. When the missile's data arrives at the receiving station there is generally a need to convert the data to a second coded waveform format to allow the receiving station to process the data. The coded waveform used at a receiving station to process a missile's flight data is identified as the Non-Return-To-Zero-Level coded waveform.
Accordingly there is a need to provide a signal converter to convert a missile's telemetry data from bi-phase-level data to non-return-to-zero-level data to allow the receiving station to process the data. There is also a need to provide a signal converter which can extract from the missile's bi-phase-level telemetry data a non-return-to-zero-level clock signal.
SUMMARY OF THE INVENTION
The present invention provides a signal converter which fulfills the need for a simplified electronics circuit which converts a bi-phase-level data stream from a missile's telemetry system to non-return-to-zero-level data for processing by a receiving station. The bi-phase-level data stream is input to the asynchronous clear input of a high level detector circuit. When the high level detector circuit detects a high level for more than half of a bit period, the high level detector circuit provides a logic zero pulse at a state S7. If the high level is not at the logic one state for a sufficient time period the high level detector circuit will not reach state s7. If the time period is too short, then the high level detector circuit is reset to state s0.
This high level logic zero pulse occurs whenever the second half of a bit period is high followed by a high in the first half of the following bit period. A sample is taken on the first half of every bit period. A low at the asynchronous input of the high level detector circuit keeps the high level detector circuit at state s0.
An NRZL clock signal generating circuit receives the logic zero pulse and then proceeds through its states s0-s10. When state S1 is reached a clock pulse is provided at the output of the NRZL clock signal generating circuit.
This clock pulse is supplied to a Flip-Flop which also receives the bi-phase-level data stream. The clock pulse then clocks the logic level of the bi-phase-level data stream through the Flip-Flop to its output thereby providing a non-return-to-zero-level coded waveform or data stream.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a detailed electronics circuit diagram of the telemetry bi-phase-level to non-return-to-zero-level signal converter constituting the present invention;
FIG. 2 illustrates a waveform for a telemetry bi-phase-level data stream;
FIGS. 3A-3G illustrate an example of the waveforms occurring at the inputs and outputs of the converter of FIG. 1 during the conversion of bi-phase-level data to non-return-to-zero-level data by the converter of FIG. 1;
FIGS. 4A-4G illustrate an enlarged portion of the waveforms of FIGS. 3A-3G;
FIGS. 5A-5G illustrate another example of the waveforms occurring at the inputs and outputs of the converter of FIG. 1 during the conversion of bi-phase-level data to non-return-to-zero-level data by the converter of FIG. 1; and
FIGS. 6A-6G illustrate a third example of the waveforms occurring at the inputs and outputs of the converter of FIG. 1 during the conversion of bi-phase-level data to non-return-to-zero-level data by the converter of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 there is shown an electronic diagram of the telemetry bi-phase-level to non-return-to-zero-level signal converter 10 constituting the present invention. Signal converter 10 receives a missile's telemetry data which is bi-phase-level (Biφ-L) data and then converts to non-return-to-zero-level (NRZ-L) data for processing by a receiving station.
Bi-phase-level data is data which has a level change occur at the center of every bit. A logic "one" is represented by a one level with a transition to the zero level. A logic "zero" is represented by a zero level with a transition to the one level. FIG. 2A represents a bi-phase-level data stream provided to a receiving station by a missile's telemetry unit which has the following bit pattern "1,0,1,1,0,0,0,1,1,0,1,0". Non-return-to-zero-level data is wherein a logic "one" is represented by a one level and a logic "zero" is represented by a zero level.
Referring to FIGS. 1, 3A-3G and 4A-4G, signal converter 10 receives an externally generated ten megahertz clock signal (FIG. 3A) at its 10 MHz input and a bi-phase-level data stream (FIG. 3B) from a missile's telemetry unit at its BIPHSE -- L input. The ten megahertz clock signal of FIG. 3A is next supplied to the CLOCK input of a high level decoder circuit 12, while the bi-phase-level data stream of FIG. 3B is supplied to the ACLR input (asynchronous clear input) of circuit 12. High level decoder circuit 12 is a state machine which is implemented by the program set forth in Appendix A.
The program language used to generate the program of Appendix A is "ALTERA MAX+PLUSII" commercially available from the Altera Corporation of San Jose, Calif. and is adapted for use with any of the Erasable Programmable Logic Device commercially available from Altera Corporation such as Altera's Model EPM5128-2 Erasable Programmable Logic Device
The ten megahertz clock signal of FIG. 3A causes high level decoder circuit 12 to be clocked from state s0 thru states s1, s2, s3, s4, s5, s6 to state s7 and then return to state s1 whenever the ACLR input to high level decoder circuit 12 is at the logic one state. When high level detector circuit 12 transitions from state s6 to state s7, the HILEV output of high level decoder circuit 12 transitions from the logic one state to the logic zero state. The transition of high level detector circuit 12 from state s7 to state s1 causes the HILEV output of circuit 12 to next transition from the logic zero state to the logic one state.
For example, after the bi-phase-level data stream of FIG. 3B first transitions to a logic one (designated by the reference numeral 30) the bi-phase-level data stream of FIG. 3B will remain at the logic one state for a time period which is sufficient to allow high level detector circuit 12 to transition from state s6 to state s7 and then to state s1 so as to allow circuit 12 to generate at its HILEV output the negative going pulse 60 (FIG. 3F). When the bi-phase-level data stream of FIG. 3B again transitions to the logic one state (reference numeral 32) for a time period which is sufficient to allow high level detector circuit 12 to transition from state s6 to state s7 and then to state s1, circuit 12 will provide at its HILEV output a negative going pulse 62 (FIG. 3F). When the bi-phase-level data stream of FIG. 3B next transitions to the logic one state (reference numeral 34) for a time period which is sufficient to allow high level detector circuit 12 to transition from state s6 to state s7 and then to state s1, circuit 12 will provide at its HILEV output a negative going pulse 64 (FIG. 3F).
At this time it should be noted that high level detector circuit 12 provide a negative going pulse whenever the bi-phase-level data stream of FIG. 3B includes a zero bit which is followed by a one bit so as to provide a time period which is sufficient to allow circuit 12 to transition from state s6 to state s7 and then to state s1. The generation of negative going pulses occurs at reference numerals 30, 32, 34, 36 and 38 as is best by the waveform of FIG. 3F.
Flip-Flop 16 has a CLRN input for receiving an externally generated reset signal which clears Flip-Flop 16 so that the Q output of Flip-Flop 16 is reset to the logic zero state. The negative going pulses of FIG. 3F including pulses 60, 62 and 64 are supplied to the IN input of an NRZL clock signal generating circuit 14 and the HILEV output of telemetry bi-phase-level to non-return-to-zero-level signal converter 10.
The program listing used to implement NRZL clock signal generating circuit 14 is set forth in Appendix B. The program language used to generate the program of Appendix B is "ALTERA MAX+PLUSII" and is also adapted for use with any of the Erasable Programmable Logic Device commercially available from Altera Corporation such as Altera's Model EPM5128-2 Erasable Programmable Logic Device.
As is best illustrated in Appendix B, NRZL clock signal generating circuit 14 is a state machine which is clocked through ten states s0, s1 s2, s3, s4, s5, s6, s7, s8, s9 and s10 by the ten megahertz clock signal of FIG. 3A in the manner set forth in Appendix B.
Referring to lines 21-26 of Appendix B, when NRZL clock signal generating circuit 14 is at state s0 and a logic one is provided to the IN input of circuit 14, NRZL clock signal generating circuit 14 will remain at state s0. If a logic zero is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s0 to state s1.
Referring to lines 27-32 of Appendix B, when NRZL clock signal generating circuit 14 is at state s1 and a logic zero is provided to the IN input of circuit 14, NRZL clock signal generating circuit 14 will remain at state s1. If a logic one is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s1 to state s2.
Referring to lines 33-38 of Appendix B, when NRZL clock signal generating circuit 14 is at state s2 and a logic zero is provided to the IN input of circuit 14, NRZL clock signal generating circuit 14 will return to state s1. If a logic one is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s2 to state s3.
Referring to lines 38-44 of Appendix B, the ten megahertz clock signal of FIG. 3A will next clock circuit 14 from state s3 through states s4, s5, s6 and s7 to state s8.
Referring to lines 44-49 of Appendix B, when circuit 14 is at state s8 and a logic zero is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s8 to state s1. If a logic one is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s8 to state s9.
Referring to lines 50-55 of Appendix B, when circuit 14 is at state s9 and a logic zero is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s9 to state s1. If a logic one is supplied to the IN input of circuit 14, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s9 to state s10.
Referring to lines 56-58 of Appendix B, when circuit 14 is at state s10, the ten megahertz clock signal of FIG. 3A will clock circuit 14 from state s10 to state s1.
Referring to FIGS. 1 and 4A-4G, whenever, NRZL clock signal generating circuit 14 is at state s1 the NRZLCLK output of circuit will provide a logic one pulse (line 60 of Appendix A). As is best illustrated by FIGS. 4C and 4E, when NRZL clock signal generating circuit 14 is at state s1 (FIG. 4E), clock pulses 48, 49, 50, 52 and 54 (FIG. 4C) are provided at the output of circuit 14 and then supplied to the NRZLCLK output of signal converter 10. As shown in FIG. 4C, signal converter 10 provides at its NRZLCLK output the NRZL clock signal of FIG. 4C which includes clock pulses 40, 42, 44, 46 and 47 as well as clock pulses 48, 49, 50, 52, 54 and 56.
The NRZL clock signal of FIG. 3C is supplied to the CLK input of D-type Flip-Flop 16 clocking the bi-phase-level data stream of FIG. 3B through Flip-Flop 16 to its Q output and then to the B input of a multiplexer 18. For example, clock pulses 40, 42, 44, 46, 50 and 54 (FIG. 3C) each clock a logic one of the data stream of FIG. 3B through Flip-Flop 16 to its Q output. In a like manner, clock pulses 47, 48, 49, 52 and 56 (FIG. 3C) each clock a logic zero of the data stream of FIG. 3B through Flip-Flop 16 to its Q output.
When a logic zero is provided through the BIPH -- NRZ input of signal converter 10 to the S (select) input of multiplexer 18 the data supplied to the B input of multiplexer 18 will pass through multiplexer 18 to its Y output and then to the OUT output of signal converter 10. This, in turn, is the non-return-to-zero-level data stream of FIG. 3D and FIG. 4D. Similarly, when a logic one is provided to the S input of multiplexer 18 the data stream of FIG. 3B, which is supplied to the A input of multiplexer 18, will pass through multiplexer 18 to the OUT output of signal converter 10.
Referring to FIGS. 1 and 5A-5G, when high level decoder circuit 12 is first clocked to state s7 (FIG. 5G) and the data stream of FIG. 5B is at the logic one state (reference numeral 81), a negative going pulse (FIG. 5F) is provide at the HILEV output of circuit 12. This negative going pulse is supplied to the IN input of NRZL clock signal generating circuit 14. Since NRZL clock signal generating circuit 14 is at state s2 (FIG. 5E), the next clock pulse of the ten megahertz clock signal of FIG. 5A will result in circuit 14 being clocked from state s2 to state s1 (FIG. 5E). At state S1 NRZL clock signal generating circuit 14 generates the NRZL clock pulse 82 (FIG. 5C).
The NRZL clock pulse 80 was previously generated by NRZL clock signal generating circuit 14 when circuit 14 transition from state S10 to state S1 (FIG. 5E) and the data stream of FIG. 5B was at a logic one (reference numeral 81). Each clock pulse 80 and 82 was generated by circuit 14 during the second half of the time period the data stream of FIG. 5B is first at the logic one state (reference numeral 81).
Referring to FIGS. 1 and 6A-6G, when high level decoder circuit 12 is clocked to state s7 (FIG. 6G) and the data stream of FIG. 6A is at the logic one state (reference numeral 87, a negative going pulse (FIG. 6F) is provide at the HILEV output of circuit 12. This negative going pulse is supplied to the IN input of NRZL clock signal generating circuit 14. Since NRZL clock signal generating circuit 14 is at state s2 (FIG. 6E), the next clock pulse of the ten megahertz clock signal of FIG. 6A will result in circuit 14 being clocked from state s2 to state s1 (FIG. 6E). At state S1 NRZL clock signal generating circuit 14 generates the NRZL clock pulse 86 (FIG. 6C). When circuit 14 previously transitioned from state s10 to state s1 (FIG. 6E) the clock pulse 84 was generated by circuit 14. Each clock pulse 84 and 86 was generated by circuit 14 during the second half of the time period the data stream of FIG. 6B is at the logic one state (reference numeral 87).
From the foregoing it may readily be seen that the present invention comprises a new, unique and exceedingly useful signal converter for converting a missile's telemetry data which is bi-phase-level data to non-return-to-zero-level data which constitutes a considerable improvement over the known prior art. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood within the scope of the appended claims, that the invention may be practiced otherwise than as specifically claimed.
Appendix A______________________________________SUBDESIGN hilevdet .sub.-- aclr :INPUT; .sub.-- hilev :OUTPUT; clock :INPUT;)VARIABLE s : MACHINE OF BITS (.sub.-- hilev,qc,qb,qa) WITH STATES (s0 = b"1000", s1 = b"1000", s2 = b"1011", s3 = b"1010", s4 = b"1110", s5 = b"1111", s6 = b"1101", s7 = b"0101"),BEGINs.clk = clock;s.reset = !.sub.-- aclr;CASE s IS WHEN s0 => s =s1; WHEN s1 => s =s2; WHEN s2 => s =s3; WHEN s3 => s =s4; WHEN s4 => s =s5; WHEN s5 => s =s6; WHEN s6 => s =s7; WHEN s7 => s =s1;END CASE;END;______________________________________
Appendix B______________________________________SUBDESIGN g4.sub.-- aclr :INPUT;tick :OUTPUT;clock :INPUT;in :INPUT;)VARIABLEs : MACHINE OF BITS (qd,qc,qb,qa)WITH STATES (s0,s1,s2,s3,s4,s5,s6,s7,s8,s9,s10);BEGINs.clk = clock;s.reset = !.sub.-- aclr;CASE s ISWHEN s0 =>IF (in) THEN s = s0;ELSE s = s1;END IF;WHEN s1 =>IF (!in) THEN s = s1;ELSE s = s2;END IF;WHEN s2 =>IF (!in) THEN s = s1;ELSE s = s3;END IF;WHEN s3 => s =s4;WHEN s4 => s =s5;WHEN s5 => s =s6;WHEN s6 => s =s7;WHEN s7 => s =s8;WHEN s8 =>IF (!in) THEN s = s1;ELSE s = s9;END IF;WHEN s9 =>IF (!in) THEN s = s1;ELSE s = s10;END IF;WHEN s10 => s =s1;END CASE;tick = (s == s1);END;______________________________________
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A signal converter for converting a bi-phase-level data stream to non-ret-to-zero-level data. The bi-phase-level data stream is input to a detector circuit. When the detector circuit detects a high level for more than half of a bit period, the detector circuit provides a logic zero pulse at a state S7. If the high level is not at the logic one state for a sufficient time period the detector circuit will not reach state s7. If the time period is to short than the detector circuit is reset to state s0. This high level pulse occurs whenever the second half of a bit period is high followed by a high in the first half of the following bit period. A sample is taken on the first half of every bit period. A low at the detector circuit keeps the detector circuit at state s0. A clock signal generating circuit receives the logic zero pulse and then proceeds through its states s0-s10. When state S1 is reached a clock pulse is provided by the clock signal generating circuit. This clock pulse is supplied to a Flip-Flop which also receives the bi-phase-level data stream. The clock pulse then clocks the logic level of the bi-phase-level data stream through the Flip-Flop to its output thereby providing a non-return-to-zero-level coded waveform or data stream.
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FIELD OF THE INVENTION AND RELATED ART
[0001] The present invention relates to a protective member removably attachable between a developer bearing member and a developer regulating member, a development cartridge having the protective member, and a process cartridge having the protective member.
[0002] Here, an image forming apparatus means an apparatus which forms an image on recording medium with the use of an electrophotographic image formation method. It includes, for example, various types of electrophotographic copying machines, electro-photographic printers (LED printers, laser beam printer, etc.), fascimileing machines, word processors, etc.
[0003] A process cartridge means a cartridge, which is removably mountable in the main assembly of an image forming apparatus and has a photoconductive drum and a minimum of a developing means.
[0004] A development unit means a unit made up of a developing means for developing a latent image formed on an electrophotographic photoconductive drum, and auxiliary members therefor.
[0005] As the structure of an image forming apparatus for forming an image on recording medium with the use of an electrophotographic image forming method, the following has been known. That is, a latent image is formed on an electrophotographic photoconductive drum by selectively exposing the numerous points on the peripheral surface of the electrophotographic photoconductive drum, and is developed into a visual image formed of developer, by placing a development unit, which contains developer, in a manner to oppose the latent image. Then, the developer image is transferred onto a recording medium. In the case of a multicolor image forming apparatus, a multicolor image is obtained by carrying out the above described development process and transfer process, for each of the predetermined color components of an intended image.
[0006] Among various developing methods, a contact type developing method, which places a development roller in contact with a photoconductive drum, a jumping type developing method, which maintains a small gap between a development roller and a photoconductive drum, and the like methods, have been well-known. As for a means for reducing the amount of the maintenance work to be carried out by a user, a process cartridge system has been known, according to which the aforementioned development unit is placed in a cartridge removably mountable in the main assembly of an image forming apparatus.
[0007] There have been proposed various auxiliary members as means for maintaining the quality of a development unit, or a process cartridge, between the time when they are shipped from a manufacturer to the time when a user begins to use them. For example, Japanese Laid-open Patent Applications 7-311536 and 2001-290370, U.S. Pat. No. 5,749,026 and U.S. Pat. No. 6,009,287, etc., disclose such structural arrangements that dispose a piece of sheet between a development blade and a development roller.
[0008] In the case of a contact type developing method in which nonmagnetic toner and a development roller are placed in contact with a photoconductive drum in order to form a toner image, it is desired that an elastic roller is employed as the development roller to avoid such a problem that a development roller is scratched or worn by the friction between the development roller and a photoconductive rum. In consideration of the chargeability of a development roller, the elastic layer of a development roller is formed of a single layer of solid rubber, a combination of a single layer of solid rubber and a thin layer of resin coated on the solid rubber layer, or the like.
[0009] There have been known various structural arrangements for keeping a toner supply roller, for example, a sponge roller, and a development blade for regulating the toner layer on a development roller, pressed directly on the peripheral surface of a development roller.
[0010] A development blade is a blade which is placed directly on the peripheral surface of the development roller to form the body of toner on the peripheral surface of a development roller, into a thin layer of toner while frictionally charging the toner (triboelectrical charge). It comprises a metallic member formed of phosphor bronze, stainless steel, carbon steel, or the like, and a pressing means. It is desired that the actual blade portion of the development blade is a piece of thin plate of springy metallic material such as phosphor bronze, stainless steel, carbon steel, or the like, or a piece of thin plate of the same material coated with a resin. A development blade is pressed directly on the peripheral surface of a development roller so that a predetermined amount of contact pressure is generated between the blade and roller. It is always kept in contact with the development roller while the apparatus is in use.
[0011] In a development unit structured so that a development blade is pressed directly on an elastic development roller, the development blade is always kept in contact with the development roller as described above. Thus, while a given portion of the elastic layer of the development roller is in the interface (contact area) between the development roller and development blade, it is kept in a deformed state, by the contact pressure.
[0012] Therefore, the portion of the elastic layer of a development roller, which remains in the contact area between a development blade and development roller while a development unit is left unused for a substantial length of time, for example, from the time when a development unit is shipped from the manufacturer to the time when an end user begins to use it, this portion of the elastic layer of the development roller sometimes fails to restore its original shape. The degree of failure, of course, is affected by various factors, for example, the vibrations, shocks, temperature, humidity, etc., to which the development unit is subjected while it remains unused.
[0013] If an end user begins to use an image forming apparatus before the deformed portion of the development roller therein fully restores its original shape, the contact pressure between the development blade and development roller slightly changes as the deformed portion of the development roller passes the contact area between the development blade and development roller, and the change in the contact pressure affects the thickness of the toner layer, toner properties in terms of electrical charge, etc., sometimes resulting in the formation of an image suffering from horizontal lines, the intervals of which correspond to the rotational cycle of the development roller.
SUMMARY OF THE INVENTION
[0014] The primary object of the present invention is to provide: a protective member capable of controlling or preventing the compressional deformation or distortion of a development roller or a developer regulating member, during the distribution of a development cartridge or a process cartridge from the factory; a development cartridge employing such a protective member; and a process cartridge employing such a protective member.
[0015] Another object of the present invention is to provide: a protective member which is capable of controlling or preventing the compressional deformation or distortion of a development roller or a developer regulating member, during the distribution of a development cartridge or a process cartridge from the factory, and which can be easily inserted, or pulled out from, between a development roller and a developer regulating member; a development cartridge employing such a protective member; and a process cartridge employing such a protective member.
[0016] Another object of the present invention is to provide a protective member capable of controlling or preventing the problem that a development roller is charged when the protective member is removed; a development cartridge employing such a protective member; and a process cartridge employing such a protective member.
[0017] Another object of the present invention is to provide a protective member usable for a developing apparatus having: a development roller which is for developing an electrostatic latent image formed on an electrophotographic photoconductive member, and has an elastic roller portion; an axle portion for supporting the elastic roller portion; and a developer regulating member for regulating the amount of the developer allowed to remain adhered to the elastic roller portion, by being placed in contact with the elastic roller portion, comprising: a contacting portion disposed on the development roller side so that it contacts the elastic roller portion when the protective member is removably mounted between the development roller and developer regulating member; a supporting portion for supporting the contacting portion, disposed on the developer regulating member side so that it contacts the developer regulating member when the protective member is removably mounted between the development roller and developer regulating member, wherein the hardness of the contacting portion is no less than a predetermined value, and is no more than the hardness of the elastic roller portion.
[0018] Another object of the present invention is to provide a development cartridge removably mountable in the main assembly of an electrophotographic image forming apparatus and comprising a development roller which is for developing an electrostatic latent image formed on an electrophotographic photoconductive member, and has an elastic roller portion and an axle portion for supporting the elastic roller portion; a developer regulating member for regulating the amount of the developer allowed to remain adhered to the elastic roller portion, by being placed in contact with the elastic roller portion; and a protective member removably disposed between the development roller and developer regulating member, and having a contacting portion disposed on the development roller side so that it contacts the elastic roller portion, and a supporting portion for supporting the contacting portion, disposed on the developer regulating member side so that it contacts the developer regulating member, wherein the hardness of the contacting portion is no less than a predetermined value, and is no more than the hardness of the elastic roller portion.
[0019] Another object of the present invention is to provide a process cartridge removably mountable in the main assembly of an electrophotographic image forming apparatus and comprising: an electrophotographic photoconductive member; a development roller which is for developing an electrostatic latent image formed on an electrophotographic photoconductive member, and has an elastic roller portion and an axle portion for supporting the elastic roller portion; a developer regulating member for regulating the amount of the developer allowed to remain adhered to the elastic roller portion, by being placed in contact with the elastic roller portion; and a protective member removably disposed between the development roller and developer regulating member, and having a contacting portion disposed on the development roller side so that it contacts the elastic roller portion, and a supporting portion for supporting the contacting portion, disposed on the developer regulating member side so that it contacts the developer regulating member, wherein the hardness of the contacting portion is no less than a predetermined value, and is no more than the hardness of the elastic roller portion.
[0020] These and other objects, features, and advantages of the present invention will become more apparent upon consideration of the following description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a schematic sectional view of the developing apparatus in the first embodiment of the present invention.
[0022] [0022]FIG. 2 is an enlarged sectional view of the essential portion of the developing apparatus in the first embodiment of the present invention.
[0023] [0023]FIG. 3 is a schematic drawing of the pressure distributing member in the first embodiment of the present invention.
[0024] [0024]FIG. 4 is a graph showing the results of the studies of the first embodiment of the present invention.
[0025] [0025]FIG. 5 is a graph showing also the results of the studies of the first embodiment of the present invention.
[0026] [0026]FIG. 6 is a schematic sectional view of the developing apparatus in the second embodiment of the present invention.
[0027] [0027]FIG. 7 is a schematic sectional view of an image forming apparatus employing the developing apparatus in the second embodiment of the present invention.
[0028] [0028]FIG. 8 is a sectional view of the development cartridge, in the third embodiment of the present invention, into which a protective member is being inserted.
[0029] [0029]FIG. 9 is a detailed sectional view of the protective member (pressure distributing member formed of urethane foam) in the third embodiment of the present invention.
[0030] [0030]FIG. 10 is a detailed sectional view of another protective member (pressure distributing member formed of soft resin) in the third embodiment of the present invention.
[0031] [0031]FIG. 11 is a detailed sectional view of the contact area, between a development blade and a development roller, with the presence of no protective member between the blade and roller.
[0032] [0032]FIG. 12 is a detailed sectional view of the contact area, between a development blade and a development roller, with the presence of a protective member between the blade and roller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] Hereinafter, the preferred embodiments of the present invention will be described in detail with reference to the appended drawings. In the following descriptions, however, the measurements, materials, and shapes of the structural components in the embodiments, their positional relationships, etc., are not intended to limit the scope of the present invention, unless specifically noted.
[0034] (Embodiment 1)
[0035] Referring to FIGS. 1 and 2, the developing apparatus in the first embodiment of the present invention will be described.
[0036] Referring to FIG. 1, a rotational drum R 1 as a member for bearing an electrostatic latent image, is rotated in the direction indicated by an arrow mark A, whereas a development roller 1 as a member for bearing developer is rotated in the direction indicated by an arrow mark B. A blade 2 as a developer regulating means is positioned so that it regulates the amount of the developer on the peripheral surface of the sleeve (development roller). The developer 3 in a container 4 is conveyed to a developer bearing member 1 by a developer supplying member 5 , which is rotated in the direction indicated by an arrow mark C. During this conveyance, the developer 3 is electrically charged by the friction between the developer 3 and the combination of the developer supplying member 5 and developer bearing member 1 , adhering thereby to the peripheral surface of the developer bearing member 1 . The developer 3 on the peripheral surface of the developer bearing member 1 is conveyed by the rotation of the developer bearing member 1 , to the interface (contact area) between the developer bearing member 1 and a developer regulating means 2 , in which it is regulated by the contact pressure between the developer regulating means 2 and developer bearing member 1 , in the amount by which it is further conveyed. After being regulated in the amount by which it is further conveyed, the developer 3 is conveyed to the development area, that is, the interface (contact area) between the electrostatic latent image bearing member R 1 and developer bearing member 1 .
[0037] The developer 3 having been frictionally charged is conveyed to the exposed points of the latent image on the electrostatic latent image bearing member R 1 by the electric field generated between the electrostatic latent image bearing member R 1 and developer bearing member 1 . The developer 3 which remained on the developer bearing member 1 is recovered by a developer supply member 5 into a container 4 .
[0038] [0038]FIG. 2 is an enlarged sectional view of the contact area between the developer bearing member 1 and regulating means 2 , with the presence of the protective member between the two means 1 and 27 , for describing in detail the first embodiment of the present invention.
[0039] Referring to FIG. 2, before the developing apparatus is used for the very first time, the protective member 7 is to be pulled out of the developing apparatus in the direction indicated by an arrow mark E, so that the peripheral surface of the developer bearing member 1 comes into contact with the regulating means 2 .
[0040] The protective member 7 in this embodiment is different from a conventional protective member in that it is made up of a foamed portion 8 , as a member which contacts the developer (or developer bearing member), and a sheet 9 as a member for supporting the foamed portion 8 . The foamed portion 8 is formed of high polymer.
[0041] Also referring to FIG. 2, the protective member 7 is inserted into the contact area between the developer bearing member 1 and regulating means 2 in such a manner that the foamed portion 8 formed of high polymer contacts the developer bearing member 1 , whereas the sheet 9 contacts the regulating means 2 .
[0042] In this embodiment, a piece of phosphor bronze which is 0.1 mm in thickness is employed as the regulating means, and the developer bearing member 1 is formed of an elastic material such as rubber.
[0043] In consideration of the degree of ease with which the foamed portion 8 formed of polymer can be inserted or pulled out, and the effectiveness of the foamed portion 8 as a pressure distributing member, the thickness of the foamed portion 8 is desired to be in the range of 0.5-2 mm. In order to prevent the regulating means 2 from being damaged when the protective member 7 is pulled out when the development unit is used for the first time, the material for the sheet 9 is desired to be low in friction.
[0044] The hardness of the developer bearing member 1 in this embodiment was in the range of 45°-55° (Asker C scale).
[0045] Then, the correlation between the hardness (Asker C scale) of the protective member 7 and the level of the image imperfection resulting from the compressional deformation of the developer bearing member 1 was examined. The method used for the examination was as follows. Several foamed members 8 different in hardness were prepared as the protective member to be sandwiched between a development blade and a development roller. Then, the images formed with the use of the foamed members 8 different in hardness were examined in terms of the imperfections traceable to the compressional deformation of the developer bearing member 1 .
[0046] The results of the examination are given in FIG. 4. The axis of abscissa represents the hardness of the foamed high polymer portion 8 , and the axis of ordinates represents the level of image imperfection resulting from the compressional deformation of the developer bearing member 1 , which occurred in the contact area between the regulating member 2 and developer bearing member 1 .
[0047] To describe the level of the compressional deformation of the developer bearing member 1 in terms of the image quality, ◯ represents the level at which no image imperfection occurred, and Δ represents the level at which slight image imperfection occurred only at the initial stage of the very first usage of the development unit (deformed portion of development roller fully recovered to the condition in which it did not cause any image imperfection in practical terms. X represents the level at which the development roller never completely recovered to the condition in which it can form an image free of imperfection. The combination of ◯ and Δ, and the combination of Δ and X, represent corresponding intermediary levels.
[0048] The results show that when a foamed high polymer portion 8 , the hardness of which was in the range of 5°-40° was used, the image imperfection traceable to the compressional deformation of the elastic developer bearing member 1 did not occur; excellent images were obtained. This proved that the hardness range of 5°-40°was the optimum hardness range for the high polymer foamed portion 8 .
[0049] Further, the correlation between the volume resistivity (Ω·cm) of the protective member 7 and the level of the memory, in terms of the image quality, created in the portion of the development roller, which was in the contact area between the protective member 7 and developer bearing member 1 , when the protective member 7 was pulled out, was studied using the following method. A plurality of protective members 7 different in the volume resistivity of the foamed high polymer portion 8 were prepared. Then, a plurality of developing devices were prepared, which were the same in the surface resistivity, that is, 10 7 Ω, and were different in the volume resistivity of the foamed high polymer portion 8 of the protective member 7 sandwiched between the regulating means 2 and developer bearing member 1 .
[0050] The results of the studies are given in FIG. 5. The axis of abscissa represents the volume resistivity of the foamed high polymer portion 8 , and the axis of ordinates represents the level of the memory, in terms of image quality, which is created by friction in the contact area between the protective member 7 and developer bearing member 1 when the protective member 7 was pulled out, and which resulted in image imperfections.
[0051] To describe the level of the memory, in the terms of image quality, which was caused by the friction between the protective member 7 and resulted in image imperfections, ◯ represents the level at which no image imperfection occurred, and A represents the level at which slight image imperfection occurred only at the initial stage of the very first usage of the development unit (memory virtually disappeared, causing no image imperfection in practical terms. X represents the level at which image imperfections occurred from the beginning of the very first usage of the development unit, and at which the formation of a small number of images could not restore the development roller to the condition in which an image free of imperfection could be formed. The combination of ◯ and Δ, and the combination of Δ and X, represent corresponding intermediary levels.
[0052] The results showed that when the foamed high polymer members 8 , the volume resistivity of which was no more than 10 10 Ω·cm, were employed, no image imperfection resulting from the memory created in the portion of the developer bearing member 1 in the contact area between the foamed high polymer portion 8 and developer bearing member 1 when the protective member 7 was pulled out of the contact area, occurred; excellent images were obtained. This proved that the optimum volume resistivity for the foamed high polymer portion 8 is no more than 10 10 Ω·cm, where the level of the deformation in terms of image quality is Δ or higher.
[0053] (Embodiment 2)
[0054] [0054]FIG. 6 shows the development unit in the second embodiment of the present invention.
[0055] In this embodiment, the developer bearing member 1 , regulating means 2 , developer 3 , container 4 , developer supply member 5 , etc., in the first embodiment are integrally disposed in a container B as a protective shell for these structural components. A protective member 10 employed in this embodiment is also placed between the developer bearing member 1 and developer regulating member 2 as in the first embodiment. The members in this embodiment, which are the same in function those in the first embodiment, are given the same referential symbols as those given in the first embodiment, and will not be described.
[0056] Referring to FIG. 6, the process cartridge in this embodiment is characterized in that it is removably mountable in the main assembly of an image forming apparatus. It is to be mounted into the apparatus main assembly after the removal of its protective member 10 .
[0057] Next, referring to FIG. 7, mounted in the image forming apparatus is a process cartridge B comprising: a photoconductive drum 1 as an image bearing member; a charge roller A 2 as a charging means for uniformly charging the photoconductive drum A 1 ; an exposing apparatus A 3 as an exposing means for forming an electrostatic latent image on the charged portion of the photoconductive drum A 1 ; and a developing means for developing an electrostatic latent image into a visual image with the use of developer. The process cartridge B also comprises a cleaning apparatus A 5 which recovers the small amount of developer remaining on the photoconductive drum A 1 after the transfer of a developer image onto a transfer medium A 4 , by scraping it away from the photoconductive drum A 1 , and recycling it for the following image formation cycles.
[0058] With the employment of the above described process cartridge in this embodiment, it is possible to reduce the amount of time and labor required to maintain the developing means which is substantially greater in wear and tear than the other components, and also to prevent the formation of an image suffering from the image imperfections traceable to the compressional deformation of the developer bearing member 1 , or the memory created when the protective member 10 is pulled out from between the regulating means 2 and developer bearing member 1 .
[0059] As described above, this embodiment of the present invention makes it possible to prevent the formation of an image suffering from the image imperfections traceable to the compressional deformation or distortion of the developer bearing member 1 which occurs during the shipment period, that is, the period from when a development cartridge is shipped out of a factory to when the development cartridge is used for the first time by an end user.
[0060] Further, this embodiment of the present invention makes it possible to eliminate the adverse effects, upon image formation, of the electrostatic memory created in a developer bearing member by the rubbing between the protective member 10 and developer bearing member 1 when the protective member 10 is removed. Therefore, an excellent image can be formed even when the process cartridge is used for the very first time.
[0061] (Embodiment 3)
[0062] Referring to FIGS. 8 - 12 , the outline of the third embodiment of the present invention will be described. FIGS. 8 and 9 are sectional views of the development cartridge, in which the protective member in this embodiment has been properly inserted. FIG. 11 is a sectional view of a development cartridge, in which the protective member has not been inserted.
[0063] Referring to FIG. 8, the protective member 333 comprises: a pressure distributing portion 333 a , as the actual protective portion, having the function of increasing the size of the area across which the contact pressure generated by the development blade 332 and development roller 305 is distributed; and an auxiliary portion 333 b as a supporting portion, to which the pressure distributing portion 333 a is bonded. The protective member 333 is attached to the development cartridge in such a manner that one end of the auxiliary member 333 b is placed in contact with the development blade 332 , with the pressure distributing portion 333 a sandwiched between the auxiliary portion 333 b and development roller 305 . The other end (bonding portion 333 c ) of the auxiliary portion 333 b is attached to the protective cover 360 with the use of a piece of two-sided adhesive tape or the like.
[0064] Thus, during the period from when a process cartridge is manufactured to when the process cartridge is used by an end user for the first time, the contact pressure generated between the development blade 332 and development roller 305 remains distributed across the larger area of the peripheral surface of the development roller 305 to prevent the deformation of the development roller 305 . As for the removal of the protective member 333 , as the protective cover 360 is removed when the process cartridge is used for the first time, the protective member 333 is automatically removed along with the protective cover 360 , preventing thereby the problem that an end user forgets to remove the protective member 333 when the process cartridge is used for the first time.
[0065] Next, the details of the embodiments of the present invention will be described.
[0066] (Pressure Distribution Mechanism)
[0067] First, the pressure distribution mechanism will be described. Referring to FIG. 11, as the development blade 332 is pressed on the development roller 305 so that a contact pressure (linear pressure) of roughly 1.96 N/m (20 gf/cm) is generated, the width of the contact area between the development roller 305 and development blade 332 , becomes roughly 1 mm. Thus, the pressure the development roller 305 receives per unit of surface is approximately 19.6×N/m 2 (2 gf/mm 2 ).
[0068] Thus, the placement of the pressure distributing portion 333 a of the protective member 333 between the development roller 305 and development blade 332 , as shown in FIG. 12, causes the compressional deformation of the pressure distributing portion 333 a . As a result, the width of the area of the development roller 305 , which is subjected to the contact pressure, is increased to approximately 3-5 mm, according to the experiments, which in turn reduces the amount of the contact pressure per unit of area, to which the development roller 305 is subjected, making it possible to control the compression deformation of the development roller 305 .
[0069] (Pressure Distributing Member)
[0070] Next, the pressure distributing portion 333 a , that is, the preferable pressure distributing portion, in this embodiment, will be described in detail. The pressure distributing portion 333 a to be sandwiched between the development roller 305 and development blade 332 is desired to have the following functions, in addition to the pressure distributing function.
[0071] (1) It does not chemically attack other structural components while the process cartridge is in storage for a given length of time;
[0072] (2) It does not become fuzzy on surfaces, when it is subjected to the vibrations, which occur during its shipment or the like; and
[0073] (3) It is superior in operability.
[0074] Further, experiments revealed that the following two structural arrangements were preferable.
[0075] First, it became evident that the usage of urethane foam with the thickness range of 0.5 mm-2 mm, as the material for the pressure distributing portion, as shown in FIG. 9, gave the pressure distributing portion preferable characteristics, not only in terms of pressure distribution, but also in terms of the aforementioned chemical attack-, fuzz, and operability, etc.
[0076] However, when the thickness of urethane foam was no less than 2 mm, it was extremely difficult to insert, or pull out, the protective member. On the other hand, when the thickness of the urethane foam was no more than 0.5 mm, the pressure distributing member was not satisfactorily effective to distribute the contact pressure. Further, when cotton pile, or the like, with a staple length of roughly 1.2 mm was used as the material for the pressure distributing portion, the pressure distributing member was satisfactory in terms of pressure distribution, but the problems regarding the fuzz could not be solved.
[0077] Further, experiments proved that paper, polyethylene-terephthalate sheet, and the like, had virtually no ability to distribute the contact pressure. Thus, urethane foam with the thickness range of 0.5-2 mm is desirable as the material for the actual pressure distributing portion 333 a of the protective member 333 which must meet the requirements that a pressure distributing portion is effective in the contact pressure distribution; does not chemically attack other structural components while the process cartridge is in storage for a given length of time; does not develop fuzz; and is superior in operability.
[0078] Referring to FIG. 10, in one of the experiments, the pressure distributing portion 333 a as a pressure distributing means is formed of a resin such as polyethylene, polypropylene, etc., instead of urethane foam.
[0079] In this case, the radius R 2 of the curvature of the development roller side of the pressure distributing portion 333 a , in terms of the sectional view, was made slightly larger than the radius R 1 of the curvature of the development roller (R 2 >R 1 ). The experiment confirmed that such a structural arrangement had the pressure distributing effect.
[0080] In the case of the protective member having a pressure distributing portion formed of urethane foam, as the protective member was inserted between the development roller 305 and development blade 332 , the pressure distributing portion (urethane foam) was compressed by the contact pressure generated between the development blade 332 and development roller 305 , conforming in shape to the peripheral surface of the development roller 305 . As a result, the contact pressure was distributed across the wider area of the development roller 305 . In comparison, in the case of the protective member having a pressure distributing portion formed of such a resin as polyethylene or polypropylene, the pressure distributing portion is shaped so that it roughly conforms in shape to the peripheral surface of the development roller 305 . This type of protective member was similarly effective for the wider pressure distribution as the protective member having the pressure distributing portion formed of urethane foam.
[0081] (Auxiliary Portion)
[0082] The pressure distributing portion 333 a of the protective member 333 , which is formed of a material such as urethane foam which is made with the use of a foaming agent is relatively large in its friction against the development roller 305 or development blade 332 , and is insufficient in structural strength. Therefore, the pressure distributing portion 333 a alone is difficult to insert when assembling a development cartridge or a process cartridge, and also is difficult to pull out. In other words, it is inferior in terms of operability.
[0083] In comparison, in the case of the pressure distributing portion 333 a molded of a resin, there is the possibility that it comes into contact with the development roller 305 , or that a user forgets to pull it out.
[0084] Therefore, the pressure distributing portion 333 a is integrated with the auxiliary portion 333 b as shown in FIGS. 8 and 9. As for the material for the auxiliary portion 333 b , the experiments showed that when the development blade 332 was a piece of thin springy plate of phosphor bronze, stainless steel, or the like, which was not coated with resin, a sheet of polyethylene-terephthalate with a thickness of approximately 150 μm was preferable.
[0085] Further, the experiments showed that when the surface of the development blade 332 was coated with resin, the auxiliary portion 333 b sometimes damaged the surface of the development blade 332 when the protective member 333 was pulled out. In such a case, it was desired that the area of the auxiliary portion 333 b , which came into contact with the development blade 332 , was coated with a lubricating substance, for example, Teflon (registered commercial name), silicon, or the like. The experiments showed that a separation sheet was preferable as the lubricating means.
[0086] The experiments also showed that in either case, in terms of ease of insertion or extraction, the auxiliary portion 333 b was desired to be placed on the development blade side rather than the development roller side.
[0087] (Integration of Protective Member with Protective Cover)
[0088] For the purpose of improving the protective member 333 in terms of usability, that is, assuring that the protective member 333 can be easily pulled out by a user, the protective member 333 may be integrated with the protective cover 306 ; the portion of the protective member 333 opposite to the edge portion sandwiched between the development blade 332 and development roller 305 may be bonded to the protective cover 306 . With the integration of the protective member 333 with the protective cover 306 , it is assured without asking for a particular attention from a user that the protective member 333 will be removed.
[0089] (Structure of Protective Member (Bonding of Various Portions))
[0090] As described above, the protective member 333 has the pressure distributing portion 333 a and auxiliary portion 333 b . It is structured so that, as it is inserted, the pressure distributing portion 333 a contacts the development roller 305 , and the auxiliary portion 333 b contacts the development blade 332 , and that it is attached to the protective cover 360 by the edge portion opposite to the edge portion to be sandwiched between the development roller 305 and development blade 332 .
[0091] As the means (bonding layer 333 c ) for attaching the pressure distributing portion 333 a to the auxiliary portion 333 b , and the means for attaching the auxiliary portion 333 b to the protective cover 306 , two-sided adhesive tape was used. This does not mean that the bonding agent is limited to two-side adhesive tape. For example, bonding means such as hot-melt or adhesive may be used as long as they do not chemically attach other structural components such as the development roller, photoconductive drum, etc., and are sufficient in adhesive strength. Further, there is no specific restriction regarding the areas of the pressure distributing portion 333 a and auxiliary portion 333 b by which they are attached, as long as the two portions 333 a and 333 b do not become separated from where they are attached.
[0092] Up to this point, the embodiments of the present invention have been described with reference to a color image forming apparatus. This does not mean that the application of the present invention is to be limited to a color image forming apparatus. In other words, the present invention is applicable to any structural arrangement in which the protective member 333 for more widely distributing the contact pressure generated between the development roller 305 and development blade 332 across the peripheral surface of the development roller 305 , is inserted between the development blade 332 and development roller 305 in a manner to be sandwiched by the blade 332 and roller 305 , which is needless to say.
[0093] As described above, according to the embodiments of the present invention, it is possible to keep more widely distributed, the contact pressure between a development blade and development roller, from when a process cartridge or a development unit is manufactured to when the process cartridge or development unit is used for the first time by an end user. Therefore, the compressional deformation of a development roller caused by the contact pressure between a development blade and a development roller can be prevented, making it possible to form an excellent image.
[0094] As is evident from the descriptions given above, according to the present invention, it is possible to control or prevent the problem that a development roller and/or a developer regulating member is deformed or distorted by the contact pressure generated between them.
[0095] Further, according to the present invention, a protective member is designed so that its supporting portion for supporting its pressure distributing portion contacts the developer regulating member. Therefore, the protective member can be easily inserted, or pulled out from, between the development roller and developer regulating member.
[0096] While the invention has been described with reference to the structures disclosed herein, it is not confined to the details set forth, and this application is intended to cover such modifications or changes as may come within the purposes of the improvements or the scope of the following claims.
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A developing cartridge detachably mountable to a main assembly of an electrophotographic image forming apparatus, the developing cartridge includes a developing roller, for developing an electrostatic latent image formed on an electrophotographic photosensitive member, having an elastic roller portion and a shaft portion supporting the elastic roller portion, a developer regulating member contactable to the elastic roller portion to regulate an amount of the developer deposited on the elastic roller portion; a protecting member including a contact portion provided at a side for contact with the elastic roller portion when the protecting member is demountably mounted between the developing roller and the developer regulating member; and a supporting portion for supporting the contact portion, the supporting portion being provided at a side for contact with the elastic roller portion when the protecting member is demountably mounted between the developing roller and the developer regulating member, wherein the contact portion has a hardness which is not less than a predetermined value and not more than a hardness of the elastic roller portion.
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FIELD OF THE INVENTION
[0001] The present invention relates to a warning device, and in particular, to a warning device without dead zones, i.e. a warning device capable of illuminating at different angles.
BACKGROUND OF THE INVENTION
[0002] Warning devices of different kinds are commonly seen in our daily lives; road block and triangular warning frame, for example, are just two of commonly seen warning devices. The technology used in these warning devices are also starkly different, some using reflective materials and others using electronic device of flashing LED (light-emitted diode). Basically, the aim is to attract strong visual attention to send warning signals.
[0003] Conventional prior art of warning devices, “Warning Frame,” ROC Pat. No. 424,812, for example, is a taper structure without illuminating. Also, “Warning Frame,” ROC Pat. No. 335,201, is installed by hanging such that illuminating bodies swing with wind. Furthermore, “Warning Frame on Vehicle Roof,” ROC Pat. No. 454,717, discloses a warning structure similar to a windmill rotating in the wind.
[0004] LED flashing lights installed in the triangular warning frame somehow do not exhibit the full potential of LED since conventional triangular warning frame has only one warning face.
[0005] It is therefore necessary to have a warning device with novel design. With long time experience in designing, production, and marketing warning devices, the applicant proposes the present “Warning Device” after numerous experiments.
SUMMARY OF THE INVENTION
[0006] To further explain the details of a warning device according to the present invention, please first refer to the schematic figures, wherein FIG. 1 is an exploded perspective view of a preferred embodiment of a warning device according to the present invention, FIG. 2 is a perspective assembly view of a warning device according to the present invention, and FIG. 3 is a schematic illustration of another embodiment of a warning device according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention can be more fully understood by reference to the following description and accompanying drawings, in which:
[0008] FIG. 1 is an exploded perspective view of a preferred embodiment of a warning device according to the present invention;
[0009] FIG. 2 is a perspective assembly view of a warning device according to the present invention; and
[0010] FIG. 3 is a schematic illustration of another embodiment of a warning device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The warning device, as shown in the figures, comprises a lower brace 1 , an upper brace 2 , and three luminous discharge tubes 3 . The lower brace 1 is a long bar with a lower brace leg 11 extending downward on the both ends of the lower brace 1 , respectively, and in the middle of the lower brace 1 is provided with a bottom hole 12 of which inner wall is provided with female thread 13 . To achieve better a better stability, the lower brace 1 is made of material with higher density, for example but not limited to, metal.
[0012] The upper brace 2 , similar to the lower brace 1 , is provided with an upper brace leg 21 on the both ends of the upper brace 2 , respectively, and in the middle of the upper brace 2 is provided a connector 22 for locating with the bottom hole 12 . The connector 22 may be a hole with threads and further engaged with a screw, may be a screw extending downward and further engaged with the bottom hole 12 by a nut, or may simply be a rod passing through the bottom 12 , which are a conventional prior art and will not discussed further.
[0013] To facilitate the supply and control of power, an electric device 23 provided on the bottom of the upper brace 2 , comprises at least an electric circuit, a battery, and a controlling switch, which is a conventional prior art and will not discussed further. Furthermore, the both ends of the upper brace 2 are provided with a sleeve 24 , respectively, extending upward. One of the sleeves 24 is connected and electricly contacted with a protruding rod 31 provided on a luminous discharge tube 3 described later.
[0014] The luminous discharge tubes 3 are tubes of, preferably but not limited to, circular cross section, comprising at least three tubes. Both ends of the luminous discharge tubes 3 are provided with connectors such that the luminous discharge tubes 3 can be connected together to form a loop. In one embodiment of the present invention, the three luminous discharge tubes 3 form a triangular shape. The connection between the luminous discharge tubes 3 is a secured connection, which is also easy to disconnect, and the connectors for the connection between the luminous discharge tubes 3 are electric terminals. Furthermore, the lower and horizontal luminous discharge tube 3 is provided with a protruding rod 31 on both ends, respectively. One of the protruding rods 31 is connected and electricly contacted with the sleeve 24 and easily detachably connected with the upper brace 2 described earlier. For the aspect of easy disconnection, a fastener may be provided for securing the connection, which is a conventional prior art and will not discussed further.
[0015] The luminous discharge tube 3 is preferably made of material pervious to light. The color of the luminous discharge tube 3 is, for example but not limited to, red. To enhance the warning effect, the inner wall of the luminous discharge tube 3 may be deposited with reflective cloth 32 . To illuminate light, a light source 33 , LED for example, may be provided to achieve a flashing effect. Consequently, the electric device 23 may be provided with a flashing light circuit, which is a conventional prior art and will not be discussed further.
[0016] Referring to FIG. 2 , when the warning device being assembled, the luminous discharge tubes 3 are connected together and electricly contacted with each other. The lower brace 1 is also connected with the upper brace 2 , which is further connected with the horizontal luminous discharge tube 3 to form a condition of being able to be placed at proper location. When the power is supplied, the luminous discharge tubes 3 can emit light.
[0017] The luminous discharge tubes 3 are tubular shapes without been shielded. Consequently, the light emitted form the luminous discharge tubes 3 can be seen at different angles, which cannot be achieved in conventional prior arts and can be considered as an innovation.
[0018] When the warning device according to the present invention is implemented, the upper brace 2 and the lower brace 1 may be replaced with a single upper brace 2 , which is made of heavier material and can support the whole structure in the upright condition.
[0019] Referring to FIG. 3 , another embodiment of the warning device according to the present invention is provided with two lower braces 1 , which are disposed on the both sides of the upper brace 2 , respectively. The lower braces 1 can be retracted back for storing or extended out for forming a frame by rotating.
[0020] While the invention has been described with reference to the a preferred embodiment thereof, it is to be understood that modifications or variations may be easily made without departing from the spirit of this invention, which is defined by the appended claims.
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A warning device is disclosed, including an upper brace comprising an electric device and an output terminal; at least three luminous discharge tubes, which are pervious to light, provided with light sources and interconnected with each one another to form a loop and to establish electric contact. One of the tubes is connected with the output terminal described above to enable the illumination without shielding.
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[0001] This application is a continuation of U.S. patent application Ser. No. 10/150,591, entitled “Delivery of Antiemetics Through an Inhalation Route,” filed May 17, 2002, Rabinowitz and Zaffaroni, which claims priority to U.S. provisional application Serial No. 60/294,203 entitled “Thermal Vapor Delivery of Drugs,” filed May 24, 2001, Rabinowitz and Zaffaroni, the entire disclosure of which is hereby incorporated by reference. This application further claims priority to U.S. provisional application Serial No. 60/317,479 entitled “Aerosol Drug Delivery,” filed Sep. 5, 2001, Rabinowitz and Zaffaroni, the entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the delivery of antiemetics through an inhalation route. Specifically, it relates to aerosols containing antiemetics that are used in inhalation therapy.
BACKGROUND OF THE INVENTION
[0003] There are a number of compositions currently marketed as antiemetics. The compositions contain at least one active ingredient that provides for observed therapeutic effects. Among the active ingredients given in such antiemetic compositions are dolasetron and granisetron.
[0004] It is desirable to provide a new route of administration for antiemetics that rapidly produces peak plasma concentrations of the compounds. The provision of such a route is an object of the present invention.
SUMMARY OF THE INVENTION
[0005] The present invention relates to the delivery of antiemetics through an inhalation route. Specifically, it relates to aerosols containing antiemetics that are used in inhalation therapy.
[0006] In a composition aspect of the present invention, the aerosol comprises particles comprising at least 5 percent by weight of an antiemetic. Preferably, the particles comprise at least 10 percent by weight of an antiemetic. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent or 99.97 percent by weight of an antiemetic.
[0007] Typically, the aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μg. More preferably, the aerosol has a mass of at least 200 μg.
[0008] Typically, the particles comprise less than 10 percent by weight of antiemetic degradation products. Preferably, the particles comprise less than 5 percent by weight of antiemetic degradation products. More preferably, the particles comprise less than 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of antiemetic degradation products.
[0009] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0010] Typically, at least 50 percent by weight of the aerosol is amorphous in form, wherein crystalline forms make up less than 50 percent by weight of the total aerosol weight, regardless of the nature of individual particles. Preferably, at least 75 percent by weight of the aerosol is amorphous in form. More preferably, at least 90 percent by weight of the aerosol is amorphous in form.
[0011] Typically, the aerosol particles have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0012] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.3.
[0013] Typically, the aerosol is formed by heating a composition containing an antiemetic to form a vapor and subsequently allowing the vapor to condense into an aerosol.
[0014] In another composition aspect of the present invention, the aerosol comprises particles comprising at least 5 percent by weight of dolasetron, granisetron, or metoclopramide. Preferably, the particles comprise at least 10 percent by weight of dolasetron, granisetron, or metoclopramide. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent or 99.97 percent by weight of dolasetron, granisetron, or metoclopramide.
[0015] Typically, the aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μg. More preferably, the aerosol has a mass of at least 200 μg.
[0016] Typically, the particles comprise less than 10 percent by weight of dolasetron, granisetron, or metoclopramide degradation products. Preferably, the particles comprise less than 5 percent by weight of dolasetron, granisetron, or metoclopramide degradation products. More preferably, the particles comprise less than 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of dolasetron, granisetron, or metoclopramide.
[0017] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0018] Typically, at least 50 percent by weight of the aerosol is amorphous in form; wherein crystalline forms make up less than 50 percent by weight of the total aerosol weight, regardless of the nature of individual particles. Preferably, at least 75 percent by weight of the aerosol is amorphous in form. More preferably, at least 90 percent by weight of the aerosol is amorphous in form.
[0019] Typically, where the aerosol comprises dolasetron, the aerosol has an inhalable aerosol drug mass density of between 5 mg/L and 150 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 10 mg/L and 120 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 20 mg/L and 100 mg/L.
[0020] Typically, where the aerosol comprises granisetron, the aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 2 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 0.2 mg/L and 1.75 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 0.4 mg/L and 1.5 mg/L.
[0021] Typically, where the aerosol comprises metoclopramide, the aerosol has an inhalable aerosol drug mass density of between 1.0 mg/L and 20 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 1.5 mg/L and 15 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 2.0 mg/L and 10 mg/L.
[0022] Typically, the aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
[0023] Typically, the aerosol particles have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0024] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3.0. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.3.
[0025] Typically, the aerosol is formed by heating a composition containing dolasetron, granisetron, or metoclopramide to form a vapor and subsequently allowing the vapor to condense into an aerosol.
[0026] In a method aspect of the present invention, an antiemetic is delivered to a mammal through an inhalation route. The method comprises: a) heating a composition, wherein the composition comprises at least 5 percent by weight of an antiemetic, to form a vapor; and, b) allowing the vapor to cool, thereby forming a condensation aerosol comprising particles, which is inhaled by the mammal. Preferably, the composition that is heated comprises at least 10 percent by weight of an antiemetic. More preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of an antiemetic.
[0027] Typically, the particles comprise at least 5 percent by weight of an antiemetic. Preferably, the particles comprise at least 10 percent by weight of an antiemetic. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of an antiemetic.
[0028] Typically, the condensation aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μ. More preferably, the aerosol has a mass of at least 200 μg.
[0029] Typically, the particles comprise less than 10 percent by weight of antiemetic degradation products. Preferably, the particles comprise less than 5 percent by weight of antiemetic degradation products. More preferably, the particles comprise 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of antiemetic degradation products.
[0030] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0031] Typically, at least 50 percent by weight of the aerosol is amorphous in form, wherein crystalline forms make up less than 50 percent by weight of the total aerosol weight, regardless of the nature of individual particles. Preferably, at least 75 percent by weight of the aerosol is amorphous in form. More preferably, at least 90 percent by weight of the aerosol is amorphous in form.
[0032] Typically, the particles of the delivered condensation aerosol have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0033] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3.0. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.3.
[0034] Typically, the delivered aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
[0035] Typically, the rate of inhalable aerosol particle formation of the delivered condensation aerosol is greater than 10 8 particles per second. Preferably, the aerosol is formed at a rate greater than 10 9 inhalable particles per second. More preferably, the aerosol is formed at a rate greater than 10 10 inhalable particles per second.
[0036] Typically, the delivered condensation aerosol is formed at a rate greater than 0.5 mg/second. Preferably, the aerosol is formed at a rate greater than 0.75 mg/second. More preferably, the aerosol is formed at a rate greater than 1 mg/second, 1.5 mg/second or 2 mg/second.
[0037] Typically, the delivered condensation aerosol results in a peak plasma concentration of an antiemetic in the mammal in less than 1 h. Preferably, the peak plasma concentration is reached in less than 0.5 h. More preferably, the peak plasma concentration is reached in less than 0.2, 0.1, 0.05, 0.02, 0.01, or 0.005 h (arterial measurement).
[0038] In another method aspect of the present invention, one of dolasetron, granisetron, or metoclopramide is delivered to a mammal through an inhalation route. The method comprises: a) heating a composition, wherein the composition comprises at least 5 percent by weight of dolasetron, granisetron, or metoclopramide, to form a vapor; and, b) allowing the vapor to cool, thereby forming a condensation aerosol comprising particles, which is inhaled by the mammal. Preferably, the composition that is heated comprises at least 10 percent by weight of dolasetron, granisetron, or metoclopramide. More preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of dolasetron, granisetron, or metoclopramide.
[0039] Typically, the particles comprise at least 5 percent by weight of dolasetron, granisetron, or metoclopramide. Preferably, the particles comprise at least 10 percent by weight of dolasetron, granisetron, or metoclopramide. More preferably, the particles comprise at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of dolasetron, granisetron, or metoclopramide.
[0040] Typically, the condensation aerosol has a mass of at least 10 μg. Preferably, the aerosol has a mass of at least 100 μg. More preferably, the aerosol has a mass of at least 200 μg.
[0041] Typically, the particles comprise less than 10 percent by weight of dolasetron, granisetron, or metoclopramide degradation products. Preferably, the particles comprise less than 5 percent by weight of dolasetron, granisetron, or metoclopramide degradation products. More preferably, the particles comprise 2.5, 1, 0.5, 0.1 or 0.03 percent by weight of dolasetron, granisetron, or metoclopramide degradation products.
[0042] Typically, the particles comprise less than 90 percent by weight of water. Preferably, the particles comprise less than 80 percent by weight of water. More preferably, the particles comprise less than 70 percent, 60 percent, 50 percent, 40 percent, 30 percent, 20 percent, 10 percent, or 5 percent by weight of water.
[0043] Typically, at least 50 percent by weight of the aerosol is amorphous in form, wherein crystalline forms make up less than 50 percent by weight of the total aerosol weight, regardless of the nature of individual particles. Preferably, at least 75 percent by weight of the aerosol is amorphous in form. More preferably, at least 90 percent by weight of the aerosol is amorphous in form.
[0044] Typically, the particles of the delivered condensation aerosol have a mass median aerodynamic diameter of less than 5 microns. Preferably, the particles have a mass median aerodynamic diameter of less than 3 microns. More preferably, the particles have a mass median aerodynamic diameter of less than 2 or 1 micron(s).
[0045] Typically, the geometric standard deviation around the mass median aerodynamic diameter of the aerosol particles is less than 3.0. Preferably, the geometric standard deviation is less than 2.5. More preferably, the geometric standard deviation is less than 2.3.
[0046] Typically, where the aerosol comprises dolasetron, the delivered aerosol has an inhalable aerosol drug mass density of between 5 mg/L and 150 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 10 mg/L and 120 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 20 mg/L and 100 mg/L.
[0047] Typically, where the aerosol comprises granisetron, the delivered aerosol has an inhalable aerosol drug mass density of between 0.1 mg/L and 2 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 0.2 mg/L and 1.75 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 0.4 mg/L and 1.5 mg/L.
[0048] Typically, where the aerosol comprises metoclopramide, the delivered aerosol has an inhalable aerosol drug mass density of between 1 mg/L and 20 mg/L. Preferably, the aerosol has an inhalable aerosol drug mass density of between 1.5 mg/L and 15 mg/L. More preferably, the aerosol has an inhalable aerosol drug mass density of between 2.0 mg/L and 10 mg/L.
[0049] Typically, the delivered aerosol has an inhalable aerosol particle density greater than 10 6 particles/mL. Preferably, the aerosol has an inhalable aerosol particle density greater than 10 7 particles/mL or 10 8 particles/mL.
[0050] Typically, the rate of inhalable aerosol particle formation of the delivered condensation aerosol is greater than 10 8 particles per second. Preferably, the aerosol is formed at a rate greater than 10 9 inhalable particles per second. More preferably, the aerosol is formed at a rate greater than 10 10 inhalable particles per second.
[0051] Typically, the delivered condensation aerosol is formed at a rate greater than 0.5 mg/second. Preferably, the aerosol is formed at a rate greater than 0.75 mg/second. More preferably, the aerosol is formed at a rate greater than 1 mg/second, 1.5 mg/second or 2 mg/second.
[0052] Typically, where the condensation aerosol comprises dolasetron, between 5 mg and 150 mg of dolasetron are delivered to the mammal in a single inspiration. Preferably, between 10 mg and 120 mg of dolasetron are delivered to the mammal in a single inspiration. More preferably, between 20 mg and 100 mg of dolasetron are delivered in a single inspiration.
[0053] Typically, where the condensation aerosol comprises granisetron, between 0.1 mg and 2 mg of granesetron are delivered to the mammal in a single inspiration. Preferably, between 0.2 mg and 1.75 mg of granisetron are delivered to the mammal in a single inspiration. More preferably, between 0.4 mg and 1.5 mg of granisetron are delivered in a single inspiration.
[0054] Typically, where the condensation aerosol comprises metoclopramide, between 1.0 mg and 20 mg of metoclopramide are delivered to the mammal in a single inspiration. Preferably, between 1.5 mg and 15 mg of metoclopramide are delivered to the mammal in a single inspiration. More preferably, between 2.0 mg and 10 mg of metoclopramide are delivered in a single inspiration.
[0055] Typically, the delivered condensation aerosol results in a peak plasma concentration of dolasetron, granisetron, or metoclopramide in the mammal in less than 1 h. Preferably, the peak plasma concentration is reached in less than 0.5 h. More preferably, the peak plasma concentration is reached in less than 0.2, 0.1, 0.05, 0.02, 0.01, or 0.005 h (arterial measurement).
[0056] In a kit aspect of the present invention, a kit for delivering an antiemetic through an inhalation route to a mammal is provided which comprises: a) a composition comprising at least 5 percent by weight of an antiemetic; and, b) a device that forms an antiemetic aerosol from the composition, for inhalation by the mammal. Preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of an antiemetic.
[0057] Typically, the device contained in the kit comprises: a) an element for heating the antiemetic composition to form a vapor; b) an element allowing the vapor to cool to form an aerosol; and, c) an element permitting the mammal to inhale the aerosol.
[0058] In another kit aspect of the present invention, a kit for delivering dolasetron, granisetron, or metoclopramide through an inhalation route to a mammal is provided which comprises: a) a composition comprising at least 5 percent by weight of dolasetron, granisetron, or metoclopramide; and, b) a device that forms a dolasetron, granisetron, or metoclopramide aerosol from the composition, for inhalation by the mammal. Preferably, the composition comprises at least 20 percent, 30 percent, 40 percent, 50 percent, 60 percent, 70 percent, 80 percent, 90 percent, 95 percent, 97 percent, 99 percent, 99.5 percent, 99.9 percent or 99.97 percent by weight of dolasetron, granisetron, or metoclopramide.
[0059] Typically, the device contained in the kit comprises: a) an element for heating the dolasetron, granisetron, or metoclopramide composition to form a vapor; b) an element allowing the vapor to cool to form an aerosol; and, c) an element permitting the mammal to inhale the aerosol.
BRIEF DESCRIPTION OF THE FIGURE
[0060] [0060]FIG. 1 shows a cross-sectional view of a device used to deliver antiemetic aerosols to a mammal through an inhalation route.
DETAILED DESCRIPTION OF THE INVENTION
[0061] Definition
[0062] “Aerodynamic diameter” of a given particle refers to the diameter of a spherical droplet with a density of 1 g/mL (the density of water) that has the same settling velocity as the given particle.
[0063] “Aerosol” refers to a suspension of solid or liquid particles in a gas.
[0064] “Aerosol drug mass density” refers to the mass of antiemetic per unit volume of aerosol.
[0065] “Aerosol mass density” refers to the mass of particulate matter per unit volume of aerosol.
[0066] “Aerosol particle density” refers to the number of particles per unit volume of aerosol.
[0067] “Amorphous particle” refers to a particle that does not contain more than 50 percent by weight of a crystalline form. Preferably, the particle does not contain more than 25 percent by weight of a crystalline form. More preferably, the particle does not contain more than 10 percent by weight of a crystalline form.
[0068] “Antiemetic degradation product” refers to a compound resulting from a chemical modification of an antiemetic. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis
[0069] Condensation aerosol” refers to an aerosol formed by vaporization of a substance followed by condensation of the substance into an aerosol.
[0070] “Dolasetron” refers to (2α,6α,8α,9aβ)-octahydro-3-oxo-2,6-methano-2H-quinolizin-8-yl-1 H-indole-3-carboxylate.
[0071] “Dolasetron degradation product” refers to a compound resulting from a chemical modification of dolasetron. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis. An example of such a degradation product is C 9 H 7 NO 2 (oxidation next to ester oxygen yielding a carboxylic acid).
[0072] “Granisetron” refers to endo-N-(9-methyl-9-azabicyclo [3.3.1] non-3-yl)-1-methyl-1H-indazole-3-carboxamide.
[0073] “Granisetron degradation product” refers to a compound resulting from a chemical modification of granisetron. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis. Examples of such degradation products include C 9 H 9 N 3 O (oxidation of carbon next to amide nitrogen to provide primary amide) and C 8 H 7 N 3 O (demethylation of C 9 H 9 N 3 O).
[0074] “Inhalable aerosol drug mass density” refers to the aerosol drug mass density produced by an inhalation device and delivered into a typical patient tidal volume.
[0075] “Inhalable aerosol mass density” refers to the aerosol mass density produced by an inhalation device and delivered into a typical patient tidal volume.
[0076] “Inhalable aerosol particle density” refers to the aerosol particle density of particles of size between 100 nm and 5 microns produced by an inhalation device and delivered into a typical patient tidal volume.
[0077] “Mass median aerodynamic diameter” or “MMAD” of an aerosol refers to the aerodynamic diameter for which half the particulate mass of the aerosol is contributed by particles with an aerodynamic diameter larger than the MMAD and half by particles with an aerodynamic diameter smaller than the MMAD.
[0078] “Metoclopramide” refers to 4-amino-5-chloro-N-[(2-diethylamino)ethyl]-2-methoxybenzamide.
[0079] “Metoclopramide degradation product” refers to a compound resulting from a chemical modification of metoclopramide. The modification, for example, can be the result of a thermally or photochemically induced reaction. Such reactions include, without limitation, oxidation and hydrolysis. Examples of such degradation products include C 8 H 9 N 2 O 2 Cl (oxidation of carbon next to amide nitrogen to provide primary amide) and C 7 H 7 N 2 O 2 Cl (demethylation of C 8 H 9 N 2 O 2 Cl).
[0080] “Rate of aerosol formation” refers to the mass of aerosolized particulate matter produced by an inhalation device per unit time.
[0081] “Rate of inhalable aerosol particle formation” refers to the number of particles of size between 100 nm and 5 microns produced by an inhalation device per unit time.
[0082] “Rate of drug aerosol formation” refers to the mass of aerosolized antiemetic produced by an inhalation device per unit time.
[0083] “Settling velocity” refers to the terminal velocity of an aerosol particle undergoing gravitational settling in air.
[0084] “Typical patient tidal volume” refers to 1 L for an adult patient and 15 mL/kg for a pediatric patient.
[0085] “Vapor” refers to a gas, and “vapor phase” refers to a gas phase. The term “thermal vapor” refers to a vapor phase, aerosol, or mixture of aerosol-vapor phases, formed preferably by heating.
[0086] Formation of Antiemetic Containing Aerosols
[0087] Any suitable method is used to form the aerosols of the present invention. A preferred method, however, involves heating a composition comprising an antiemetic to form a vapor, followed by cooling of the vapor such that it condenses to provide an antiemetic comprising aerosol (condensation aerosol). The composition is heated in one of four forms: as pure active compound (i.e., pure dolasetron, granisetron, or metoclopramide); as a mixture of active compound and a pharmaceutically acceptable excipient; as a salt form of the pure active compound; and, as a mixture of active compound salt form and a pharmaceutically acceptable excipient.
[0088] Salt forms of antiemetics (e.g., dolasetron, granisetron, or metoclopramide) are either commercially available or are obtained from the corresponding free base using well known methods in the art. A variety of pharmaceutically acceptable salts are suitable for aerosolization. Such salts include, without limitation, the following: hydrochloric acid, hydrobromic acid, acetic acid, maleic acid, formic acid, and fumaric acid salts.
[0089] Pharmaceutically acceptable excipients may be volatile or nonvolatile. Volatile excipients, when heated, are concurrently volatilized, aerosolized and inhaled with the antiemetic. Classes of such excipients are known in the art and include, without limitation, gaseous, supercritical fluid, liquid and solid solvents. The following is a list of exemplary carriers within the classes: water; terpenes, such as menthol; alcohols, such as ethanol, propylene glycol, glycerol and other similar alcohols; dimethylformamide; dimethylacetamide; wax; supercritical carbon dioxide; dry ice; and mixtures thereof.
[0090] Solid supports on which the composition is heated are of a variety of shapes. Examples of such shapes include, without limitation, cylinders of less than 1.0 mm in diameter, boxes of less than 1.0 mm thickness and virtually any shape permeated by small (e.g., less than 1.0 mm-sized) pores. Preferably, solid supports provide a large surface to volume ratio (e.g., greater than 100 per meter) and a large surface to mass ratio (e.g., greater than 1 cm 2 per gram).
[0091] A solid support of one shape can also be transformed into another shape with different properties. For example, a flat sheet of 0.25 mm thickness has a surface to volume ratio of approximately 8,000 per meter. Rolling the sheet into a hollow cylinder of 1 cm diameter produces a support that retains the high surface to mass ratio of the original sheet but has a lower surface to volume ratio (about 400 per meter).
[0092] A number of different materials are used to construct the solid supports. Classes of such materials include, without limitation, metals, inorganic materials, carbonaceous materials and polymers. The following are examples of the material classes: aluminum, silver, gold, stainless steel, copper and tungsten; silica, glass, silicon and alumina; graphite, porous carbons, carbon yams and carbon felts; polytetrafluoroethylene and polyethylene glycol. Combinations of materials and coated variants of materials are used as well.
[0093] Where aluminum is used as a solid support, aluminum foil is a suitable material. Examples of silica, alumina and silicon based materials include amphorous silica S-5631 (Sigma, St. Louis, Mo.), BCR171 (an alumina of defined surface area greater than 2 m 2 /g from Aldrich, St. Louis, Mo.) and a silicon wafer as used in the semiconductor industry. Carbon yams and felts are available from American Kynol, Inc., New York, N.Y. Chromatography resins such as octadecycl silane chemically bonded to porous silica are exemplary coated variants of silica.
[0094] The heating of the antiemetic compositions is performed using any suitable method. Examples of methods by which heat can be generated include the following: passage of current through an electrical resistance element; absorption of electromagnetic radiation, such as microwave or laser light; and, exothermic chemical reactions, such as exothermic solvation, hydration of pyrophoric materials and oxidation of combustible materials.
[0095] Delivery of Antiemetic Containing Aerosols
[0096] Antiemetic containing aerosols of the present invention are delivered to a mammal using an inhalation device. Where the aerosol is a condensation aerosol, the device has at least three elements: an element for heating an antiemetic containing composition to form a vapor; an element allowing the vapor to cool, thereby providing a condensation aerosol; and, an element permitting the mammal to inhale the aerosol. Various suitable heating methods are described above. The element that allows cooling is, in it simplest form, an inert passageway linking the heating means to the inhalation means. The element permitting inhalation is an aerosol exit portal that forms a connection between the cooling element and the mammal's respiratory system.
[0097] One device used to deliver the antiemetic containing aerosol is described in reference to FIG. 1. Delivery device 100 has a proximal end 102 and a distal end 104 , a heating module 106 , a power source 108 , and a mouthpiece 110 . An antiemetic composition is deposited on a surface 112 of heating module 106 . Upon activation of a user activated switch 114 , power source 108 initiates heating of heating module 106 (e.g, through ignition of combustible fuel or passage of current through a resistive heating element). The antiemetic composition volatilizes due to. the heating of heating module 106 and condenses to form a condensation aerosol prior to reaching the mouthpiece 110 at the proximal end of the device 102 . Air flow traveling from the device distal end 104 to the mouthpiece 110 carries the condensation aerosol to the mouthpiece 110 , where it is inhaled by the mammal.
[0098] Devices, if desired, contain a variety of components to facilitate the delivery of antiemetic containing aerosols. For instance, the device may include any component known in the art to control the timing of drug aerosolization relative to inhalation (e.g., breath-actuation), to provide feedback to patients on the rate and/or volume of inhalation, to prevent excessive use (i.e., “lock-out” feature), to prevent use by unauthorized individuals, and/or to record dosing histories.
[0099] Dosage of Antiemetic Containing Aerosols
[0100] The dosage amount of an antiemetic in aerosol form is generally no greater than twice the standard dose of the drug given orally. For instance, dolasetron, granisetron, and metoclopramide are given at strengths of 100 mg , 1 mg, and 10 mg respectively for the treatment of emesis. As aerosols, 20 mg to 150 mg of dolasetron, 0.2 mg to 2 mg of granisetron, and 1 mg to 20 mg of metoclopramide are generally provided for the same indication. A typical dosage of an antiemetic aerosol is either administered as a single inhalation or as a series of inhalations taken within an hour or less (dosage equals sum of inhaled amounts). Where the drug is administered as a series of inhalations, a different amount may be delivered in each inhalation.
[0101] One can determine the appropriate dose of antiemetic containing aerosols to treat a particular condition using methods such as animal experiments and a dose-finding (Phase I/II) clinical trial. One animal experiment involves measuring plasma concentrations of drug in an animal after its exposure to the aerosol. Mammals such as dogs or primates are typically used in such studies, since their respiratory systems are similar to that of a human. Initial dose levels for testing in humans is generally less than or equal to the dose in the mammal model that resulted in plasma drug levels associated with a therapeutic effect in humans. Dose escalation in humans is then performed, until either an optimal therapeutic response is obtained or a dose-limiting toxicity is encountered.
[0102] Analysis of Antiemetic Containing Aerosols
[0103] Purity of an antiemetic containing aerosol is determined using a number of methods, examples of which are described in Sekine et al., Journal of Forensic Science 32:1271-1280 (1987) and Martin et al., Journal of Analytic Toxicology 13:158-162 (1989). One method involves forming the aerosol in a device through which a gas flow (e.g., air flow) is maintained, generally at a rate between 0.4 and 60 L/min. The gas flow carries the aerosol into one or more traps. After isolation from the trap, the aerosol is subjected to an analytical technique, such as gas or liquid chromatography, that permits a determination of composition purity.
[0104] A variety of different traps are used for aerosol collection. The following list contains examples of such traps: filters; glass wool; impingers; solvent traps, such as dry ice-cooled ethanol, methanol, acetone and dichloromethane traps at various pH values; syringes that sample the aerosol; empty, low-pressure (e.g., vacuum) containers into which the aerosol is drawn; and, empty containers that fully surround and enclose the aerosol generating device. Where a solid such as glass wool is used, it is typically extracted with a solvent such as ethanol. The solvent extract is subjected to analysis rather than the solid (i.e., glass wool) itself. Where a syringe or container is used, the container is similarly extracted with a solvent.
[0105] The gas or liquid chromatograph discussed above contains a detection system (i.e., detector). Such detection systems are well known in the art and include, for example, flame ionization, photon absorption and mass spectrometry detectors. An advantage of a mass spectrometry detector is that it can be used to determine the structure of antiemetic degradation products.
[0106] Particle size distribution of an antiemetic containing aerosol is determined using any suitable method in the art (e.g., cascade impaction). An Andersen Eight Stage Non-viable Cascade Impactor (Andersen Instruments, Smyrna, GA) linked to a furnace tube by a mock throat (USP throat, Andersen Instruments, Smyrna, GA) is one system used for cascade impaction studies.
[0107] Inhalable aerosol mass density is determined, for example, by delivering a drug-containing aerosol into a confined chamber via an inhalation device and measuring the mass collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient.
[0108] Inhalable aerosol drug mass density is determined, for example, by delivering a drug-containing aerosol into a confined chamber via an inhalation device and measuring the amount of active drug compound collected in the chamber. Typically, the aerosol is drawn into the chamber by having a pressure gradient between the device and the chamber, wherein the chamber is at lower pressure than the device. The volume of the chamber should approximate the tidal volume of an inhaling patient. The amount of active drug compound collected in the chamber is determined by extracting the chamber, conducting chromatographic analysis of the extract and comparing the results of the chromatographic analysis to those of a standard containing known amounts of drug.
[0109] Inhalable aerosol particle density is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device and measuring the number of particles of given size collected in the chamber. The number of particles of a given size may be directly measured based on the light-scattering properties of the particles. Alternatively, the number of particles of a given size is determined by measuring the mass of particles within the given size range and calculating the number of particles based on the mass as follows: Total number of particles=Sum (from size range 1 to size range N) of number of particles in each size range. Number of particles in a given size range=Mass in the size range/Mass of a typical particle in the size range. Mass of a typical particle in a given size range=π*D 3 *φ/6, where D is a typical particle diameter in the size range (generally, the mean boundary MMADs defining the size range) in microns, φ is the particle density (in g/mL) and mass is given in units of picograms (g −12 ).
[0110] Rate of inhalable aerosol particle formation is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the number of particles of a given size collected in the chamber is determined as outlined above. The rate of particle formation is equal to the number of 100 nm to 5 micron particles collected divided by the duration of the collection time.
[0111] Rate of aerosol formation is determined, for example, by delivering aerosol phase drug into a confined chamber via an inhalation device. The delivery is for a set period of time (e.g., 3 s), and the mass of particulate matter collected is determined by weighing the confined chamber before and after the delivery of the particulate matter. The rate of aerosol formation is equal to the increase in mass in the chamber divided by the duration of the collection time. Alternatively, where a change in mass of the delivery device or component thereof can only occur through release of the aerosol phase particulate matter, the mass of particulate matter may be equated with the mass lost from the device or component during the delivery of the aerosol. In this case, the rate of aerosol formation is equal to the decrease in mass of the device or component during the delivery event divided by the duration of the delivery event.
[0112] Rate of drug aerosol formation is determined, for example, by delivering an antiemetic containing aerosol into a confined chamber via an inhalation device over a set period of time (e.g., 3 s). Where the aerosol is pure antiemetic, the amount of drug collected in the chamber is measured as described above. The rate of drug aerosol formation is equal to the amount of antiemetic collected in the chamber divided by the duration of the collection time. Where the antiemetic containing aerosol comprises a pharmaceutically acceptable excipient, multiplying the rate of aerosol formation by the percentage of antiemetic in the aerosol provides the rate of drug aerosol formation.
[0113] Utility of Antiemetic Containing Aerosols
[0114] The antiemetic containing aerosols of the present invention are typically used to treat emesis.
[0115] The following examples are meant to illustrate, rather than limit, the present invention.
[0116] Metoclopramide hydrochloride is commercially available from Sigma (www.sigma-aldrich.com). Dolaseteron mesylate and granisetron hydrochloride are commercially available in solution (ANZEMET® and KYTRIL® respectively). Both compounds can be isolated using standard methods in the art.
EXAMPLE 1
General Procedure for Obtaining Free Base of a Compound Salt
[0117] Approximately 1 g of salt (e.g., mono hydrochloride) is dissolved in deionized water (˜30 mL). Three equivalents of sodium hydroxide (1 N NaOH aq ) is added dropwise to the solution, and the pH is checked to ensure it is basic. The aqueous solution is extracted four times with dichloromethane (˜50 mL), and the extracts are combined, dried (Na 2 SO 4 ) and filtered. The filtered organic solution is concentrated using a rotary evaporator to provide the desired free base. If necessary, purification of the free base is performed using standard methods such as chromatography or recrystallization.
EXAMPLE 2
General Procedure for Volatilizing Compounds from Halogen Bulb
[0118] A solution of drug in approximately120 μL dichloromethane is coated on a 3.5 cm×7.5 cm piece of aluminum foil (precleaned with acetone). The dichloromethane is allowed to evaporate. The coated foil is wrapped around a 300 watt halogen tube (Feit Electric Company, Pico Rivera, Calif.), which is inserted into a glass tube sealed at one end with a rubber stopper. Running 60 V of alternating current (driven by line power controlled by a variac) through the bulb for 5-45 s (granisetron) or 90 V for 3.5 seconds (dolasetron) affords thermal vapor (including aerosol), which is collected on the glass tube walls. Reverse-phase HPLC analysis with detection by absorption of 225 nm light is used to determine the purity of the aerosol. (When desired, the system is flushed through with argon prior to volatilization.)
[0119] Granisetron aerosol (1 mg) was obtained in 100% purity using this procedure. Dolasetron (0.7 mg) was obtained in greater than 99% purity (argon flush).
EXAMPLE 3
Particle Size, Particle Density, and Rate of Inhalable Particle Formation of Granisetron Aerosol
[0120] A solution of 1.1 mg granisetron in 100 μL dichloromethane was spread out in a thin layer on the central portion of a 3.5 cm×7 cm sheet of aluminum foil. The dichloromethane was allowed to evaporate. The aluminum foil was wrapped around a 300 watt halogen tube, which was inserted into a T-shaped glass tube. Both of the openings of the tube were sealed with parafilm, which was punctured with fifteen needles for air flow. The third opening was connected to a 1 liter, 3-neck glass flask. The glass flask was further connected to a large piston capable of drawing 1.1 liters of air through the flask. Alternating current was run through the halogen bulb by application of 90 V using a variac connected to 110 V line power. Within 1 s, an aerosol appeared and was drawn into the 1 L flask by use of the piston, with collection of the aerosol terminated after 6 s. The aerosol was analyzed by connecting the 1 L flask to an eight-stage Andersen non-viable cascade impactor. Results are shown in table 1. MMAD of the collected aerosol was 1.1 microns with a geometric standard deviation of 2.2. Also shown in table 1 is the number of particles collected on the various stages of the cascade impactor, given by the mass collected on the stage divided by the mass of a typical particle trapped on that stage. The mass of a single particle of diameter D is given by the volume of the particle, πD 3 /6, multiplied by the density of the drug (taken to be 1 g/cm 3 ). The inhalable aerosol particle density is the sum of the numbers of particles collected on impactor stages 3 to 8 divided by the collection volume of 1 L, giving an inhalable aerosol particle density of 2.3×10 7 particles/mL. The rate of inhalable aerosol particle formation is the sum of the numbers of particles collected on impactor stages 3 through 8 divided by the formation time of 6 s, giving a rate of inhalable aerosol particle formation of 3.8×10 9 particles/second.
TABLE 1 Determination of the characteristics of a granisetron condensation aerosol by cascade impaction using an Andersen 8-stage non-viable cascade impactor run at 1 cubic foot per minute air flow. Mass Particle size Average particle collected Number of Stage range (microns) size (microns) (mg) particles 0 9.0-10.0 9.5 0.004 8.9 × 10 3 1 5.8-9.0 7.4 0.008 3.8 × 10 4 2 4.7-5.8 5.25 0.008 1.1 × 10 5 3 3.3-4.7 4.0 0.020 6.0 × 10 5 4 2.1-3.3 2.7 0.056 5.4 × 10 6 5 1.1-2.1 1.6 0.201 9.4 × 10 7 6 0.7-1.1 0.9 0.163 4.3 × 10 8 7 0.4-0.7 0.55 0.073 8.4 × 10 8 8 0-0.4 0.2 0.090 2.2 × 10 10
EXAMPLE 4
Drug Mass Density and Fate of Drug Aerosol Formation of Granisetron Aerosol
[0121] A solution of 1.1 mg granisetron in 100 μL dichloromethane was spread out in a thin layer on the central portion of a 3.5 cm×7 cm sheet of aluminum foil. The dichloromethane was allowed to evaporate. The aluminum foil was wrapped around a 300 watt halogen tube, which was inserted into a T-shaped glass tube. Both of the openings of the tube were sealed with parafilm, which was punctured with fifteen needles for air flow. The third opening was connected to a 1 liter, 3-neck glass flask. The glass flask was further connected to a large piston capable of drawing 1.1 liters of air through the flask. Alternating current was run through the halogen bulb by application of 90 V using a variac connected to 110 V line power. Within seconds, an aerosol appeared and was drawn into the 1 L flask by use of the piston, with formation of the aerosol terminated after 6 s. The aerosol was allowed to sediment onto the walls of the 1 L flask for approximately 30 minutes. The flask was then extracted with acetonitrile and the extract analyzed by HPLC with detection by light absorption at 225 nm. Comparison with standards containing known amounts of granisetron revealed that 0.4 mg of>93% pure granisetron had been collected in the flask, resulting in an aerosol drug mass density of 0.4 mg/L. The aluminum foil upon which the granisetron had previously been coated was weighed following the experiment. Of the 1.1 mg originally coated on the aluminum, all of the material was found to have aerosolized in the 6 s time period, implying a rate of drug aerosol formation of 0.2 mg/s.
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The present invention relates to the delivery of antiemetics through an inhalation route. Specifically, it relates to aerosols containing antiemetics that are used in inhalation therapy. In a method aspect of the present invention, an antiemetic is delivered to a patient through an inhalation route. The method comprises: a) heating a thin layer of an antiemetic, on a solid support, to form a vapor; and, b) passing air through the heated vapor to produce aerosol particles having less than 5% antiemetic degradation products. In a kit aspect of the present invention, a kit for delivering an antiemetic through an inhalation route is provided which comprises: a) a thin layer of an antiemetic drug and b) a device for dispensing said thin layer an antiemetic as a condensation aerosol.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Utility patent application claims priority benefit of the U.S. provisional application for patent Ser. No. 61/150,609 filed on Feb. 6, 2009 under 35 U.S.C. 119(e). The contents of this related provisional application are incorporated herein by reference for all purposes.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX
[0003] Not applicable.
COPYRIGHT NOTICE
[0004] A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0005] The present invention relates generally to medical training. More particularly, the invention relates to a method of pathologic correlation for radiology resident education.
BACKGROUND OF THE INVENTION
[0006] Radiology is a very dynamic, rapidly changing, technologically oriented specialty. The field of medicine has come to depend heavily on radiologists' interpretation of images to determine diagnoses and clinical management of patients. It is crucial and necessary that radiologists in training are provided with proper feedback and further instruction about their interpretation of studies.
[0007] However, radiologists often have less direct involvement with patients and the physicians involved in the patients' care. Due to conflicts with efficiency and workflow, it becomes difficult for radiologists to discuss interesting cases with other physicians (e.g., pathologists, surgeons, etc.) during a given workday. This makes learning for the radiology resident an especially challenging process.
[0008] It is therefore an objective of the present invention to provide a software application system design that uses information technology (IT) to integrate RIS and hospital electronic medical records system (EMRS) within picture archiving and communications systems (PACS) to promote learner based education. Such a design would enable radiology residents to review interesting cases they have interpreted and correlate their findings with the pathology results and discharge diagnoses.
[0009] Over the last 20 years computers have become increasingly affordable. With the development of high-capacity physical media for storage of digital information, along with increasing CPU power, it has become very feasible to use computers to store, transmit, and display images of biomedical relevance. Simultaneously, the development of networks has arguably been the single most dramatic recent development in IT, due to their contribution to the fusion of computing and communications.
[0010] The development and commercial availability of relational database management systems (RDMS), which allow for storage and retrieval of huge amounts of data and images, is an integral component of IT. First described by E. F. Codd at IBM in 1970, a relational database is a collection of data items organized as a set of formally described tables from which data can be accessed or re-assembled in many different ways without having to reorganize the database tables. The utilization of RDMS, in coordination with the widespread use and accessibility of the Internet has led to a revolution in information dissemination and retrieval.
[0011] Development of communications networks, databases, and programming languages led to the development of EMRS and more recently the PACS. PACS was implemented to handle the increasing proportion of digital images generated from new medical imaging modalities. Radiology, due to extensive use of images, is one field in medicine that has significantly benefited from the Internet and other IT innovations. For example, with PACS, radiology education, worldwide consultation, and scientific presentation via the Internet have become a reality because medical images as well as text information can be transported via the Internet.
[0012] Currently, the Internet offers a variety of radiological resources that supplement and extend information from current sources such as books and periodicals. Digital teaching files, networked multimedia textbooks, and online continued medical education (CME) credits have become a reality. With the recent developments of PACS and the evolution of standards (e.g., Digital Imaging and Communications in Medicine (DICOM)), the development of a digital teaching files system is facilitated, allowing the radiologist to benefit from the advantages of digital imaging technology to edit and share image collections.
[0013] The information technology revolution has dramatically changed the traditional education process. The Internet, powerful databases, and sophisticated software allow for sharing educational information worldwide, making educational materials available to radiology residents 24 hours a day. Such technologies can be used more effectively to develop creative and useful software to further promote the education of radiology residents.
[0014] In view of the foregoing, there is a need for improved techniques for using IT to integrate RIS and hospital EMRS within PACS to create a system of digital teaching files for radiology residents.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0016] FIG. 1 is a block diagram illustrating an exemplary resident interesting case application system, in accordance with an embodiment of the present invention;
[0017] FIG. 2 is a flowchart illustrating an exemplary method for obtaining feedback from fellow residents and practicing radiologists, in accordance with an embodiment of the present invention;
[0018] FIG. 3 is a flowchart illustrating a process for an exemplary software application to generate differential diagnoses based on a region of interest, in accordance with an embodiment of the present invention; and
[0019] FIG. 4 illustrates a typical computer system that, when appropriately configured or designed, can serve as a computer system in which the invention may be embodied.
[0020] Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale.
SUMMARY OF THE INVENTION
[0021] To achieve the forgoing and other objects and in accordance with the purpose of the invention, a method and a system for integrating Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within Picture archiving and communications systems (PACS) to promote learner based education is presented.
[0022] In one embodiment a method for integrating Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within Picture archiving and communications systems (PACS) to promote learner based education is presented. The method includes steps for flagging an interesting patient case for follow-up on diagnoses, steps for submitting the flagged interesting patient case, steps for requesting a report for the interesting patient case, steps for requesting feedback on a patient case interpretation, steps for requesting a report generation from the feedback, steps for identifying an abnormality in a patient case image, steps for providing information regarding the abnormality, steps for requesting a differential diagnoses and steps for receiving the differential diagnoses.
[0023] In another embodiment for integrating Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within Picture archiving and communications systems (PACS) to promote learner based education is presented. The method includes the steps of flagging an interesting patient case, being viewed at a PACS workstation, for follow-up on diagnoses. Submitting the flagged interesting patient case, wherein the EMRS is queried for diagnoses information for the interesting patient case. Requesting a report for the interesting patient case where at least one diagnoses is available. Requesting feedback on a patient case interpretation, wherein information from Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within Picture archiving and communications systems (PACS) is sent to consulting physicians for reviewing. Requesting a report generation from the reviewing. Identifying an abnormality in a patient case image using the PACS workstation. Providing information regarding the abnormality. Requesting a differential diagnoses, wherein the information and the differential diagnoses table, (DDT) are used to produce the differential diagnoses. Receiving the differential diagnoses.
[0024] In another embodiment for integrating Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within Picture archiving and communications systems (PACS) to promote learner based education is presented. The system includes means for flagging an interesting patient case, being viewed in PACS, for follow-up on diagnoses and for submitting the flagged interesting patient case, wherein the EMRS is queried for diagnoses information for the interesting patient case. The system further includes means for requesting a report for the interesting patient case where at least one diagnoses is available. The system further includes means for requesting feedback on a patient case interpretation, wherein information from Radiology Information System (RIS) and a hospital electronic medical records system (EMRS) within (PACS) is sent to consulting physicians for reviewing and means for requesting a report generation from the reviewing. The system further includes means for identifying an abnormality in a patient case image using the PACS workstation and for providing information regarding the abnormality. The system further includes means for requesting a differential diagnoses, wherein the information and the EMRS are used to produce the differential diagnoses and means for receiving the differential diagnoses from a pre-populated differential diagnoses table (DDT).
[0025] Other features, advantages, and object of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The present invention is best understood by reference to the detailed figures and description set forth herein.
[0027] Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive.
[0028] The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings.
[0029] Detailed descriptions of the preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0030] During a regular clinical day, radiologists need to work very efficiently and often encounter numerous interesting cases. Due to the hectic work environment, radiologists seldom have the opportunity to confirm their findings after the definitive pathological diagnosis becomes available. However, this process of going back to review an interesting case and correlate their radiological interpretation with pathological diagnoses can be a very reinforcing and educational process.
[0031] With this in mind, preferred embodiments of the present invention provide an application system designed for a PACS workstation that promotes resident education. In preferred embodiments the PACS workstation comprises a resident interesting cases database (RICD) designed using the object oriented relational model after taking into consideration all the requirements from the end users such as, but not limited to, education chairs of the radiology department, residency program directors, etc. Using preferred embodiments, radiology residents are able to flag interesting cases for future follow-up, for either pathologic diagnoses or discharge diagnoses, simply by marking a checkbox on the case at the PACS workstation. Obtaining feedback for radiology examination interpretation from fellow residents and practicing radiologists can also be a great learning tool. Preferred embodiments of the present invention also enable residents to obtain feedback for case interpretation from colleagues.
[0032] Radiologists and radiology residents must memorize and be able to recall an impressive number of differential diagnoses after identifying the abnormality in any given case. Preferred embodiments of the present invention can be used to aid in the learning process and may be applied in real time to improve the efficiency and accuracy of the examination interpretation by providing a software application to generate differential diagnoses based on a region of interest.
[0033] FIG. 1 is a block diagram illustrating an exemplary resident interesting case application system, in accordance with an embodiment of the present invention. In the present embodiment, the resident interesting case application comprises a PACS workstation 101 , a RICD 103 , an EMRS database 105 , and multiple programs for performing various functions. PACS workstation 101 enables a resident to view information pertaining to a patient case such as, but not limited to, patient information, a study ID, the patient medical record number (MRN), any images taken of the patient, etc. If the resident determines that the case he is viewing is interesting, the resident may indicate this in the patient record by checking an interesting case box 107 . Once the patient record is closed for a case that has been flagged as interesting, a preparation program 109 that is running in the background prepares the resident and case information including, but not limited to, patient MRN, study ID, interpretation, images, etc. for submission to RICD 103 .
[0034] In the present embodiment, information is transferred from PACS workstation 101 to RICD 103 , which is on another server, via email. An automated email can be generated by preparation program 109 once a study of interest is closed in which the email comprises the information mentioned above in a text format. Those skilled in the art, in light of the present teachings, will readily recognize that a multiplicity of different means may be used to transfer information from the PACS workstation to the RICD such as, but not limited to, DICOM. In the present embodiment, a receiving software program 111 running on the server with RICD 103 upon receiving the email parses out the information, checks the information for accuracy, and writes the data into RICD 103 . RICD 103 is a relational database comprising a patient information table 113 , a hospital information table 115 , and a resident interesting case file table 117 . Each record in a relational database must be unique. Therefore, the unique identifier within resident interesting case file table 117 is the resident ID, patient MRN, and PACS workstation generated study ID. Each record in resident interesting case file table 117 comprises the following fields: resident ID, patient MRN, PACS generated study ID, date of admission, indication for study field, clinically relevant patient information (e.g., age, medical history, symptoms), radiology report (i.e., description field), and fields for pathological diagnoses and discharge diagnoses. A query program 119 running every 24 hours interfaces with EMRS database 105 and runs a query on all patient records whose fields for pathological diagnosis or discharge diagnosis are blank in RICD 103 . This finds the cases within RICD 103 that do not provide diagnosis or discharge information so this information may be added to the case if available. In alternate embodiments, the query program may run at different intervals for example, without limitation, every 12 hours, weekly, monthly, etc. In the present embodiment, the key identifiers for the query are the patient ID and date of admission from RICD 103 . An update program 121 then searches the tables of EMRS database 105 for the information missing from the cases compiled by query program 119 . EMRS database 105 comprises a patient information table 123 , a hospital information table 125 , a radiology table 127 , a labs table 129 , and a pathology table 131 . EMRS is a relational database. The search results of update program 121 are populated to the appropriate database record fields in RICD 103 .
[0035] Finally, user-friendly reports comprising a list of all the interesting cases are automatically generated for each resident in the training program by a report program 133 . These reports are made available to the residents upon sending a request on a PACS workstation. These reports give the resident the option to look up specific cases based on when the study was performed or the radiologic diagnoses. Such an application system enables the residents to gain a better grasp of the subject with minimal interruption of daily workflow. The system reinforces what the residents already know with pathological correlation and also enables the residents to learn from their mistakes. For example, without limitation, if the pathological diagnoses are different from their original interpretation, the resident can go back to the original study, review the pertinent clinical information and learn from it.
[0036] FIG. 2 is a flowchart illustrating an exemplary method for obtaining feedback from fellow residents and practicing radiologists, in accordance with an embodiment of the present invention. This method enables a resident or staff radiologist to forward a study they have interpreted for a second opinion. The user begins by pressing a “Send Case for Feedback” button on the PACS workstation toolbar and selects the physicians he would like to ask for a second opinion in step 201 . The system then retrieves the user ID, the patient MRN and the accession number for the case and enters the case into a questionable studies table in step 203 . The study is then sent to the queue(s) of the consulting physician(s) in step 205 . The consulting physician(s) review the study and either agree or disagree with the original interpretation in step 207 . This feedback along with any additional comments is entered into a feedback table in step 209 . Reports can then be generated in step 211 , and in step 213 these reports are available for review and learning upon request.
[0037] FIG. 3 is a flowchart illustrating the process of an exemplary software application to generate differential diagnoses based on a region of interest, in accordance with an embodiment of the present invention. Each imaging modality is different, and the present embodiment is an application for CT examinations. This application takes user input and generates a list of differential diagnoses. A similar concept can be used in alternate embodiments to create applications for other imaging modalities such as, but not limited to, MRI, Ultrasound, Plain Films, and Nuclear Medicine. With Computed Tomography (CT), lesion characterization is based on density, with Magnetic Resonance Imaging (MRI), lesion characterization is based on sequence and signal characteristics, with ultrasound, lesion characterization is based on the type of acoustic enhancement, Nuclear Medicine is functional imaging and is dependent on preferential uptake of the radiopharmaceutical by different organs. With plain films, lesion characterization is based on opacity/luceny. Therefore, each modality will require a different set of pre-populated values in the differential diagnoses table. So for example, if the ROI is placed on a CT image, after gathering all the necessary information, the program will search in the CT_DDT table to find a match to come up with the differential diagnoses.
[0038] Referring to FIG. 3 , the process begins in step 301 by identifying the abnormality in the image. Then, in step 303 , the radiologist draws an area of interest around the site of interest. The application then displays a pop up box into which the radiologist enters the organ system and location and describes the abnormality (i.e., density, shape, size, calcifications, fat, etc.) in step 305 . In step 307 the radiologist presses a “Generate differential diagnosis” button. The system generates and displays differential diagnoses in step 309 by searching a DDT database for differential diagnoses that match the information entered in step 305 . The radiologist may then use this information to help finalize their report.
[0039] Those skilled in the art will readily recognize, in accordance with the teachings of the present invention, that any of the foregoing steps and/or system modules may be suitably replaced, reordered, removed and additional steps and/or system modules may be inserted depending upon the needs of the particular application, and that the systems of the foregoing embodiments may be implemented using any of a wide variety of suitable processes and system modules, and is not limited to any particular computer hardware, software, middleware, firmware, microcode and the like. For any method steps described in the present application that can be carried out on a computing machine, a typical computer system can, when appropriately configured or designed, serve as a computer system in which those aspects of the invention may be embodied.
[0040] FIG. 4 illustrates a typical computer system that, when appropriately configured or designed, can serve as a computer system in which the invention may be embodied. The computer system 400 includes any number of processors 402 (also referred to as central processing units, or CPUs) that are coupled to storage devices including primary storage 406 (typically a random access memory, or RAM), primary storage 404 (typically a read only memory, or ROM). CPU 402 may be of various types including microcontrollers (e.g., with embedded RAM/ROM) and microprocessors such as programmable devices (e.g., RISC or SISC based, or CPLDs and FPGAs) and unprogrammable devices such as gate array ASICs or general purpose microprocessors. As is well known in the art, primary storage 404 acts to transfer data and instructions uni-directionally to the CPU and primary storage 406 is used typically to transfer data and instructions in a bi-directional manner. Both of these primary storage devices may include any suitable computer-readable media such as those described above. A mass storage device 408 may also be coupled bi-directionally to CPU 402 and provides additional data storage capacity and may include any of the computer-readable media described above. Mass storage device 408 may be used to store programs, data and the like and is typically a secondary storage medium such as a hard disk. It will be appreciated that the information retained within the mass storage device 408 , may, in appropriate cases, be incorporated in standard fashion as part of primary storage 406 as virtual memory. A specific mass storage device such as a CD-ROM 414 may also pass data uni-directionally to the CPU.
[0041] CPU 402 may also be coupled to an interface 410 that connects to one or more input/output devices such as such as video monitors, track balls, mice, keyboards, microphones, touch-sensitive displays, transducer card readers, magnetic or paper tape readers, tablets, styluses, voice or handwriting recognizers, or other well-known input devices such as, of course, other computers. Finally, CPU 402 optionally may be coupled to an external device such as a database or a computer or telecommunications or internet network using an external connection as shown generally at 412 , which may be implemented as a hardwired or wireless communications link using suitable conventional technologies. With such a connection, it is contemplated that the CPU might receive information from the network, or might output information to the network in the course of performing the method steps described in the teachings of the present invention.
[0042] It will be further apparent to those skilled in the art that at least a portion of the novel method steps and/or system components of the present invention may be practiced and/or located in location(s) possibly outside the jurisdiction of the United States of America (USA), whereby it will be accordingly readily recognized that at least a subset of the novel method steps and/or system components in the foregoing embodiments must be practiced within the jurisdiction of the USA for the benefit of an entity therein or to achieve an object of the present invention. Thus, some alternate embodiments of the present invention may be configured to comprise a smaller subset of the foregoing novel means for and/or steps described that the applications designer will selectively decide, depending upon the practical considerations of the particular implementation, to carry out and/or locate within the jurisdiction of the USA. For any claims construction of the following claims that are construed under 35 USC §112 (6) it is intended that the corresponding means for and/or steps for carrying out the claimed function also include those embodiments, and equivalents, as contemplated above that implement at least some novel aspects and objects of the present invention in the jurisdiction of the USA. For example, the servers and databases on which the programs and medical records reside and the steps performed by the programs on these servers may be performed and/or located outside of the jurisdiction of the USA while the remaining method steps and/or system components of the forgoing embodiments are typically required to be located/performed in the US for practical considerations.
[0043] Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing a system using IT to promote resident education according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. For example, the particular implementation of the application may vary depending upon the particular type of medical field to which it is applied. The applications described in the foregoing were directed to radiology implementations; however, similar techniques are to apply similar applications to different medical fields such as, but not limited to, emergency medicine, surgery, pathology, etc. Non-radiology implementations of the present invention are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims.
[0044] Claim elements and steps herein have been numbered and/or lettered solely as an aid in readability and understanding. As such, the numbering and lettering in itself is not intended to and should not be taken to indicate the ordering of elements and/or steps in the claims.
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A method and a system for integrating a Radiology Information System (RIS) and hospital electronic medical records system (EMRS) within picture archiving and communications systems (PACS) to promote learner based education includes steps and means for flagging an interesting patient case, being viewed in PACS, for follow-up on diagnoses. Submitting the flagged interesting patient case, wherein the EMRS is queried for diagnoses information for the interesting patient case. Requesting a report for the interesting patient case where at least one diagnoses is available. Requesting feedback on a patient case interpretation, wherein information from PACS workstation and EMRS is sent to consulting physicians for reviewing. Requesting a report generation from the reviewing. Identifying an abnormality in a patient case image using the PACS workstation. Providing information regarding the abnormality. Requesting a differential diagnoses, wherein the information and the differential diagnoses table (DDT) are used to produce the differential diagnoses. Receiving the differential diagnoses.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of U.S. patent application Ser. No. 11/652,780 filed Jan. 12, 2007 now abandoned, and claims the benefit of U.S. Provisional Application No. 60/763,996 filed Jan. 31, 2006.
FIELD OF THE INVENTION
The present invention relates generally to protective footwear for dogs or other pets, to provide protection from heat of a pavement or other surface on which the pet is walking, or from rough terrain, wet, dirty or icy surfaces, and the like, and also to protect injured paws or paws on which medication has been applied.
BACKGROUND OF THE INVENTION
Protective booties, socks, or shoes have been proposed for pets such as dogs in the past, both to protect the animal's paws when outdoors, and also to prevent soiling of indoor floors when the animal returns from a walk or the like. The owner simply removes the booties before the animal enters the house. Such footwear is generally non-disposable and must be washed between uses, and is often of a relatively complex and cumbersome nature. For example, U.S. Pat. No. 6,546,704 of Fisher describes a dog boot comprising a planar flexible sheet of material comprising a high friction outer layer, a foam central layer, and a fabric inner layer. The sheet is designed to be wrapped around the leg and foot and snapped together with fastener straps:
U.S. Pat. No. 5,452,685 of Thomas describes a dog bootie comprising a tube of canvas material or the like having a closed bottom end and hook and loop fastening means around the open top. U.S. Pat. No. 5,495,828 of Solomon et al. describes animal boots each comprising a pliable sleeve with a waterproof outer layer and a fabric inner layer, and an adjustable fastening strap secured around the sleeve adjacent the open end by means of hook and loop type fastener material.
One problem in these sleeve-like booties with fastener straps using hook and loop material or buckle-like fasteners is that they may tend to slip off or be pulled off by the dog or other pet. They also can be awkward to fasten around the animal's legs.
To solve these aforementioned problems, the present invention provides a disposable protective bootie having an elastic loop to secure the bootie to the animal's leg. The protective bootie is suitable for both indoor and outdoor use. The protective bootie may be used to protect the animal's paws from unwanted or potentially harmful materials, such as snow, ice, mud, chemicals, or other debris. With a sufficient cushion, the protective bootie may be used to protect the animal from extreme weathers and to provide additional comforts to the animal. Furthermore, the protective bootie may also be used to protect other surfaces such as floors, from getting soiled by the animal. The protective bootie of the present invention is relatively inexpensive, and can readily be modified to suit different size animals and supplied to pet owners in bulk quantities for convenience.
SUMMARY OF THE INVENTION
According to one of the embodiment of the present invention, a protective bootie for an animal is provided, which comprises a sleeve having a lower closed end and an upper open end for receiving the animal's paw, and an elastic loop having an inner end attached to the sleeve at a predetermined distance from the open end of the sleeve and projecting outwardly from the sleeve. The sleeve of the protective bootie has a front and rear panel, which each have a paw section proximate to the lower closed end and a leg section proximate to the upper open end. As used herein, the term “leg section” refers to a section of the panel that is in contact with an ankle, or an ankle and a leg of the animal when in use. The paw section of the rear panel may function as a bootie sole. The leg section of the bootie has an upper end as the upper open end of the protective bootie, and a lower end attached to the paw section.
The elastic loop is adapted to the animal's leg for securing the protective bootie to the animal's leg by looping around the leg at least once. The elastic loop has a predetermined extended length to be adapted to the animal's leg by looping around the leg at least once when the paw is inserted into the closed end of the sleeve, whereby the sleeve is secured in position. The elastic loop may be looped once, twice, or more around the animal's leg, as needed for sufficient gripping force. The elastic loop is much faster and easier to engage about the leg than fastener straps or the like.
In another embodiment, the protective bootie further comprises an elastic strip, which is attached in proximity to the open end of the sleeve for gripping against the animal's leg while the sleeve is in use, for additional security. The elastic strip may be secured on an inner surface of the sleeve opening, so as to engage the animal's leg and fur directly for added slip resistance. Furthermore, the upper open end of the leg section may have a width larger than the lower end that is connected to the paw section of the protective bootie. The length of elastic strip at the upper end of the leg section is selected such that the upper open end of the protective bootie is larger in width than the lower end of the leg section when the elastic strip is fully extended, and is still capable of engaging the animal's leg and fur to provide additional slip resistance when in use. The leg section of the protective bootie may have the shape of a trapezoid with the longer base at the upper open end and the shorter base attached to the paw section.
In yet another embodiment, the protective bootie also comprises an ankle pleat, which is a transverse fold extending between the opposite sides of the rear panel at a location which corresponds approximately to the animal's ankle. The ankle pleat, when the bootie is worn, provides a bend that separates the paw section from the leg section of the sleeve. In this case, the elastic loop may be attached to the leg section of the sleeve, adjacent or just above the ankle pleat.
In still another embodiment, the paw section of the front or rear protective bootie also has at least one secondary layer attached to the interior and/or exterior surface of the paw section. The secondary layer may be a non-skid or non-slip layer that is attached to the exterior surface of the paw section of the rear panel. The non-skid layer can be made of various types of rubberized materials, such as vinyl, latex, neoprene, silicone, and the like, for durability, wear resistance and increased traction on various types of terrain. The non-skid layer may also be textured, such as with a paw print, to provide additional tractions. The secondary layer may function as a cushion or reinforced toe, which is attached to the interior and/or exterior surface of the paw section to provide additional protections and/or comforts for the animal. As such, the thickness of the paw section of the rear panel may be thicker than the leg portion.
In an alternative embodiment, the protective bootie also contains an inner layer that can be impregnated with a fragrance, a pharmaceutical, a moisturizer, or the like. The impregnated material may release the above fragrance, moisturizer, or pharmaceutical through the process of hydration to act as an emollient on the paw pad of the animal.
The sleeve of the protective bootie may be of multiple piece construction. In a two piece construction, for example, the sleeve is formed by a pair of opposing front and rear side walls or panels which are secured together along at least one side edge and the closed lower end of the sleeve. The side walls may be formed by two separate sheets of material of predetermined shape and dimensions joined together by sewing or bonding along their peripheral edges to form the opposite sides and closed end of the sleeve. Alternatively, the sleeve of the protective bootie may be manufactured from a single piece of flexible material. For example, a single sheet of material may be cut to form the opposite side walls and then folded along its center line before being sewn along the opposing free side edges and lower end.
The sleeve is made from a suitably inexpensive, disposable material which has a non-skid or skid-resistant outer surface, and which is substantially waterproof or liquid impervious to protect the animal's paws from getting wet in snow or rain. In certain embodiments, the sleeve was made from a laminate comprising a layer of polyethylene on the outer surface of the bootie and a layer of spun bond polypropylene on the inner surface of the bootie. This material is relatively inexpensive yet is very strong and tear resistant.
The disposable animal booties of this invention provide a quick and convenient means for protecting an animal's paws when leaving the home on walks or the like. The booties protects the paws against both hot and cold surfaces in summer and winter, as well as against snow, ice, mud or the like, and against other materials such as dirt, chemicals, or other debris they may pick up while walking. The booties also protect floor surfaces in the home against soiling by a dog's muddy paws or the like, and can protect injured paws while the animal is walking outdoors or indoors. They can simply be removed and discarded on return to the home. The booties may also be used indoors when a pet has to have medication (e.g., antimicrobials), moisturizer, ointment or the like applied to their pads or elsewhere on the paws. The bootie protects the medication and prevents it from coming off on surfaces where the pet is sitting or walking, and also prevents the animal from licking off the medication, which is a common problem. The booties are relatively inexpensive and can be provided to pet owners in bulk quantities for convenience.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is better understood from the following detailed description of an exemplary embodiment of the invention, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts, and in which:
FIG. 1 is a bottom plan view of an animal bootie according to an exemplary embodiment of the invention;
FIG. 2 is a cross-section on the line 1 A- 1 A of FIG. 1 ;
FIG. 3 is a top plan view of the animal bootie of FIG. 1 ;
FIG. 4 is a top plan view similar to FIG. 3 showing the elastic loop secured around the bootie;
FIG. 5 is a front elevation view illustrating the bootie in use and secured over an animal's paw;
FIG. 6 is a rear elevation view illustrating the bootie in use;
FIG. 7 is a top plan view of a cut out blank of material prior to folding to form the bootie according to an exemplary embodiment of the present invention;
FIG. 8 is a bottom plan view of an animal bootie according to an alternative exemplary embodiment of the invention, when the elastic strip is fully extended;
FIG. 9 is a bottom plan view similar to FIG. 8 with the elastic strip fully relaxed; and
FIG. 10 is a top plan view of a cut out blank of material prior to folding to form the protective bootie of FIGS. 8 and 9 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 6 illustrate a disposable animal bootie 10 according to an exemplary embodiment of the present invention, while FIG. 7 illustrates a blank of material which may be used for making the bootie.
The animal bootie 10 basically comprises an elongate sleeve 12 having a rounded, closed end 14 and an open end 15 , and a loop 16 of elastic material having an inner end 17 secured to a side seam of the sleeve by stitching or the like, so that the loop projects outwardly from the sleeve when not in use.
The sleeve 12 has a front wall 18 and a rear wall 19 secured together along their peripheral side edges and lower end edges by stitching to form seam 20 , as generally indicated in FIG. 2 , and then turned inside out so that the stitching is concealed on the inside of the bootie. A strip 22 of elastic or rubberized material is secured around the open end 15 of the sleeve and has a length smaller than the circumference of the open end of the sleeve, so that the opening is gathered or drawn inwardly, as indicated in the drawings. The strip 22 is sewn along the upper ends of the sheets of material forming the front and rear walls before folding them together and sewing the final side seam.
FIG. 7 illustrates a suitable blank 23 for forming the sleeve 12 . This may be formed by cutting two separate sheets of appropriate shape and dimension for forming the front and rear walls 18 , 19 , or a single sheet may be cut to the illustrated shape and then folded along the central seam or fold line 24 to form the sleeve. This reduces the amount of stitching required and therefore the cost of manufacture. If formed from two separate sheets, the sheets is first sewn together along central seam 24 , and then the strip 22 of elastic is sewn across the upper edges of the connected sheets on the side which corresponds to the inner surface of the sleeve, as indicated in dotted lines. The sheets is then folded together along central seam 24 and sewn together along the aligned side edges 26 and lower end edges 28 . In an exemplary embodiment, a transverse fold 30 is formed across the width of the sheet which comprises the rear wall 19 of the finished sleeve. The fold is located at a position which is adjacent the ankle of the animal when the sleeve is in use, so that a bend or joint is formed at this location, separating a paw portion of the sleeve from a leg engaging portion of the sleeve, as can be seen in FIGS. 5 and 6 .
Elastic loop 16 is formed from a strip of elastic material, which may be a nylon covered, braided elastic or equivalent, and is a stronger elastic material than the elastic strip 22 around the open end of the sleeve. Both the strip forming loop 16 and the strip 22 may be of the order of ⅛ to ⅜ inches in width. The ends of the strip or band forming the loop 16 are sewn into one of the side seams of the sleeve so that the loop projects outwardly when the bootie is not in use, as best illustrated in FIGS. 1 and 3 .
Loop 16 is located relatively close to fold 30 , as indicated, and between the fold and the open upper end 15 of the sleeve. In an exemplary embodiment, loop 16 is located at a point which is approximately one third of the distance from the open end 15 to the closed end of the sleeve, and the fold 30 may be located one third to one half of the distance from the open end 15 to the closed end. Ideally, the elastic loop 16 is located just above the animal's paw when the bootie is worn, adjacent the ankle, and the fold 30 is located at the ankle. Although the bootie extends several inches up the animal's leg from loop 16 in the illustrated embodiment, it may be made shorter in alternative embodiments, with the open end located only an inch or so above the elastic loop 16 to provide a gripping area for loop 16 . In this case, the elastic strip 22 around the open upper end of the sleeve may be eliminated.
FIGS. 5 to 6 illustrate use of the booties to protect an animal's paws 32 . When the animal, such as a dog, is going outdoors for a walk or the like, the owner simply pulls a bootie 10 over each paw. The elastic strip 22 around the open end grips against the animal's leg to hold the bootie in place while the owner stretches loop 16 and pulls it over the paw so that it engages around the sleeve 12 and enclosed leg, as indicated in FIGS. 4 to 6 . The elastic strip 22 is exposed on the inner side of the opening 15 , so that it can grip against the animal's leg or fur, so that there are fewer tendencies for the bootie to slip down prior to application of the securing loop 16 . If necessary, depending on the circumference of the animal's leg, the loop 16 can be looped around the sleeve and leg more than once, until a sufficiently tight yet comfortable fit is achieved. The booties can be secured over all four paws of an animal relatively quickly, with the upper elastic 22 holding them in position while the loops 16 are engaged around the respective sleeves. The bootie is quite comfortable for the animal so that they are less likely to try to bite or scratch them off.
The protective booties of this invention is be made in a range of sizes depending on the size and type of animal. Table 1 below is an example of a range of different sizes for different breeds of dog. The dimensions are such that the bootie is always extending above the ankle joint of the dog.
It can be seen that the securing loop or band 16 has an extended length which is around double the relaxed length, which is sufficient for extending the loop around the animal's paw and the sleeve, into the operative position illustrated in FIGS. 4 to 6 .
FIGS. 8 and 9 illustrate a protective bootie 10 according to an alternative embodiment of the present invention. The upper open end 55 of the leg section 61 has a width larger than the lower end 56 that is connected to the paw section 60 of the protective bootie 10 . The length of elastic strip 22 is selected as such that the upper open end 55 is larger in width than the lower end of the leg section when the elastic strip 22 is fully extended, but is still capable of engaging the animal's leg and fur to provide additional slip resistance when in use. As shown in FIG. 8 , in the fully extended state, the leg section 61 of the protective bootie 10 is in the shape of a trapezoid with the longer base at the upper open end 55 and the shorter base 56 connected to the paw section 60 around the ankle pleat.
FIG. 10 illustrates a suitable blank 73 for forming the sleeve of the protective bootie in FIGS. 8 and 9 . This is formed by cutting two separate sheets of appropriate shape and dimension for forming the front and rear walls 18 and 19 . A transverse fold 30 is formed across the width of the sheet which comprises the rear wall 19 of the finished sleeve, which separates the paw section 60 from the leg section 61 . In this exemplary embodiment, the leg section 61 has the shape of a trapezoid with the longer base at the upper open end 55 and the shorter base 56 connected to the paw section 60 .
The material selected for sleeve 12 is a relatively lightweight, inexpensive, moisture resistant material, which in one embodiment is strong and water resistant. In other embodiments, while not being water resistant, the material is particle-resistant. The material is preferably inexpensive and could also be biodegradable so that the booties can be bought in large quantities and discarded after use. One suitable material is a laminate comprising a spun bonded polypropylene layer laminated to or co-extruded with a layer of polyethylene with a non skid coating for forming the outer surface of the sleeve. Other suitable non-skid materials include vinyl latex, neoprene or silicone. These materials are available from several manufacturers. Skid-resistance is useful when an animal is walking on slippery or icy surfaces. Other suitable materials are polyvinyl chloride (PVC) or the like.
TABLE 1
B
Paw
Length &
C
D
A
bottom
Total Bootle
Paw
Size
Paw Width
elastic
Weight
Length
Dog Type
Height
XX-small
1.″
1.5-″
2-5 lbs
3.5″
Chihuahua/Pomeranian/
1″
Yorkshire
Terrier/Pug/Young
Puppies/Tea Cup Poodle
X Small
1.5″
2″
10-15 lbs
5.5″
Silky Terrier/Japanese
1″
Chin/Maltese/Poodle/Pug/
French Bulldog/Miniature
Pincher/Pug/
Small
2″
2.5″
20-40 lbs
6″
Cocker Spaniel/Miniature
1.5″
Poodle/Toy Poodle/
Norfolk Terrier/Shi
Tzu/Whippet/Miniature
Pincher/Daschund
Medium
2.5″
3.3″
40-50 lbs
7″
Cocker Spaniel/Chow
2″
Chow/Standard
Poodle/Beagle/Bull
Dog/Dalmatian/Fox
Terrier/Doberman/
Large
3″
3.75′
50-70
8″
Golden Retriever/German
2.25″
Shephard/Bulldog/Doberman/
Basset
Hound/Bloodhound/Husky/
Irish Setter/Rottweiler/
Akita/Weimaraner
X Large
3.5″
4.5″
70-90
9.5″
Labrador Retriever/Golden
2.5″
Retriever/Siberian Husky/
Irish Wolfhound
XX Large
4″
5.5″
90 plus
12″
Bullmastif/Great
2.5″
Dane/saint Bernard/Irish
Setter/Husky/Akita
E
F
G
Top Elastic
Tope elastic
Lower loop
H
Scale, using the
total length
total length
elastic length
Lower loop elsatic
Size
Paw width
when relaxed
when stretched
when relaxed
when streteched
XX-small
XX Small 1″-1.5″
1″
2″
2″
4″
X Small
X Small 1.5″-2″
2″
4″
2.5″
5″
Small
Small 2″-2.5″
3″
6″
3″
6″
Medium
Medium 2.5″-3″
4″
8″
3.5″
7″
Large
Large 3″-3.5″
5″
10″
4″ maybe a little
8″
less
X Large
X Large 3.5″-4″
6″
12″
4.5″
9″
XX Large
XX Large 4+″
7″
14″
5″
10″
In one embodiment, the outer surface includes a non-skid layer in the shape of a paw print 41 , which may be made of latex. In another embodiment, the bootie includes a reinforced toe. In yet another embodiment, the bootie includes a reflective strip or member attached thereto.
The disposable booties of this invention are particularly useful for animals such as dogs which often go outside on walks or the like, regardless of weather conditions. The booties are easy to secure over the animal's paws, simply by sliding the sleeve over the paw and then stretching the elastic loop 16 around the leg and sleeve to hold the bootie in place to provide protection from elements in the environment. An animal wearing the booties may have their paws protected from hot surfaces such as pavements or beaches in summer and from cold or icy surfaces in winter. The paws are also kept clean and protected even if walking on muddy or wet surfaces, or in snow.
The booties may also provide some protection against rough terrain, debris, allergens leaves, and seed pods which may otherwise stick to the animal's fur and cause discomfort, requiring removal by the owner after the walk. Some protection against non-naturally occurring environmental elements, such as chemicals, glass shards, or the like which may be encountered during a walk is also provided. On return from the walk or other time spent outside, the booties can simply be removed and discarded before the animal enters the home, avoiding potential soiling of indoor surfaces by wet, soiled or muddy paws.
Another advantage of the booties of this invention is that they can be used to protect a sore or injured paw to reduce discomfort to the animal, and to protect a bandaged paw or a paw to which medication such as an antimicrobial ointment, powder, or a moisturizer, has been applied. This helps to keep the ointment on the affected area for a longer period, because the animal is most likely unable to lick it off, and also prevents the ointment from being spread onto other surfaces. In one example of the invention, a plurality of booties could be packaged together with a tube of ointment or moisturizer, for convenient use by an animal owner in treating or moisturizing the animal's paws over an extended period of time.
Although an exemplary embodiment of the invention has been described above by way of example only, it is understood by those skilled in the field that modifications may be made to the disclosed embodiment without departing from the scope of the invention.
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A pet bootie is formed by a sleeve of pliable, disposable and liquid impervious material having a closed end for receiving an animal's paw and an open end. A loop of elastic material has an inner end secured to the sleeve at a predetermined distance from the open end of the sleeve and projecting outwardly from the sleeve. The loop is of predetermined extended length for allowing the loop to be extended around the sleeve and the animal's leg when the paw is inserted into the closed end of the sleeve, whereby the sleeve is secured in position.
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This application is a Continuation of pending U.S. patent application Ser. No. 12/536,086, filed Aug. 5, 2009, and entitled “DC-DC Converter with a Constant On-Time Pulse Width Modulation Controller”, the entirety of which is incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a controller of a DC-DC converter, and more particularly to a DC-DC converter with a constant on time (COT) pulse width modulation (PWM) controller.
2. Description of the Related Art
DC-DC converters are widely used for various electronic devices. A constant on-time (COT) voltage regulator is one type of DC-DC converter. In general, a COT voltage regulator may turn on a main switch during a fixed period when a feedback voltage is smaller than a reference voltage, and the COT voltage regulator may adjust a turn off period of the main switch so that a steady output voltage may be provided. An output capacitor with a high equivalent series resistance (ESR) disposed in parallel with a load is necessary for a conventional COT voltage regulator, so that a steady output voltage may be provided. However, although a high ESR may help to provide system stability, for a COT voltage regulator, probability of output ripples increase due to the high ESR, which negatively influence the output voltage and power conversion efficiency of the COT voltage regulator.
U.S. Pat. No. 6,583,610 discloses a voltage regulator which operates in ripple-mode and comprises a virtual ripple generator. The virtual ripple generator provides a regulator feedback signal that includes a generated ripple component as a composite signal. The composite signal is generated according to an actual output signal and a ripple signal synchronized to switching cycles of the voltage regulator. Thus, the regulation feedback signal reflects the DC value of the output signal and is responsive to transient changes in the output signal level.
BRIEF SUMMARY OF THE INVENTION
DC-DC converters are provided. An exemplary embodiment of the DC-DC converter for converting an input voltage into an output voltage is provided. The DC-DC converter comprises an input node for receiving the input voltage, an output node for providing the output voltage to a load, an inductor coupled between the output node and a first node, a first transistor coupled between the input node and the first node, a second transistor coupled between the first node and a ground, and a Pulse Width Modulation (PWM) controller. The PWM controller comprises an error amplifier, a first comparator, a PWM generator, and a ramp generator. The error amplifier receives a reference voltage and the output voltage to generate an error signal according to a difference between the reference voltage and the output voltage. The first comparator compares the error signal with a ramp signal to generate a trigger signal. The PWM generator generates a PWM signal with a fixed turn-on time, wherein a frequency of the PWM signal is adjusted according to the trigger signal, the input voltage and the output voltage. The ramp generator generates the ramp signal according to the PWM signal, the input voltage and the output voltage. The PWM controller provides the PWM signal to control the first transistor and the second transistor, so as to convert the input voltage into the output voltage.
Furthermore, another exemplary embodiment of a DC-DC converter for converting an input voltage into an output voltage is provided. The DC-DC converter comprises an input node for receiving the input voltage, an output node for providing the output voltage to a load, an inductor coupled between the output node and a first node, a first transistor coupled between the input node and the first node, a second transistor coupled between the first node and a ground, and a PWM controller. The PWM controller comprises an error amplifier, a sense unit, a compensation unit, a first comparator, a PWM generator, and a ramp generator. The error amplifier receives a reference voltage and the output voltage to generate an error signal according to a difference between the reference voltage and the output voltage. The sense unit senses the inductor to generate a sense current. The compensation unit generates a compensation signal according to the error signal and the sense current. The first comparator compares the compensation signal with a ramp signal to generate a trigger signal. The PWM generator generates a PWM signal with a fixed turn-on time, wherein a frequency of the PWM signal is adjusted according to the trigger signal, the input voltage and the output voltage. The ramp generator generates the ramp signal according to the PWM signal, the input voltage and the output voltage. The PWM controller provides the PWM signal to control the first transistor and the second transistor, so as to convert the input voltage into the output voltage.
Moreover, another exemplary embodiment of a DC-DC converter for converting an input voltage into an output voltage is provided. The DC-DC converter comprises an input node for receiving the input voltage, an output node for providing the output voltage to a load, an inductor coupled between the output node and a first node, a first transistor coupled between the input node and the first node, a second transistor coupled between the first node and a ground, and a PWM controller. The PWM controller comprises an error amplifier, a sense unit, a compensation unit, a first comparator, a PWM generator, and a ramp generator. The error amplifier receives a reference voltage and the output voltage to generate an error signal according to a difference between the reference voltage and the output voltage. The sense unit generates a sense current corresponding to a loading of the load. The compensation unit generates a compensation signal according to the sense current and a ramp signal. The first comparator compares the compensation signal with error signal to generate a trigger signal. The PWM generator generates a PWM signal with a fixed turn-on time, wherein a frequency of the PWM signal is adjusted according to the trigger signal, the input voltage and the output voltage. The ramp generator generates the ramp signal according to the PWM signal, the input voltage and the output voltage. The PWM controller provides the PWM signal to control the first transistor and the second transistor, so as to convert the input voltage into the output voltage.
A detailed description is given in the following embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
The invention can be more fully understood by reading the subsequent detailed description and examples with references made to the accompanying drawings, wherein:
FIG. 1 shows a DC-DC converter according to an embodiment of the invention;
FIG. 2 shows a waveform diagram illustrating the relationship between the PWM signal S PWM and a current I L flowing through the inductor L of FIG. 1 ;
FIG. 3A shows a PWM generator according to an embodiment of the invention;
FIG. 3B shows a waveform diagram of the signals in the PWM generator of FIG. 3A ;
FIG. 4A shows a ramp generator according to an embodiment of the invention;
FIG. 4B shows a waveform diagram of the signals in the ramp generator of FIG. 4A ;
FIG. 5 shows an example illustrating a waveform diagram of the signals of the DC-DC converter of FIG. 1 ;
FIG. 6 shows another example illustrating a waveform diagram of the signals of the DC-DC converter of FIG. 1 ;
FIG. 7 shows a DC-DC converter according to another embodiment of the invention.
FIG. 8 shows a DC-DC converter according to another embodiment of the invention;
FIG. 9 shows a DC-DC converter according to another embodiment of the invention; and
FIG. 10 shows a DC-DC converter according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best-contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention and should not be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
FIG. 1 shows a DC-DC converter 100 according to an embodiment of the invention. The DC-DC converter 100 converts an input voltage V IN received from an input node N in into an output voltage V OUT . The DC-DC converter 100 comprises two transistors MU and ML, an inductor L, a control unit 110 and a PWM controller 120 . The transistor MU is coupled between the input node N in and a node N 1 , and the transistor ML is coupled between the node N 1 and a ground GND. In this embodiment, the transistors MU and ML are N-type transistors which function as the switches. The control unit 110 receives a pulse width modulation (PWM) signal S PWM provided by the PWM controller 120 and controls the transistors MU and ML to switch on or off according to the PWM signal S PWM . The inductor L is coupled between the node N 1 , and an output node N out , wherein the output voltage V OUT is outputted to a load 180 via the output node N out . Furthermore, an output capacitor C 1 with a lower equivalent series resistance (ESR) is coupled between the N out and the ground GND, and a resistor Resr represents an ESR of the output capacitor C 1 .
As shown in FIG. 1 , the PWM controller 120 comprises a ramp generator 130 , a PWM generator 140 , a compensation unit 150 , an error amplifier 160 and a comparator 170 . The error amplifier 160 receives a reference voltage Y REF and the output voltage V OUT to generate an error signal V ERR according to a difference between the reference voltage V REF and the output voltage V OUT . The compensation unit 150 coupled between an output terminal of the error amplifier 160 and the comparator 170 is used to compensate the error signal V ERR , and the compensation unit 150 comprises a resistor 152 coupled to the output terminal of the error amplifier 160 and a capacitor 154 coupled between the resistor 152 and the ground GND. After the error signal V ERR is compensated, the comparator 170 compares the error signal V ERR with a ramp signal S RAMP provided by the ramp generator 130 to generate a trigger signal S TR . The PWM generator 140 generates the PWM signal S PWM according to the trigger signal S TR , the input voltage V IN and the output voltage Y OUT . The ramp generator 130 generates the ramp signal S RAMP according to the PWM signal S PWM , the input voltage Y IN and the output voltage Y OUT .
FIG. 2 shows a waveform diagram illustrating the relationship between the PWM signal S PWM and a current I L flowing through the inductor L of FIG. 1 . Referring to FIG. 1 and FIG. 2 together, during a period T on (i.e. a turn-on time of the PWM signal), the PWM signal S PWM controls the transistor MU to turn on and controls the transistor ML to turn off. During a period T off (i.e. a turn-off time of the PWM signal), the PWM signal S PWM controls the transistor MU to turn off and controls the transistor ML to turn on. As shown in FIG. 2 , the current I L has a minimum current value I min (ex. I min =O) at time t 1 , and then the current I L starts to increase and reaches a maximum current value I max at time t 2 , wherein I max =2×I avg and I avg represents an average current value of the current I L . Next, the current I L starts to decrease and reaches the minimum current value I min at time t 3 . A rising slope SI of the current I L may be given by the following Equation (1):
S 1 = V IN - V OUT L = 2 × I avg T on . ( 1 )
According to the Equation (1), the period T on may be given by the following Equation (2):
T on = 2 × I avg × L V IN - V OUT . ( 2 )
In addition, a falling slope S 2 of the current I L may be given by the following Equation (3):
S 2 = V OUT L = 2 × I avg T off . ( 3 )
According to the Equation (3), the period T off may be given by the following Equation (4):
T off = 2 × I avg × L V OUT . ( 4 )
Therefore, according to the Equations (2) and (4), a period T and a frequency F SW of the PWM signal S PWM may be given by the following Equations (5) and (6), respectively:
T
=
T
on
+
T
off
=
2
×
I
avg
×
L
(
1
V
IN
-
V
OUT
+
1
V
OUT
)
;
and
(
5
)
F
SW
=
1
T
=
1
2
×
I
avg
×
L
×
(
V
IN
-
V
OUT
)
×
V
OUT
V
IN
.
(
6
)
Suppose that the period T on has a relationship with a ratio of the output voltage V OUT to the input voltage V IN , i.e.
T on = RCK ( V OUT V IN ) ,
wherein the parameters R, C and K are constant. Therefore, the period T on may be rewritten as the following Equation (7) to obtain the following Equation (8):
T on = R C K ( V OUT V IN ) = 2 × I avg × L V IN - V OUT ;
and ( 7 ) 2 × I avg × L = R C K ( V OUT V IN ) ( V IN - V OUT ) . ( 8 )
According to the Equation (8), the period T off may be rewritten as the following Equation (9):
T off = 2 × I avg × L V OUT = R C K ( V IN - V OUT V IN ) . ( 9 )
Thus, according to the Equations (7) and (9), the period T of the PWM signal S PWM may be rewritten as the following Equation (10):
T
=
Ton
+
Toff
=
R
C
K
(
V
OUT
V
IN
)
+
R
C
K
(
V
IN
-
V
OUT
V
IN
)
=
R
C
K
.
(
10
)
Due to the parameters R, C and K being constant, the period T of the PWM signal S PWM is fixed.
FIG. 3A shows a PWM generator 300 according to an embodiment of the invention. The PWM generator 300 comprises an amplifier 310 , a current generating unit 320 , a comparator 330 , a transistor MI, a resistor R RT and a capacitor C ON . The amplifier 310 has an inverting input terminal coupled to a node N 2 , a non-inverting input terminal for receiving a voltage V 1 and an output terminal coupled to a gate of the transistor M 1 , wherein the voltage V 1 is a voltage in proportion to the input voltage V IN , i.e. VI=KI×V IN . The current generating unit 320 is used as an example for description, and does not limit the invention. For example, the current generating unit 320 may be a current mirror circuit. When the trigger signal S TR is triggered, a current I 1 provided by the current generating unit 320 may flow through the transistor MI and the resistor R RT , wherein a current value of the current I 1 is determined according to the voltage VI and the resistor R RT , ex. I 1 =VI/R RT =KI×V IN /R RT . Simultaneously, the capacitor C ON is charged by a current I 2 provided by the current generating unit 320 when the trigger signal S TR is triggered. In one embodiment, a current value of the current I 2 is equal to that of the current I 1 , ex. I 2 =K 1 ×V IN /R RT . In another embodiment, the current I 2 is a current in proportion to the current I 1 .
FIG. 3B shows a waveform diagram of the signals in the PWM generator 300 of FIG. 3A . Referring to FIG. 3A and FIG. 3B together, a voltage V c represents a voltage across the capacitor C ON . The comparator 330 is used to compare the voltage V C with a voltage V 2 , wherein the voltage V 2 is a voltage in proportion to the output voltage V OUT , i.e. V 2 =K 2 ×V OUT . When the voltage V C is smaller than the voltage V 2 , an active state of the PWM signal S PWM is asserted, i.e. the period T on . On the contrary, when the voltage V C is larger than the voltage V 2 , an inactive state of the PWM signal S PWM is asserted, i.e. the period T off . Therefore, the period T on and the period T off may be given by the following Equations (11) and (12), respectively:
T on = C ON I 2 dV 2 = R RT C on ( K 2 K 1 ) V OUT V IN ;
and ( 11 ) Toff = R RT C on ( K 2 K 1 ) V IN - V OUT V IN . ( 12 )
Due to the resistor R RT , the capacitor C ON and the parameters K 1 and K 2 being constant, the period T on and the period T off are determined according to the input voltage V IN and the output voltage V OUT .
FIG. 4A shows a ramp generator 400 according to an embodiment of the invention. The ramp generator 400 comprises an amplifier 410 , two transistors M 2 and M 3 , a capacitor C OFF and a current source 420 . The amplifier 410 has an invelting input terminal coupled to the transistor M 2 , a non-inverting input terminal for receiving a voltage V 3 and an output terminal coupled to the inverting input terminal, wherein the voltage V 3 is a voltage in proportion to a difference between the input voltage V IN and the output voltage V OUT , i.e. V 3 =K 3 ×K 1 ×(V IN −V OUT ). The transistor M 2 is coupled between the output terminal of the amplifier 410 and a node N 3 , and the transistor M 3 is coupled between the node N 3 and the current source 420 , wherein the ramp signal S RAMP is a voltage at the node N 3 . The transistors M 2 and M 3 are controlled by the PWM signal S PWM and a signal SB PWM , respectively, wherein the signal SB PWM is a reversed signal for the PWM signal S PWM . Therefore, the transistor M 2 is turned on and the transistor M 3 is turned off when an active state of the PWM signal S PWM is asserted, and the transistor M 2 is turned off and the transistor M 3 is trned on when an inactive state of the PWM signal S PWM is asserted.
FIG. 4B shows a waveform diagram of the signals in the ramp generator 400 of FIG. 4A . Referring to FIG. 4A and FIG. 4B together, the ramp signal S RAMP represents the voltage of the node N 3 , i.e. a voltage across the capacitor C OFF . When an active state of the PWM signal S PWM is asserted, the transistor M 2 is turned on and the transistor M 3 is turned off, such that the capacitor C OFF is charged by the amplifier 410 via the transistor M 2 , and then the voltage across the capacitor C OFF is charged to a voltage level of the voltage V 3 . On the contrary, when an inactive state of the PWM signal S PWM is asserted, the transistor M 2 is turned off and the transistor M 3 is turned on, such that the capacitor C OFF is discharged by the current source 420 via the transistor M 3 , and then the voltage across the capacitor C OFF is decreased until a subsequent active state of the PWM signal S PWM is asserted. In the embodiment, the current source 420 may sink a current I 3 from the node N 3 to the ground GND to decrease the ramp signal S RAMP , wherein the current I 3 corresponds to the input voltage V IN . The current source 420 is used as an example, and does not limit the invention. In one embodiment, a current value of the current I 3 is equal to that of the current I 1 of the PWM generator 300 in FIG. 3A , ex. I 3 =KI×V IN /R RT . In another embodiment, the current I 3 is a current in proportion to the current U 1 . Therefore, a voltage variation dV RAMP of the ramp signal S RAMP during the period T off may be given by the following Equation (13):
dV RAMP = I 3 C OFF dT = K 1 × V IN R RT × C OFF T off = K 1 × V IN R RT × C OFF × R RT C ON ( K 2 K 1 ) V IN - V OUT V IN = K 2 ( C ON C OFF ) ( V IN - V OUT ) = V 3 - V steady , ( 13 )
wherein a voltage level V steady represents an ideal steady voltage level of the error signal V ERR in FIG. 1 . Therefore, according to the Equation (13), the voltage level V steady of the error signal V ERR may be given by the following Equation (14):
V steady = V 3 - K 2 ( C ON C OFF ) ( V IN - V OUT ) = K 3 × K 1 ( V IN - V OUT ) - K 2 ( C ON C OFF ) ( V IN - V OUT ) = ( ( K 3 × K 1 ) - K 2 ( C ON C OFF ) ) ( V IN - V OUT ) . ( 14 )
By choosing the parameters K 1 , K 2 and K 3 and the capacitors C ON and C OFF appropriately, the error signal V ERR is designed to operate at a direct current (DC) operation voltage level, i.e. the ideal steady voltage level V steady .
Referring to FIG. 1 , a fine adjustment of the error signal V ERR is automatically performed for a feedback loop of the DC-DC converter 100 according to the determined DC operation voltage level of the error signal V ERR , so as to determine a time period that the trigger signal STR is triggered for every period T of the PWM signal S PWM , thus obtaining a pseudo fix frequency PWM controller.
FIG. 5 shows an example illustrating a waveform diagram of the signals of the DC-DC converter 100 of FIG. 1 . By using the error amplifier 160 to generate the error signal V ERR and comparing the error signal V ERR with the ramp signal S RAMP to adjust a duty cycle of the PWM signal S PWM , an included angle θ between the error signal V ERR and the ramp signal S RAMP is large at time t 4 and sufficient to avoid noise interference, thus increasing a signal to noise ratio (SNR) thereof. FIG. 6 shows another example illustrating a waveform diagram of the signals of the DC-DC converter 100 of FIG. 1 . Referring to FIG. 6 and FIG. 1 together, the period T H represents that the load 180 has a higher loading, and the period T L represents that the load 180 has a lower loading. In addition, the load 180 is changed from the lower to higher loading at time t 5 and changed from the higher to lower loading at time t 6 . When the loading of the load 180 is changed, the comparator 170 may immediately adjust the time period that the trigger signal S TR is triggered by comparing the ramp signal S RAMP and the error signal V ERR . Therefore, the DC-DC converter 100 may promptly provide the output voltage V OUT in response to the loading of the load 180 , thereby increasing system stability.
FIG. 7 shows a DC-DC conve1ter 700 according to another embodiment of the invention. The DC-DC converter 700 is applied to a capacitor C 2 with a smaller or zero ESR. Compared with the PWM controller 120 of FIG. 1 , a PWM controller 720 of the DCDC converter 700 further comprises a sense unit 730 for sensing a current flowing through the inductor L to generate a sense current I sense to a compensation unit 710 , wherein the sense current I sense corresponds to the loading of the load 180 . The compensation unit 710 comprises a resistor 712 , a capacitor 714 , a resistor R comp coupled between the error amplifier 160 and the comparator 170 , and a current source 716 for sinking a current I 4 from the resistor R comp to the ground GND. In one embodiment, the current I 4 is a current in proportion to the sense current I sense . The current source 716 is used as an example, and does not limit the invention. In the embodiment, a current value of the current I 4 is equal to that of the sense current I sense . Therefore, a voltage across the resistor R comp is determined according to the sense current I sense and a resistance of the resistor R comp . The compensation unit 710 receives the error signal V ERR and generates a compensation signal V COMP to the comparator 170 according to the error signal V ERR and the voltage across the resistor R comp , such that the comparator 170 of the PWM controller 720 may compare the compensation signal V COMP with the ramp signal S RAMP provided by the ramp generator 130 to generate the trigger signal S TR . The compensation signal V COMP comprises a feedback signal from the output voltage V OUT associated with a feedback signal from the current flowing through the inductor L, thus avoiding harmonic oscillation and assuring that the output voltage V OUT is stabilized when the capacitor C 2 with a smaller ESR. In addition, by adjusting the resistor R comp or detecting a gain of the sense current I sense , a gain of a current loop component is adjusted to increase system stability.
FIG. 8 shows a DC-DC converter 800 according to another embodiment of the invention. Compared with the DC-DC converter 700 of FIG. 7 , the sense unit 730 of the DC-DC conve1ter 800 is coupled to a node between the transistor MU and the transistor ML, and senses a current flowing through the transistor ML to generate the sense current I sense . Similarly, the sense current I sense provided by the sense unit 830 corresponds to the loading of the load 180 .
FIG. 9 shows a DC-DC converter 900 according to another embodiment of the invention. Compared with the DC-DC converter 700 of FIG. 7 , the DC-DC converter 900 further comprises a resistor R sense coupled between the transistor ML and the ground GND. Furthermore, the sense unit 730 of the DC-DC converter 900 is coupled to the resistor R sense , and senses a current flowing through the resistor R sense to generate the sense current I sense . Similarly, the sense current I sense provided by the sense unit 930 corresponds to the loading of the load 180 .
FIG. 10 shows a DC-DC converter 1000 according to another embodiment of the invention. In a PWM controller 1020 of the DC-DC converter 1000 , the comparator 170 compares the error signal V ERR with a compensation signal V comp provided by a compensation unit 1010 to generate the trigger signal S TR . In the embodiment, the sense unit 730 senses a current flowing through the inductor L to generate the sense current I sense , wherein the sense current I sense corresponds to the loading of the load 180 . In one embodiment, the sense unit 730 may sense a current flowing through the transistor ML to generate the sense current I sense . In another embodiment, the DC-DC converter 1000 further comprises a resistor coupled between the transistor ML and the ground GND, e.g. the resistor R sense of FIG. 9 , and the sense unit 730 may sense a current flowing through the resistor to generate the sense current I sense . The compensation unit 1010 comprises the resistor 712 , the capacitor 714 , a resistor R comp coupled between the sense unit 730 and the ramp generator 130 , and a current source 716 for sinking a current I 4 from the resistor R comp to the ground GND. Therefore, the compensation unit 1010 generates the compensation signal V COMP to the comparator 170 according to the sense current I sense , a voltage across the resistor R comp and the ramp signal S RAMP . Similarly, the compensation signal V COMP comprises a feedback signal from the output voltage V OUT associated with a feedback signal from the current flowing through the inductor L, thus avoiding harmonic oscillation and assuring that the output voltage V OUT is stabilized when the capacitor C 2 with a smaller ESR. In addition, by adjusting the resistor R comp or detecting a gain of the sense current I sense , a gain of a current loop component is adjusted to increase system stability.
While the invention has been described by way of example and in terms of preferred embodiment, it is to be understood that the invention is not limited thereto. Those who are skilled in this technology can still make various alterations and modifications without departing from the scope and spirit of this invention. Therefore, the scope of the present invention shall be defined and protected by the following claims and their equivalents.
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A DC-DC converter including a Pulse Width Modulation (PWM) controller for converting an input voltage into an output voltage is provided. The PWM controller includes: an error amplifier, receiving a reference voltage and a feedback voltage and provides an error signal; a compensation unit coupled to an output of the error amplifier, compensating the error signal and comprising a first resister and a first capacitor; a ramp generator, generating a ramp signal according to a constant on time PWM signal; a first comparator coupled to the compensation unit and the ramp generator, comparing the compensated error signal with the ramp signal to generate a trigger signal; and a PWM generator coupled to the first comparator, providing the constant on time PWM signal according to the trigger signal, an input voltage of the DC-DC converter and the output voltage of the DC-DC converter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to coating devices, and in particular to coating devices having blades utilized for coating paper or cardboard.
2. Description of Related Technology
It is known in the art of paper coating to utilize peripherally grooved coating blades which volumetrically meter a coating material via said grooves as measured by the cross-sectional area of the grooves. Coating blades of this type are relatively expensive to use because they wear rapidly, requiring frequent and rapid blade exchange. The production of coating blades from highly wear-resistant material presents difficulties because, for example, the use of wear-resistant material can reduce accuracy with respect to the size of the blade groove cross-section and/or the roundness thereof.
An attempt has been made to solve the blade wear problem by providing a coating device comprising a plurality of aligned coating disks having various hardness and diameters as disclosed in DE 39 23 850.
SUMMARY OF THE INVENTION
It is an object of the invention to overcome one or more of the problems described above. It is also an object of the invention to provide a coating device or element which reduces to a minimum operational hindrances caused by wear on a coating blade.
According to the invention, a coating device is provided which includes a plurality of parallel coating blade lamellae made from highly wear-resistant material. The lamellae are disposed against one another in a housing and held thereby, forming a lamella packet wherein each lamella of the packet is disposed at the same inclination with respect to a plane perpendicular to a longitudinal axis of the packet. The inclination of the lamellae is adjustably controlled by at least one adjusting device acting on the packet. Thus, a change in lamellae inclination also changes a step-wise configuration of a surface contour formed by neighboring lamellae of the packet.
Other objects and advantages of the invention will be apparent to those skilled in the art from the following detailed description taken in conjunction with the drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial-sectional view of a coating device according to the invention.
FIG. 2 is a cross-sectional view of the device of FIG. 1.
FIG. 3 is an axial-sectional view of a second embodiment of a coating device according to the invention.
FIG. 4 is a partial front-elevational view of a third embodiment of a coating device according to the invention showing a rotatably driveable coating blade packet.
FIG. 5 is a partial side-elevational view of the coating device of FIG. 4.
FIG. 6 is a reduced cross-sectional view of the coating device of FIG. 4.
FIG. 7a is a partial cross-sectional view of coating blade lamellae taken in a direction of a longitudinal axis of a lamella packet.
FIG. 7b is a partial cross-sectional view of a second embodiment of a coating blade lamella taken in a direction of a longitudinal axis of a lamella packet.
FIG. 7c is a partial cross-sectional view of a third embodiment of coating blade lamella taken in a direction of a longitudinal axis of a lamella packet.
DETAILED DESCRIPTION OF THE INVENTION
According to the invention, coating blade wear is compensated for by adjusting the inclination of coating blade lamellae in a coating blade packet, causing the simple displacement of individual lamella of a coating blade packet. Also according to the invention, it is possible to significantly increase the lifetime of a coating device by using a rotating coating blade packet. Such a packet can also be designed so that the inclination of the individual coating blade lamellae is adjustable. However, in such an embodiment, action of the resting displacing elements must be made possible, for example, with the aid of an axial ball bearing.
According to FIG. 1, coating blade lamellae, generally designated 2, made of highly wear-resistant material are combined to form a packet 3 disposed in a housing, generally designated 1. The lamellae have a thickness of between about 0.2 mm and about 0.6 mm. The lamellae 2 are pressed against one another by adjusting devices 4 and 4' mounted on the housing 1. The devices 4 and 4' also adjust the inclination of the lamellae 2. A stop 13 abuts against a front face of the packet 3 at a central region thereof. The stop 13 provides a point of rotation for the lamella packet 3. A cylindrical worm spring 5 abuts against an opposite side of the packet 3 in a region near a substrate to be coated (not shown) and provides support for the packet by providing a force counter to the force of the adjusting device 4'. Pressure strips 7, 7', 7", etc., made of material having a very low surface friction (e.g., made from a polished plate or polymer sold under the trademark "Teflon" (E.I. du Pont de Nemours, Co., Wilmington, Del.)) are disposed above the lamella packet. The strips 7, 7', 7", etc. permit adjustable movement of the coating blade lamellae 2 with low friction in spite of the contact pressure placed against the lamellae 2 by pressing devices in the form of pressure tubings 6 which are disposed along a length of the packet 3 and at a back portion thereof. The pressure tubings 6 provide local contact pressure to the individual lamellae and thus control the contact pressure from the lamellae to a substrate to be coated in a direction toward the contact line between the lamellae and the substrate. The pressure inside of the pressure tubings 6 can be adjusted so that the contact pressure of the coating blade packet 3 on a paper web (not shown) or a counter roll (not shown) guiding a paper web is as uniform as possible.
The material of the coating blade lamellae 2 is chosen from known wear-resistant materials; especially preferred materials are carbides, oxides or other sintered materials. Hydraulic or pneumatic systems may be utilized as adjusting devices. Adjusting devices according to the invention also include magnetostrictive and piezoelectric devices.
With reference to FIG. 2, an individual coating blade lamella 2 includes a projection 9 in a region of the coating surface of the lamella packet 3.
In FIG. 1, intermediate spaces between neighboring coating blade lamellae 2 are shown which are designed with angular, preferably rectangular edges, forming a step-wise configuration of a coating surface contour of the packet 3. Such edges form the metering cross-sectional areas between the individual lamellae 2. By changing the inclination of the lamella packet 3, the size of the metering cross-sections are altered. As a result, wear of the individual lamellae can be compensated for and a constant outlet cross-section (metering cross-sectional area) can be maintained during a prolonged operation of the coating device.
The lamella packet 3 is ground, so that the coating blade lamellae 2 will have an absolutely equal "height dimension" (alignment, for example, between the contact pressure tubings 6 and projections 9). This also favorably results in a somewhat broader, flat contact surface of the coating blade lamellae on a substrate.
In an embodiment of a coating device according to the invention shown in FIG. 3, a lamella packet 3' is held in a housing 1' similar to the lamella packet 3 and housing 1 shown in FIG. 1. However, in the embodiment shown in FIG. 3, instead of pressure tubings 6, spring elements 20 are provided for pressing the lamellae against a paper web or counter roll. Using pressure pads and slide strips 23 and 24, respectively, disposed at either side of the spring elements 20, contact pressure is applied to the packet 3' via positioning elements 25. To support the coating blade packet 3', cylindrical worm springs 26 are disposed in a region above and below the coating blade packet 3' at one side thereof, the springs 26 being disposed within the housing 1'. An adjusting device 4" presses against the lamellae packet 3' at a side thereof opposite the worm springs 26.
FIGS. 4 to 6 illustrate a coating device according to the invention having a coating blade packet 3" consisting of annular coating blade lamellae 2". The packet 3" is rotatably driven by a central drive rod 12 disposed eccentrically to the coating blade lamellae 2". The drive rod 12 has outer toothing 14. The toothing 14 engages a corresponding inner toothing 15 of the individual coating blade lamellae 2". In order to provide lamellae support and adjustment similar to the embodiments of the invention shown in FIGS. 1 and 3, the coating blade packet 3" of FIGS. 4-6 is preferably supported at the ends thereof by an axial ball bearing (axially acting). The rate of rotation of the coating blade packet during operation is preferably less than 1 rpm.
With reference to FIG. 6, supporting devices for the lamellae packet 3" are provided in the form of guide shoes 31, 32, and 33, which are preferably made of polyurethane or other synthetic material resistant to sliding wear, such as polytetrafluoroethylene (PTFE, e.g. "Teflon"). Springs 38, 39, and 35 mounted on the device, press against the shoes 31, 32, and 33, respectively, and provide contact pressure to the packet 3". Adjusting devices 37 are provided for placing scraping pressure (i.e., doctoring pressure) on the packet 3" as are provided in the other embodiments described herein.
FIGS. 7a, 7b, and 7c illustrate individual coating lamella 2a, 2b, and 2c, respectively, according to the invention. A coating surface of the lamella 2a, 2b, and 2c is defined by a recess 18, 18', and 18", respectively. The orientation of the coating blade lamellae is preferably as shown in FIG. 1 so that if the inclination of the lamellae is increased, the intermediate space between neighboring coating blade lamellae will also increase. By shaping the lamellae as shown in FIGS. 7a-7c, an outlet cross-sectional area for the metering of coating material can be achieved, even at an angle of inclination of 0° (with respect to a direction perpendicular to the packet axis). However, the recesses should not be too large in order to provide for sufficient variations of the outlet cross-sectional area in case of wear of the lamellae.
If the coating blade lamellae are inclined in the direction shown in FIG. 7a, the inclination would need to be set very large at the beginning of the coating operation (i.e. for a new lamella packet), with the inclination being gradually reduced (i.e., directed more upright) as the lamellae in the packet become worn. However, such an embodiment does not appear to result in relatively long-lived operation.
The foregoing detailed description is given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications within the scope of the invention will be apparent to those skilled in the art.
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A coating device includes a plurality of parallel coating blade lamellae made from highly wear-resistant material. The lamellae are disposed against one another in a housing and held thereby, forming a lamella packet wherein each lamella of the packet is disposed at the same inclination with respect to a plane perpendicular to a longitudinal axis of the packet. The inclination of the lamellae is adjustably controlled by at least one adjusting device acting on the packet. Thus, a change in lamellae inclination also changes a step-wise configuration of a surface contour formed by neighboring lamellae of the packet.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 10/060,616 filed Jan. 30, 2002, currently pending, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates generally to the management of cattle for varying market needs such as quality, food safety, and the consistent improvement of beef quality for one or more target markets. More specifically, the invention relates to the methods and processes for analyzing and improving the carcass value of beef cattle for the production of beef for human consumption by identifying, measuring, sorting and tracking animals individually and grouping animals into specific market groups for increased value and consistency with in each group. This process allows duplication of results by tracking performance at multiple levels and tracing results back to the base genetic lines of individual animals allowing the selection from that genetic pool for specific traits relating to marketing goals.
DESCRIPTION OF RELATED ART
[0003] A working cattle ranch is a very complex operation and it is where the genetic makeup and processing management for individual animals are set and cannot be changed by natural means. It is the genetic blueprint that determines all the different attributes of the individual calf from the time of conception to the final destination in life.
[0004] The rancher today does not have to give up ownership when the calves leave his or her ranch or control. Through retained ownership interests, it is possible to cultivate and develop the end product before selling the calves at one or more marketing points to one or more market targets. It is in this concept that this invention was developed for and designed to implement. It also provides the flexibility for the rancher to take advantage of all situations and know his or her margin of profit at any time in the production chain for differing markets. This information allows the rancher to be able to determine the optimum time and market to sell the beef calves.
[0005] There are many genetic and processing principals that will enhance the weight of an animal or improve its rate of gain and/or economic efficiency, and overall market desirability and consistency. Hybrid vigor is one such method where two genetic lines are crossed to produce an F1 Cross. This F1 cross can be created by two different bloodlines within or between breed types of cattle. These methods are primarily designed to improve animal weight, but pay little or no attention to other factors such as, economic efficiency, processing and feeding environments, or the ability to replicate the targeted market traits and reduce the non-targeted market traits with any consistency.
[0006] The historical use of multiple cattle breeds and cross breeding has resulted in a very diverse beef cattle population with variable eating qualities such as tenderness, taste, fat content, size of cut as well as many other factors. The beef cattle industry is constantly changing at ever increasing rates, due to consumer demands, food safety and other issues. Although some may disagree, cattle producers are in the food business, in contrast to the ranching business. Meat competes with other sources of protein available on the market, some of which are less expensive compared to the cost of beef. Beef is a very “elastic” commodity, or in other words, is sometimes called a luxury type item. With this in mind, this translates to the higher consistent quality being the true goal of each market group. In plain terms, when people purchase or order a steak, they expect to have an enjoyable eating experience. A recent national survey showed that twenty percent of the time consumers do not have an enjoyable steak dining experience, in part due to poor quality beef. Poor quality may arise from a number of many different factors, one being the failure for the product to be of consistent quality within the market group targeted. (I.e.: not all United States Department of Agriculture grade “Choice” steaks have the same taste, tenderness or cutting qualities.) However, the largest failure is lack of ability to identify, track, sort, and replicate the better quality cattle consistently for specific markets.
[0007] Until, recently there was little incentive for the rancher or cattle producer to spend time tracking data needed for different markets. Only in very recent years has the long-term practice of buying cattle on the average cash market been curtailed. Until now, the practice of purchasing cattle on the average cash market allowed undesirable types of cattle to sell for a premium at the expense of the more desirable beef quality types of cattle. In other words, the beef packer buyer bought a large number of cattle based on the average value of the cattle he or she purchases. The only cattle priced correctly were the average cattle. The poor quality cattle received a premium price, greater than their true carcass value, and the higher quality cattle were discounted to make up the losses in the lower quality cattle. This practice encouraged cattle producers to do less than an adequate job in the selection of genetic resources for the cattle herd on the ranch. In fact, the cheapest cattle the cattle producer could raise brought the highest premium for its quality. The net result of this type of production and buying practices resulted in a steady decline in the consumption (market share) of beef by the consumer for the last twenty-five years.
[0008] In the mid to late 1990's cattle markets began to significantly change. Beef packing companies began to purchase greater numbers of cattle on a formula basis, and thus began to control via contract greater numbers of available slaughter cattle population. The formula basis was a new way of purchasing cattle from owners. In the past, cattle purchases were on a cash average basis and all cattle needed for the week were normally traded in the first two days of the week setting the price for the rest of the week. The formula basis, however, caused cattle producers to sell their beef with discounts for undesirable market traits in the carcass, and premiums for desirable market traits. The large change came when beef packing plants had enough contracted formula cattle and therefore did not need to purchase cash average basis cattle. This results in a severe cash price market drop when few cattle are needed on the cash market. Today, the average cash market is rarely used except when no other means is available for the seller of the cattle. Market participants have now created a cattle market based on the value of the processed product the consumer demands.
[0009] Cattle producers must now consider and determine the end product value of the cattle they produce. Fortunately, technological improvements in live animal carcass evaluation are in prominent use today. For example, U.S. Pat. No. 4,745,472 (Hayes), which issued May 17, 1988 and others have proposed ways to accurately measure and collect data on an animal's physical dimensions and weight by using video imaging techniques. Similarly, ultrasound back fat measurements of cattle is known in the art from the work of Professor John Brethour of Kansas State University's Fort Hayes Experimental Station, as explained in an article entitled “Cattle Sorting Enters a New Age” appearing at pages 1-5 and 8 of the September, 1994 issue of D.J. FEEDER MANAGEMENT. Professor Brethour has used the data from such measurements to project and estimated optimum shipping or end date (OED) for the measured animals. Also, various methods of sorting and weighing cattle have been known or proposed, as disclosed, for example, in U.S. Pat. No. 4,288,856 (Linseth) and U.S. Pat. No. 4,280,448 (Ostermann). Cattle Scanning Systems of Rapid City, S. Dak., markets a computerized video imaging and sorting system that includes weighing and scanning external dimensions of each animal, assigning a frame score and muscle score to the animal based on such dimensions, calculating a predicted optimal end weight and marketing date from the composite score and current weight data, and then sorting the animals for feeding according to their optimal marketing dates. Feedlots across the country are equipped with ultrasound machines that identify cattle electronically and measure cattle ribeye size, back fat thickness and marbling scores before the animal is processed.
[0010] The characteristics of calves are now measured earlier based on carcass quality for the market goals of the producer. Cattle with high beef quality will have a consistent market in the future where lower beef quality will be discounted or not purchased at all depending on demand. There are many different systems for the rancher to acquire data that will guide in decision making for the producer. Some measure yearling weights and concentrate on weaned weight of calves, some measure probability of gains at feedlots, or of ribeye area and back fat. However, none have addressed the complete picture of production methods, genetic replication, economic efficiency, and marketing targets of consistent quality in differing marketing groups or levels and traced the data back to the individual cow and bull in a herd to a total system that is sensitive to changes in consumer demands.
[0011] In view of the above described prior at, a need exists for an improved method of managing cattle production by the cattle producer. Likewise, a need exists for an improved method of tracking and evaluating the genetic development and replication of beef cattle to improve management of cattle herds, improve beef quality and increase investment returns on cattle for the cattle producer.
SUMMARY OF THE INVENTION
[0012] The present invention relates to an improved cattle management system and method which increases the carcass value at sale by selective breeding and physical maintenance programs designed to improve the consistent beef quality of the herd and improving the overall profitability of each individual member of the cattle herd by using a holistic approach where all economically important traits, as well as the growing/processing environment, are considered in the process collectively. The system allows the rancher or cattle producer to collect data on individual cattle, determine and minimize his production costs and evaluate options in marketing at any time from the weaning stage to the final carcass stage.
[0013] The primary objective of the present invention is to provide a system and method of cattle selection, management and care which leads to better performance with market goals in mind that is not only traceable to certain individuals, but has the ability to be replicated. This system utilizes a method in which each animal is uniquely identified and allocated performance and economic data, which is recorded and traced back to the cow and bull pairing that produced the individual calf which allows the cattle producer to make informed management decisions based on the target market in which the cattle producer desires his cow herd to perform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 is a flow chart depiction summarizing the first collection of data and overall method of improving and maintaining the cowherd characteristics and traits by utilizing the invention disclosed herein;
[0016] FIG. 2 is a flow chart diagram setting forth the method and system of cowherd management for achieving improved beef quality, herd physical characteristics and increased economic profitability based on the collection of the previous history of data;
[0017] FIG. 2A is a flow chart depiction of the data collected and returned on calves participating in the cowherd management system disclosed herein showing the data collected during each phase of production on a repeated basis;
[0018] FIG. 2B is a flow chart depiction of the process wherein the calf is selected as a cull or feeder based on the calf weaning weight to cow weight ratio;
[0019] FIG. 2C depicts an alternative process wherein the production cost and profits associated with a particular genetic line determines whether a breeding pair is culled or maintained as a breeding unit;
[0020] FIGS. 3A-3E are data tables representing the collection of actual performance and economic data returned on each individual in the cow herd and the data returned from each phase of production of the calf showing relative values participating in the method disclosed herein;
[0021] FIG. 4 is an example of an actual chart setting forth a marketing grid of the calculated grades with premiums and discounts for a targeted base market of choice/yield grade 3 associated with a cow herd consisting of 116 heifers showing relative values participating in the method disclosed herein; and,
[0022] FIG. 5 depicts an alternative embodiment of the invention disclosed herein which provides a cattle producer with the ability to identify and track a meat product from conception to consumption.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] Turing to FIG. 1 , the method by which a cowherd 102 is selected and refined for improved physical and beef producing characteristics is shown. The cowherd 102 population is mated to selected bulls 103 . The cows 102 and bulls 103 are selected by using actual and/or EPD data for desirable traits, which further the goal of the intended market level. Some of the important traits are fertility, birth weight, environmental suitability and efficiency. The offspring/calves 104 are then processed when the youngest calf 104 is no younger than 60 days old. Cows 102 and calves 104 are rounded up and brought in to a contained area called working pens. Cows 102 and calves 104 are separated into different holding pens. Cows 102 are then treated for external and in some areas internal parasites, checked for proper identification tags, which are replaced if, needed due to loss or unreadable numbers and overall checked for any physical problem(s) that needs attention. The cows 102 are then placed into a pen located adjacent to the pen the calves 104 are to be processed. Then the calves 104 are processed individually in the following minimum standard manner: A brand is placed in the proper Beef Quality Assurance location and manner, vaccination with a chemically altered vaccine type is done for certain diseases and killed types of vaccines for others depending on the disease vaccinated against. Bulls are castrated and each calf 104 is given both an electronic identification tag as well as a visual identification tag. However, the electronic identification at this stage is optional. As each calf 104 is processed, the calf 104 is allowed to return to its mother 102 . After all the calves 104 have been processed and the cows 102 have had some time to find their calves 104 , the cows 102 and calves 104 are released back to the location desired by the cattle producer.
[0024] From this time to weaning, the cattle producer matches up which cow 102 and which calf 104 go together, called pairs. A tally list is usually kept to prevent recording repeats of the same pairs and so that the cattle producer can take the data an input it into a database for future reference. The cattle are then checked from time to time for about 6 months.
[0025] After approximately 6 months or when the calves 104 are about 50% of the body weight of the cows 102 , the cows 102 and calves 104 are again gathered into holding pens and separated. At this stage of production the calves 104 are then weighed individually and again processed in the following manner as referenced by the National Cattleman's Beef Association criteria, vaccines are given in modified live form for various diseases, treatment for external and internal parasites is given and if not done earlier an Electronic Identification Tag is inserted. The calf's 104 data is recorded in a manner, which reflects the type of vaccination, location of vaccination on the animal, weight and Visual Identification Number as well as a correlated Electronic Identification Number.
[0026] After the processing of the weaned calves 104 , they are transferred to holding pens usually in a central area for feeding purposes for about 10 days, and after that are then turned out on grass or wheat or some other high protein feed for a minimum of 35 days more. This process is sometimes called VAC-45, where the cattle are held for at least 45 days after vaccination before moving the cattle to distant locations. This allows the vaccines to take effect and reduces stress on the calves 104 . The cows 102 are then processed after the calves 104 are processed, Each cow 102 is individually weighed and looked over to determine again if any physical needs should be tended to. The cows 102 are also treated for both internal and external parasites as well as given any vaccinations that are deemed necessary at the time.
[0027] Upon the completion of the 45 day period, the calves 104 now called feeders 105 or yearlings are at their lowest economic efficiency, where costs are in most cases higher than revenues if sold. Nevertheless, the feeders 105 can be sold on the cash market by the cattle producer. However, for most economic gains they are usually placed on grass or wheat if available, for a period of time that it takes the calves to gain enough weight to reach the 750 to 800 pound range. At the end of this stage of production, the feeders 105 are then shipped to a feedlot. It should be noted that this stage of production known as the feeder phase 105 could terminate at any point after the 45-day period has been completed, depending of availability of wheat or grass and or other concerns both economical and environmental. Prior to shipping to the feedlot, feeders 105 are sorted into groups that correlate with USDA quality grades of Beef, namely Choice or better 106 , Low Choice/Select 107 and non-graded culls 108 , based on prior data where available and within each group by weight in increments of 100 pounds or less. Where prior data is not available such as in the first year's data pass, known performance probabilities of certain genetic lines are used, based on actual data and/or Estimated Progeny Differences known as “EPD's” of cows 102 and bulls 103 . The culls 108 may be grouped due to poor performance, phenotype, deformities, size/weight, health, as well as a host of other considerations.
[0028] At this stage of production as shown in FIG. 2 , the economic, genetic and performance data now link individuals in specific groups to individual cows 102 and bulls 103 . From this point of production to the end of production at the carcass level the data becomes easier to acquire and more complete and accurate. This data includes culls 108 , and close attention is then paid to the reasons for the culls 108 . If a genetic link can be made the individual cow 102 or bull 103 , then that individual is then also placed in the group of culls 108 . In the case of the culls 108 each individual is marketed to a market that returns the highest possible returns unless health problems prevent marketing due to condemnation of the carcass.
[0029] The beginning of the live cattle phase 110 is when the feeders 105 are shipped to a feedlot. At this point, two things happen, first, the live cattle 110 are converted from an animal that eats mainly cellulose to an animal that eats mainly starch. Second, the data on all economic measurements are easily captured due to the confined environment and controlled inputs.
[0030] Live cattle 110 are processed by; retrieving individual weights, tagging for lot number identification if not already done at an earlier stage and sorted by sex and into groups that are 50 to 100 pound ranges upon entrance to the feedlot. Data again is entered by visual or electronic identification and match up to past data to continue a data history of each individual animal which traces back to create a historical report of what each cow 102 has produced. At the end of this stage of production is when the live cattle 110 are marketed to targeted market grids. The Choice or better 106 group is marketed on a grid that that optimizes economic returns and matches the predicted carcass performance of USDA grade choice or better. The Low Choice/Select group 107 likewise marketed to a grid that optimizes economic returns and matches the predicted carcass performance of USDA grade Low Choice or Select.
[0031] The next phase of production, the live cattle 110 are marketed to targeted market grids. Upon completion of harvest by the packer, individual carcass 112 return data is then broken down into economic important measurements. These measurements include: Back fat, ribeye area, Kidney/pelvic/heart fat measurements, hot carcass weight, dressing percent, yield grade, quality grade, and marbling score. Economic data includes: price per pound for each USDA grade and yield grade division, premiums and discounts, and other service charges and/or bonus revenue. This carcass 112 data along with the final closeout data which includes days on feed, average daily gain, dry matter conversion, in weight, and out weight, as well as final cost of feeding and services from the feedlot during the live phase 110 of the production is returned to the cattle producer for integration into the data history in each individual animal produced and this data history is then linked to each individual cow 102 and bull 103 .
[0032] This data and production process stream is then repeated for the next breeding and production season to more refine the next set of offspring 104 which is again linked back to the individual cow 102 and bull 103 to create a historical data stream for each individual cow 102 and bull 103 . However, each data pass the starting population of cows 102 and bulls 103 is now altered to reflect changes due to return data from prior calves 104 history of prior breeding and production seasons. This allows the cattle producer to change combination and market targets for individual cows 102 and bulls 103 and their calves 104 , or do away with the genetic line altogether by placing them in the cull group 108 . Also, as data is compiled on each individual cow 102 and bull 103 , each animal's data history makes production from certain combinations more predictable each time and allows individual cows 102 to be grouped into targeted market herds 115 , where the performance, and economic returns are highly predictable for the calves 104 at any level of production from weaning as feeders 105 to the final phase or stage of production at the carcass level 112 .
[0033] FIG. 2A depicts the data collection process during the different phases of production which provides for the determination of and selection of bulls, cows and calves with desirable characteristics for improving the overall cowherd in terms of genetic lineage, production benefits and profits.
[0034] FIG. 2B represents another depiction of the feeder 105 or cull 108 determination made with respect to the ratio formed between the calf weaning weight compared with the mother's weight at weaning. Initially, the calf is born (Step 202 ) as previously discussed herein. After approximately 6 months or when the calves 104 are about 50% of the body weight of the cows 102 , the cows 102 and calves 104 are again gathered into holding pens and separated. At this stage of production, the calves 104 are then weighed individually and again processed in the following manner as referenced by the National Cattleman's Beef Association criteria, vaccines may given in modified live form for various diseases, treatment for external and internal parasites is given and if not done earlier or later, and an Electronic Identification Tag is inserted. The calf's 104 physical and processing data is recorded in a manner, which reflects the type of vaccination, location of vaccination on the animal, weight and Visual Identification Number as well as a correlated Electronic Identification Number (Step 204 ). The calf's weaning weight is then divided by its mother's weight (Step 206 ). In the shown embodiment, if the ratio of the calf's weaning weight is less than 50% of the calf's mother's weight (Step 208 ), the calf is determined to be a cull (Step 210 ), then slaughtered and processed (Step 212 ). Likewise, the bull that produced the calf may then be castrated to prevent future breeding by the bull in order to reduce the possibility of diluting the genetic lines with lower grade calves (Step 214 ). Alternatively, if the calf's weaning weight to mother's weight ratio is equal to or greater than 50% (Step 216 ), the calf is vaccinated if not done earlier (Step 218 ), castrated if not raised for breeding purposes (Step 220 ), designated as a feeder and sent to a feedlot for weight gain (Step 222 ), and then slaughtered (Step 224 ). In this embodiment, the calf weaning weight to cow weight ration is determinative as to whether the calf if graded as a cull or feeder.
[0035] FIG. 2C is a flow diagram which illustrates an alternative process by which the genetic quality of calves produced for beef production is selected and maintained. A feeder calf is slaughtered (Step 228 ) and the ratio of the costs associated with the production of the calf versus the price of the calf at the “railhead” (i.e. being sold to the beef processor) is calculated (Step 230 ). An array of ratios is created by the cattle producer (Step 232 ) for each of the calves slaughtered. The ratios are then normalized to a predetermined value, in this example the value is 100 (Step 234 ). If the normalized ratio results in a figure above 100 (Step 236 ), the parentage and genetic lineage of the calf is identified (Step 238 ) from the recorded calf data records as discussed in FIGS. 1 and 2 . If it is determined that the calf's father has sired multiple calves with normalized ratios exceeding 100, the bull is then culled and processed for slaughter (Step 240 ). Likewise, if the calf's mother has borne multiple calves with normalized ratios exceeding 100, the cow is culled and processed for slaughter (Step 242 ). In contrast, if the normalized ratio is below 100 (Step 244 ), the calf's sire and mother are retained as a breeding pair for the next season (Step 246 ).
[0036] FIGS. 3A-3E are representative data which are collected on each member of the herd during processing. FIG. 3A contains the data collected for live cow 102 identification. The data gather on each cow 102 includes the Cow Visual Identification Number 302 and Cow Electronic Identification Number 304 which may be stored within the cow ear tag number and electronically accessed by means known in the art. The owner of the cow 102 is noted in column 306 the date the cow 102 was last processed is noted 308 . The Cow Weight 310 is measured at the time of weaning so that a ratio may be determined to establish whether the cow 102 produces above or below the average of the cow herd by measuring the actual body weight produced each season. Individual comments 312 and Cow Location 314 data are recorded as observed. The Service Year 316 represents the date or year the cow 102 is placed into the breeding herd. This allows the cattle producer to know the actual ages of the cows 102 in the herd and make informed decisions on managing the age of the herd for maximum herd health and economic return.
[0037] FIG. 3B represents typical data recorded on each calf 104 through development to the feeder 105 stage of production. The Type of Vaccine 320 administered to each calf is noted. These vaccines may include Chemically Altered (CA), Killed (K), or Modified Live (ML) vaccines. The date each calf 104 is vaccinated is recorded 324 . The Vaccine Lot Number 322 is recorded which includes each administered vaccine's serial number, lot number and expiration date. Vaccination data attributable to difference vaccines given according the vaccination schedule are recorded as shown 326 , 328 , 330 . The Weaning Weight 332 of each calf 104 is noted along with the Weaning Date 334 . Next, the Percentage of the Cow's Body Weight Produced at Weaning 336 is determined by the cow's 102 weight divided by each calf's 104 weight at weaning.
[0038] FIG. 3C depicts the data collected and monitored on each individual calf 104 during production. The Year of Production 340 is noted along with each steer's Electronic Identification Number 342 . The same data is recorded for each heifer 344 , 346 .
[0039] FIG. 3D contains data concerning each feeder calf's 105 shipping data. The Shipping Weight 350 and Shipping Date 352 represent the weight of the calf 105 when shipped to the Live Phase of production to the feedlot, respectively. The Gain at Stocker 354 is the weight gain of the calf 105 during the feeder phase of production. The Feedlot Location 356 represents the feedlot to which the feeder calf 105 is shipped for Live Production 110 .
[0040] FIG. 3E sets forth the data recorded during the Carcass Phase 112 . The Days on Feed (DOF) 360 of each Live Cattle 110 is calculated as the number of days the Feeder 105 is fed at the feedlot until the day the Feeder 105 is sent to the beef packer for processing. The Feed In Weight 362 is determined as the actual arrival weight of the feeder 105 at the time it is placed in the feedlot. The Feed Out Weight 364 is the actual weight of the feeder 105 at the time it is removed from the feedlot for shipment to the beef processor. The Hot Carcass Weight 368 is measured after processing by the beef packer. The Average Daily Gain 370 is calculated by subtracting the Feed In Weight 362 from the Feed Out Weight 364 and dividing the difference by the Days On Feed 360 . A Dressing Percentage 372 is calculated and the Ribeye Area (REA) 374 , Back Fat 376 and Kidney/Pelvic/Heart Content (KHP) 378 of each individual carcass is measured and recorded during processing by the beef packer. The Actual Yield Grade 380 is then determined on a scale of 1 through 5 where a ranking of 5 designating a high fat and low red meat content. The Actual Yield Grade (YG) 380 is calculated according the formula:
YG=2.5+(2.5×Back Fat)+(0.2×KHP)+(0.0038×Hot Carcass Wt.)−(0.32×REA)
[0041] The Marbling Score 382 is determined from the measured intramuscular fat content of the carcass which is contained in the ribeye between the 12 th and 13 th rib. This score determines the quality grade of each carcass, which is measure in 100 point increments and ranked as follows: Prime=Abundant (Ab), Slightly Abundant (SLA), Moderate (Mt); Choice=Modest (Md); Small (Sm); Select Slight (Sl); Standard=Traces. A Prime grade represents the highest quality beef product.
[0042] FIG. 4 is a Carcass Payment and Discount Grid which sets for the exemplary values, scores and statistics for 116 head of cattle produced by the method discussed herein. From the data shown in the Grid, 5.17% of the cattle processed were of Prime quality, 91.36% were rated as Choice, and 3.45% were rated as Select. Based on these values and the data obtained during production as shown in FIGS. 3A-3E , the genetic lines of the animals processed are identified and compared to the processing grade of each cow's 102 ancestors allowing the cattle producer to make informed breeding and production decisions based on the profitability of that cow's genetic lineage.
[0043] With reference to FIG. 5 , a flow chart depicting an alternative embodiment of the invention disclosed herein is shown. Initially, the cattle producer may select a breeding pair to produce a calf projected at achieving a predetermined target market (e.g. Prime grade for meat production) (Step 502 ). Next, the calf is born (Step 504 ) and identified with a unique visual identifier (e.g. a brand) or an electronic identification device (e.g. an electronic ear tag) (Step 506 ). The calf is then placed into the cattle producer's production plan as a feeder and sent to a feedlot for weight gain (Step 508 ). After a predetermined period of time or an optimal weight is reached by the calf, the calf is sent to a beef packer for processing and graded (Steps 510 and 512 ). The meat is then packaged by the beef packer (Step 514 ) and, ultimately, the meat product is consumed (Step 516 ). During the production phase of the calf (Steps 506 - 514 ), data is collected on the calf such as weight, owner and feedlot location and affiliated with the unique identifier given to the calf at birth (Step 518 ). This method provides a method by which a consumer may identify and locate the cattle producer, feedlot and beef packer which were involved in the production of the meat product consumed by the consumer as a source of a quality product or, alternatively, in the event the meat product causes a detrimental effect on the health of the consumer.
[0044] While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes without departing from the scope of invention. Accordingly, it is intended that the appended claims encompass any alternative embodiments of the invention not disclosed herein that are within the ordinary skill of a person knowledgeable in the art.
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A method and system to generate the highest level of return on investment of a cattle ranch producing beef to the consumer. Through the use of computer software integrated with an individual cow and calf identification system, the method and system disclosed herein allows a cattle producer to analyze the yearly production characteristics of each individual cow's calf or calves through all the various phases of growth and production with an accumulation of the economic cost and gain of value up to the end product as a feeder or cull. The total value of the carcass at the end of production, expressed as a sum of the costs associated with producing each animal minus the market value of the animal, allows the animal's economic value to be expressed by one figure which can then be used to judge the cow's ability to produce animals that meet all predetermined economically important genetic traits. This system and method of cow herd management provides a continuing improvement in the efficiency of the ranching operation and a better product for the consumers.
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FIELD OF THE INVENTION
[0001] The present invention refers in general to the area of devices for endoscopic use and more specifically relates to a teleoperated endoscopic capsule able to move autonomously in various areas of the human body and in particular in the gastrointestinal tract, with an active control of its locomotion.
DESCRIPTION OF THE STATE OF THE ART
[0002] In recent years interest in devices which enable endoscopic investigations and treatments to be performed autonomously and in a minimally invasive way has grown considerably. An autonomous image vision system with wireless data transmission, integrated in a small pill, received recently the approval for clinical evaluation in the US. The system comprises a CMOS imager, a transmitter, LEDs for illumination and a power supply from watch-like batteries. See for example U.S. Pat. No. 5,604,531. The main limitation of this device relates to the lack of active control of the locomotion: the capsule proceeds by normal peristalsis and it cannot be stopped during its journey. Semiautomatic solutions are also known, based on a so-called “inchworm” model of locomotion, such as for example the endoscopic device described in WO02/68035. These systems have limited control potential of the locomotion parameters and no possibility of varying their speed. They also have the disadvantage of sliding with their body along the walls of the body cavity in which they move without being able to avoid any injuries or pathologic areas.
[0003] Endoscopic devices are also known which are operated from the outside by means of fields of force (for example magnetic fields) which require the patient to wear suitable apparatus for generation of the field. Refer for example to the device known as Norika 3, produced by the Japanese firm RF System Lab. However use of this device may be awkward and risky due to the possible interferences with other biomedical devices which may be used by the patient. Moreover endoscopic devices with external operation of this type entail the risk of side effects due to prolonged exposure to electromagnetic fields.
OBJECTS AND SUMMARY OF THE INVENTION
[0004] The object of the present invention is to provide a device for endoscopic use capable of autonomous movement and power supply within a body cavity, with the possibility of controlling its movements from the outside so as to allow the performance of medical, diagnostic and therapeutic procedures and in particular for transmitting images of areas of interest of the body cavity traversed.
[0005] Another object of the present invention is to provide a device for endoscopic use of the type mentioned above with such dimensions as to be able to be swallowed and which is adaptable to the locomotion environment, with the possibility of being stopped, rotated, accelerated and decelerated as required as a result of commands teletransmitted from the outside.
[0006] A further object of the present invention is to provide a device for endoscopic use of the type mentioned above provided with legs with several degrees of freedom which can extend radially therefrom and permit locomotion and adaptation thereof to the various shapes of the body area covered, without damaging the tissue with which they come into contact.
[0007] Yet a further object of the present invention is to provide a system for endoscopy within a human body cavity which allows an operator to control the locomotion of a teleoperated endoscopic capsule equipped with its own locomotion means, swallowed by a patient, and the reception of images and data acquired thereby.
[0008] These objects are achieved with the endoscopic capsule according to the invention, whose basic features are disclosed in claim 1 . Further important features are given in the dependent claims.
[0009] According to the invention, a teleoperated endoscopic capsule is provided for diagnostic and therapeutic purposes inside a human body cavity, comprising a body with a plurality of locomotion modules on its surface, suitable for moving it inside the body cavity, an energy source and a microcontroller inside said body for actuating said locomotion modules on the basis of commands teletransmitted by an operator, a video camera for capturing images, controlled by the microcontroller, and a transceiver system for receiving the commands teletransmitted by the operator and for transmitting the images acquired via the video camera.
[0010] In a particularly preferred embodiment of the invention, the capsule is provided with legs able to extend radially from its body and having at least two degrees of freedom, of which one is active, to allow their movement from a rest position, more particularly situated along the body of the capsule, to a radially extended position, and a passive one for bending the legs around an intermediate portion thereof to adapt them to the deformability of the tissue on which they abut during the movement of the capsule.
[0011] Preferably, to operate the movement of the legs actuator means are provided consisting of shape memory alloy (SMA) wires acting, two by two for each leg, in opposition one to the other.
[0012] In a particularly preferred embodiment of the invention, the capsule is provided with legs with grasping means, consisting in particular of microhooks at their free ends, to increase friction with the slippery and deformable tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Further features and advantages of the endoscopic capsule according to the present invention will be made clearer by the following description of one of its embodiments, given by way of a non-limiting example with reference to the accompanying drawings in which:
[0014] FIG. 1 is a perspective view of the endoscopic capsule according to the invention;
[0015] FIG. 2 is an enlarged, axially sectioned view of the endoscopic capsule of FIG. 1 ;
[0016] FIG. 3 is a perspective view of a locomotion module of the endoscopic capsule of FIG. 1 ;
[0017] FIG. 4 is a side perspective view of a leg with which the locomotion module of FIG. 3 is equipped;
[0018] FIG. 5 is a variant of the leg of FIG. 4 ;
[0019] FIG. 6 is a block diagram of the mechatronic architecture for locomotion of the capsule;
[0020] FIG. 7 is a block diagram of the control system on board the capsule;
[0021] FIG. 8 is a block diagram illustrating the system of actuation of the legs.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring to FIGS. 1 and 2 , the endoscopic capsule according to the invention is formed by a substantially cylindrical body 1 , preferably made in a biocompatible plastic material, having a longitudinally spaced front end and rear end and defining an internal chamber 2 for housing a video camera (not shown) for capturing images, electrical power supply and the control electronics, as will be explained herein below. At the ends of the body 1 closure caps 3 are attached and the cap placed at the front end has an aperture for the optical system of the video camera, for the administration of drugs and for the passage of bioptic or surgical instruments.
[0023] Along the side surface of the body 1 equally spaced axial grooves 4 are formed (six in the present embodiment of the invention), suitable for housing respective locomotion modules, generically denoted by 5 , each one comprising a leg 6 and an actuator unit 7 .
[0024] More particularly, referring also to FIG. 3 , each locomotion module 5 comprises an elongated support 8 , of such a size as to be able to be housed in a corresponding groove 4 , along which a channel 9 is formed axially. At one end of the channel 9 a pin 10 is placed transversely and a pulley 11 is keyed on the pin 10 . The leg 6 extends radially from the pulley 11 . At the other end of the channel 9 transmission rollers 12 are placed, freely rotating on a transverse pin 13 integral with the support 8 , while additional transmission rollers 14 are provided near the pulley 11 in the seat 9 , likewise rotating on a transverse pin 15 attached to the support 8 . In a possible embodiment of the invention the pulley 11 is made in aluminium, while the pins 12 and 14 are in a non-conductive material, for example glass.
[0025] The locomotion modules 5 are placed on the body 1 in such a way that the legs 6 are alternatively at one and the other end, so that definitively, in the present embodiment of the invention, the capsule is provided with three legs at one end and three legs at the other, spaced angularly through 120° and staggered through 60°.
[0026] Referring to FIG. 4 , each leg 6 is formed by a rod-shaped element in two portions 6 a and 6 b connected by a knee portion 6 c with increased flexibility. The portion 6 a has at its free end a joint 16 for snap connection in a special seat 17 of the pulley 11 , and at an intermediate point a retaining shoulder 17 a . The portion 6 b has a substantially circular end 18 and a plurality of microhooks 19 , turned in the same direction extends radially therefrom.
[0027] In the currently preferred embodiment of the invention, the leg 6 is made in SMA (Shape Memory Alloy) in a superelastic phase at room temperature. In this way it is possible to exploit the relatively high elasticity of the metal, which allows deformation of up to 8%, much higher than those of a normal metal, together with its mechanical strength and biocompatibility. In this way it is also possible to make the legs 6 via an electroerosion process from a small plate of this metal alloy.
[0028] The leg 6 therefore has two degrees of freedom, of which one is active around the pulley 11 , for the movement of the leg in the longitudinal direction, and a passive one around the knee portion 6 c to adapt the leg to the deformability of the tissue on which it abuts.
[0029] The actuator unit 7 allows angular movements of the leg 6 of a controllable extent between a rest position, wherein the leg 6 is extended longitudinally in the seat 9 of the support 8 , and a position of maximum radial extension angularly spaced through 120° in relation to the rest position. The actuator unit 7 , shown in particular in FIGS. 2 and 4 , is formed, for each leg 6 , by a pair of wires 20 and 21 in SMA with one end attached to the pulley 11 at diametrically opposite parts, while the other end is connected to the power supply system via contacts, not shown, provided on a contact plate 22 placed at one end of the support 8 , the wires 20 and 21 being coupled to the contact palte 22 by means of attachment dowels 23 . The wires 20 and 21 have two transmissions at transmission rollers 12 and 14 in order to maximise the contraction of the metal. Note that in FIG. 2 , for each of the two locomotion modules 5 shown sectioned, only one of the two wires 20 and 21 in SMA provided has been drawn for the sake of clarity of illustration.
[0030] The two wires 20 and 21 act in opposition. The rotation of the pulley, and hence of the leg 6 , is produced by actuating alternately one of the two wires. Actuation is achieved by passing current through one wire and causing its heating to the transition temperature which varies according to the SMA chosen. Having reached the transition temperature the wire contracts suddenly, rotating the pulley, while the cold wire is deformed through the action of the hot wire.
[0031] The leg 6 has, at the knee portion 6 c , two opposite appendages 25 which limit to a few degrees rotation of the leg 6 in the direction of its elongation, while on the opposite side of the leg 6 an additional pair of appendages 26 can be provided, suitable for abutting one against the other after an extensive, relative rotation of the portion 6 b in relation to the portion 6 a . The pair of appendages 26 therefore limit the extent of the bending to which the leg 6 may be subjected so as to prevent possible damage.
[0032] In the embodiment of FIG. 5 , the leg 6 is formed by a rod-shaped element along which a plurality of flexible joints 6 c are provided to improve its adaptability to the various conditions encountered along a journey. The leg 6 according to this embodiment also has a plurality of microhooks 19 present not only along the edge of its free end 18 , but also along a whole edge of the leg 6 so as to create directional friction along the whole leg and not only at its free end.
[0033] The endoscopic capsule according to the invention is able to move, rotate and stop inside a body cavity, such as for example the gastrointestinal (GI) tract, as a result of commands teletransmitted by an outside operator. The capsule is moved forwards by actuating in a synchronised manner the legs 6 whose free ends force against the walls delimiting the body cavity. This forcing action is regulated by the possibility of the leg to deform at its knee portion 6 c , reducing the risk of damaging tissue. The microhooks 19 provided at the free end of the legs 6 increase the friction between the ends of the leg and the tissue, friction otherwise very low due to the slippery and deformable nature of the tissue walls involved. The microhooks are turned backwards in relation to the forward movement, i.e. towards the rear end of the body 1 , in order to have a differential friction coefficient at the interface required for propulsion of the capsule.
[0034] FIG. 6 illustrates the overall mechatronic architecture of the system of control of the locomotion of the endoscopic capsule according to the invention. Basically this system is composed of a capsule system, denoted by C, and an external control system, identified by the EXTERNAL CONTROLLER block, which forms the interface with the operator, which transmits the commands to the capsule through this block via a radio signal. The operator selects the commands, such as move forwards, stop, rotate, turn back, and these commands, once transmitted to the capsule, are interpreted by the internal microcontroller into operations of a lower level to activate the of actuation sequence necessary for generating the required command.
[0035] For actuation of the legs 6 a microcontroller (ÿP) is provided, housed in the body 1 of the capsule for generating a train of pulses according to the Pulse Width Modulation (PWM) technique. As shown in FIG. 7 , the microcontroller sends the actuation signals to the drivers of the actuators of the legs 6 , whose angle of aperture is monitored via suitable sensors which also allow a closed-cycle control to be carried out. The microcontroller also processes the signals from the vision system and a two-directional data transmission system is provided (TRANSCEIVER block).
[0036] The data transmission system is based on transmission in RF and uses commercial systems. The band of transmission used can be that operating in the VHF or UHF field, for example a frequency of 433 MHz could be used. Among the commercial components which can be used, mention is made of those of Microchip, Cypress Microsystem, Chipcon AS SmartRF and others.
[0037] The capsule system remains in a standby condition until a command is received from the external controller. Once the signal has been received, the type of command to be performed is identified. The commands to be performed relate both to locomotion and sensor monitoring. In practice, if information is required on the status of the capsule, the microcontroller sends, via the transmission system, the status of the various sensors on board and this allows a reconstruction of the position of the individual legs and to have, for example, information on whether the legs are open or closed. In the case instead of a locomotion command, the microcontroller has to determine which type of locomotion to carry out, that is to say whether to go forwards, backwards, rotate left or right, move one leg only or a subgroup of legs (which occurs in the case of locomotion on areas where it is not necessary to move all the legs but instead just a few are sufficient and this with a view to saving energy). Once the action to be taken has been determined, the microcontroller sends voltage pulses of a value between 3.3V and 5V to the drivers for activation of the actuator. Once the operation has been performed, the microcontroller checks that there are no actions to be performed so as to return to a standby condition.
[0038] As shown in FIG. 8 , the driver is composed of a step-up DC_DC converter required to increase the V in of the battery by at least 8 times its value (the commercial components which can be used for this purpose are MAX668-669 from MAXIM or similar). The V out of the step-up charges a capacitor. The actuator is energised by discharging the capacitor for a period of time equal to a few milliseconds on the same actuator. Activation of discharging of the capacitor is generated by the microcontroller through the closure of the switch shown in FIG. 8 .
[0039] For the external control of the movements and of the functions of the endoscopic capsule, in the present embodiment of the invention a man-machine interface has been developed in Visual Basic through which all the instructions necessary for movement of the legs can be sent by telemetering, while exploration instructions are pre-programmed on the microcontroller on board the capsule. Naturally other equivalent known types of interface can be used as an alternative.
[0040] In a practical embodiment of the invention a capsule was made, approximately 17 mm in diameter and 30 mm in length with legs of approximately 15 mm in length. In a prototype wires in SMA were used for actuating the legs with diameter of 75 microns. The consumption of the capsule for an inspection of the entire gastrointestinal tract, assumed to be roughly equal to 8 metres, was compatible with latest-generation batteries whose energy stored in them is of the order of 2 Wh/cc.
[0041] The endoscopic capsule according to the invention, has, compared to known endoscopic capsules, a number of advantages, including:
the ability to move forwards, turn back and turn around on the basis of the diagnostic needs identified by the member of the medical staff; the ability to stop, contrasting the peristaltic forward forces, thanks to the microhooks with which the legs are equipped or the simple radial outward bending of the same legs; dimensional adaptability to the various gastrointestinal areas; greater safety compared to semi-autonomous endoscopes with inchworm locomotion, and also traditional endoscopes, which slide on the tissue without the possibility of avoiding lesions or pathologic sites. With a legged endoscopic capsule improved control of the trajectory is possible and the capsule can pass through critical areas without touching them. In fact the positioning of the legs can be accurately controlled by exploiting the transmitted visual information as a guide; better movement controllability in terms of length of the step, frequency, trajectory and accuracy and improved adaptability to the anatomical and biomechanical features of the environment in which it has to operate; greater speed of locomotion in that the legs can act as a system of amplification of the movements of the microactuators for actuation of the same, thus generating a higher overall speed; greater convenience of use, in that the patient is not required to wear systems for the generation of fields of force and reduction of the possible risks associated therewith.
[0049] The endoscopic capsule according to the invention can advantageously be coated with a biocompatible and biodegradable layer which avoids accidental outward bending of the legs in the mouth, making the process of swallowing easier. When the capsule reaches the stomach the coating can then be destroyed, allowing the possibility of movement of the legs. In the exploration of areas of small dimensions, such as the small intestine, with an average span of 2 cm, the capsule can proceed with the legs semi-bent, while in areas of greater gauge, such as the colon, with approximately 5 cm of diameter, the capsule can proceed with the legs almost completely extended.
[0050] The number of legs with which the capsule can be equipped depends on the speed which is to be reached and the complexity of the single step of locomotion.
[0051] Various changes and modifications to the invention may be clear on the basis of the present description. These changes and additions are understood to come within the scope and spirit of the invention, as set forth in the following claims.
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A teleoperated endoscopic capsule for diagnostic and therapeutic purposes inside an animal body cavity, comprising a body ( 1 ) with a plurality of locomotion modules ( 5 ) placed on its surface, suitable for moving said body in the body cavity. The capsule also comprises an energy source inside said body and a microcontroller in the body ( 1 ) for actuating the locomotion modules ( 5 ) on the basis of commands teletransmitted by an operator. A video camera is then provided for capturing images controlled by said microcontroller and a transceiver system for receiving the commands teletransmitted by the operator and for transmitting the images gained through the video camera.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a load-lock unit and, more particularly, to a load-lock unit for transferring a wafer between atmospheres having different pressures.
2. Description of the Related Art
When a semiconductor wafer is to be transferred between a process chamber for processing a semiconductor wafer in a vacuum atmosphere and the outside (atmospheric pressure), a load-lock unit is used to improve the operation efficiency by shortening the time required for evacuation. With this load-lock unit, for example, to load the wafer in the process chamber from the outside, the wafer is first placed in a load-lock chamber, the interior of the load-lock chamber is evacuated to a predetermined pressure, the load-lock chamber is opened to communicate with the atmosphere in the process chamber, and then the wafer is loaded into the process chamber.
A semiconductor wafer has a crystal orientation. Thus, when a wafer is to be processed or tested, not only its central position but also its orientation or direction of arrangement sometimes needs to be aligned.
For example, in an ion implantation unit, as shown in FIG. 1, ions generated by an ion generator I disposed in a terminal unit T are deflected by an analyzing magnet M and sequentially implanted in a wafer W on a turntable 1a (upright during ion implantation) in a process chamber through an acceleration tube A. Each wafer must be placed on the turntable 1a from the outside to be correctly aligned.
For this purpose, conventionally, as shown in FIG. 2, wafers W are transferred one by one to an aligning unit OD from a carrier 3 disposed at a predetermined position outside the process chamber 1 by a transfer robot R1 on the outer air side. An orientation error and a positional error of the center of each wafer are detected by the aligning unit OD, and two correcting steps for correction of the orientation and central position are performed to correct the errors, thus positioning the wafer W. Then, the wafer W in the aligning unit OD is transferred to a load-lock unit 2 by the transfer robot R1. The load-lock unit 2 is evacuated, and the wafer W is transferred to the turntable 1a from the load-lock unit 2 by a transfer robot R2 on the process chamber 1 side.
In such a conventional method, however, when the wafers are transferred into the load-lock unit one by one from the carrier, they must pass through the aligning unit, resulting in an increase in number of wafer handling times. Thus, damage to the wafer tends to occur or particles of dust tend to attach the wafer, leading to a decrease in yield. At the same time, as the number of handling times is increased, the loading time is prolonged, decreasing the processing throughput of the load-lock unit.
Regarding the aligning unit, a servo mechanism for moving the wafer in X and Y directions is need to correct, e.g., the central position of the wafer. As a result, the aligning unit becomes complicated and costly and requires an additional installation space for the servo mechanism.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compact load-lock unit which can increase the throughput and yield.
It is another object of the present invention to provide a wafer transfer system which can efficiently correct a positional error of a wafer.
According to the present invention, there is provided a load-lock unit which is disposed between first and second atmospheres, stores a wafer transferred from the first atmosphere, is blocked off from the first atmosphere, is thereafter set in the same atmosphere as or a similar atmosphere to the second atmosphere, and is opened to communicate with the second atmosphere in order to transfer the wafer to the second atmosphere, comprising a load-lock chamber, holding means, disposed in the load-lock chamber, for holding the wafer, rotating means for rotating the wafer held by the holding means, and error detecting means for detecting a positional error of the center of the wafer and an orientation error of the wafer on the basis of data obtained by radiating light on the wafer which is rotating.
According to the present invention, there is also provided a transfer system comprising a load-lock unit which is disposed between first and second atmospheres, stores a wafer transferred from the first atmosphere, is blocked off from the first atmosphere, is thereafter set in the same atmosphere as or a similar atmosphere to the second atmosphere, and is opened to communicate with the second atmosphere in order to transfer the wafer to the second atmosphere, transfer means for transferring the wafer in the load-lock unit to a predetermined position in the second atmosphere, and control means for controlling the transfer means,
the load-lock unit comprising a load-lock chamber, holding means, disposed in the load-lock chamber, for holding the wafer, rotating means for rotating the wafer held by the holding means, and error detecting means for detecting a positional error of the center of the wafer and an orientation error of the wafer on the basis of data obtained by radiating light on the wafer which is rotating, and
the control means controlling the transfer means so that the wafer is disposed at the predetermined position in the second atmosphere after the positional error of the center of the wafer and the orientation error of the wafer are corrected on the basis of data from the error detecting means.
Furthermore, according to the present invention, there is also provided a transfer system comprising a first load-lock unit which is disposed between first and second atmospheres, stores a wafer transferred from the first atmosphere, is blocked off from the first atmosphere, is thereafter set in the same atmosphere as or a similar atmosphere to the second atmosphere, and is opened to communicate with the second atmosphere in order to transfer the wafer to the second atmosphere, a second load-lock unit having the same arrangement as that of the first load-lock unit, transfer means for transferring the wafer in each of the first and second load-lock units to a predetermined position in the second atmosphere, and control means for controlling the transfer means,
each of the first and second load-lock units comprising a load-lock chamber, holding means, disposed in the load-lock chamber, for holding the wafer, rotating means for rotating the wafer held by the holding means, and error detecting means for detecting a positional error of the center of the wafer and an orientation error of the wafer on the basis of data obtained by radiating light on the wafer which is rotating, and
the control means controlling the transfer means so that the wafer is disposed at the predetermined position in the second atmosphere after the positional error of the center of the wafer and the orientation error of the wafer are corrected on the basis of data from the error detecting means.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a view showing an overall arrangement of a conventional ion implantation unit;
FIG. 2 is a view showing a conventional wafer transfer system of the ion implantation unit;
FIG. 3 is a longitudinal sectional view showing a load-lock unit according to an embodiment of the present invention;
FIG. 4 is a view for explaining the positional relationship between a wafer and an optical path;
FIGS. 5 to 8 are sectional views showing various arrangements of a light-receiving section and a light-emitting section;
FIG. 9 is a view showing a wafer transfer system according to another embodiment of the present invention; and
FIG. 10 is a sectional view showing a partial arrangement of the load-lock unit shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be described with reference to the accompanying drawings.
FIG. 3 is a sectional view showing an arrangement of a load-lock unit according to an embodiment of the present invention. In this embodiment, a bottomed cylindrical member 4 which is open upward and a lid plate 4a constituted by, e.g., a glass plate for closing the open surface of the cylindrical member 4 constitute a load-lock chamber 5. A magnetic seal (not shown) is disposed in a cylindrical base portion 4c vertically extending downward from the central portion of the lower surface of the bottom portion of the cylindrical member 4. A rotating shaft 4b which rotates about a vertical axis is hermetically inserted in the load-lock chamber 5 at the central position of the bottom portion through the magnetic seal.
A motor (not shown) is coupled to the lower end of the rotating shaft 4b, and a turntable 4d is provided at the upper end of the rotating shaft 4b. A chuck unit comprising electrodes 4e for electrostatically chucking a wafer is disposed on the upper surface of the turntable 4d. In this arrangement, the chuck unit and the turntable 4d constitute a holding portion.
Air supply paths 6 each having an exhaust path for evacuating the load-lock chamber 5 are provided at, e.g., two portions under the cylindrical member 4. The air supply paths 6 have exhaust pipes 6a and 6b, respectively, for performing a two-step evacuation.
A window 7 constituted by a glass plate is mounted on part of a side surface of the cylindrical member 4, and a box member 7a is mounted on the cylindrical member 4 to cover the outer surface of the window 7. A light-emitting section 8a for emitting a laser beam is disposed on the bottom portion of the box member 7a. A mirror 8b, a cylindrical lens 8c, and a light-receiving section 8d are housed in the box member 7a. The mirror 8b reflects the laser beam, which has been emitted upward from the light-emitting section 8a, at a right angle toward the interior of the load-lock chamber 5. The lens 8c shapes the spot of the laser beam into a thin elongated shape. The light-receiving section 8d receives the laser beam returned from the load-lock chamber 5.
A mirror 8e which reflects at a right angle a laser beam incident through the window 7 in order to form an optical path perpendicular to the path of the wafer and a mirror 8f which reflects the laser beam reflected by the mirror 8e to the outside of the window 7 are arranged in the load-lock chamber 5. The positions of the pair of mirrors 8e and 8f are set at places where the center of the major axis of a slit section S of the laser beam is located on, e.g., the periphery (excluding a linear portion l called an orientation flat) of the wafer W, as shown in FIG. 4, when the center of the wafer coincides with the center of rotation of the rotating shaft 4b.
The light-emitting section 8a, the mirror 8b, the lens 8c, and the light-receiving section 8d constitute a first unit together with the window 7 and the box member 7a. The mirrors 8e and 8f in the load-lock chamber 5 are mounted on a U-shaped common holding member 8g was to constitute a second unit and are fixed to the window 7 through a fixing member 8h.
If the respective members are combined to constitute the first and second units as described above, the relative positional relationship among the light-emitting section 8a, the mirror 8b, and the objective lens 8c and the position of the light-receiving section 8d of the first unit are preset, and the positions of the pair of mirrors 8e and 8f of the second unit are preset. Thus, to incorporate the first and second units in the load-lock unit, only the positions of the two units need be set. As a result, an optical path can be easily set with a high precision in a small load-lock unit.
The light-receiving section 8d is connected to an operating means 9 for calculating a positional error amount of the wafer W in the load-lock chamber 5, i.e., the amount of error in central positioning and orientation (rotation angle) of the wafer W on the basis of an electrical signal corresponding to an amount of light received by the light-receiving section 8d. In FIG. 3, the light-emitting section 8a, the light-receiving section 8d, and the operating means 9 constitute a positional error detecting means of the wafer. The load-lock unit according to this embodiment has the arrangement described above.
In the above-described embodiment shown in FIG. 3, the light-emitting and light-receiving sections 8a and 8d are combined as the first unit and disposed in the box member 7a. However, they are not limited to this arrangement but can be disposed at various positions.
In the arrangement shown in FIG. 5, a light-emitting section 8a is disposed outside the box member 7a, and a laser beam emitted from the light-emitting section 8a is incident on a load-lock chamber 5 through a transparent plate 8i. The arrangement shown in FIG. 5 is advantageous in that a mirror 8b can be omitted.
In the arrangement shown in FIG. 6, a light-emitting section 8a is disposed below a load-lock chamber 5, and a laser beam emitted from the light-emitting section 8a is incident on a load-lock chamber 5 through a transparent plate 8j. The arrangement shown in FIG. 6 is advantageous in that mirrors 8b and 8e can be omitted. Although not shown in FIG. 6, a lens 8c can be disposed either inside or outside the load-lock chamber 5.
In the arrangement shown in FIG. 7, a light-receiving section 8d is arranged above a load-lock chamber 5, and a laser beam from the load-lock chamber 5 is incident on the light-receiving section 8d through a transparent plate 8k. The arrangement shown in FIG. 7 is advantageous in that a mirror 8f can be omitted. In the arrangement shown in FIG. 7, the position of a light-emitting section 8a can be any of those shown in FIGS. 3, 5, or 6. When the light-emitting section 8ais disposed at the position shown in FIG. 6, all the mirrors can be omitted.
In the arrangement shown in FIG. 8, a light-receiving section 8d is disposed in a load-lock chamber 5. The arrangement shown in FIG. 8 is advantageous in that a mirror 8f can be omitted as in FIG. 7. In the arrangement shown in FIG. 8, the position of the light-emitting section 8a can be any one shown in FIGS. 3, 5, or 6.
Operation of the load-lock unit described above will now be described with reference to FIG. 3.
A gate (not shown) of the load-lock chamber 5 on the outer air side is opened, and a non-processed wafer W disposed in an outer air is loaded in the load-lock chamber 5 by a transfer mechanism (not shown) through its intake port, placed on the turntable 4d, and fixed on the turntable 4d by the electrostatic chuck. The gate on the outer air side is closed and the load-lock chamber 5 is evacuated to a predetermined vacuum degree. A motor (not shown) is driven to rotate the wafer W once while the light-emitting section 8a emits a laser beam. If a starting point of data detection is near the vertex of the orientation flat, a peak corresponding to the vertex of the orientation flat appears at two ends of the detection data, thus sometimes causing inconvenience in data read access. Hence, the wafer W is normally rotated through about 360°+5°.
The amount of laser beam received by the light-receiving section 8d corresponds to the position of the periphery of the wafer W in the laser beam range. Thus, the distance from the center of rotation to the periphery of the wafer w within the laser beam range at each angular position can be obtained by the operating means 9 on the basis of an electrical signal output from the light-receiving section 8d. The orientation flat l for determining the crystal orientation is formed in the wafer W. Therefore, an error amount of the center of the wafer W from a correct position and an error amount (error amount in rotation angle) of the orientation of the wafer W from a correct position can be simultaneously detected by obtaining the distance described above at each angular position of the wafer W.
The positional error of the center of the wafer need not be that from the correct position but can be a distance from a certain reference point, and the error in rotation angle can be an angle of the orientation flat with respect to a certain reference line.
Then, the electrostatic chuck is released, a gate (not shown) in the process chamber is opened, and the wafer W is loaded in the process chamber through its outlet port by the transfer mechanism (not shown).
The positional error of the center of the wafer and the error in rotation angle of the wafer can be detected in this manner in the load-lock unit. In this embodiment, e.g., an aligning mechanism (not shown) may be incorporated in the load-lock unit to correct these errors. Alternatively, alignment may be performed when the wafer is transferred into the process chamber from the load-lock unit as in another embodiment to be described below.
FIG. 9 shows part of a transfer system for transferring a wafer to a turntable 1a in a process chamber 1 of an ion implantation unit from the outside (atmospheric pressure). In this system, first and second load-lock units 11a and 11b each having an optical path unit 10 including light-emitting and receiving sections and mirrors as shown in FIG. 3 are disposed adjacent to each other.
A transfer mechanism 12 comprising, e.g., an articulated robot is provided in the process chamber 1. A control unit 13 for controlling the transfer mechanism 12 on the basis of an operation result is connected to the output of an operating means 9 connected to the optical path unit 10. Reference numeral 14 denotes a transfer mechanism on the outer air side; and 15a and 15b, denote wafer carriers disposed at predetermined positions.
Operation of the system shown in FIG. 9 will now be described.
The non-processed wafers W buffered in the carrier 15a or 15b disposed in the outer air are loaded one by one in the first load-lock unit 11a at a lower portion in FIG. 9 by the transfer mechanism 14 through a gate G1 on the outer air side. When one wafer W is transferred, the gate G1 is closed, and the load-lock unit 11a is evacuated. The wafer W is rotated during or after evacuation, as described above, and the positional error of the wafer W is detected by the operating means 9 by a positional error detecting means 100, i.e., on the basis of an electrical signal from the optical path unit 10.
Subsequently, a gate G2 on the process chamber 1 side is opened and the wafer W in the load-lock unit 11a is transferred to a predetermined position on the turntable 1a by the transfer mechanism 12. At this time, the control unit 13 supplies a control signal to the transfer mechanism 12 so that the positional error of the center and the error in rotation angle of the wafer W occurring in the load-lock unit 11a are corrected on the basis of the operation result (positional error amount of the wafer) supplied from the operating means 9 when the wafer W is placed at the predetermined position on the turntable 1a.
Regarding control of the transfer mechanism 12, the positional error amount may be corrected when the transfer mechanism 12 is to receive the wafer W in the load-lock unit 11a or 11b or is to place the wafer W on the turntable 1a, or in a process after the transfer mechanism 12 receives the wafer W and before the transfer mechanism 12 is to place the wafer W.
Regarding correction of the positional error detected in the load-lock unit, the error in rotation angle of the wafer W may be corrected by the rotating shaft 4b in the load-lock unit, and only the positional error of the center of the wafer W may be corrected by the transfer mechanism 12.
Since the system shown in FIG. 9 has two load-lock units, while a wafer W is being loaded from one load-lock unit 11a or 11b in the process chamber 1, alignment (detection of a positional error) of the next wafer W can be performed on the other load-lock unit 11b or 11a. Thus, the waiting time normally required for alignment can be eliminated so as to increase the throughput.
Regarding the gate G1 of each of the load-lock units 11a and 11b, if the wafer inlet port is formed to have a surface 16 inclined at, e.g., 45° with respect to the vertical axis, and the gate G1 for opening and closing the inlet port is provided with a pivotal member 17 which pivots about a horizontal axis P, as shown in FIG. 10, the path of movement of the gate G1 will not be widened in the transverse direction, and its movement distance can be minimized, thus minimizing the installation space. In this case, the gate G1 may be linearly moved in the vertical direction in place of being pivoted, or the arrangement described above may be applied to the gate G2 on the side of the process chamber.
Detection of the positional error of the wafer is not limited to the method described in this embodiment, and, e.g., light reflection by the periphery of the wafer may be utilized for this detection.
The present invention is not limited to wafer transfer between atmospheres having different pressures but can be similarly applied to wafer transfer between atmospheres having different types of gases.
As has been described above, according to the present invention, since the positional error of the wafer is detected in the load-lock unit, conventional handling including temporarily placing the wafer on the aligning unit can be eliminated. As a result, damage to the wafer and particles of dust attached to the wafer can be decreased, thus increasing the yield. In addition, since the time required for loading can be shortened, the throughput can be increased, and since the aligning unit can be eliminated, the size of the entire system can be reduced. Furthermore, since the positional error is detected on the basis of data obtained by rotation of the wafer, a large-size system such as a TV camera need not be used, thus avoiding an increase in size of the load-lock unit.
In particular, when the positional error of the wafer detected in the load-lock unit is corrected by the transfer mechanism disposed in the process chamber in, e.g., a vacuum atmosphere, transfer and correction of the positional error can be simultaneously performed, thus further increasing the throughput. In this manner, when the positional error is corrected at the final position of the wafer, e.g., at a position close to the turntable in the process chamber, high-precision alignment can be performed.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, and representative devices, shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A load-lock unit is disposed between first and second atmospheres, for storing a wafer transferred from the first atmosphere, and which is blocked off from the first atmosphere, thereafter being set in an atmosphere at least substantially similar to the second atmosphere, and opened so as to communicate with the second atmosphere in order to transfer the wafer to the second atmosphere. The load-lock unit includes a load-lock chamber, a holding mechanism, disposed in the load-lock chamber for holding the wafer, a rotating mechanism for rotating the wafer held by the holding mechanism, and an error detecting mechanism for detecting a positional error of the center of the wafer and an orientation error of the wafer on the basis of data obtained by radiating light on the wafer which is rotating.
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FIELD OF THE INVENTION
This invention pertains to bonded sputter target/backing plate assemblies and methods of making such assemblies. More particularly, in forming such assemblies, one of the bonding surfaces is treated, either by roughening so as to produce a surface roughness of at least about 120 R a , or by drilling a plurality of holes in the bonding surface. This surface treatment assists in forming a mechanical interlock between the sputter target and backing plate in the bonded assembly.
BACKGROUND OF THE INVENTION
Cathodic sputtering is widely used for the deposition of thin layers of material onto desired substrates. Basically, this process requires a gas ion bombardment of the target having a face formed of a desired material that is to be deposited as a thin film or layer on a substrate. Ion bombardment of the target not only causes atoms or molecules of the target materials to be sputtered, but imparts considerable thermal energy to the target. This heat is dissipated beneath or around a backing plate that is positioned in a heat exchange relation with the target. The target forms a part of a cathode assembly which together with an anode is placed in an evacuated chamber filled with an inert gas, preferably argon. A high voltage electrical field is applied across the cathode and the anode. The inert gas is ionized by collision with electrons ejected from the cathode. Positively charged gas ions are attracted to the cathode and, upon impingement with the target surface, dislodge the target material. The dislodged target materials traverse the evacuated enclosure and deposit as a thin film on the desired substrate that is normally located close to the anode.
In addition to the use of an electrical field, increasing sputtering rates have been achieved by the concurrent use of an arch-shaped magnetic field that is superimposed over the electrical field and formed in a closed loop configuration over the surface of the target. These methods are known as magnetron sputtering methods. The arch-shaped magnetic field traps electrons in an annular region adjacent to the target surface, thereby increasing the number of electron-gas atom collisions in the area to produce an increase in the number of positive gas ions in the region that strike the target to dislodge the target material. Accordingly, the target material becomes eroded in a generally annular section of the target face, known as the target raceway.
In a conventional target cathode assembly, the target is attached to a nonmagnetic backing plate. The backing plate is normally water-cooled to carry away the heat generated by the ion bombardment of the target. Magnets are typically arranged beneath the backing plate in well defined positions in order to form the above noted magnetic field in the form of a loop or tunnel extending around the exposed face of the target.
In order to achieve good thermal and electrical contact between the target and the backing plate, these members are commonly attached to each other by use of soldering, brazing, diffusion bonding, clamping or epoxy cements.
To a certain extent soft solders can accommodate stresses exerted on the target/backing plate assembly that occur upon cooling. These stresses can be considerable in light of the significant differences in thermal expansion coefficients that may exist between the target and backing plate metals. However, the relatively low joining temperatures associated with the "soft" solders reduce the temperature range over which the target can be operated during sputtering.
In some cases, in order to overcome the problem of joining one or more nonwettable materials by soldering, precoating with a metal is used to enhance solderability. These coatings may be applied by electroplating, sputtering or other conventional means.
Another method which is applicable and used to some extent in target joining is that of explosive bonding or welding. By this technique, bonds are produced that combine solid state bonding and a mechanical interlocking as a result of the surface irregularities produced in the form of "jetting." The bonds are strong and reliable. The disruption of the initial mating surfaces during the dynamic bonding pulse negates the need for extreme surface cleanliness or preparation. See, e.g., John G. Banker et al., "Explosion Welding", ASM Handbook, Vol. 6, Welding, Brazing and Soldering; pp. 303-305 (1993).
Smooth surface diffusion bonding is an applicable method of bonding but has only limited use in the bonding of sputtering target components. The bond is produced by pressing the material surfaces into intimate contact while applying heat to induce metallurgical joining and diffusion to varying extent across the bond interface. Bonding aids, metal combinations which are more readily joined, are sometimes applied to one or both of the surfaces to be bonded. Such coatings may be applied by electroplating, electrolyze plating, sputtering, vapor deposition or other usable technique for depositing an adherent metallic film. It is also possible to incorporate a metallic foil between bonding members which foil has the ability to be more easily bonded to either of the materials to be joined. The surfaces to be joined are prepared by chemical or other means to remove oxides or their chemical films which interfere with bonding.
An additional technique for bonding as described in U.S. Pat. No. 5,230,459 includes the pre-bonding step of providing machined grooves in the surface of one of the components to be solid state bonded. This feature causes disruption of the bond surface of the associated component during heated pressure application. The material having the greater strength or hardness will normally be provided with the grooves such that, during bonding, it will penetrate into the softer member with the softer metal substantially filling the grooves.
Solder bonds of materials with widely differing thermal expansion rates are susceptible to shear failure initiating at the extreme edges of the bond interface when the solder is too weak for the application. The result commonly experienced is debonding during service. The need for intermediate coatings applied to materials that are difficult to wet and solder presents problems including adherence reliability of the applied coating and substantial added cost of applying the coating. The higher melting temperature solders used for high power applications are stronger but are far less forgiving of the stresses developed in the materials system. Targets of large size present greater stress problems as well as greater difficulty of producing sound bonds across the entire bond surface. As sputtering target sizes and power requirements increase, the soft solders become less applicable for joining of the material systems involved.
Explosive bonding is a comparatively costly bonding method. For example, such bonding requires that the materials be provided in an oversized condition to allow for predictable damage at the periphery of the target assembly, thereby adding to material cost. Also, the conditions for achieving acceptable products must be adjusted for different component sizes and combinations of materials, and although the bonds offer good strength, the bond interfaces are variable in physical character. In addition, this method is not applicable to a material system having one component which is brittle or which has limited ductility.
Smooth surface diffusion bonding requires extreme care in preparation and in maintaining surface cleanliness prior to and during the bonding operation to ensure reliable bond qualities. Because the diffusion bond interfaces are planar, they are subject to stressing in simple shear which commonly leads to peeling away at the ends of the bond area. The formation of brittle intermetallics at the bond interface, which increase in thickness with the associated long times of heat exposure, add to the potential of bond shear failure.
Groove bonding is applicable to bonding many dissimilar materials, but is limited to materials that have dissimilar melting temperatures because the process must occur near the melting temperature of the lower melting point alloy. This also precludes the use of this technique for similar metals. It is also possible that the saw tooth nature of the grooves may act as a stress concentrator and promote premature cracking in the alloys near the bonds. Furthermore, machining of the grooves is a time consuming operation.
Accordingly, it is an object of the invention to provide a convenient, inexpensive method for bonding target and backing plate materials that are either similar or dissimilar, that will be capable of withstanding thermal expansion and contraction stresses exerted thereon during and after sputtering.
SUMMARY OF THE INVENTION
This invention is directed to an improved sputter target/backing plate assembly and a method for making such an assembly. The assembly includes a sputter target having a bonding surface which is bonded to the bonding surface of an underlying backing plate. The method of forming the bonded assembly includes treating one of the bonding surfaces, either by roughening at least a portion of one of the bonding surfaces so as to produce a roughened portion having a surface roughness of at least about 120 R a , or by drilling a plurality of holes in one of the bonding surfaces. The method further includes orienting the sputter target and backing plate to form an assembly having an interface defined by the bonding surfaces, subjecting the assembly to a controlled atmosphere, heating the assembly, and pressing the assembly so as to bond the bonding surfaces.
When surface roughening is used, preferably, the surface roughening is accomplished by particle blasting, shot peening, etching or a combination thereof. The roughening step may include roughening substantially the entire bonding surface of at least one of the sputter target and backing plate, or if desired, the surface to be roughened may be masked or covered in such a way as to form a specific roughened pattern, such as a grid-like pattern. In a preferred form of the invention, the roughening step includes roughening at least a portion of the bonding surface of the sputter target, and in a more preferred form, substantially all of the target bonding surface is roughened.
Although the roughened portion should have a surface roughness of at least 120 R a , the surface roughness preferably ranges from about 120 R a to about 150 R a , and more preferably is about 135 R a after the roughening step.
When the treating step includes drilling a plurality of holes in one of the bonding surfaces, the holes typically are distributed over substantially all of the bonding surface. Preferably, the holes are spaced approximately one half inch apart from one another, with each of the holes having a diameter of about 3/64 in. and a depth of about 0.065 in. When each hole is machined, some of the metal forms a peripheral burr at the mouth of the hole, which should be retained as a part of the bonding surface. Then when the sputter target and backing plate are bonded together, each burr forms a mechanical interlock with material from the other one of the bonding surfaces in the bonded assembly. When drilled holes are used, the holes preferably are placed in the bonding surface of the sputter target.
The controlled atmosphere used in forming the bonded sputter target/backing plate assembly preferably is a vacuum, inert gas, reducing gas or combination thereof.
Any of a number of different materials may be used for the sputter target and backing plate. Preferably, the sputter target is made of titanium, aluminum, molybdenum, cobalt, chromium, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold, tungsten, silicon, tantalum, vanadium, nickel, iron, manganese or germanium, or an alloy thereof. The backing plate preferably is made of aluminum, copper, steel, or titanium, or an alloy thereof.
In the heating step, the assembly typically is heated to a temperature somewhat below the homologous melting point of the metal used for the backing plate. More specifically, when the backing plate is aluminum or an aluminum alloy, the assembly preferably is heated to a temperature of from about 300° C. to about 575° C., and when copper or a copper alloy is used, the assembly is heated to a temperature of from about 540° C. to about 1015° C. If the backing plate is made of steel, the temperature in the heating step should range from about 730° C. to about 1320° C., while if titanium or a titanium alloy is used, the temperature should be from about 890° to about 1570° C.
In the pressing step, the assembly preferably is pressed at a pressure of from about 30 MPa to about 140 MPa.
One of the benefits of sputter target/backing plate assemblies made according to the method is improved strength and resistance to shear failure, due primarily to the surface treatment of one of the bonding surfaces. This enhanced strength and resistance to bond failure allows such assemblies to be used at higher operational sputtering temperatures and extends the range of target sizes which may be used without compromising structural reliability.
Furthermore, the methods used for treating the bonding surface, such as particle blasting, shot peening, etching and drilling, result in manufacturing time savings and cost savings when compared with the extensive surface preparation required for smooth surface diffusion bonding or with the machining of grooves used in groove bonding. In addition, several prior art methods require lengthy exposure of an assembly to temperatures which can deleteriously alter the microstructure of the target, thereby degrading the target's performance. However, the temperatures used in the present method allow the solid state bond to be formed while minimizing excessive exposure to high temperatures.
These and other benefits and advantages will be apparent to those of ordinary skill in the art on review of the following Figures and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the bonding surface of a sputter target prior to surface roughening;
FIG. 2 is a top view of the sputter target of FIG. 1 after surface roughening;
FIG. 3 is a cross-sectional view of the sputter target of FIG. 2 taken along line 3--3;
FIG. 4 is an exploded cross-sectional view of an unbonded assembly showing the roughened sputter target of FIG. 3 and a corresponding unroughened backing plate disposed above;
FIG. 5 is a cross-sectional view of a bonded sputter target/backing plate assembly;
FIG. 6 is a closeup cross-sectional photograph taken at 6 of FIG. 5 showing the bond formed between the bonding surfaces of the sputter target and backing plate at 400× magnification;
FIG. 7 is a top view of a quadrant of the sputter target of FIG. 1 showing a plurality of holes drilled in the bonding surface;
FIG. 8 is a cross-sectional view of a portion of the sputter target of FIG. 7 taken along line 8--8; and
FIG. 9 is a cross-section of the portion of the sputter target shown in FIG. 8 bonded to a backing plate to form a bonded sputter target/backing plate assembly.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 4, in a preferred form of the invention, a sputter target 10 having a machined bonding surface 12 is prepared for bonding with a backing plate by roughening the machined bonding surface 12. The roughened bonding surface 14 may be formed by any of a number of techniques, including for example, particle blasting, shot peening, etching or a combination thereof. Particle blasting with grit is a preferred method because the equipment generally is readily available and easy to use, and this method produces a more uniformly roughened surface.
As shown in FIGS. 2 and 3, the roughening treatment may be applied substantially to the entire bonding surface 14. However, if desired, the roughening treatment may be applied only to a particular portion or portions of the bonding surface, either in a random fashion or in a particular pattern. A particular pattern may be achieved by masking certain portions of the bonding surface prior to surface roughening. For example, if desired, a grid-like pattern of unroughened bonding surface may be created by masking the unroughened bonding surface with intersecting vertical and horizontal strips of a rubberized tape such as masking tape prior to surface roughening. Furthermore, referring to FIG. 4, in a preferred form of the invention, only the bonding surface 14 of the sputter target 10 receives the roughening treatment, while the bonding surface 18 of the backing plate 16 remains unroughened. However, if desired, the invention may be practiced by roughening at least a portion of the backing plate bonding surface in lieu of roughening the sputter target. Alternatively, the roughening step may include roughening at least a portion of both sputter target and backing plate bonding surfaces.
In practicing the invention, the particular surface or surfaces to be roughened should be treated so as to have a surface roughness of at least 120 R a . As used herein, the term "surface roughness" is defined as the arithmetic average deviation of the surface expressed in micro-inches from a mean line or center line, with R a being the nationally adopted symbol for surface roughness. Preferably, this surface roughness should be from about 120 R a to about 150 R a , and more preferably is about 135 R a after the roughening step. As seen in FIGS. 3-4, the roughening step produces an uneven surface topography on the bonding surface treated.
In a preferred method of forming the bonded assembly, the roughened portion is cleaned prior to bonding to remove any particles which may remain after grit blasting, shot peening or etching. Any of a number of different methods may be used to remove the particles, and since this is not a degreasing step, a dry lint-free wipe may be used. If desired, the bonding surface of the unroughened component of the assembly (typically the backing plate when the sputter target is roughened) may be cleaned with an acetone wipe or other degreasing composition, such as isopropyl alcohol or soap and water, to remove machining oils, fingerprints and the like.
As an alternative to surface roughening, one of the bonding surfaces may be treated by drilling a plurality of holes in the bonding surface. For example, referring to FIG. 7, a plurality of holes 28 is drilled in the bonding surface 14' of the sputter target 10'. Although only one quadrant is shown, in an actual embodiment, the drilled holes 28 are evenly distributed across the entire bonding surface 14' in generally concentric rings. However, if desired, the drilled holes may be aligned in the bonding surface in any other pattern, such as in the form of a grid, or they may be placed in the bonding surface in a purely random array. In a preferred embodiment, the holes are spaced approximately one half inch apart from one another, and each hole has a diameter of about 3/64 in. and a depth of about 0.065 in.
Referring to FIG. 8, after each hole 28 has been drilled, it has a peripheral burr or fin 30 at the mouth of the hole 28, formed of excess metal material. These burrs or fins are left intact so that when the sputter target and backing plate are bonded together, the burrs provide a slight mechanical interlock with the metal of the other component, thereby aiding in the bonding of the assembly.
Although it is preferred to drill the holes in the bonding surface of the target, the invention may be practiced by drilling holes in the bonding surface of the backing plate instead, or in both bonding surfaces.
Once one of the bonding surfaces has been treated by surface roughening or drilling of holes as described above, the sputter target and backing plate may be bonded using a technique such as hot isostatic pressing (HIPing) or uniaxial hot pressing (UHPing). Referring to FIG. 4 as an example, the sputter target 10 and backing plate 16 are oriented to form an assembly 20 having an interface defined by their bonding surfaces 14, 18. Then, if UHPing is used, this unbonded assembly is placed between a pair of plungers, platens or rams. These rams are contained within a control chamber which allows for the control of temperature, pressure and other atmospheric conditions.
The controlled atmosphere is a vacuum, reducing gas or inert gas, or a combination thereof. Preferably, the controlled atmosphere is a vacuum of about 10 -2 torr or greater. A vacuum is preferred because it provides more control in preventing reoxidation of the metals. However, if desired, any reducing gas may be used such as, for example, nitrogen with 5 to 10 weight percent of hydrogen. Or, if desired, any inert gas may be used as well.
In addition to adjusting the atmosphere, the temperature in the uniaxial hot press control chamber is increased in order to heat the unbonded assembly. The assembly is heated to a temperature somewhat below the homologous melting point (T m ) of the metal used for the backing plate. Preferably, the assembly is heated to a temperature in the range of from about 0.60 T m to about 0.95 T m , and more preferably, within the range of about 0.75 T m to about 0.90 T m . Referring to Table 1, these temperature ranges are shown for various metals typically used as the backing plate material. By elevating the temperature of the assembly to a temperature somewhat below the melting point of the backing plate material, the backing plate softens, and upon pressing, forms a tight interface with the treated bonding surface of the sputter target.
TABLE 1______________________________________TEMPERATURE VALUES AS A FRACTION OF THEHOMOLOGOUS MELTING POINT T.sub.mBackingPlateMaterial 0.6 T.sub.m 0.75 T.sub.m 0.9 T.sub.m 0.95 T.sub.m______________________________________Cu 815° K. 1015° K. 1220° K. 1228° K. 542° C. 742° C. 947° C. 1015° C.Steel 1005° K. 1255° K. 1505° K. 1590° K. 732° C. 982° C. 1232° C. 1317° C.Ti 1165° K. 1455° K. 1745° K. 1844° K. 892° C. 1182° C. 1472° C. 1571° C.Al 573° K. 723° K. 823° K. 848° K. 300° C. 450° C. 550° C. 575° C.______________________________________
As the assembly is heated, a compressing force is applied on the assembly by the rams in a uniaxial direction. The pressure on the assembly is elevated typically to a range of from abut 30 MPa to about 140 MPa.
The assembly is maintained in the control chamber under these temperature, pressure and atmospheric gas conditions typically for a period of from about 30 minutes to about 60 minutes, thereby forming the bonded sputter target/backing plate assembly.
Alternatively, the assembly may be bonded using hot isostatic pressing (HIPing). If HIPing is used, the treated sputter target and backing plate are oriented to form an assembly having an interface defined by the bonding surfaces, and this assembly is placed within a HIPing canister. Any canister may be used as long as it is deformable and is able to withstand HIPing conditions. Typically, a steel can having a side wall, bottom plate, top plate and sealable opening for pulling a vacuum is used. Once the assembly is placed in the HIPing canister, a vacuum is pulled, typically on the order of 10 -2 torr or greater. This canister then is placed within a HIPing chamber which is adapted to withstand severe temperature and pressure conditions. The ambient atmosphere in the HIPing chamber is replaced with a true inert gas, such as argon or helium. In addition, the temperature and pressure in the HIPing chamber are increased as discussed above with respect to UHPing, in order to form a bonded sputter target/backing plate assembly. Referring to Table 1, the assembly is heated to a temperature somewhat below the homologous melting point of the metal used for the backing plate. Preferably, the assembly is heated to a temperature in the range of from about 0.60 T m to about 0.95 T m , and more preferably, within the range of about 0.75 T m to about 0.90 T m . Furthermore, with respect to pressure, the HIPing canister and assembly contained therein are compressed from all sides at a pressure of from about 30 MPa to about 140 MPa. The assembly preferably is maintained at the desired temperature, pressure and atmospheric conditions for a period of about 60 minutes. When metals having different coefficients of expansion are used for the sputter target and backing plate, it is advantageous to remove a portion of the increased pressure from the HIPing chamber while maintaining an elevated temperature, thereby reducing the risk of bond cracking due to tensile stresses.
As shown in FIGS. 5 and 6, when the roughened sputter target 10 and backing plate 16 are bonded together to form a bonded assembly 22, the roughened bonding surface 14 of the sputter target 10 slightly compresses and deforms the bonding surface 24 of the softer backing plate 16 thereby creating a tight bond interface 26.
Referring to FIG. 9, when the sputter target 10' and backing plate 16' are bonded together to form a bonded assembly 22', metal from the backing plate 16' flows into the drilled holes 28 formed in the bonding surface 14' of the sputter target 10'. Furthermore, as the sputter target 10' and backing plate 16' are pressed together, the peripheral burr 30 at the mouth of each hole is pushed downward and forms a slight mechanical interlock with the backing plate material which has flowed into the hole or cavity 28' in the bonding surface 14' of the sputter target 10', thereby creating a tight bond interface. The bonding surface of the bonded backing plate 16' is shown as item 24'.
The metals used for the sputter target and backing plate may be any of a number of different metals, either in pure or alloy form. For example, the sputter target may be made of titanium, aluminum, molybdenum, cobalt, chromium, ruthenium, rhodium, palladium, silver, osmium, iridium, platinum, gold, tungsten, silicon, tantalum, vanadium, nickel, iron, manganese, germanium, or an alloy thereof. In addition, the backing plate may be made of aluminum, copper, steel, titanium, or an alloy thereof. Preferred sputter target/backing plate metal pairings include a titanium-tungsten target bonded to an aluminum backing plate, a titanium-tungsten target bonded to a titanium backing plate, a titanium target bonded to an aluminum backing plate, an aluminum target bonded to an aluminum backing plate, a titanium target bonded to a titanium backing plate, a molybdenum target bonded to a copper backing plate, a cobalt target bonded to a copper backing plate, a chromium target bonded to a copper backing plate, and a target formed of a precious metal such as ruthenium, rhodium, palladium, silver, osmium, iridium, platinum or gold, bonded to a copper backing plate. If a titanium-tungsten alloy is used, the alloy preferably includes about 10% to 15% titanium by weight.
Although the method has been described in conjunction with a disc-shaped sputter target/backing plate assembly, it will be readily apparent to one of ordinary skill that the method may be used to bond sputter targets and backing plates having any of a number of different shapes and sizes.
EXAMPLES
Example 1
The Formation of Bonded Sputter Target/Backing Plate Assemblies
Several disc-shaped target/backing plate assemblies were produced using pure titanium for the targets and 2024 aluminum for the backing plates. Each disc-shaped target measured 152 mm×15.2 mm, while each disc-shaped backing plate measured 152 mm×25.4 mm. The bonded surface of each of the titanium targets was machined flat, and then several of the targets were given different surface treatments. Two of the targets received a protective covering of masking tape formed in a grid on the bonding surface. Strips of 5 mm wide tape were spaced 10 mm apart in both vertical and horizontal directions on the bonding surface. These masked sputter targets were grit-blasted using the following procedure. Each target was placed in a grit blast cabinet, and the air pressure on the grit blast machine was set to 60 psi. Then, using grit No. 46, the bonding surface of the target was grit-blasted by holding the grit blast nozzle at a 45° angle approximately 1.5 in. to 2 in. from the bonding surface. The grit blasting was continued in a sweeping motion until all exposed target bonding surfaces had a rough gray surface. Then, compressed air was used to blow any loose particles off the target, the masking tape was removed and the target bonding surface was cleaned with alcohol. Two additional target samples were entirely grit-blasted using the above procedure, but without any masking or covering protecting any portion of the bonding surface.
Several other titanium targets were prepared for bonding by drilling holes in the target bonding surface. For two of the target samples, holes were drilled in a grid-like pattern approximately 0.4 in. apart from each other. Each hole had a width of about 3/64 in. and a depth of about 0.065 in. For two other samples, holes having the same width and depth were used; however, these holes were formed in a concentric-ring pattern and were spaced approximately 0.5 in. apart from each other.
Each of the titanium targets was then paired with a 2024 aluminum backing plate and loaded into an evacuated steel hot isostatic press can. Each can was then hot isostatically pressed (HIPed) in order to form a bonded assembly. Once a press can containing an assembly was loaded into the HIPing control chamber, the chamber was filled with argon and the temperature and pressure increased to a temperature of about 900° F. and a pressure of about 6000 psi. The sputter target/backing plate assembly was maintained under these conditions for about 60 minutes, at which point the pressure was reduced quickly from 6000 psi to about 5000 psi, which cooled the assembly somewhat. Then, the assembly was cooled to ambient temperature by reducing the temperature by approximately 120° F. every hour. In addition, the pressure in the HIPing chamber was returned to ambient pressure over that same time period. Each of the target/backing plate assemblies discussed above was hot isostatically pressed using the same process.
Example 2
Measurement of Bond Integrity
The bond integrity of each of the titanium/aluminum assemblies formed in Example 1 was measured by ultrasonic techniques to determine the percentage of the bond surface actually bonded. Two samples were tested for each surface preparation type, with averaged ultrasonic results given in Table 2.
TABLE 2______________________________________Surface Preparation % Surface Bonded-Ultrasonic______________________________________Smooth Surface 99Grit-blasted (no mask) 100Grit-blasted (mask) 100Drilled Holes (concentric rings) 100Drilled Holes (grid) 100______________________________________
The grit-blasted assemblies and the assemblies employing drilled holes showed 100% bonding while the smooth surface assembly was approximately 99% bonded.
Example 3
Tensile Strength of the Bonds
The loaded assemblies formed in Example 1 were sectioned into bars 101.6 mm long by 25.4 mm wide. Then, a hole was drilled through each bonded assembly near one end, perpendicular to the bond interface, and a 25.4 mm deep saw cut was made from that same end, along the plane of the bond interface to prepare for tensile testing. Tensile tests then were run using an Instron Universal Testing Machine Model TTC. The samples were pulled in tension with the direction of applied stress perpendicular to the bond. Two samples were tested for each surface preparation type, and the average of the two tensile test results for each bond are given in Table
TABLE 3______________________________________ Tensile StrengthSurface Preparation at Bond Failure______________________________________Smooth Surface 5.16 MPaGrit-blasted (no mask) 11.8 MPaGrit-blasted (mask) 12.7 MPaDrilled Holes (concentric rings) 8.3 MPaDrilled Holes (grid) 13.4 MPa______________________________________
The tensile strengths at failure of the grit-blasted and drilled-hole samples are approximately twice that for the smooth samples.
The preferred embodiments and examples discussed above are provided by way of illustration only and are not intended to limit the scope of the invention, which is to be determined by the following claims:
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This invention is directed to an improved method for making a bonded sputter target/backing plate assembly as well as assemblies produced therefrom. The assembly includes a sputter target having a bonding surface which is bonded to the bonding surface of an underlying backing plate. The method of forming the bonded assembly includes treating one of the bonding surfaces, either by roughening at least a portion of one of the bonding surfaces so as to produce a roughened portion having a surface roughness (R a ) of at least about 120 micro inches, or by drilling a plurality of holes in one of the bonding surfaces. The method further includes orienting the sputter target and backing plate to form an assembly having an interface defined by the bonding surfaces, subjecting the assembly to a controlled atmosphere, heating the assembly, and pressing the assembly so as to bond the bonding surfaces.
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FIELD OF THE INVENTION
[0001] The described invention is an innovative solvent deasphalting, hydroconversion processing configuration for converting bitumen or heavy oils and producing a transportable synthetic crude oil (SCO). The invention results in a high yield of specification SCO which will contain greatly reduced or nil undesirable asphaltenes, no undesirable vacuum bottoms or coke product and is accomplished with minimal investment cost compared to currently known methods. Synthetic crude is the primary product from a bitumen/extra heavy oil upgrader facility used in connection with oil sand production. SCO can also be output from an oil shale extraction process. The properties of the synthetic crude depend to a large extent on the feedstock quality and on the process used in the upgrading. Relative to the feedstock, SCO is lower in sulfur, has an API gravity in the 20-35° range, and is also known as “upgraded crude”.
[0002] In this invention, the total heavy oil or bitumen feedstock is initially fractionated in a crude or atmospheric still to produce straight-run atmospheric gas oil (AGO), atmospheric residue (AR), and the light diluent which is used to transport the bitumen or heavy oil from the field. The diluent is returned to the field. All or a large portion of the AR stream is sent to a vacuum still to produce straight run vacuum gas oil (VGO) and a vacuum residue feedstream. In one embodiment, a portion of the AR bypasses the vacuum still and is thereafter sent downstream for blending in the final synthetic crude oil product.
[0003] The vacuum residue feedstream and/or a portion of the atmospheric residue feedstream are thereafter fed to a solvent deasphalter process unit to create a deasphalted oil (DAO) stream and an asphaltene stream. The asphaltene product stream can be utilized for fuel or as a feed to a gasification unit to produce hydrogen and/or syngas for upstream oil production. All or a portion of the DAO stream is processed along with a hydrogen stream in an ebullated-bed reactor operating at high severity conditions to produce a greater than seventy percent (70%) and preferably greater than seventy-five (75%) percent conversion rate of the vacuum residue portion of ebullated-bed feedstream. The ebullated-bed products are thereafter blended with the portion of the DAO stream that was not processed in the ebullated-bed reactor, bypassed atmospheric residue, the straight run AGO, and the straight run VGO to produce a synthetic crude oil.
[0004] Once the level of severity in the ebullated-bed unit is set (primarily the vacuum residue conversion level), the fraction of the AR that bypasses the vacuum still or the fraction of the DAO that bypasses the ebullated-bed conversion unit can be set to attain the required final SCO qualities. Hydrogen for the ebullated-bed unit can be obtained via a natural gas-steam reformer or via gasification of a portion of the ebullated-bed heavy product, asphaltenes, or straight run vacuum residue. The invention results in a high yield of specification SCO, no coke product and is accomplished with minimal investment and operating costs. Unlike much of the SCO commercially produced, the invention SCO may contain both straight run and conversion vacuum residue. The SCO will be stable as a result of removal of feedstock asphaltenes, selection of optimal operating conditions in the ebullated-bed conversion unit and the proper blending technique to combine the bypassed bitumen/heavy oil AR or DAO and the conversion products.
BACKGROUND OF THE INVENTION
[0005] The world's higher quality light natural crude oils are those generally having an API gravity greater than 30° with sulfur content less than 0.5 percent. These high quality light natural crudes cost the least to refine into a variety of highest value end products including petrochemicals and therefore command a price premium. More important, however, world refinery capacity is geared to a high proportion of light natural crude oils with an API of 30° or higher.
[0006] It is generally accepted that world supplies of light crude oils recoverable by the conventional means of drilling wells into reservoirs and the use of nature's pressure, or by pumping to recover the oil, will be diminished to the extent that in the coming decades these supplies will no longer be capable of meeting the world demand.
[0007] To find relief from oil supply shortage it will be necessary to substantially increase processing of the vast world reserves of coal and viscous oil, bitumens in tar sands and kerogens in oil shale. These sources of crude oil remain largely unexploited today although recovery of oil from tar sands is in practice in Canada. The development of technology for the production of synthetic oil as an alternative to the light crude oil found in nature continues to be plagued by the large capital investments required in recovery and production facilities and a long wait for return on investment. In addition, large expenditures are required to construct or retrofit refineries for synthetic oils recovered from heavy oils and bitumens. In addition, present synthetic oil plants for processing heavy oils, or bitumens from tar sands, have focused more on the development of systems for recovery and production than on energy efficiency, maximization of yield and high environmental processing standards. Except for South Africa's Sasol process, which benefits from low cost labor used in coal mining, straight coal liquefaction is not yet cost competitive with synthetic oil produced from tar sands bitumen or heavy oils.
[0008] It is therefore of considerable importance that methods are found to produce synthetic crudes to replace the rapidly depleting reserves of light natural crudes available from conventional sources and at a cost at least approaching these crudes and fully competitive with the crudes being recovered at higher cost from under the sea or from frontier areas such as the extreme north with its rigorous climate. It is also important that light synthetic crudes are comprised in desired proportions of a mixture of aromatic, naphthenic and paraffinic components as these three families of compounds comprise essential feedstock to refinery capacity producing today's transportation fuels and feedstocks for the petrochemical industry.
[0009] Accordingly, applicants have disclosed an invention which is an innovative solvent deasphalting, hydroconversion processing configuration for converting these heavy oils and/or bitumens to produce a transportable synthetic crude oil. In the invention, the heavy oil or bitumen feedstock is only partially processed in the hydroconversion unit, there is no secondary hydrotreating, nor is there any coke to dispose of using this novel process.
[0010] The entire heavy oil or bitumen feedstock is first fractionated in a crude still and thereafter all or a portion of the atmospheric residue and/or vacuum residue created in the fractionation process is fed to a solvent deasphalting process unit. The deasphalter asphaltene product is used as fuel or sent to gasification. All or a portion of the deasphalter DAO product is then fed to an ebullated-bed hydroconversion reactor along with a hydrogen stream. The hydrogen stream can be produced through gasification of the SDA asphaltenes. The ebullated-bed reactor operates at relatively high severity and gives a conversion rate of greater than seventy percent (70%) and preferably greater than seventy-five (75%) percent. The entire converted products from the 5 ebullated-bed reactor are thereafter mixed with the straight-run distillates (AGO, VGO), by-passed DAO, and, in some cases, bypassed atmospheric residue from the heavy crude oil or bitumen feedstock plus produced butanes to create the final synthetic crude product.
[0011] These and other features of the present invention will be more readily apparent from the following description with reference to the accompanying drawing.
SUMMARY OF THE INVENTION
[0012] An objective of the invention is to provide an innovative processing configuration for maximizing feedstock processing capacity and liquid SCO yield at minimal required investment.
[0013] Another objective of the invention to allow the processing of bitumen or heavy oil with no solid coke product, which can present a disposal problem.
[0014] It is a further objective of the present invention to utilize maximum size and throughput ebullated-bed reactors for maximum total heavy oil or bitumen feedrate and SCO production.
[0015] It is another object of the invention to further reduce the required plant investment by bypassing either a portion of the atmospheric residue or the DAO stream from being processed in the ebullated-bed reactor.
[0016] It is yet a further object of the present invention to minimize or completely remove all feedstock and conversion product asphaltenes from the final SCO product to insure its stability and compatibility.
[0017] The heavy oil or bitumen feedstock is initially fractionated in crude still to produce straight-run AGO, atmospheric residue, and diluent which is returned to the field. The diluent is added to the raw bitumen at the field in order to transport the blend to the processing complex. A portion of the atmospheric residue is then sent to a vacuum still for further fractionation and the production of a straight run VGO and a vacuum residue stream. The vacuum residue feedstream and/or the atmospheric residue feedstream are thereafter processed along with a hydrogen stream in solvent deasphalting unit to produce deasphalted oil and an asphaltene product. A portion of the deasphalted oil is further processed along with a hydrogen stream in an ebullated-bed reactor system operating at relatively high severity conditions to produce a greater than seventy-five (75%) percent conversion rate. The ebullated-bed products are thereafter blended with the atmospheric residue which was by-passed and the straight run distillates (VGO and AGO) to produce a synthetic crude oil. The asphaltene stream can be utilized or sold as fuel or can be gasified and the hydrogen created from such gasification is utilized in the ebullated-bed reactors.
[0018] Once the level of severity in the ebullated-bed unit is set, the fraction of the AR stream which bypasses the deasphalting and ebullated-bed conversion steps and/or the fraction of the DAO which bypasses the ebullated-bed step can be determined to attain the required final SCO qualities. Hydrogen for the ebullated-bed unit can be obtained via a natural gas-steam reformer or via gasification of the asphaltene product from the solvent deasphalter. The invention results in a high yield of stable and compatible specification SCO, no undesirable coke product and is accomplished with minimal investment and operating costs.
[0019] More particularly, the present invention describes a novel process configuration process for converting heavy oil or bitumen feedstocks to transportable synthetic crude oil comprising:
[0020] a) feeding a bitumen or heavy oil feedstock to a crude still to provide an atmospheric residue stream, a straight run atmospheric gas oil stream, and diluent stream; and
[0021] b) feeding a portion of said atmospheric residue stream to a vacuum fractionator to create a vacuum residue stream and a straight run vacuum gas oil stream; and
[0022] c) feeding said vacuum residue stream along with a portion of said atmospheric residue stream that was not processed in step b) to a solvent deasphalter to produce a deasphalted oil stream and an asphaltene stream;
[0023] d) feeding a portion of the deasphalted oil stream and a hydrogen stream to an ebullated-bed reactor system to create a full-range liquid conversion product stream and a recovered butanes stream; and
[0024] e) blending said full-range liquid conversion product stream, the portion of the deasphalted oil stream that was not processed in step d) above, the portion of the atmospheric residue stream that was not processed in steps b) or c), said straight run vacuum gas oil stream, said recovered butanes stream and said straight run atmospheric gas oil stream to create a synthetic crude oil.
[0025] In one embodiment the heavy oil or bitumen feedstream has the following properties: API gravity less than 15°, sulfur content greater than 3 W % and vacuum residue content greater than 35%. In another embodiment, a portion of the atmospheric residue stream bypasses the vacuum still and is fed to the ebullated bed unit along with the vacuum residue stream.
[0026] The ebullated-bed reactor operates at the following range of conditions: reactor total pressure of 1,000 to 3,000 psia, reactor temperature of 750 to 850° F., hydrogen feedrate of 1,500 to 12,000 SCF/Bbl, liquid hourly space velocity of 0.1 to 1.5 hr −1 , and a daily catalyst replacement rate of 0.05 to 1.0 lb/Bbl of feedstock.
[0027] Generally such hydroprocessing is in the presence of catalyst containing group VI or VIII metals such as platinum, molybdenum, tungsten, nickel, cobalt, etc., in combination with various other metallic element particles of alumina, silica, magnesia and so forth having a high surface to volume ratio. More specifically, catalyst utilized for hydrodemetallation, hydrodesulfurization, hydrodenitrification, hydrocracking etc., of heavy oils and the like are generally made up of a carrier or base material; such as alumina, silica, silicaalumina, or possibly, crystalline aluminosilicate, with one more promoter(s) or catalytically active metal(s) (or compound(s)) plus trace materials. Typical catalytically active metals utilized are cobalt, molybdenum, nickel and tungsten; however, other metals or compounds could be selected dependent on the application.
[0028] The ebullated-bed reactor system maybe comprised of one, two or three stages in series and may incorporate phase separation between the reactor stages to offload the gas from the first stage reactor.
[0029] In the process according to the invention, the overall conversion percentage of the feedstream processed in the ebullated-bed reactor hydrocarbon feedstream is preferably greater than 50% wt, and more preferably greater than 65%, more preferably greater than 70% and again more preferably greater than 75%.
[0030] In one embodiment, the hydrogen stream from step d) above is obtained via gasification of the SDA asphaltenes.
[0031] Between 0 and 100% percent of the atmospheric residue stream from step a) above may bypass step b) and is thereafter fed into the solvent deasphalter of step c) along with the vacuum residue stream. Additionally, between 10 and 80 percent of the DAO produced in step c) may also bypass the ebullated-bed reactor system in step c).
[0032] Depending upon the quality of the SCO product desired, a portion of the straight run atmospheric gas oil stream, vacuum gas oil stream or full-range liquid conversion product stream may not be included in the synthetic crude.
[0033] Also depending upon the quality of the SCO product desired, the straight run vacuum and atmospheric gas oil streams may be hydrotreated or hydrocracked prior to be blended into the synthetic crude oil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a schematic flowsheet of the high conversion partial upgrading process of heavy oil or bitumen feedstock using solvent deasphalting and DAO hydrocracking.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The heavy oil or bitumen stream 10 enters the plant battery limits. Typically, this stream contains 10-40% light diluent which is used to transport the bitumen from the field to the processing complex. The heavy oil or bitumen feedstream is first processed through a crude atmospheric fractionator 12 to create an atmospheric residue stream 14 nominally boiling above 650° F. , a straight run atmospheric gas oil stream 15 , and a light diluent stream 11 which is returned to the field. Although not shown in the drawing and depending upon the quality of the SCO product desired, the straight run atmospheric gas oil stream 15 may be hydrotreated and or hydrocracked prior to being blended in the SCO product 36 . The atmospheric fractionator 12 is also called an atmospheric still. As shown in the drawing, a portion of the atmospheric residue stream 14 may bypass the downstream processing steps and be blended into the SCO product 36 . This bypass is shown as stream 14 a (bypass vacuum fractionator) and stream 13 (bypasses all processing).
[0036] The net atmospheric residue stream 14 from the crude atmospheric fractionator 12 is thereafter sent to a vacuum fractionator 16 to create a vacuum residue stream 18 nominally boiling above 975° F. and a straight run vacuum gas oil (VGO) stream 20 nominally boiling between 650° F. and 975° F. The vacuum fractionator 16 is also commonly called a vacuum still. As shown as a dotted line in the drawing, a portion of the atmospheric residue stream 14 , generally between 10% and 80%, may be directly sent to the solvent deasphalting (SDA) unit 22 . This stream is labeled in the drawing as 14 a and is sent directly to the solvent deasphalter unit 22 after mixing with the vacuum residue stream 18 . The straight run VGO stream 20 is thereafter routed together with the straight run AGO stream 15 to the final SCO product 36 . Although not shown in the drawing, the straight run atmospheric gas oil stream 15 and the straight run VGO stream 20 may be hydrotreated and or hydrocracked prior to being blended in the SCO product 36 .
[0037] The vacuum residue feed stream 18 and any portion of the atmospheric residue stream 14 a that that bypassed the vacuum fractionator 16 is thereafter sent to a solvent deasphalter 22 unit (SDA) where it is separated into deasphalted oil (“DAO”) stream 24 and an asphaltene stream 25 .
[0038] The solvent utilized in the SDA unit 22 may be any suitable hydrocarbonaceous material which is a liquid within suitable temperature and pressure ranges for operation of the countercurrent contacting column, is less dense than the feed streams 18 , 14 a, and has the ability to readily and selectively dissolve desired components of the feed streams 18 , 14 a and reject the asphaltic materials also commonly known as pitch or asphaltenes. The solvent may be a mixture of a large number of different hydrocarbons having from 3 to 14 carbon atoms per molecule, such as light naphtha having an end boiling point below about 200° F. (93° C.).
[0039] Preferably, the SDA unit 22 is operated with a C 3 /C 4 /C 5 solvent to obtain a high DAO yield such that the DAO can be treated in a classic fixed-bed reactor or more preferably due to high feedstock contaminant metals content, in an ebullated-bed unit. More specifically, the solvent may be a relatively light hydrocarbon such as ethane, propane, butane, isobutane, pentane, isopentane, hexane, heptane, the corresponding mono-olefinic hydrocarbons or mixtures thereof. Preferably, the solvent is comprised of paraffinic hydrocarbons having from 3 to 7 carbon atoms per molecule and can be a mixture of two or more hydrocarbons. For instance, a preferred solvent may be comprised of a 50 volume percent mixture of normal butane and isopentane.
[0040] The solvent deasphalting conditions include a temperature from about 50° F. (10° C.) to about 600° F. (315° C.) or higher, but the deasphalter 22 operation is preferably performed within the temperature range of 100° F. (38° C.) to 400° F. (204° C.). The pressures utilized in the solvent deasphalter 22 are preferably sufficient to maintain liquid phase conditions, with no advantage being apparent to the use of elevated pressures which greatly exceed this minimum. A broad range of pressures from about 100 psig (689 kPag) to 1,000 psig (6,900 kPag) are generally suitable with a preferred range being from about 200 psig (1,380 kPag) to 600 psig (4,140 kPag).
[0041] In the SDA Unit, an excess of solvent to charge stock should preferably be maintained. The solvent to charge stock volumetric ratio should preferably be between 2:1 to 20:1 and preferably from about 3:1 to 9:1. The preferred residence time of the charge stock in the solvent deasphalter 11 is from about 10 to 60 minutes.
[0042] The asphaltene stream 25 from the solvent deasphalter unit 22 can be utilized as fuel or can be sent to a gasification plant (not shown) where it produces hydrogen stream 27 that is required for the ebullated-bed unit 26 and can also produce power and/or medium BTU syngas for the upgrader and upstream resource recovery. Gasification of this stream could include capture of the carbon dioxide which is a by-product of the gasification process.
[0043] A portion of the DAO stream 24 from the solvent deasphalter unit 22 is thereafter combined with a hydrogen stream 27 and sent to an ebullated-bed reactor system 26 for hydroconversion. This stream is designated as stream 24 b. Depending upon the cost and availability of natural gas and plant requirements, the hydrogen consumption stream 27 can be obtained via steam methane reforming or gasification of a suitable heavy process stream, including the asphaltene (pitch) product from the deasphalter. As mentioned above, a portion of the DAO stream, generally between 10% and 80%, bypasses the ebullated-bed reactor unit 26 and is shown in the drawing as 24 a. This DAO bypass stream does not contain a significant quantity of undesirable asphaltenes and is thereafter directly blended in the final SCO product stream 36 .
[0044] The ebullated-bed unit 26 utilizes one or more high conversion ebullated-bed reactors in series. The net DAO vacuum residue stream 24 b is hydrocracked and hydrogenated in the ebullated-bed reactor(s) 22 . The conversion of vacuum residue is high and preferably in the range of 75 to 90%. A full range (C5+) product 30 and recovered butanes 32 are produced and are sent to SCO blending 36 . In one embodiment, the small quantity of unconverted DAO vacuum residue can be separated from the full range ebullated-bed product and excluded from the SCO product. In this embodiment, the unconverted residue could be utilized as gasifier feedstock. The combination of streams 15 , 20 , 24 a, 30 , 32 and 13 form the final SCO product 36 .
[0045] This invention will be further described by the following examples, which should not be construed as limiting the scope of the invention. The first example illustrates the processing configuration where a portion of the AR stream bypasses the SDA and ebullated-bed units and all the DAO is processed in the ebullated-bed unit. In the second example, all the AR is processed in the SDA unit, however a portion of the DAO is bypassed around the ebullated-bed unit.
EXAMPLE 1
[0046] A total of 100,000 BPSD of bitumen is processed utilizing the novel configuration disclosed herein. Inspections on the bitumen feedstock are shown in Table 1. The 100,000 BPSD flowrate and bitumen inspections are net of the light diluent which is used to transport the heavy feedstock from the field. The objective of the processing configuration is to produce a maximum yield of stable, transportable SCO meeting Canadian pipeline specifications. These specifications are API Gravity greater than 19° and a 7° C. viscosity less than 350 cSt. The amount of bitumen atmospheric residue bypassed is determined by attaining the partially upgraded SCO specifications. In this example, 100 KBPSD of total crude were processed in the crude still, 71.3% of the atmospheric residue is sent to vacuum fractionation and 28.7% of the atmospheric residue bypasses the processing units and is blended with the ebullated-bed products and eventually routed to final SCO. The crude still also produces 17,600 BPSD of AGO.
[0047] Based on the iterative calculation, 58,700 BPSD of the 82,400 BPSD of total atmospheric residue from the bitumen is routed to the vacuum still to produce VGO and a vacuum residue. The other portion of the atmospheric residue (23,700 BPSD) bypasses the vacuum still and is routed to final SCO blending. The straight run AGO (17,600 BPSD) and VGO (19,700 BPSD) are routed for blending into the final SCO product. Flowrates of the major streams are shown in Table 2.
[0048] This vacuum residue feedstream is thereafter sent to the Solvent Deasphalting Unit (SDA) to produce an asphaltene product (to fuel or gasification) and Deasphalted Oil (DAO) feedstream. The total SDA Unit feedrate is 39.0 KBPSD. Typically a pentane or similar solvent is utilized in the SDA Unit to maximize the yield of DAO and minimize the asphaltene yield. In this example, the SDA Unit produces 27.0 KBPSD of DAO and 12.0 KBPSD of asphaltenes. The total DAO product, which contains significant CCR and metals, is sent to the ebullated-bed hydrocracking unit.
[0049] A gasification plant could be specified to process the SDA asphaltenes (12.0 KBPSD). This gasification plant produces 54.4 MMSCFD of hydrogen, which is that, required for the H-Oil DC Unit and can also produce power and/or medium BTU syngas for the upgrader and upstream resource recovery. This is particularly advantageous for a bitumen SAGD (Steam Assisted Gravity Drainage) operation. It is estimated for this example, that in addition to the required hydrogen, the gasification plant could produce 48,500 MM Btu/Day of excess syngas.
[0050] The feedrate to the DAO ebullated-bed conversion unit is 27.0 KBPSD. The DAO ebullated-bed operates at a residue conversion level of >75 W % which has been demonstrated for Western Canadian feedstocks. The products from the ebullated-bed unit will contain a very low concentration of asphaltenes and will be stable. Prior Axens research has demonstrated that the blend of ebullated-bed products and straight run bitumen is stable. The total hydrogen consumption in the ebullated-bed unit is 54.4 MM SCFD and as discussed above, can be obtained via gasification of the SDA asphaltenes. The liquid product yields from the ebullated-bed unit are shown in Table 2 and sum to 29,200 BPSD, 8% higher than the 27,000 BPSD feedrate as a result of volume expansion due to hydrogenation.
[0051] The final SCO product is a blend of the bypassed atmospheric residue from the bitumen, the overheads from the distillation units, the ebullated-bed total liquid product and all available butanes. Table 3 shows the components of the final SCO blend and important inspections; the bitumen feedstock used for the example is also shown for comparison. The SCO rate is 90.8 KBPSD with 20.4° API gravity and 2.5 W % sulfur. The typical Canadian pipeline viscosity is met. The SCO contains 20.7 V % material boiling greater than 975° F., compared to 50.6 V % in the heavy crude. The SCO liquid yield as a percentage of the crude rate is 90.8 V %. This is a high value considering that a portion of the crude (i.e., the asphaltenes) utilized to produce the required hydrogen and upstream energy requirements.
[0000]
TABLE 1
Feed Inspections
Bitumen
Stream
Gravity, ° API
9.3
Sulfur, W %
4.3
Nitrogen, W %
0.40
Conradson Carbon Residue, W %
13.6
Distillation, V %
IBP-350° F.
0
350-650° F.
17.6
650-975° F.
31.8
975° F. +
50.6
[0000]
TABLE 2
Example 1: Summary of Flowrates
Basis: 100 KBPSD of Undiluted Bitumen
Stream
Flowrate, kBPSD
Bitumen to Crude Still
100.0
AGO to SCO Blending
17.6
Total Atmospheric Residue
82.4
Atmospheric Residue Bypassed
23.7
Atmospheric Residue to Vacuum Still
58.7
VGO to SCO Blending
19.7
Vacuum Residue to SDA Unit
39.0
SDA Asphaltenes to Gasification or Fuel
12.0
SDA DAO to Ebullated-Bed Unit
27.0
Ebullated-Bed Products (C 5 + )
29.2
Naphtha
6.5
Diesel
10.2
VGO
8.2
Unconverted Residue
4.3
Total SCO
90.8
Hydrogen Required, MMSCFD
54.4
Syngas Export from Gasifier, MM Btu/Day
48,500
[0000]
TABLE 3
SCO Yield
Units
Feed
SCO
Total SCO
BPSD
100,000
90,837
Yield on Crude
V %
—
90.84
Gravity
° API
9.3
20.4
Sulfur
W %
4.29
2.50
Nitrogen
W %
0.40
0.24
Conradson Carbon Residue
W %
13.6
5.3
Nickel + Vanadium
Wppm
290
99
Distillation
C 4 -350° F.
V %
—
7.8
350-650° F.
V %
17.6
30.6
650-975° F.
V %
31.8
40.9
975° F. +
V %
50.6
20.7
Viscosity @7° C.
cSt
—
<350
EXAMPLE 2
[0052] In this example, the same feedstock as in Example 1 (see Table 1) is processed to produce a transportable SCO. A total of 100,000 BPSD of bitumen or heavy oil crude was processed. The 100,000 BPSD flowrate and bitumen inspections are net of the light diluent which is used to transport the heavy feedstock from the field. The objective of the processing configuration is to produce a maximum yield of stable, transportable SCO meeting Canadian pipeline specifications. These specifications are API Gravity greater than 19° and a 7° C. viscosity less than 350 cSt. In this case, all of the bitumen is processed in the atmospheric still, vacuum still and SDA Unit. A portion of the SDA DAO product bypasses the ebullated-bed hydrocracking unit and is routed to SCO blending. The amount of bypassed DAO is determined by attaining the partially upgraded SCO specifications. In this example, 100 KBPSD of total crude were processed in the crude still, 53.3% of the SDA DAO is sent to the ebullated-bed unit and 46.7% of the DAO bypasses the ebullated-bed and is routed to SCO blending.
[0053] Flowrates of the major streams are shown in Table 4. The crude still separates the 100,000 BPSD of bitumen into 17,600 BPSD of AGO and 82,400 BPSD of AR. The vacuum still is fed the entire AR stream and produces 27,700 BPSD of VGO and 54,700 BPSD of vacuum residue. The entire vacuum residue product is fed to the SDA Unit.
[0054] The total SDA Unit feedrate is 54.7 KBPSD. Typically a pentane solvent is utilized in the SDA Unit to produce deasphalted oil (DAO) and an asphaltene stream. In this example, the SDA Unit produces 37.9 KBPSD of DAO and 16.9 KBPSD of asphaltenes. A portion of the DAO is sent to a high conversion ebullated-bed hydroconversion unit. The other portion of the DAO bypasses the conversion unit and is routed to SCO blending. The split is determined by attaining partially upgraded SCO specifications of a minimum of 19° API gravity and a viscosity of less than 350 cSt at 7° C. In this example, 100 KBPSD of total crude are processed, 37.9 KBPSD of DAO are produced in the SDA Unit; 20.2 KBPSD is sent to a H-Oil DC ebullated-bed reactor Unit and 17.7 KBPSD bypasses the H-Oil DC ebullated-bed reactor Unit and is sent for blending into the final synthetic crude oil product.
[0055] The gasification plant can be specified to process the SDA asphaltenes (16.9 KBPSD). This gasification plant produces 40.5 MMSCFD of hydrogen, which is that, required for the H-Oil DC ebullated-bed reactor Unit and can also produce power and/or medium BTU syngas for the upgrader and upstream resource recovery. It is estimated for this example, that in addition to the required hydrogen, the gasification plant would produce 81,200 MM Btu/Day of excess syngas.
[0056] The feedrate to the DAO ebullated-bed conversion unit 20.2 KBPSD and is near the maximum rate for a single train, single stage unit with a specified maximum reactor size. This reactor size is normally limited by either fabrication or transportation constraints. The ebullated-bed reactor unit operates at a residue conversion level >80 W % which has been demonstrated for Western Canadian feedstocks. The products from ebullated-bed reactor unit will contain insignificant asphaltenes and will be stable. Prior research has demonstrated that the blend of H-Oil DC products and straight run bitumen or heavy oil components is extremely stable. The total hydrogen consumption in the ebullated-bed reactor Unit is 40.5 MM SCFD and can be obtained via gasification of the SDA asphaltenes.
[0057] The final SCO product is a blend of the bypassed DAO, the overheads from the distillation units (VGO and AGO), the H-Oil DC C 5 + total product and all available butanes. Table 5 shows the components of the final SCO blend and important inspections; the heavy crude feedstock used for the example is also shown. The SCO rate is 85.2 KBPSD with 20.3° API gravity and 2.6 W % sulfur. The typical Canadian pipeline viscosity is met. The SCO contains 22.2 V % material boiling greater than 975° F., compared to 50.6 V % in the heavy crude. The SCO liquid yield as a percentage of the crude rate is 85.2 V %. This is a high value considering that a portion of the crude is utilized to produce the required hydrogen and upstream energy requirements.
[0000]
TABLE 4
Example 2: Summary of Flowrates Basis:
100 KBPSD of Undiluted Bitumen
Stream
Flowrate, kBPSD
Bitumen to Crude Still
100.0
AGO to SCO Blending
17.6
Atmospheric Residue to Vacuum Still
82.4
VGO to SCO Blending
27.7
Vacuum Residue to SDA Unit
54.7
SDA Asphaltenes to Gasification or Fuel
16.9
SDA DAO
37.9
DAO to SCO (Bypass)
17.7
DAO to Ebullated-Bed Unit
20.2
Ebullated-Bed Products
21.8
Naphtha
4.8
Diesel
7.7
VGO
6.2
Unconverted Residue
3.2
Total SCO
85.2
Hydrogen Required, MMSCFD
40.5
Syngas Export from Gasifier, MM Btu/Day
81,200
[0000]
TABLE 5
SCO Yield
Units
Feed
SCO
Total SCO
BPSD
100,000
85,220
Yield on Crude
V %
—
85.22
Gravity
° API
9.3
20.3
Sulfur
W %
4.29
2.59
Nitrogen
W %
0.40
0.20
Conradson Carbon Residue
W %
13.6
3.8
Nickel + Vanadium
Wppm
290
45
Distillation
C 4 -350° F.
V %
—
6.2
350-650° F.
V %
17.6
29.6
650-975° F.
V %
31.8
42.0
975° F.+
V %
50.6
22.2
Viscosity @7° C.
cSt
—
<350
[0058] The invention described herein has been disclosed in terms of specific embodiments and applications. However, these details are not meant to be limiting and other embodiments, in light of this teaching, would be obvious to persons skilled in the art. Accordingly, it is to be understood that the drawings and descriptions are illustrative of the principles of the invention, and should not be construed to limit the scope thereof.
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The described invention discloses an innovative solvent deasphalter and hydroconversion-processing configuration for converting bitumen or heavy oils to produce a transportable synthetic crude oil (SCO). The innovative processing scheme disclosed herein maximizes the synthetic crude oil yield at a minimal investment compared to currently known methods.
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RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/538,685, which entered national stage on Nov. 10, 2005 now U.S. Pat. No. 7,946,408, from International Application No. PCT/GB2003/05453, filed Dec. 15, 2003. Co-pending U.S. patent application Ser. No. 10/538,685 claims priority benefits to Foreign Application No. GB 0300411.6 under 35 U.S.C §365(b). Each of these applications is hereby incorporated in their entirety by reference. This application claims priority benefits to co-pending U.S. patent application Ser. No. 10/538,685 under 35 U.S.C §120.
FIELD OF THE INVENTION
This invention relates to an acceptor for money items such as coins and banknotes and has particular but not exclusive application to a multi-denomination acceptor.
BACKGROUND OF THE INVENTION
Coin and banknote acceptors are well known. One example of a coin acceptor is described in our GB-A-2 169 429. The acceptor includes a coin rundown path along which coins pass through a coin sensing station at which sensor coils perform a series of inductive tests on the coins in order to develop coin parameter signals which are indicative of the material and metallic content of the coin under test. The coin parameter signals are digitised and compared with stored coin data by means of a microcontroller to determine the acceptability or otherwise of the test coin. If the coin is found to be acceptable, the microcontroller operates an accept gate so that the coin is directed to an accept path. Otherwise, the accept gate remains inoperative and the coin is directed to a reject path.
In banknote validators, sensors detect characteristics of the banknote For example, optical detectors can be used to detect the geometrical size of the banknote, its spectral response to a light source in transmission or reflection, or the presence of magnetic printing ink can be detected with an appropriate sensor. The parameter signals thus developed are digitised and compared with stored values in a similar way to the previously described prior art coin acceptor. The acceptability of the banknote is determined on the basis of the results of the comparison.
When a number of coins or banknotes of the same denomination are passed through an acceptor, successive values of coin or banknote parameter data are thus developed. When the distribution of the values of these signals is plotted as a graph, the result is a bell curve, with a central peak and tails on opposite sides. The shape of the graph may typically although not necessarily be Gaussian.
The distribution illustrates that for a money item, such as a coin or banknote of a particular denomination, the most probable value of the corresponding parameter signal lies at the peak of the bell curve, with a decreasing probability to either side. In prior coin and banknote acceptors data is stored in a memory, corresponding to acceptable ranges of parameter signal for a particular denomination. The acceptor compares the value for a coin or banknote under test with the stored data to determine authenticity. The data may define windows in terms of upper and lower limit values; or as a mean value and a standard deviation, such that the window comprises a predetermined number of standard deviations about the mean. By making the stored windows narrow, an increased discrimination is provided between true money items and frauds. However, if the windows are made too narrow, the rejection rate of true money items increases, disadvantageously. The width of the windows is thus selected as a compromise between these two factors. Attempts to defraud coin or banknote acceptors typically involve the manufacture of facsimile coins or banknotes, which cause the acceptor to produce parameter signals which lie within the stored acceptance windows. Hitherto, coin acceptors have been provided with relatively wide and narrow window widths so that the operator can manually select the wide window width for normal operation and the narrow window width if frauds are being presented for validation. An example is described in Japanese unexamined patent application no Hei 2-197985.
A number of different approaches have been proposed to vary the window width dynamically to improve discrimination between true and false coins. In U.S. Pat. No. 5,355,989, a coin acceptor is described which switches automatically from a first normal acceptance window for a true coin, to a second narrower window when a coin parameter signal produced by testing a coin falls in a region of the normal window for the true coin corresponding to a low acceptance probability region for the coin concerned. A group of fraudulent coins may all have similar characteristics and they may cause the acceptor to produce parameter signals which lie within the normal window, but the parameter signals consistently have a value which is not centred on the high probability peak region of the window associated with the true coin and instead are centred on the lower probability tail regions of the bell curve distribution within the normal window. When the parameter signal falls within this low probability region, the second narrower window is then used for the next tested coin. If the next coin has a parameter falling in the narrower window it is a true coin, but if not, it is a fraud that should be rejected. This approach seeks to prevent frauds carried out by the use of coins of a particular low value denomination, from a foreign currency set, with characteristics that correspond but are not exactly the same as a high value coin of the currency set that the acceptor is designed to accept. It will be understood that the foreign denomination coins exhibit their own generally Gaussian distribution of parameter signals, and if the low probability or tail region of this distribution partially overlaps a corresponding region of the distribution for the true coin that the acceptor is designed to accept, then the low value foreign coins will sometimes be accepted as true coins.
Another approach is described in EP-A-0480736, in which the acceptance window is based on the value of a coin parameter for previous acceptable coins, as long as the previous coin parameter values do not deviate significantly from one another. This enables the coin acceptor to self-tune the window to take account of changes in operating parameters such as temperature and other long term drifts. A danger with this approach is that the coin acceptor can be taught to modify its window so as to accept frauds by using fraudulent coins similar to true coins. To overcome this problem, a so-called near miss area is defined and if a coin parameter signal from a coin under test falls in this area, this indicates the risk of a fraud and the window is shifted away from the area to prevent the window position being influenced by the potential fraud. However, the position of the near miss area is critical in order to avoid falsely detecting true items as a fraud attack. To this end the near miss area must be a reasonable distance outside of the true coin population (particularly if the error in positioning the centre of the window is taken into account). This creates a gap were a sufficiently close fraud attempt can still trigger a window shift before it is spotted in the near miss area. It may also be possible to utilise slightly modified true coins or even a different fraud on the other side of the window to train the window towards the original fraud attempt. The method described in EP-A-0480736 is therefore only of use for relatively poor quality frauds and a more stringent systems is needed to counter a stronger fraud attack.
SUMMARY OF THE INVENTION
The present invention provides an alternative approach, which does not involve the complication of having to control the window width.
According to the invention there is provided a method of accepting of money items, comprising: generating individual money items signals with a value that is a function of respective items of money under test, developing for each of the money items under test, a transformed money item signal as a function of the value of the money item signal and at least one variable parameter that is a function of the acceptability criterion for the money item under test, making a comparison of the values of the transformed money item signals with a window limit value, and accepting each money item in dependence upon said comparison.
The variable parameter may be a function of history data relating to the values of the money item signals for previously tested money items.
The transformed money item signal may developed by transforming the money item signal according to the outcome of a rules based expert system that determines the occurrence of the acceptability criterion. More particularly, the transformed money item signal may be developed by scaling the money item signal for a money item under test in accordance with an amplification factor determined in dependence on the outcome of a comparison of data based on previously tested money items with one or more rules. Different amplification factors may be used, depending on the outcome of the comparisons for the rules.
An average of data corresponding to the money item signals for previously tested money items may be compared with a first limit value lying within a window delimited by said window limit, and if the average is not within said first limit, the money item signal for a money item under test may be scaled in accordance with the amplification factor.
Also, a maximum value of data corresponding to the values of money item signals for previously tested money items may be compared with a second limit value lying within a window delimited by said window limit, and if said maximum value is not within said second limit, the money item signal for a money item under test may be scaled in accordance with the amplification factor.
The window limit may delimit an acceptance window as deviation relative to a window mean, and the value of a money item signal for a money item may be adjusted relative to the window mean, mode or median, whereby to produce an error signal and the transformed money item signal may be developed from the error signal.
The invention also includes an acceptor for money items, comprising: sensor circuitry to provide individual money items signals of a value as a function of respective items of money under test, and a processor configuration to develop for each of the money items under test, a transformed money item signal as a function of the value of the money item signal and at least one variable parameter that is a function of a acceptability criterion for the money item
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more fully understood an embodiment thereof will now be described by way of example with reference to the accompanying drawings in which:
FIG. 1 is a schematic block diagram of a coin acceptor in accordance with the invention;
FIG. 2 is a schematic block diagram of the circuits of the acceptor shown in FIG. 1 ;
FIG. 3 is a schematic block diagram of a coin acceptance process carried out by the microcontroller shown in FIG. 1 ;
FIG. 4 illustrates the configuration of an acceptance window with a fixed window limit;
FIG. 5 is a schematic diagram of data derived from successive coins under test in relation to the fixed window data and other limits; and
FIG. 6 is a flow diagram of a coin acceptance process in accordance with the invention.
DETAILED DESCRIPTION
Overview of Coin Acceptor
FIG. 1 illustrates the general configuration of an acceptor according to the invention, for use with coins. The coin acceptor is capable of validating a number of coins of different denominations, including bimet coins, for example the euro coin set and the UK coin set including the bimet £2.00 coin. The acceptor includes a body 1 with a coin run-down path 2 along which coins under test pass edgewise from an inlet 3 through a coin sensing station 4 and then fall towards a gate 5 . A test is performed on each coin as it passes through the sensing station 4 . If the outcome of the test indicates the presence of a true coin, the gate 5 is opened so that the coin can pass to an accept path 6 , but otherwise the gate remains closed and the coin is deflected to a reject path 7 . The path through the acceptor for a coin 8 is shown schematically by dotted line 9 .
The coin sensing station 4 includes four coin sensing coil units S 1 , S 2 , S 3 and S 4 , which are energised in order to produce an inductive coupling with the coin. Also, a coil unit PS is provided in the accept path 6 , downstream of the gate 5 , to act as a credit sensor in order to detect whether a coin that was determined to be acceptable, has in fact passed, into the accept path 6 .
The coils are energised at different frequencies by a drive and interface circuit 10 shown schematically in FIG. 2 . Eddy currents are induced in the coin under test by the coil units. The different inductive couplings between the four coils and the coin characterise the coin substantially uniquely. The drive and interface circuit 10 produces corresponding digital coin parameter data signals R s , namely R 1 , R 2 , R 3 , R 4 , as a function of the different inductive couplings between the coin and the coil units S 1 , S 2 , S 3 and S 4 . A corresponding signal is produced for the coil unit PS. The coils S have a small diameter in relation to the diameter of coins under test in order to detect the inductive characteristics of individual chordal regions of the coin.
In order to determine coin authenticity, the coin parameter signals produced by a coin under test are fed to a microcontroller 11 , which is coupled to a memory 12 . The microcontroller 11 processes the coin parameter signals R 1 . . . R 4 derived from the coin under test and compares the outcome with corresponding stored values held in the memory 12 . The stored values are held in terms of windows having upper and lower value limits. Thus, if the processed data falls within the corresponding windows associated with a true coin of a particular denomination, the coin is indicated to be acceptable, but otherwise is rejected. If acceptable, a signal is provided on line 13 to a drive circuit 14 which operates the gate 5 shown in FIG. 1 so as to allow the coin to pass to the accept path 6 . Otherwise, the gate 5 is not opened and the coin passes to reject path 7 . The coin acceptance process performed by the microcontroller 11 may be modified or updated in response to an external input received on line 16 .
The microcontroller 11 compares the processed data with a number of different sets of operating window data from the memory 12 , appropriate for coins of different denominations so that the coin acceptor can accept or reject more than one coin of a particular currency set. If the coin is accepted, its passage along the accept path 6 is detected by the post acceptance credit sensor coil unit PS, and the unit 10 passes corresponding data to the microcontroller 11 , which in turn provides an output on line 15 that indicates the amount of monetary credit attributed to the accepted coin.
The sensor coil units S each include one or more inductor coils connected in an individual oscillatory circuit and the coil drive and interface circuit 10 includes a multiplexer to scan outputs from the coil units sequentially, so as to provide data to the microcontroller 11 . Each circuit typically oscillates at a frequency in a range of 50-150 kHz and the circuit components are selected so that each sensor coil S 1 -S 4 has a different natural resonant frequency in order to avoid cross coupling between them.
As the coin passes the sensor coil unit S 1 , its impedance is altered by the presence of the coin over a period of—100 milliseconds. As a result, the amplitude of the oscillations through the coil is modified over the period that the coin passes and also the oscillation frequency is altered. The variation in amplitude and frequency resulting from the modulation produced by the coin is used to produce the coin parameter signals R 1 . . . R 4 representative of characteristics of the coin.
Coin Acceptance Process
FIG. 3 is a schematic illustration of the process carried out by the microcontroller 11 . The process will be described in relation to one of the coin parameter signals R s in order to simplify the description and it will be understood that a corresponding process will be carried out for each of the coin parameter signals individually. As shown in FIG. 3 , coin parameter signal R s is derived from the coin interface and drive circuitry 10 shown in FIG. 2 . The signal R s is converted into a digital signal with a numerical value that corresponds to the coin that gave rise to the signal. The digital conversion may be carried out by the micro controller 11 or within the coin drive and interface circuitry 10 itself. The value of coin parameter signal R 5 is compared with a fixed window limit in step S 3 . 1 , the window limit being stored in the memory 12 . A coin acceptance or rejection signal is produced depending on the outcome of the comparison, as shown at steps S 3 . 2 and S 3 . 3 .
Artificial intelligence (AI) is utilised to transform at step S 3 . 4 the value of the coin parameter signal R 5 prior to the comparison with the fixed window limit at step S 3 . 3 . The AI functionality transforms the coin parameter signal to take account of a number of factors, more particularly, the history of previous coins accepted or rejected, rumours such as indications from adjacent coin acceptors that fraudulent coins are being used in the vicinity and environmental inputs such as changes in temperature. For example, the coin parameter signals may be transformed as described in our EP-A-0399694 to take account of temperature changes or the presence of metal objects in the vicinity of the sensor coils, prior to comparison with the fixed window limit.
In this example, the AI functionality comprises a rules based expert system as will now be explained in more detail.
FIG. 4 illustrates an example of the fixed window used for the comparison process of step S 3 . 1 . The window is stored in terms of a mean value M corresponding to the average value of the coin parameter signal for a coin of a particular denomination. In order to accommodate coins which deviate from the mean, upper and lower fixed window limits W 1 and W 2 are provided around the mean and may be stored in terms of a deviation relative to the mean M. In the example of FIG. 4 the upper and lower window limits W 1 , W 2 are ±7 relative to the mean M but of course other values can be used, which need not be symmetrically disposed about the mean. By providing a window, coins which deviate slightly from the mean will also be accepted. It will be appreciated that if the window width (W 2 −W 1 ) is made too wide, there is an increased risk of fraudulent coins being accepted whereas if the Window width is made too narrow, there is a risk that a significant number of true coins will be rejected. The window width needs to be a compromise between these two considerations.
Hitherto it has been proposed to change the window when previous coin readings indicate that there is a risk that a fraudulent coin is being presented to the coin acceptor. The following example of the present invention provides an alternative, improved approach using AI in the form of a rules based expert system. The positive going region of the window from the mean value M to the fixed window limit W 2 will be considered, namely region A in FIG. 4 . It will be understood that similar considerations apply to the negative going region from mean value M to window limit W 1 , which will not be explained in detail in order to simplify the description.
Referring to FIG. 5 , the data derived from the latest or new value of the coin parameter signal R s is shown together with N previous values for previously tested coins of the same denomination H 1 5 . . . HN 5 . The value of the coin parameter signal for each of the tested coins is shown as a black dot and the coin parameter value has been re-valued relative to the mean M for the fixed window. More particularly, the microcontroller 11 adjusts the values of the coin parameter signals R 5 , H 1 5 etc so as to produce corresponding adjusted data D for use in the rules based system. For example, considering the coin parameter R 5 for the coin currently under test, this gives rise to data D new where D new =R S −M In this example, D new =3 Corresponding adjusted historic data D 1 . . . D N are also derived corresponding to the historic coin parameter signals H 1 S . . . HN S .
In this example, D 1 =4 and D N =9.
The microcontroller 11 is configured to store a predetermined number of previous values of the data D N for previously tested coins of the same denomination and to keep a running average of therm. For example, the last 10 values of D N may be stored and a running average AVGD N is computed. Also, the maximum value Max D n is determined from the stored data D n on a running basis. The values of Max D n and AVGD N are used as history data in the coin acceptance process.
Referring again to FIG. 4 , when a number of true coins are tested, the corresponding value of AVGD N should lie close to the mean M. If the average value lies significantly away from the mean, this indicates there is a risk that the validator is under attack by fraudster using false coins. Also, if the value of Max D n lies more towards the window limit W 2 than the mean M this indicates an increased risk that a fraud attempt is being made.
FIG. 6 illustrates how the history data is used in the transformation of step S 3 . 4 and the subsequent comparison of the transformed data, with the fixed window limit of step. S 3 . 1 . Referring to FIG. 6 in detail, the validation process starts at step S 6 . 0 and at step S 6 . 1 , an “under attack” flag UA is set to the value “false”. Similarly, an amplification factor A is initially set to a value of unity and a transformed data parameter T new is initialised to zero.
Then, at step S 6 . 2 the value of AVGD N is compared with an acceptability criterion defined by a limit value L 1 shown in FIG. 5 . Thus, if the average value of D n for the last 10 coins under test deviates significantly from the mean M, beyond the limit L 1 , then there is a risk that the coin acceptor is under attack by a fraudster and the flag UA is set to “true” at step S 6 . 3 . Also, the amplification factor A is set to a value >1. In this example, the amplification factor is set to a value of 3 for use subsequently in the transformation process to be described hereinafter.
At step S 6 . 4 , the previously computed value of Max D n is compared with an acceptability criterion defined by a guard limit L 2 , the value of which is shown in FIG. 5 . If Max D n exceeds this limit value, this indicates that one of the previously tested coins has a value of D close to the fixed window limit W 2 , signifying the risk of a fraud amongst recently detected coins. In this case, the flag UA is set to “true” at step S 6 . 5 , indicating that the coin acceptor is under attack by a fraudster. Also, the amplification factor A is set to a value >1 e.g. 4.
Then, at step S 6 . 6 , the condition of the flag UA is tested to determine if the acceptor is under attack by a fraudster. If there is no fraud attack, the value of the transformed data parameter T new is set to be the same value as D new corresponding to the coin under test. The value of T is then compared with a limit value L 3 at step S 6 . 9 . The limit value L 3 corresponds to the fixed window limit W 2 shown in FIG. 5 . Thus, if the value of T new is less than L 3 , the data corresponds to an acceptable value of D new and hence an acceptable value of R S for the coin under test.
Conversely, if the T new exceeds the fixed window limit L 3 then the coin should be rejected as shown at step S 6 . 11 .
In the event that the test of step S 6 . 6 indicates the validator to be under attack, the value of D new for the coin under test is transformed using the amplification factor set at step S 6 . 3 or S 6 . 5 . The transformation is carried at step S 6 . 8 so that the parameter T new adopts a value of D new *A. The transformed or amplified value is then compared with the fixed window limited L 3 at step S 6 . 9 as previously described. Thus, when the coin acceptor is under attack by a fraudster, a more stringent test is applied to the coin data D. It will be understood that because of the amplification factor, the actual value D new for the coin under test needs to be much closer to the value of the mean M for the window in order to be less than the fixed limit L 3 as compared with the situation where the validator is not under attack and the amplification factor A is not applied.
Thus, in accordance with the invention, a more stringent test is applied when the acceptor is under fraud attack and in accordance with the invention, a fixed window limit L 3 is utilised so that there is no need to change the window position or to switch between different window widths to achieve automatic security protection.
Many modifications and variations fall within the scope of the invention. For example, in certain situations, it may be preferable to test the value of AVGD N against the limit value L 1 after testing the value of Max D n against limit L 2 . Also, the value of the amplification factor is not limited to the values given above and can be altered according to particular circumstances.
In the example described hereinbefore, the acceptability criteria corresponding to the limits L 1 and L 2 constitute fraud criteria for determining when a fraud attack occurs, and one or more amplification factors greater than one (A>1) are used in order to provide enhanced discrimination against frauds. However, when a run of acceptable coins has occurred, it may be advantageous to use an amplification factor 0>A<1 to increase the likelihood of coins being accepted when the risk of occurrence of a fraud is relatively low.
Also, the data used to produce the running average AVGD N and also Max D n may be time dependent, so that coin parameter signals from coins tested more than a particular time ago will be ignored for the purposes of determining AVGD N and Max D n .
Furthermore, the rules based expert system can include additional or alternative rules for determining the criteria under which the amplification factor A is applied in response to a fraudster. Also, different rules can be used that do not use comparisons between scaled signals and thresholds. Furthermore, transformations other than a simple amplification may be used, such as non-linear transformations, offsets and combinations thereof. For example, as shown schematically in FIG. 3 , rumours (I) from adjacent coin acceptors that a fraudster is in the vicinity of a group of machines may be used to set the value of the amplification factor A or other transformation for a period of time so as to apply a more stringent test to coins in response to the rumour. The rumour data may be received on input 16 shown in FIG. 2 . Also, environmental inputs such as temperature may be applied to impose additional rules based tests to the data as a function of temperature or time of day, for example in a situation where frauds are found to happen at particular times e.g. pub closing time. Also, environmental inputs may be used to shift the window limits W 1 , W 2 long term over time to take account of changes in temperature or other factors.
In the foregoing example, the processing of signals for one of the sensors S is described and it will be understood that each of sensor output is processed individually. The processing for one sensor may however take account of the outcome for another sensor and the occurrence of a fraud criterion for one of the sensors may be, used to set an acceptability criterion for the processing of signals for another of the sensors.
The invention is not limited to the use of an expert, rules based system to perform the AI process shown at step S 3 . 4 in FIG. 3 . Alternatives include fuzzy logic, the neural network or a genetic algorithm.
It will be appreciated that the various rules of the rules based system may be applied individually or collectively on a time basis so that a rule may be applied for a particularly time period and then removed either in response to a coin acceptance event or in response to external factors
It will also be appreciated that the invention is not restricted to coin validators but may be used for other money items such as tokens, banknotes, cards and other items having an attributable monetary value.
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A method and system for accepting money items. The method for accepting money items comprises generating a money item signal that corresponds to a money item under test, determining a level of risk of a fraud attempt, and determining a fraud attempt based on the level of risk. The method further comprises generating a transformed money item signal as a function of the level of risk and the money item signal in response to determining the fraud attempt. The method further comprises comparing the transformed money signal to window limit values to generate a result and accepting or rejecting the money item based on the result.
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CLAIM OF PRIORITY
This application claims priority under 35 USC §365(c) to International Patent Application Serial No. PCT/US2010/049146, entitled “Combined Sonic/Pulsed Neutron Cased Hole Logging Tool”, filed on Sep. 16, 2010, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
This disclosure relates to formation and casing evaluation tools and methods of formation evaluation, and more particularly a combination sonic and pulsed neutron tool for formation evaluation through casing, and casing and cementing integrity evaluation and methods for use for same.
BACKGROUND
In many reservoirs throughout the world it is necessary to hydraulically fracture the reservoir to produce commercial quantities of oil and gas. In order to design such hydraulic fracture stimulation treatments it is desirable to understand the in-situ stress profiles. To calculate the in-situ stress profile it is desirable to have mechanical rock properties and pore pressure data in and around the target producing zones of the reservoir. Previously, it was necessary to obtain much of the needed data used in the stimulation designs with logs run in an open hole environment, while the well was being drilled, or in open hole logging runs after the desired interval had been penetrated and before casing had been placed in the wellbore. Obtaining the data in an open hole environment while the drilling rig is on location results in the well operator incurring the cost of the drilling rig time while the logging operation is conducted. Additionally, it is sometimes necessary to remove the drill string and bit and then rerun the drill string and bit to the bottom of the hole and remove it again (aka “make a wiper trip in and out of the hole”) to circulate and condition the drilling fluids (aka “drilling mud”) to prepare the open hole for formation evaluation tools. This conditioning of the open hole results in additional costs for the drilling fluids and additional rig time costs. Use of an open hole formation evaluation tool (aka “open hole logging”) has some risks. In highly deviated and/or horizontal wells it is sometimes difficult to get the open hole formation evaluation tools (aka “logging tools”) to the portion of the wellbore in the desired geologic intervals, necessitating additional rig time and expense. It is also possible that the logging tools may become stuck in the wellbore which may necessitate expensive retrieval operations (aka “fishing operations”) to retrieve the stuck logging tools. If the logging tools are not able to be retrieved, it may be necessary to drill a replacement portion for the wellbore or even abandon the wellbore and drill a new well.
A need exists for obtaining formation evaluation data (aka “log data”) to be used in wellbore design and hydraulic fracture stimulation design in an alternative manner to open hole logging. A further need exists for a cased hole combination logging tool for use in analyzing casing(s) and cement integrity in a well bore.
SUMMARY
The present disclosure provides an alternative through casing formation evaluation tool to open hole formation evaluation tools by combining pulsed neutron and sonic technology in a mono-cable format for use in a single cased hole logging run. This is an efficient and cost saving approach to obtaining the desired formation evaluation data (aka “log data”) for well design and hydraulic stimulation design and for a cased hole combination logging tool for use in analyzing casing(s) and cement integrity in a wellbore. Since the wellbore is cased, the drilling rig may be removed before a logging run using the tool of the present disclosure, and therefore considerable money is saved by avoiding the rig time incurred during open hole logging. The combined tool and method of the present disclosure also saves money by making only a single cased hole logging trip versus several trips necessary to obtain the data using individual tools each in a single logging run. Risk of losing logging tools in the well is minimized by using cased hole logging versus open hole logging. It is generally easier to get the logging tools to the desired geologic zones in a cased hole as opposed to an open hole, especially in highly deviated or horizontal wellbores. Risk of losing tools in a cased hole is minimized by using a single logging run with the combination tool in the cased hole instead of multiple runs with single tools.
The data obtained with the combined tool of the present disclosure provides formation measurements through casing(s) and cement. The tools may obtain data on casing(s) string and cement integrity; fluids saturations and rock properties of the reservoir; including DTC (compressional slowness); DTS (shear slowness); minimum horizontal stress profile; porosity; simple mineralogy; matrix sigma; pseudo density; and full wave information. The robustness of the gathered data is useful for optimal well design and for improved hydraulic fracture and acidization stimulation design and placement used in completing and stimulating the well and for determining the integrity of one or more casing strings and cement in the wellbore.
In some embodiments, the combined tool string may be less than 3 inches in outside diameter, thereby allowing for ease of conveyance of the tool string in small internal diameter cased wellbores, tubing, drill pipe and within highly deviated and horizontal wellbores (aka “high dog leg” severity).
The combined pulsed neutron and sonic cased hole formation evaluation may be accomplished in several ways: real time gathered data transmitted via an electrical or fiber optic cable, or wired continuous rod; memory mode by storing a portion of the gathered data in memory module(s) in the tool string and conveyed on above cables or slickline or wired continuous rod; and in a hybrid telemetry method where a portion of the gathered data is transmitted via an electrical or fiber optic cable or continuous wired rod and a portion of the gathered data is stored in the memory modules(s) in the tool string and retrieved when the tool string is removed from the wellbore.
The collected data is processed in a CPU at the surface to obtain more robust rock property data about the one or more geologic formations. The rock properties are selected from the group consisting of Poisson's Ratio, Young's Modulus, compression slowness, shear slowness, minimum horizontal stress profile and inelastic measurements leading to simple mineralogy and matrix sigma (Spwla — 2009_T), Sigma (or capture cross-section) and ratio measurement for porosity (SPE30597) and pseudo density (SPE94716). The robustness of the processed rock property data is useful for optimal well design and for improved hydraulic fracture and acidization stimulation design and placement used in completing and stimulating the well and for determining the integrity of one or more casing strings and cement in the wellbore.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic of a first implementation of a combination sonic and pulsed neutron tool for formation evaluation through casing;
FIG. 2 is a schematic of a second implementation of a combination sonic and pulsed neutron tool for formation evaluation through casing;
FIG. 3 is a schematic of a third implementation of a combination sonic and pulsed neutron tool for formation evaluation through casing; and
FIG. 4 is a functional schematic of possible combinations of the elements of a combination sonic and pulsed neutron tool and system.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
Referring now to FIG. 1 , wherein there is illustrated a schematic of a first embodiment of the combination logging tool string 1000 for use inside of a cased wellbore. The logging tool string 1000 is conveyed into the wellbore on a conveyance string 100 which may include one or more of the following: an electric and/or fiber optic cable 101 ; a slickline cable 102 ; a wired conveyance rod 103 ; coiled tubing string 104 ; and a wired coiled tubing string (including electrical cable and/or fiber optics) 105 . The tool string 1000 includes: a gamma ray/casing collar telemetry module 110 connected to a first crossover tool 112 . A second crossover tool 114 may be used to connect the first crossover tool to a first end 210 of a sonic array tool 200 . The sonic array tool may include centralizers 230 . A third crossover tool 116 may be used to connect a lower end 220 of the sonic array tool to a flexible sub 300 (aka “serpentine or knuckle joint”) that allows decoupling of a centralized tool. A pulsed neutron tool 400 may be connected at a first end 410 to a second end of the flexible sub 300 . In some embodiments, in the tool string 1000 , the sonic array tool 200 is disposed above the flexible sub 300 and the pulsed neutron tool 400 is disposed below the flexible sub. Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . If the pulsed neutron tool 400 is below the sonic tool 200 , a crossover tool 116 may be used to receive either a termination bull plug 119 at the lower end of the tool string or, alternatively, an additional crossover 120 may be attached to crossover 116 to connect to additional tools (not shown) that may be used in the string 1000 . If the sonic tool 200 is positioned below the neutron tool 400 , then a crossover tool 118 may be used to receive either a termination bull plug 119 at the lower end of the tool string 1000 or, alternatively, an additional crossover 120 may be attached to crossover 118 to connect to additional tools (not shown) that may be used in the string 1000 .
By way of example, a Halliburton mono-cable telemetry module model 1553 may be used in combination with Halliburton's slim bore hole sonic array tool (SBSAT) and Halliburton's pulsed neutron tool model RMT-i or TMD-3d (1553). The flexible sub 300 may be Halliburton's 6-6 flex connector. It will be understood that other telemetry modules and sonic array tools and neutron tools and flexible subs manufactured and provided by Halliburton and/or other third parties may be used in implementations of the present disclosure.
By way of further explanation, the present disclosure as discussed above may use a continuous wired rod ( 103 ) that includes the features of encapsulating fiber optic and/or copper wire within a smooth, round semi rigid outer layer(s). The rigidity of the continuous wired rod may allow pushing/pulling tool strings, possibly eliminating mechanical tractors.
Referring now to FIG. 2 , wherein there is illustrated a schematic of an alternative implementation of the combination logging tool string 2000 for use inside of a cased wellbore. The logging tool string 2000 is conveyed into the wellbore on a conveyance string 100 which may include one or more of the following: an electric and/or fiber optic cable 101 ; a slickline cable 102 ; a wired conveyance rod 103 (see discussion hereinafter); coiled tubing string 104 ; and a wired coiled tubing string (including electrical cable and/or fiber optics) 105 . The tool string 2000 includes: a memory module 150 which is connected to a crossover tool 114 . The memory module is connected to a first end 210 of a sonic array tool 200 . A crossover tool 116 may be used to connect the lower end 220 of the sonic array tool to a flexible sub 300 . A pulsed neutron tool 400 is connected at a first end 410 to a second end of the flexible sub 300 . In some embodiments in the tool string 1000 , the sonic array tool 200 is disposed above the flexible sub 300 and the pulsed neutron tool 400 is disposed below the flexible sub 300 . Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . If the pulsed neutron tool 400 is below the sonic tool 200 , a crossover tool 116 may be used to receive either a termination bull plug 119 at the lower end of the tool string or, alternatively, an additional crossover 120 may be attached to crossover 116 to connect to additional tools (not shown) that may be used in the string 2000 . If the sonic tool 200 is positioned below the neutron tool 400 , then a crossover tool 118 may be used to receive either a termination bull plug 119 at the lower end of the tool string or, alternatively, an additional crossover 120 may be attached to crossover 118 to connect to additional tools (not shown) that may be used in the string 2000 .
Referring now to FIG. 3 , wherein is illustrated a schematic of an alternative implementation of a combination logging tool string 3000 . The alternative tool string 3000 is similar to the first embodiment of the combination logging tool string 1000 for use inside of a cased wellbore. The tool string 3000 is conveyed into the wellbore on a conveyance string 100 which may include one or more of the following: an electric and/or fiber optic cable 101 ; a slickline cable 102 ; a wired conveyance rod 103 or coiled tubing string 104 ; a wired coiled tubing string (including electrical cable and/or fiber optics) 105 . The tool string 3000 may include: a gamma ray/casing collar telemetry module 110 which is connected to a first crossover tool 112 . A second crossover tool 114 may be used to connect the first crossover tool to a first end 210 of a sonic array tool 200 . A third crossover tool 116 may be used to connect the lower end 220 of the sonic array tool to a flexible sub 300 . A pulsed neutron tool 400 is connected at a first end 410 to a second end of the flexible sub 300 . In some embodiments in the tool string 1000 , the sonic array tool 200 is disposed above the flexible sub 300 and the pulsed neutron tool 400 is disposed below the flexible sub 300 . Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . The alternative tool string 3000 further includes a memory module 150 connected to the sonic array tool 200 and may include a second memory module 150 connected to the pulsed neutron tool 400 . If the pulsed neutron tool 400 is below the sonic tool 200 , a crossover tool 116 may be used to receive either a termination bull plug 119 at the lower end of the tool string or, alternatively, an additional crossover 120 may be attached to crossover 116 to connect to additional tools (not shown) that may be used in the string 2000 . If the sonic tool 200 is positioned below the neutron tool 400 , then a crossover tool 118 may be used to receive either a termination bull plug 119 at the lower end of the tool string 3000 or, alternatively, an additional crossover 120 may be attached to crossover 118 to connect to additional tools (not shown) that may be used in the string 3000 .
Referring to FIG. 4 , there is illustrated a functional schematic of possible combinations of the elements of a formations evaluation system 500 . The system may include a CPU 510 located at the surface. A mono conductor 512 may be used to transmit data up or down the mono-cable to or from the formations evaluation tools comprising the tool string when the tool string is lowered into a cased wellbore. The mono-cable is connected to a telemetry module 514 . A downhole tool bus 530 is included in the tool string. A gamma ray casing collar module 520 may be included in the string. A pulsed neutron module 522 and a sonic array module 524 may be included as is illustrated in section 570 of the system. In a hybrid embodiment 580 , memory bank modules 540 may receive and store data from one or more of the gamma ray/casing collar tool 520 , the pulsed neutron tool 522 , and the slim array sonic tool 524 ; alternatively, an additional memory bank module 550 may be included in the tool string system 500 to receive and store data from one or more of the gamma ray/casing collar tool 520 , the pulsed neutron tool 522 , and the slim array sonic tool 524 . The tool string may further include a battery pack and a memory CPU module 560 .
The tool string 1000 , as previously described, may be assembled by connecting a conveyance string 100 to a gamma ray/casing collar telemetry module 110 ; connecting a flexible sub 300 at first end to a sonic array tool 200 ; connecting a pulsed neutron tool 400 at a second end of the flexible sub. Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . In operation, the tool string is lowered into the cased wellbore via the electric mono-cable. The tool string is passed inside the well casing across one or more geologic formations which are outside the wellbore casing. Data is collected with the sonic array tool and the pulsed neutron tool and transmitted via the electric mono-cable to a CPU 510 located at the surface of the earth. The collected data is processed to obtain selected rock property data about the one or more geologic formations. The rock properties are selected from the group consisting of Poisson's Ratio, Young's Modulus, compression slowness, shear slowness, minimum horizontal stress profile, porosity, simple mineralogy, matrix sigma, and pseudo density. Additionally, the tool string 1000 may gather data for determining the integrity of one or more casing strings and cement in the wellbore. The pulsed neutron log may gather data on gas effect and fluid flow behind and between casing strings. The sonic tool may gather data on the cement bond between the casing and the cement and the cement and the formation.
The tool string 2000 , as previously described, may be assembled by connecting a slickline 102 or coiled tubing string 104 to a sonic array tool 200 . The flexible sub 300 is connected at one end to the sonic array tool 200 and at a pulsed neutron tool 400 at a second end of the flexible sub. Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . In operation, the tool string 2000 is lowered into the cased wellbore via the slickline or coiled tubing string. The tool string is passed inside the well casing across one or more geologic formations outside of the cased wellbore. Data is collected with the sonic array tool and the pulsed neutron tool and stored in the memory module(s) 150 . The tool string 2000 is removed from the wellbore and the collected data is retrieved from the memory module 150 and processed to obtain selected rock property data about the one or more geologic formations. The rock properties are selected from the group consisting of Poisson's Ratio, Young's Modulus, compressional slowness, shear slowness, minimum horizontal stress profile, porosity, simple mineralogy, matrix sigma, and pseudo density. Additionally, the tool string 2000 may gather data for determining the integrity of one or more casing strings and cement in the wellbore. The pulsed neutron log may gather data on gas effect and fluid flow behind and between casing strings. The sonic tool may gather data on the cement bond between the casing and the cement and the cement and the formation.
A hybrid tool string 3000 may be assembled by connecting a conveyance string 100 to a gamma ray/casing collar telemetry module 110 ; connecting a flexible sub 300 at first end to a sonic array tool 200 ; connecting a pulsed neutron tool 400 at a second end of the flexible sub. A first memory module 150 may be connected to the pulsed neutron tool 400 . If desired, a second memory module 150 may be connected to the sonic tool 200 . Alternatively, the pulsed neutron tool 400 may be disposed above the flexible sub 300 and the sonic array tool 200 may be disposed below the flexible sub 300 . In operation, the tool string 3000 is lowered into the cased wellbore via the electric mono-cable. The tool string is passed inside the casing across one or more geologic formations outside of the cased wellbore. Data is collected with the sonic array tool and the pulsed neutron tool and all or a portion of the collected data is transmitted via the electric mono-cable to a CPU 510 located at the surface of the earth. A portion of the collected data may be stored in the memory module(s) 150 . The tool string is removed from the wellbore and the collected data is processed in combination with the data transmitted to the surface via the mono-cable to obtain selected rock property data about the one or more geologic formations. The rock properties are selected from the group consisting of Poisson's Ratio, Young's Modulus, compressional slowness, shear slowness, minimum horizontal stress profile, porosity, simple mineralogy, matrix sigma, and pseudo density. Additionally, the tool string 300 may gather data for determining the integrity of one or more casing strings and cement in the wellbore. The pulsed neutron log may gather data on gas effect and fluid flow behind and between casing strings. The sonic tool may gather data on the cement bond between the casing and the cement and the cement and the formation.
During operations of the combined tool string 1000 , 2000 , and 3000 , data may be gathered simultaneously in one pass across the geologic formations by the sonic array tool 200 and the pulsed neutron tool 400 . Alternatively, data may be gathered selectively by either the pulsed neutron tool 400 or the sonic array tool 2000 as the tool string 1000 , 2000 , and 3000 is passed one or more times across the selected geologic formation.
During operations of the combined tool string 1000 , 2000 , and 3000 , data on the casing and cement integrity may be gathered simultaneously in one pass across the casing by the sonic array tool 200 and the pulsed neutron tool 400 . Alternatively, data may be gathered selectively by either the pulsed neutron tool 400 or the sonic array tool 2000 as the tool string 1000 , 2000 , and 3000 is passed one or more times across the selected casing interval.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other implementations are within the scope of the following claims:
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A through casing formation evaluation tool string 1000, 2000, 3000 including a conveyance string 100 , a sonic array tool 200 , a pulsed neutron tool 400 and one or more downhole memory modules 160, 540, 550 . A method of through casing formation evaluation and casing and cementing integrity evaluation includes lowering a tool string into a cased wellbore; concurrently collecting data with the sonic array tool and pulsed neutron tool and transmitting at least a portion of the collected data via a conveyance string to a CPU located at the surface of the earth; storing a portion of the collected data in a memory module disposed in the tool string; removing the tool string from the wellbore; processing the collected data in the CPU to obtain selected rock property data about the one or more of the geologic formations and/or cement integrity.
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BACKGROUND OF THE INVENTION
The present invention relates generally to an air/fuel ratio control system for an internal combustion engine. More particularly, the invention relates to an air/fuel ratio control system for lean-mixture combustion in an internal combustion engine while maintaining engine fluctuations within a predetermined allowable range.
In recent years, lean-mixture combustion has been considered to be good for fuel economy in an internal combustion engine. As less fuel is consumed in each cycle of engine revolution, it is apparent that lean-mixture combustion in the engine will save fuel and provide better fuel economy. On the other hand, lean-mixture combustion has been considered to increase engine roughness and cycle-to-cycle fluctuations in engine revolution. This may degrade engine preformance and drivability.
When the engine running condition is out of the predetermined allowable range, and thus the engine is running in an unstable manner, such unstable conditions may be recognized by checking for variations in the crank shaft angular positions at which the pressure within an engine cylinder is maximized. In general, the crankshaft angular position corresponding to the minimum advance for best torque (MBT) remains constant or at least within a fixed fluctuation range when the engine is running smoothly. On the other hand, when the engine is running unstably or roughly, a variation of the crankshaft angular position at which the internal pressure in the combustion chamber is maximized becomes significant. Therefore, if variation of the crankshaft angular position at which the maximum internal pressure is obtained exceeds a predetermined allowable range, engine roughness or instability can be recognized.
SAE Paper No. 770,217, Feb. 28-Mar. 4, 1977, written by Isao NAGAYAMA, Yasushi ARAKI and Yasuo IIOKA discusses vehicle driveability with reference to FIG. 9 thereof. In the disclosure of this SAE Paper, the driveability limit was set to the point where the driver judged subjectively that the level of vehicle surge produced was unacceptable. The observed relationship between cycle-to-cycle fluctuation of I.M.E.P. and vehicle surge level is shown in FIG. 9 of the SAE Paper. In the test vehicle, especially when it was in third gear, the region of torque fluctuation rate greater than 50% and cycle-to-cycle fluctuation rate greater than 10% exhibitted unacceptable levels of vehicle surge. To aid understanding of the required stability of the engine and, in turn, of roughness of the engine, the disclosure of SAE Paper No. 770217 is hereby incorporated by reference.
As will be appreciated, by making the air/fuel mixture leaner, the cycle-to-cycle fluctuation rate as well as the torque fluctuation rate is increased causing the engine to run roughly. To cure the engine roughness, the air/fuel ratio is controlled to supply a richer mixture. As will be appreciated herefrom, in a lean mixture combustion system, it is essential to detect the engine roughness to perform enrichment in order to prevent the engine from falling into seriously rough operation.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide an air/fuel ratio control system for an internal combustion engine, which control system allows combustion of a leaner mixture and can maintain the engine stability within an allowable range.
Another and more specific object of the present invention is to provide an air/fuel ratio control system which detects engine roughness based on the variation of the crankshaft angular position at which maximum internal pressure in the combustion engine is obtained or at which the engine output torque peak is obtained, to perform enrichment of the air/fuel mixture when the detected variation exceeds preset acceptable limits and otherwise to make the mixture ratio leaner as long as the engine continues to run stably.
A further object of the invention is to provide an air/fuel ratio control system which precisely controls the air/fuel ratio at the border between stable and unstable engine operation in order to minimize fuel consumption.
According to the present invention, an air/fuel ratio control system is provided with a pressure sensor adapted to detect the internal pressure in a corresponding engine cylinder, and a crank angle sensor. A controller is adapted to detect the peak value of the pressure sensor output and the corresponding crankshaft angular position. The detected crankshaft angular position is compared with given lower and upper thresholds which define a predetermined normal angular range. If the detected crankshaft angular position is occasionally out of the normal angular range, the occurrences of such combustion in which the maximum internal pressure is obtained at a crankshaft angular position outside of the normal angle range are counted. When the counter value exceeds a predetermined value, then the air/fuel ratio is controlled to supply a richer mixture in order to prevent the engine from operating roughly.
In the preferred embodiment, the number of engine cylinders in which the maximum combustion pressure at the crankshaft angular position out of the normal range occurs is counted. When the counted number of cylinders exceeds a given number, then enrichment of the air/fuel mixture is performed. On the other hand, as long as the crankshaft angular positions at which the maximum pressures in the combustion chambers are obtained, remain within the normal angle range, the mixture is made leaner at a predetermined rate until engine roughness is detected in the foregoing manner.
In one aspect of the invention, an air/fuel ratio control system for an internal combustion engine comprises a first detector for detecting engine operating conditions to produce an engine operating condition indicative signal representative of a basic fuel delivery parameter, a second detector for detecting cycle-to-cycle fluctuations of the output of each of the engine cylinders to produce a detector signal when the engine fluctuation rate is outside of a given allowable range, a counter means for counting occurrences of the non-allowable engine fluctuations in each engine cylinder and outputting a first counter signal representative of the number of engine cylinders in which non-allowable engine fluctuations are detected, and a controller unit responsive to the engine operating condition indicative signal for deriving a fuel delivery amount based thereon, and deriving an air/fuel ratio which varies in the direction of a leaner mixture at a first given rate as long as the first counter signal value remains less than a given threshold and in the direction of a richer mixture at a second given rate when the first counter signal value is equal to or greater than the given threshold.
According to the present invention, there is further provided a method for controlling the air/fuel ratio for lean mixture combustion in which cycle-to-cycle fluctuations in combustion pressure in each cylinder are detected and checked to see if they are within a predetermined acceptable range. Detection of the cycle-to-cycle fluctuations is made by detecting the variation of the crankshaft angular position at which the maximum pressures within each engine cylinder are obtained. The variation magnitude and/or the detected crankshaft angular position is checked to see if it is in a predetermined range. When an unacceptable range of fluctuation is detected, the occurrences thereof for each cylinder are counted. The total occurrence and number of the cylinders in which unacceptable fluctuations occur are checked in order to monitor the roughness of the engine. When the engine is judged to be running roughly, enrichment of the air/fuel ratio is carried out in order to keep the engine running smoothly.
In one aspect of the invention, a method for controlling the air/fuel ratio comprises the steps of: detecting engine operating conditions to derive a fuel delivery amount depending thereupon, detecting engine roughness in each engine cycle, judging if the detected engine roughness is within a predetermined acceptable range, counting occurrences of an unacceptable range of engine roughness in each cylinder, comparing the number of the engine cylinders in which unacceptable engine roughness is detected within a given duration with a predetermined first threshold, and controlling the air/fuel mixture so as to lean out the mixture at a first given rate as long as the number of cylinders is less than the first threshold and to enrich the mixture at a second given rate when the number of cylinder is greater than the first threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the invention, which, however, should not be taken to limit the invention but are for understanding and explanation only.
In the drawings:
FIG. 1 is a fragmentary illustration of an air induction system of an internal combustion engine to which the preferred embodiment of air/fuel ratio control system according to the present invention is applied;
FIG. 2 is a fragmentary illustration of a fuel supply sysem in the internal combustion engine of FIG. 1;
FIG. 3 is a block diagram of the preferred embodiment of the air/fuel ratio control system according to the present invention;
FIG. 4 is a block diagram of a fuel injection valve driver circuit employed in the air/fuel ratio control system of FIG. 3;
FIG. 5 is a timing chart of the fuel injection valve driver circuit of FIG. 4;
FIG. 6 shows the relationship between battery voltage and a voltage dependent correction value (T s ) which is stored in a memory unit in the control system of FIG. 3 and is read out in terms of the battery voltage to correct a basic fuel injection amount;
FIG. 7 shows the relationship between engine coolant temperature and a starting enrichment correction value (KAs) which is stored in the memory of the control system and read out in terms of the engine coolant temperature when a starter switch is turned on;
FIG. 8 shows the relationship between the engine coolant temperature and an acceleration enrichment correction value (KAi) which is stored in the memory unit and read out in terms of the engine coolant temperature when the engine is started;
FIG. 9 shows the relationship between the engine coolant temperature and a temperature-dependent correction value (Ft) which is stored in the memory unit and read out in terms of the engine coolant temperature;
FIG. 10 shows the variation of a temperature dependent function (TST) stored in the memory unit to be read out in terms of the engine coolant temperature;
FIG. 11 shows the variation of a engine speed-dependent function (KNST) stored in the memory unit to be read out in terms of the instantaneous engine speed;
FIG. 12 shows the variation of a time-dependent function (KTST) stored in the memory unit and read out in terms of a time period measured after the starter switch is turned on;
FIG. 13 shows the relationship between cycle-to-cycle fluctuations and engine roughness;
FIGS. 14(a) to (c) respectively show exemplary variations of the internal pressure in the engine combustion chamber in relation to the crank shaft angular position, in which the air/fuel mixture ratio of FIG. 14(a) is the richest and the air/fuel ratio of FIG. 14(c) is the leanest;
FIGS. 15(a) to (c) respectively show exemplary distributions of the crankshaft angular positions at which the maximum internal pressure in the combustion chambers is obtained, in which the mixtures burned in the engine combustion chamber respectively correspond to those in FIGS. 14(a) to (c);
FIG. 16 shows the relationship between occurrence of roughness in the engine and the air/fuel ratio;
FIG. 17 is a front elevation of a crank angle sensor applied to the control system of FIG. 3;
FIG. 18 shows waveforms of the crank reference signal C ref and the crank position signal C pos ;
FIG. 19 is a sectional view of the engine showing installation of a pressure sensor in the control system of FIG. 3;
FIG. 20 is a partial cross-section of the pressure sensor;
FIG. 21 is an exploded perspective view of the pressure sensor;
FIG. 22 shows the relationship between internal stress and external force in the pressure sensor;
FIG. 23 is a flowchart of a program for monitoring engine roughness;
FIG. 24 is an explanatory illustration of a sample register in the control system of FIG. 3;
FIG. 25 is an explanatory illustration of a register for storing occurrences of unacceptable fluctuations in each engine cylinder;
FIG. 26 is a flowchart of a program for determining the fuel injection amount and the fuel injection pulse width;
FIG. 27 is a block diagram of a modification of the control system of FIG. 3; and
FIG. 28 is a flowchart of a modified program for detecting engine roughness.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, particularly to FIGS. 1 and 2, a typically constructed fuel injection internal combustion engine to which the preferred embodiment of an air-fuel ratio control system is applied, is illustrated. FIG. 1 shows the induction system of the fuel injection internal combustion engine. An air intake passage 10 includes a throttle chamber 12 in which a pivotably controlled throttle valve 14 adjusts the intake air quantity depending upon its angular position. The throttle valve 14 is cooperatively connected to an accelerator pedal (not shown) in a per se well-known manner for adjusting the angular position thereof and thereby adjusting the intake air flow rate Q. A throttle position sensor 16 is assciated with the throttle valve 14 to detect the angular position of the throttle valve and produce a throttle angle signal having a value representative of the throttle valve angular position. An air flow meter 18 is provided in the air intake passage 10 at a point upstream of the throttle chamber 12 and downstream of an air cleaner 20. The air flow meter 18 has a flap 22 pivotable according to the flow rate of the intake air to produce an air flow signal (Sq) representative of intake air flow rate Q.
The air intake passage 10 is connected to each of the engine combustion chambers 24 via an intake manifold 26 into which one or more fuel injection valves 28 are inserted. In addition, the intake manifold 26 is connected to an exhaust passage 30 via an exhaust gas recirculation passage (not shown). An intake or suction valve 34 is provided in each combustion chamber 24 to control suction timing of the air/fuel mixture in synchronization with the engine revolution.
An engine cylnder block 36 with a cylinder head 38 defining the combustion chamber or chambers 24 therein has a water jacket 40 through which an engine coolant circulates for dissipation of the engine heat. A piston 42 is reciprocably housed in an engine cylinder 44 formed in the engine cylinder block for reciprocation as the engine runs. A spark ignition plug 46 is engaged to the cylinder head 38 so as to expose its electrodes to the combustion chamber 24 in order to effect spark ignition at a controlled timing in synchronization with the engine revolution. A pressure sensor 48, which detects the internal pressure in the combustion chamber and produces a pressure signal S p having a value representative of the pressure in the combustion chamber 24, is attached to the cylinder block. A coolant temperature sensor 50 is inserted into the water jacket 40 for detecting an engine coolant temperature to produce a temperature signal S t having a value representative of temperature condition of the engine coolant.
An idling air passage 52 bypasses the throttle valve 14 to allow passage of intake air therethrough. An idle adjuster screw 54 is associated with the idling air passage 52 for adjusting the engine idling speed. An auxiliary intake passage 56 with a vacuum controlled actuator 57 for adjusting auxiliary air flow rate is also connected to the air intake passage 10 via a reference pressure passage (not shown).
A crank angle sensor 58 is associated with an engine crankshaft for producing a position signal pulse after every given unit of crankshaft rotation, e.g. 1°, and a crank reference signal C ref pulse at a predetermined angular positin of each crankshaft rotation.
The throttle position sensor 16, the air flow meter 18, the coolant temperature sensor 50, the pressure sensor 48 and the crank angle sensor 58 are connected to a controller 100 to feed respective signals as engine operational parameter-indicative signals to the controller.
FIG. 2 shows the fuel injection system of the fuel injection internal combustion engine. A fuel tank 60 is connected to a fuel pump 62 via a suction tube 64. The fuel pump 62 pressurizes the fuel to circulate though the fuel supply circuit 66 and to provide fuel pressure for injection through the fuel injection valve 28. A fuel damper 68 for absorbing pulsatile fuel flow surges in the fuel supply circuit, and a fuel filter 70 is inserted in the fuel supply circuit. The fuel supply circuit 66 is connected to the fuel injection valve 28 via a fuel rail 72. In addition, the fuel supply circuit 66 is connected to a fuel return circuit 74 via a pressure regulator 76. The pressure regulator 76 adjusts the fuel pressure supplied to the fuel injection valve 28 in relative to the intake air vacuum pressure which is introduced through a conduit 78 to act as a reference pressure, and returns extra fuel to the fuel tank via the fuel return circuit 74.
A choke valve 80 supplies additional fuel under cold engine conditions.
FIG. 3 schematically shows the preferred embodiment of the air/fuel ratio control system according to the present invention. As set forth above, the controller 100 is connected to the throttle position sensor 16, the air flow meter 18, the pressure sensor 48, the coolant temperature sensor 50 and the crank angle sensor 58 for detecting the engine operating condition. The controller 100 may comprise a digital computer or processor such as a microcomputer. Analog-to-digital converters 102, 104, 106 and 108 are respectively interposed between the throttle position sensor 16, the air flow meter 18, the pressure sensor 48 and the coolant temperature sensor 50 and the controller 100 in order to convert the throttle position signal S T , the flow rate signal S q , the pressure signal S p and the coolant temperature signal S t from their analog forms into corresponding digital signals.
The controller 100 is also connected to a vehicle battery 110 in order to receive battery voltage S v via an analog-to-digital converter 112. A starter switch 114 is also connected to the controller 100, which starter switch produces an ON/OFF signal depending upon its switch position. For instance, the starter switch 114 supplies an ON signal to the controller 100 while the engine is cranking.
On the other hand, the crank angle sensor 58 is connected to an engine speed counter 116 in order to supply the crank reference signal C pos to the latter. The engine speed counter 116 is adapted to produce an engine speed signal S N having a value indicative of the revolution speed of the engine determined on the basis of the crank reference signal.
The pressure sensor 48 is adapted to detect the internal pressure in the engine combustion chamber 24 to produce the pressure signal S p representative of the instantaneous pressure in the combustion chamber. In the shown embodiment, four pressure sensor 48-1, 48-2, 48-3 and 48-4 are used to detect the internal pressures in each of the four combustion chambers 24. A multiplexer 118 is interposed between the analog-to-digital converter 108 and the pressure sensors 48-1, 48-2, 48-3 and 48-4. The multiplexer 118 is connected to the controller 100 to receive a selector signals S s which selects one of the pressure sensors 48-1, 48-2, 48-3 and 48-4 to pass the corresponding pressure signal to the analog-to-digital converter 108, in synchronization with the engine revolution. Specifically, according to the shown embodiment, the controller 100 is adapted to detect the maximum internal pressure in the currently igniting combustion chamber and accordingly sends the selector signal S s to pass the pressure signal S p produced by the pressure sensor which measures the internal pressure of the corresponding igniting combustion chamber.
To detect the state of engine revolution, the controller 100 is provided with a crank position signal counter 120 for counting the pulses of the crank position signal C pos from the crank angle sensor 58 and inputted to CPU 122 through an input interface 124. The crank position signal counter 122 produces an angle signal S.sub.θ having a value representative of the crankshaft angular position. In the shown embodiment, the crankshaft angular position at which the #1-cyclinder is in its top dead center (TDC) is assigned the value 0°. The crank angle signal counter 120 is adapted to count up to 720° and then reset to zero.
When the multiplexer 118 is operated by the selector signal to pass one of the pressure signals S p1 , S p2 , S p3 and S p4 to the controller 100, the pressure signal value is sampled and stored in a sample register 126. From the sampled pressure signal values, the controller derives the peak or maximum pressure P max and the crankshaft angular position θ pmax at which the internal pressure in the corresponding combustion chamber 24 is maximized.
As is well known, the basic fuel injection amount T p is calculated on the basis of the intake air flow rate Q and the engine speed N according to the following formula:
T.sub.p =K(Q/N) (1)
where K is a constant.
The basic fuel injection amount T p is corrected by correction values respectively depending upon the engine operating conditions, such as battery voltage, coolant temperature condition, engine roughness and so forth.
In the shown embodiment, a correction value depending upon the battery voltage V s varies according to the characteristics illustrated in FIG. 6. As will be appreciated from FIG. 6, the battery voltage dependent correction value T s is obtained from the following equation:
T.sub.s =a+b(14-V) (2)
where a and b are constants.
The battery voltage dependent correction value T s may be stored in a memory 130 unit in the controller 100 in the form of a look-up table. The look-up table will be representated hereafter by the reference numeral 132. The table 132 is accessed according to the battery voltage inputted from the vehicle battery via an input interface 116.
A correction value KA s for smooth cranking operation or smooth engine start-up characteristics is determined on the basis of the engine coolant temperature condition when the starter switch 108 is closed. The variation of the correction value KA s is represented by the characteristics shown in FIG. 7. The correction value KA s , in other words, the starting enrichment correction value, is stored in the memory 130 in the form of a look-up table 134 which is accessed according to the coolant temperature when the starter switch 108 is first closed. The correction value KA s is gradually reduced to zero at a given rate while the engine is running. Therefore, the correction value KA s as shown in FIG. 7 is the initial value thereof.
While the engine is still cold after idling, an acceleration enrichment correction will be performed in order to improve the start-up characteristics of the vehicle so that vehicle can smoothly "pick up". For this purpose, an acceleration enrichment correction value KA i is stored in the memory 130 in the form of a look-up table 136, with the characteristics shown in FIG. 8. The correction value KA i is read out in response to a throttle angle signal indicating acceleration, with reference to the coolant temperature at the moment of acceleration demand. The correction value KA i is gradually reduced to zero at a given rate after acceleration enrichment is performed with the read-out initial correction value KA i .
During engine warm-up, a temperature dependent correction will be performed by modifying the basic fuel injection value with a temperature dependent correction value F t . The correction value F t is stored in the memory 130 in the form of a look-up table 122. This look-up table 138 is accessed according to the cooling temperature signal S t and varies depending upon the coolant temperature as shown in FIG. 9.
An additional correction mediated by an exhaust gas O 2 sensor (not shown) or an exhaust gas temeprature sensor (not shown) will be performed.
During engine cranking, the engine starting enrichment correction will be made in accordance with the following equations:
T.sub.1 =T.sub.p ×(1+KA.sub.s)×1.3+T.sub.s (3)
T.sub.2 =TST×KNST×KTST (4)
where TST is a function of the coolant temperature varying according to the coolant temperature as illutrated in FIG. 10; KNST is a function of the engine speed N varying according to the engine speed as illustrated in FIG. 11; and KTST is a function of the period after the starter switch 114 is closed to start the engine which varies as illustrated in FIG. 12.
The starting enrichment correction is performed by choosing the one of the foregoing T 1 and T 2 which is larger than the other. The functions TST, KNST and KTST are stored in the memory 130 the form of look-up tables 140, 142 and 144, as shown in FIG. 3.
According to the shown embodiment, another correction is made in accordance with engine roughness. As set forth above, during lean-mixture combustion, engine roughness, or more specifically cycle-to-cycle engine speed fluctuation, increases with the leanness of the air/fuel ratio. This is due to fluctuations in combustion quality in the combustion chamber. For instance, when a lean mixture is used, the transmission speed of the combustion front in the mixture gas in the combustion chamber varies significantly. This implies a rather high possibility of engine knocking and mis-firing. This fluctuation in combustion quality may be recognized by checking the crankshaft angular position at which the internal pressure P in the combustion chamber is maximized. As roughness increases, the range of variation of the crankshaft angular position at maximum internal pressure becomes wider than during engine operation with a richer mixture.
The relationships of combustion fluctuations and engine roughness with respect to the mixture ratio are illustrated in FIG. 13, which were obtained by varying the mixture ratio while holding the ignition timing at MBT (Minimum advance for Best Torque). As will be appreciated from FIG. 13, increases in the mixture ratio cause retardation of the crankshaft angular position at which the internal pressure in the combustion chamber is maximized and widening of the range variation of of the maximum pressure crankshaft position. Exemplary fluctuations and analyses thereof are shown in FIGS. 14 and 15. In FIGS. 14, (a), (b) and (c) respectively show traces of the variation of the internal pressure in the combustion chamber at various mixture ratios, namely, FIG. 14(a) shows combustion of the richest mixture and FIG. 14(c) shows combustion of the leanest mixture. On the other hand, FIGS. 15(a), (b) and (c) respectively show distributions of the crankshaft angular position at which the internal pressure in the combustion chamber is maximized, which crankshaft angular position will be hereafter referred to as "maximum pressure angle Q pmax ". The mixture ratios used in the experiments of FIGS. 15(a), (b) and (c) correspond to those of FIGS. 14(a), (b) and (c) respectively. As will be appreciated, when the mixture is sufficiently rich, the range of variation of the maximum pressure angle Q pmax remains within a normal range (16° to 20° ATDC) which is approximately centered on the spark advance at MBT. On the other hand, when the mixture is lean, engine roughness is increased so that the range of variation of the maximum pressure angle Q pmax extends beyond the normal range. The hatched areas in FIGS. 15(b) and (c) represent occurrences of the maximum pressure angle Q pmax outside of the normal range.
FIG. 16 shows illustrates the frequency of occurrences of the maximum pressure angle Q pmax outside of the normal range. As will be appreciated, when the occurrence frequency is low, the engine is regarded as running stably, while when the occurrence frequency is high, the engine is regarded as running unstably. Therefore, by monitoring occurrences of the maximum pressure angle Q pmax outside of the normal range, the degree of engine roughness can be measured.
Accordingly, the correction of the fuel injection amount depending upon the engine roughness may be performed on the basis of the frequency of occurrences of the maximum pressure angle Q pmax outside of the normal range.
The controller 100 thus produces a pulse-form fuel injection signal T A having a pulsewidth representative of the fuel injection amount derived by correcting the basic fuel injection amount T p by the correction values described above. The fuel injection signal T A is output via an output unit 146 to the fuel injection valve driver circuit 160 including an electrically controlled actuator 162 (see FIG. 4) to open and close the fuel injection valve 28. As shown in FIG. 4, the fuel injection valve driver circuit 160 includes a register 164 which is adapted to temporarily hold the fuel injection pulse T A . The register 164 is associated with a comparator 166 to reset the latter in response to the leading edge of the fuel injection pulse. The fuel injection pulse T A is also supplied to a clock counter 168 which is, in turn, connected to a clock generator 170 to receive a clock pulse signal. The clock counter 168 is adapted to count the pulses of the clock signal and output a counter signal indicative of its counter value. The clock counter 168 is responsive to the leading edge of the fuel injection pulse T A to clear its counter value to zero.
The register 164 outputs a register signal indicative of the stored pulse width of the fuel injection pulse T A to the comparator 166. The comparator 166 compares the register signal value with the counter signal value from the clock counter 168. The comparator 166 outputs a LOW-level comparator signal as long as the register signal value is larger than the counter signal value. The comparator 166 outputs a comparator signal to the base electrode of a transistor 172. The transistor 172 is turned OFF by the LOW-level comparator signal to supply a bias voltage to the actuator 162 which energizes the fuel injection valve 28 to its open position. The comparator signal level remains LOW while the register signal value is greater than the counter signal value. The comparator signal level goes HIGH when the counter signal value becomes equal to the register signal value to turn the transistor 172 on. As a result, the actuators 162 are deactivated to close the fuel injection valve. Therefore, the fuel injection valve is opened for a duration corresponding to the fuel injection pulse width.
The crank angle sensor 58 and the pressure sensors 48-1, 48-2, 48-3 and 48-4 are used to recognize the maximum pressure angle θ pmax . As shown in FIG. 17, the crank angle sensor has a rotor fixed to the crankshaft 282 for rotation therewith. Slits 283 for the crank position signals C pos are arranged radially symmetrically around the rotor 281. The separation between each of the adjacent slits 283 correspond to 1° of crankshaft rotation. Slit 284 and slits 285 are arranged at positions corresponding to respectively predetermined crankshaft angular positions corresponding the top dead center of each of the cylinders. The slit 284 is formed at a position corresponding to compression top dead center of #1-cylinder and has a greater length than the slits 285 which are formed at positions respectively corresponding to compression top dead centers of the other cylinders. A photoelectric sensor element 286 faces one surface of the rotor 281 to produce a crank position signal C pos and crank reference signal C ref as shown in FIG. 18.
Though a specific structure has been illustrated above for the preferred embodiment, it is possible to replace the illustrated crank angle sensor with any type or structure of crank angle sensor. Furthermore, though the shown engine speed sensor 116 counts the crank position signal pulses C pos and produces the engine speed signal S N , this engine speed counter 116 is not always necessary for the control system and can be replaced with any engine speed detector or sensor adapted to detect the engine revolution speed and to produce an engine speed indicative signal. It would also be possible to calculate the engine speed parameter by processing the crank angle signals, e.g., the crank position signals C pos or crank reference signals C ref in the controller. Furthermore, a crank angle sensor which produces only the crank position signal would also be applicable to the control system.
FIGS. 19 to 22 show an example of the pressure sensor 48 adapted to detect the internal pressure in the combustion chamber 24. The shown pressure sensor 48 is in the form of washer for a fastener bolt.
As shown in FIG. 19, the cylinder head 34 is attached to the cylinder block 36 by means of cylinder head bolts 49 (only one of which is shown). An annular pressure sensor 48 takes the form of the washer and fits around a section of the bolt 49 outwardly projecting from the cylinder head 34. The pressure sensor 48 is clamped between the cylinder head 34 and the head of the bolt 49 in a manner similar to a normal washer.
FIGS. 20 and 21 show the details of the pressure sensor 48. The pressure sensor 48 includes a casing or body having a pair of upper and lower metal discs 481 and 482 aligned and spaced axially. These discs 481 and 482 each have a central bore accommodating the cylinder head bolt. The body of the pressure sensor has concentrically arranged inner and outer rings 484 and 485 positioned between the discs 481 and 482 and extending coaxially with respect to the discs 481 and 482. These rings 484 and 485 have equal axial dimensions, by which the discs 481 and 482 are distant from each other. The rings 484 and 485 are radially spaced to define an annular inside space in conjunction with the discs 481 and 482. The rings 484 and 485 are made of relatively rigid metal, such as steel. Upper end faces of the rings 484 and 485 are welded to the lower end face of the upper disc 481. Lower end faces of the rings 484 and 485 are welded to the upper end face of the lower disc 482. The central bore of the inner ring 484 is designed to receive the cylinder head bolt.
A ring-shaped sensing member 486 is disposed in the inside space and extends coaxially with respect to the discs 481 and 482. The sensing member 486 includes axially aligned ring electrode 487, and ring-shaped mechanical-electro transducing members 488 and 489, such as ceramic piezoelectric elements, sandwiching the electrode 487 therebetween. The upper end face of the electrode 487 contacts and is attached to the lower end face of the upper piezoelectric element 488. The lower end face of the predetermined clearance 490 in an original condition where the pressure sensor 48 is detached from the bolt 49 (see FIG. 19). The upper end face of the piezoelectric element 488 is in contact with the lower end face of the upper disc 481 when the pressure sensor 48 is attached in place around the bolt 49, as described hereinafter. The upper piezoelectric element 488 serves to produce an electrical signal, which can be applied between the upper disc 481 and the electrode 486.
The pressure sensor 48 fits around the bolt 49 (see FIG. 19) in such a manner that the bolt 49 extends through the central bores of the discs 481 and 482, and the inner ring 484. The top surface of the pressure sensor 48 contacts the head of the bolt 49. The bottom surface of the pressure sensor 48 contacts the cylinder head 34 (see FIG. 19). In this way, the pressure sensor 48 is clamped between the bolt 49 and the cylinder head 34. The output signal of the pressure sensor 48 is transmitted via its body and terminal.
As shown in FIG. 22, as an external force F applied to the pressure sensor 48 increases from zero to a preset threshold level Fs, internal stress σp of the piezoelectric elements 488 and 489 remains zero, since the clearance 490 is maintained and hence the sensing member 486 remains out of contact with the upper disc 481 and receiving no external force. When the external force F reaches the threshold level Fs, deformation of the body of the sensor 48 assumes a value at which the clearance 490 disappears and thus the sensing member 486 comes into contact with the upper disc 481. As the external force F increases from the threshold level Fs, the internal stress σp increases linearly with the external force F. In FIG. 22, the broken line indicates the relationship between external force F and internal stress σpo of the piezoelectric elements 488 and 489 obtained under conditions where the sensing member 486 originally contacts the upper disc 481, which corresponds to a conventional case. As is apparent from FIG. 22, this internal stress σpo increases proportionally with increases in the external force F from zero.
A similar pressure sensor has been disclosed in the Published Japanese Utility Model Application No. 40-10332, published on Apr. 7, 1965. The disclosure of the above-identified Published Japanese Utility Model Application is hereby incorporated by reference.
As will be appreciated, the pressure sensor 48 is attached to the engine cylinder head at locations respectively adapted to detect variation of vibration due to variation of the internal pressure in the combustion chamber 24. In the preferred embodiment, the pressure sensor 48-1 is attached to the cylinder head at the location corresponding to the #1-cylinder to produce the pressure signal S p1 representative of the internal pressure in the #1-cylinder. Similarly, the pressure sensors 48-2, 48-3 and 48-4 are respectively adapted to detect the internal pressure of respectively corresponding #2-, #3- and #4-cylinders to produce the pressure signals S p2 , S p3 and S p4 . Though the pressure sensor in the shown embodiment has been attached to the engine cylinder head by mean of the cylinder head bolt, it may be possible to attach the pressure sensor by different way, for example, by mean of the spark ignition plug. Therefore, manner of attching the pressure sensor to the engine cylinder head may not be specified to the shown specific manner. Further, it would be possible replace the pressure sensor as illustrated with any appropriate sensor adapted to detect the internal pressure in the combustion chamber and to produce a pressure indicative signal.
The operation of the control system of FIG. 3 for detecting the engine roughness will be described in detail with reference to the flowchart of FIG. 23. The flowchart of FIG. 23 is designed to be executed by CPU 122 every time the crank position signal C p is inputted from the crank angle sensor 58. The engine roughness detecting program of FIG. 23 is stored in a program memory 152 of the memory unit 130 and read by the CPU 122 in response to the crank position signal C pos . The CPU 122, at the same time, feeds the crank position signal C pos to the crank position signal counter 120. The crank position signal counter 120 outputs the counter signal having a value representative of the crankshaft angular position to the CPU 122 when accessed.
In response to the crank position signal C pos the program of FIG. 23 is executed. Immediately after START, the crank position signal counter 120 is accessed to read the counter value representative of the crankshaft angular position θ at a block 1002. At a block 1004, the counter value θ is checked to see if it is equal to 720°, which value corresponds to crankshaft angular position at which #1-cylinder is at compression top dead center. If the counter value is equal to 720°, then the counter is reset to zero at a block 1006. Otherwise, the counter value θ is checked to see if it is within the angular range of 0° to 60°, indicating that the #1-cylinder is in its combustion stroke at a block 1008. If the counter value is indicative of a crankshaft angular position within the range of 0° to 60°, then a flag register 154 is set to 1, indicating that the CPU is sampling pressure data in the #1-cylinder at a block 1010. Then, CPU feeds the selector signal S s to the multiplexer 118 in order to transmit the pressure signal S p1 of the pressure sensor 48-1 through the output unit 146. The pressure signal S p1 indicative of the pressure in the #1-cylinder is stored in the corresponding address of the sample register 126 at a block 1014.
As shown in FIG. 24, the sample register 126 has a plurality of storage addresses to store the sampled pressure signal values in order. Namely, the address θ 1 is adapted to store the first pressure signal value, the address θ 2 is adapted to store the second pressure signal value, and so on. The CPU 122 loads each of the storage addresses θ 1 to θ 60 according to a counter value R n in a counter 148, which counter value R n is incremented by one (1) per each cycle of program execution, at a block 1016.
In the shown embodiment, the sample register 126 is adapted to sample the pressure signal value for the crankshaft rotation from the top dead center to 60° after the top dead center (ATDC). Therefore, the sample register 126 has 60 storage addressed θ 1 and θ 60 and the counter 148 is adapted to count to 61 before being reset to zero.
The counter value R n is checked at a block 1018. If the counter value R n is less than 61, program execution goes to END. On the other hand, when the counter value is equal to 61, the CPU refers to the sample register 126 to find out the peak value or maximum pressure P max and the storage address θ pmax which holds the maximum pressure signal value P max . Since the storage address number corresponds to the crankshaft angular position from TDC, the address number of the storage address in which the maximum pressure signal value P max is stored is representative of the maximum pressure angle θ pmax . This determination of the maximum pressure angle θ pmax is performed at a block 1020. The obtained maximum pressure angle θ pmax is compared with lower and upper thresholds θ L and θ U at a block 1022. When the maximum pressure angle θ pmax is greater than the lower threshold θ L and less than the upper threshold θ U , then the program execution goes to END. If the maximum pressure angle θ pmax is equal to or less than the lower threshold θ L or equal to or greater than the upper threshold θ U , a register 150 is incremented by 1 at a block 1024.
As shown in FIG. 25, the register 150 has a plurality of register addresses, one of which is accessed by the CPU according to the value of the flag register 154. Therefore, one of the register addresses #1 to #4 is incremented by 1 at the block 1024. Each register address #1 to #4 corresponds to a cylinder. Therefore, the value in each register address represents the number of occurrences of the maximum pressure angle out of the normal angle range which is defined by the lower and upper thresholds θ L and θ U .
When the crankshaft angular position θ is out of the range 0° to 60°, then the crankshaft angular position θ is again checked to see if it is within a range of 180° to 240° at a block 1028. If the crankshaft angular position θ is within the range, i.e., 180° to 240°, then, the flag register 154 is set to 3, representing sampling of the pressure signal from the pressure sensor 48-3 adapted to detect the internal pressure of the #3-cylinder at a block 1030. Then, the CPU 122 feeds the selector signal S s to the multiplexer 118 in order to transmit the pressure signal S p3 . At a block 1032, the pressure signal value of the pressure signal S p3 is loaded into the corresponding storage address of the sample register 126. After this step 1032 of sampling the pressure signal value, control goes to the step 1016 and the subsequent steps of detecting the maximum pressure angle θ max and judging whether the obtained maximum pressure angle θ pmax is within the normal angle range.
If the crankshaft angular position θ when checked at the block 1028 is out of the range 180° to 240° ATDC then it is checked again for the range 360° to 420° at a block 1034. If it is in this range, the flag register 154 is set to 4 at a block 1036. At the same time, the selector signal S s is fed to the multiplexer 118 to pass the pressure signal S p4 from the pressure sensor 48-4. The pressure signal S p4 is stored in the corresponding address of the sample register 126, at a block 1038. After this step 1038, program control goes to the step 1016 and the subsequent steps of detecting the maximum pressure angle θ pmax and judging whether the obtained maximum pressure angle is within the given normal angle range.
If the crankshaft angular position θ when checked at the block 1034 is out of the range 360° to 420°, the angle θ is once again checked to see if it is in a range of 540° to 600° at a block 1040. If the answer of the block 1040 is NO, program goes to END. On the other hand, if YES, the flag register 154 is set to 2 at a block 1042. At this time, the selector signal S s is fed to the multiplexer 118 to pass the pressure signal S p2 from the pressure sensor 48-2. As a result, the pressure signal value P 2 of the pressure signal S p2 is sampled at a block 1044. After sampling the pressure signal value P 2 , process goes to the block 1016 and the subsequent blocks as set forth above.
As set forth above, by execution of the program of FIG. 23, occurrence of combustion in which the maximum pressure angle θ pmax is out of the given normal range is monitored. In the foregoing embodiment, the lower threshold θ L is 10° ATDC and the upper threshold θ U is 25° ATDC. Therefore, when the maximum pressure angle θ pmax is in a range of 10° ATDC to 25° ATDC, the combustion in the cylinder being checked is regarded as taking place normally or stably. When the maximum pressure angle θ pmax is out of the range (10° ATDC to 25° ATDC), it is regarded that the combustion in the checked cylinder is taking place unstably. Such occurrences of unstable combustion are counted by the register 150. As illustrated in FIG. 25, the register 150 employed in the shown embodiment has four register address adapted to hold values representative of the occurrences of unstable combustion in each of the engine cylinders.
FIG. 26 is a flowchart of a program for determining a fuel injection pulse T A having a pulse width determined on the basis of the engine operating condition and taking the engine roughness condition into account. This program of FIG. 26 is executed per every 180° of crankshaft rotation. Therefore, the program of FIG. 26 is executed in response to the crank angle signals indicative of every 180° of crankshaft rotation.
Soon after START, the basic fuel injection amount T p is determined on the basis of the engine speed signal S N indicative of the instantaneous engine speed N and the air flow rate signal S Q indicative of the instantaneous air flow rate or engine load Q, according to the foregoing equation (1), at a block 1102. The basic fuel injection amount T p is corrected by various correction parameters, such as the battery voltage, the engine coolant temperature and so forth. To make necessary corrections, correction tables 132, 134, 136, 138, 140, 142 and 144 are accessed according to the correction parameters input. This correction is performed at a block 1104.
After the step 1104, the register 150 is checked to obtain the number of cylinders in which unstable combustion has occurred, at a block 1106. The number n 2 of the cylinders is compared with a given value N 2 at a block 1108. In the shown embodiment, the given value N 2 is 2. If the counter number n 2 is equal to or greater than the given value N 2 , the correction value is determined such that fuel injection amount is increased by a given increment (K L ) to make the air/fuel mixture richer at a block 1110.
If the counter number n 2 is less than the given value N 2 , then the final value of register value n 1 of the current cylinder is read out and compared with a given value N 1 at a block 1112. If the net value of the register value n 1 is greater than the given value N 1 , control goes to the step 1110 to determine the correction value for enrichment. In the shown embodiment, the given value N 1 is 3.
If the value n 1 is smaller than the given value N 1 , then the correction value is determined so as to decrease the fuel injection amount by a given increment (K L ) in order to lean out the air/fuel mixture at a block 1114. After this, a register 156 is incremented by 1 at a block 1116. The value n 3 of register 156 is compared to a given value N 3 , e.g., 24 at a block 1118. If the register value n 3 is larger than the given value N 3 , the register 156 is reset at a block 1120 and the register 150 is cleared at a block 1122. This ensures that the counting operations above will be averaged over a given number, e.g. 4, of engine cycles. Similarly, after determining the correction value for enrichment at the block 1110, the registers 156 and 150 are cleared at blocks 1120 and 1122.
If the register value n 3 , when checked at the block 1118, is less than the given value N 3 , then correction of the fuel injection amount by the determined correction value is performed at a block 1124. After the block 1122, control goes to the block 1124 to determine the corrected fuel injection amount based on the determined correction value. Based on the corrected fuel injection amount, the fuel injection pulse width T A representative of the corrected fuel injection amount is derived at a block 1126. This fuel injection pulse width T A is transferred and stored in the register 164 of the fuel injection valve driver circuit 160.
It should be appreciated that although the foregoing control system has been illustrated as having only one processor used in common to detect the engine roughness and to generate the fuel injection pulse by time sharing, it would be possible to employ separate processors respectively adapted to determine the engine roughness and the fuel injection pulse. Furthermore, although the foregoing embodiment make the mixture leaner by decreasing the fuel injection amount, it would also be possible to make the mixture rate leaner by increasing an exhaust gas recirculation rate. In this case, a known exhaust gas recirculation control valve (EGR control valve) may be controlled to increase the EGR rate.
A modification of foregoing embodiment of the air/fuel ratio control system has been illustrated in FIGS. 27 and 28. In this modification, the lower and upper thresholds θ L and θ U are adjusted according to the preceding maximum pressure angles. The thresholds θ L and θ U are varied in such a manner that an average value θ' pmax is calculated from preceding maximum pressure angles θ pmax . The oldest maximum pressure angle among four preceding maximum pressure angles is replaced by the instantaneous maximum pressure angle. By averaging to four preceding maximum pressure angles, the average value θ' pmax is obtained. The lower threshold θ L is obtained by subtracting a given value a L from the average value θ' pmax . On the other hand, the upper threshold θ U is obtained by adding a given value a U for the average value θ' pmax .
To store the four preceding maximum pressure angles θ pmax , a shift-register 158 is provided in the controller 100 as shown in FIG. 27. The shift-register 158 is designed to replace the oldest data with incoming data. For instance, the shift-register 158 receives fresh data during execution of the program of FIG. 28, which data is representative of the instantaneous maximum pressure angle. In response to the fresh data, the oldest among the four last maximum pressure angle values is cleared. Thus, the fresh data is stored in the shift-register 158 as one of the four maximum pressure angle data.
As shown in FIG. 28, after the block 1020 of FIG. 23, a block 1021 is inserted in order to derive the lower and upper thresholds θ L and θ U . In this block, the average value θ' pmax of the stored four maximum pressure angles is calculated. The given values a L and a U are respectively subtracted and added to the average value θ' pmax to obtain the lower and upper thresholds. At the block 1022, the derived lower and upper thresholds θ L and θ U are compared with the instantaneous maximum pressure angle θ pmax to detect engine roughness. If the instantaneous maximum pressure angle θ pmax is in the range defined by the lower and upper thresholds θ L and θ U , then the program goes to END. On the other hand, if the instantaneous maximum pressure angle is out of the range between the lower and upper thresholds, then the corresponding address of the register 150 is incremented by "1".
As set forth above, according to the present invention, engine roughness is detected by detecting fluctuations in the crankshaft angular position at which the internal pressure in the combustion chamber is maximized each cycle of engine revolution. The air/fuel control system controls the mixture ratio of the air/fuel mixture and makes the latter leaner as long as the cycle-to-cycle fluctuation of the maximum pressure angle is maintained within a predetermined allowable range. When the maximum pressure angle is out of the allowable range, the air/fuel ratio is controlled so as to make the mixture richer. In the shown embodiment, engine roughness out of the allowable range is detected when the number of cylinders in which the maximum pressure angle is out of the allowable range is greater than a given number and/or when the number of occurrences of the maximum pressure angle out of the allowable range is greater than a given number. Accordingly, the air/fuel mixture ratio is controlled to reduce consumption of the fuel due to lean mixture combustion without causing any serious unstability or roughness in the engine.
While the specific embodiment has been illustrated hereabove in order to fully disclose the invention, it is possible to modify or embody the invention otherwise without departing from the gist or content of the invention as defined in the appended claims. For example, in order to detect engine roughness and determine the fuel injection pulse width continuously or sequentially two processor units may be provided. Furthermore, for example, engine roughness may be detected in other ways, for example, by analysis of engine body vibrations or the like. Therefore, it should be appreciated that the present invention should not be understood to be limited to the specific embodiment disclosed hereabove but to include all of the possible embodiments and/or modifications thereof.
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An air/fuel ratio control system is applicable to lean mixture combustion internal combustion engines. The control system determines the value of the mixture ratio at which engine stability can switch between stable and unstable conditions. As long as the engine continues to run in a stable condition in which the engine roughness is within an acceptable range, the mixture is intermittently leaned out by a given proportion. On the other hand, when engine roughness in an unacceptable range is detected, the mixture ratio is enriched by a given proportion to overcome the unacceptable engine roughness. Enrichment of the mixture is continued until engine roughness within the acceptable range is detected.
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BACKGROUND OF THE INVENTION
Many bowlers prefer to wear a wrist support to prevent unwanted movement of the wrist as the ball is swung and released. In order to improve ball control and to obtain greater spin, some bowlers use a wrist support which includes a resilient pad that is positioned at the palm of the hand when the wrist support is worn. The pad is to fill the space between the palm of the hand and the surface of the ball to provide better contact with the ball to lead to better control. An example of such a wrist support is found in U.S. Pat. Nos. 3,031,680 and D. 251,337.
Prior wrist supports with a palm pad have had certain shortcomings, however. One difficulty arises from the fact that the pad is made complementary to the pocket and, therefore, has only one position as the wrist support is worn. Consequently, it is not possible to adjust the position of the pad relative to the main body of the wrist support. This means that the position of the pad is fixed and cannot be adjusted. As a result, the pad may not be positioned correctly for some sizes and shapes of hands, so that it will not properly serve its function of enhancing ball control and may cause the hand to assume an uncomfortable and awkward position.
Another difficulty stems from the shape of the pad which has been used. It has been a generally pie-shaped device, tapering in thickness from a maximum at the center of the curved edge to the point where the straight edges meet. The curved edge is positioned at the heel of the palm as the device is used, with the point up near the juncture of the forefinger and second finger. With the pad being positioned in this manner, it can cause discomfort to the user of the device and hamper movement of the hand, because it does not comply with the shape or points of flexure of the hand.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides an improved wrist support with a palm pad, overcoming the difficulties with the prior art devices noted above. The flexible body of the device is adapted to wrap around the hand and wrist of the user, with straps holding the wrist support in position. A rigid reinforcement may be included in the portion of the support over the back of the hand and wrist to prevent unwanted movement.
On the portion of the device that fits over the palm, there is a relatively large pocket open at one end. This receives a resilient pad which is of smaller overall lateral dimensions than the pocket. Accordingly, it is possible to move the pad around in the pocket relative to the body. This permits precise positioning of the pad so that the user of the device can be sure that the pad is at the right place on the palm of his hand to fit his own anatomy. The opening to the pocket is concealed by the outer part of the wrist support as it is worn, protecting the pad and improving the appearance of the wrist support.
The pad is shaped so as to have two relatively straight edges meeting at a rounded corner where the pad is the thickest. This part of the pad fits at the base of the heel of the hand, not interfering with movement of the hand while at the same time enabling the pad to take up the space between the hand and the bowling ball. An arcuate edge of the pad, where it has tapered to its minimum dimension, extends from the end of one of the straight edges and is positioned just below the base of the fingers on the palm of the hand when the wrist support is in use. This, again, avoids interference with the movement of the hand at the knuckles. From the other end of the arcuate edge is a short straight edge that is adjacent the side of the hand, which connects to another straight edge which extends near the base of the thumb. By the construction of the pad in this manner, greater comfort and improved control of the bowling ball can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view of one side of the wrist support of this invention in the open position;
FIG. 2 is a plan view of the other side of the wrist support;
FIG. 3 is a transverse sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is an exploded perspective view showing the components of the wrist support;
FIG. 5 is a perspective view illustrating the wrist support as it is worn;
FIG. 6 is a perspective view of the pad of the wrist support taken from adjacent one end;
FIG. 7 is a perspective view of the pad of the wrist support taken from the opposite end; and
FIG. 8 is a plan view illustrating the relationship of the pad and the wrist support with the hand of the user.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The wrist support 10 of this invention includes a principal body portion 11, adapted to be wrapped around the hand and wrist of the user, with three straps 12, 13 and 14 at one end which are used in securing the device. The wrist support is secured by a suitable fastening means, such as a hook and pile fastener marketed under the trademark VELCRO. The pile portions 15, 16 and 17 are on the ends of the straps 12, 13 and 14, respectively, on one side of the wrist support, and mate with the hook portions 18, 19 and 20 which are on the other side and adjacent the opposite end of the principal portion 11 of the device.
The components of the wrist support, shown in exploded perspective in FIG. 4, include an outer layer 22 made up of two pieces 23 and 24 of flexible sheet material, such as polyvinylchloride. The two sections 23 and 24 are stitched together at a seam 25 in which the corresponding sides of the two sections are superimposed. Inasmuch as the edges are contoured to be slightly concave, as viewed in FIG. 4, this seam imparts a desired shape to the wrist support when it is completed, helping it conform to the side of the hand and wrist of the user.
Extending from the seam 25, the section 23 includes two elongated more-or-less parallel edges 26 and 27 which continue to form edges of the straps 12 and 14, respectively. An inclined outer edge 28 of the section 23 angles outwardly from a rounded notch 29 near the base of the strap 13 to the strap 12.
Above the section 24 of the layer 22 is a metal reinforcement 31 which serves to keep the wrist relatively rigid when the support is worn. The reinforcement is elongated and wider at one end 32, with a slight concavity about its longitudinal axis, as seen in FIG. 4.
Next is a layer 34 of cushioning material, such as a 1/4-inch thick layer of resilient foam plastic. The layer 34 fits over the section 24 of the layer 22, and past the seam 25 to the portion of the section 23 adjacent the seam. An extension 35 on the layer 34 projects over the section 23 to the inner ends of the straps 13 and 14. However, the inclined edge 36 of the layer 34 is recessed inwardly of the extension 35 so that the area of the section 23 between the edges 26 and 28 is free of the cushioning material.
A second outer layer 37 of flexible sheet material, such as fabric reinforced polyvinylchloride, fits over the cushioning layer 34 and, hence, over the section 24 of the other outer layer 22. The layer 37 extends over part of the section 23 of the layer 22, with short projections 38 and 39 that help define the inner ends of the straps 13 and 14. Beyond the extensions 33 and 34, the edge of the layer 37 includes an arcuate recess 40 corresponding to the rounded notch 29 of the section 23. A straight edge 41 completes the end of the layer 37, inclining inwardly from the recess 40 to an arcuate edge 42, which is at the upper portion of the layer 37, as shown in FIG. 4. Therefore, when superimposed on the layer 22, the layer 37 does not cover the space between the edges 26 and 28 of the section 23, although the edge 41 extends beyond the edge 36 of the cushioning material 34.
The area of the section 23 between its edges 26 and 28, and slightly inwardly of that location, is covered by a smaller flexible sheet 44, which may be of the same material as that used for the layers 22 and 37. The sheet 44 includes a relatively long edge 45 which follows the contour of the edge 26 of the section 23. At one end, the edge 45 meets a relatively long straight edge 46 at an acute angle. A short straight edge 47 joins the longer edge 46 at an obtuse angle. The edge 47 is roughly parallel to the edge 45. An inclined edge 48 is arcuate at its end portions so as to be complementary to the edge 28 of the section 23. A short projection 49 at the end of the edges 45 and 48 fits over the inner end of the strap 12 in the completed wrist support. A narrow strip 50 of cushioning material, such as resilient foam plastic, is bonded to the undersurface of the sheet 44 along the edge 48. The sheet 44 is attached to the sheet 23 by stitches that extend along its edges 45, 47 and 48, and at the edge of the projection 49. The edge 46, however, is hemmed, but it is not attached to any other portion of the wrist support. The result is a pocket, open at the straight edge 46, which overlaps the edge 41 of the layer 37 beyond the cushioning layer 34, so that there is no cushioning material at the vicinity of the pocket.
In the assembly, stitches 52 around the periphery secure the layer 37 to the layer 22, with the cushioning material 34 and reinforcement 31 between them. Three additional rows of stitching 53, 54 and 55 extend transversely across the assembly and facilitate the bending and shaping of the wrist support. The latter row of stitching also serves to secure the reinforcing member 31 within the space above the sheet section 24. A generally L-shaped row of stitching 56 confines the edge 36 of the cushioning layer 34. Also, the VELCRO fastenings 15, 16 and 17 are sewn to the straps 12, 13 and 14, and their mating fastenings 18, 19 and 20 are stitched to the undersurface of the section 24 of the sheet 22. Ventilation holes 57 are provided through the assembly.
The pocket defined between the sheet 23 and the overlying smaller sheet member 44 receives a pad 58 of foam plastic material which possesses some resilience. This pad, which is shown enlarged in FIGS. 6 and 7, includes two generally straight edges 59 and 60, which are approximately at right angles to each other, meeting at a rounded corner 61. A relatively short, generally straight edge 62 extends at an obtuse angle from the end of the edge 59 opposite from the corner 61. The edge 62, in turn, connects at an obtuse angle to a straight edge 63, which is longer than the edge 62, but substantially shorter than either of the edge 59 or the edge 60. The outer ends of the edges 59 and 63 are interconnected by an arcuate edge 64, which is not sharply curved. The corner 61 is opposite from the curved edge 64.
The bottom surface 65 of the pad 58, as it is shown in FIGS. 6 and 7, is flat. The top surface 66, however, is slightly domed being convexly rounded.
The pad 58 is tapered in thickness. Its greatest thickness is at the corner 61, from which it tapers to the edges 63 and 64. At the latter locations, the undersurface 65 meets top surface 66. The taper is along the edge 60 and the connected edges 59 and 62, so that these edge portions have a finite thickness. This thickness tapers from the corner 61 along the edge 60 to the juncture of the edge 60 and the edge 64. Similarly, the thickness of the pad becomes progressively less along the edge 59 and the edge 62 to the point where the edge 62 meets the edge 64.
The lateral dimension of the pad 58 is less than the lateral dimension of the pocket that receives it. Hence, the pad 58 can be moved, to a limited extent, within the pocket and, therefore, can assume different positions relative to the remainder of the wrist support. The pad 58 is placed in the pocket with its domed side 66 adjacent the sheet 44. The corner 61 of the pad faces toward the edge 47 of the smaller sheet member 44 which forms the upper portion of the pocket as it appears in FIG. 1. This places the edge 59 of the pad adjacent the edge 48 of the sheet 44 and the edge 60 adjacent the edge 46 at the opening to the pocket. The edges 62 and 63 face toward the inner end of the pocket, and the arcuate edge 64 of the pad is adjacent the edge 45 of the sheet 44.
In use of the wrist support, the sheets 37 and 44 provide the undersurface which engages the hand and wrist of the user. The palm of the hand fits over the sheet 44 with the crotch of the thumb at the inner end of the strap 12, while the laterally adjacent part of the body 10 engages the inside of the wrist. This positions the edge of the wrist support body defined by the edges 26 and 45 of the sheets 23 and 44 at the proximal ends of the fingers.
The area at the seams 53, 54 and 55 provides a second portion of the body of the wrist support which is bent around the side of the hand and the wrist. The third portion of the wrist support, beyond the seam 50 and within which is the reinforcing member 31, is folded over the back of the hand and the wrist. This permits the strap 12 to extend over the back of the hand below the knuckles so that the VELCRO fastening 15 on the strap 12 can mate with the fastening 18 on the sheet member 24. The two closely spaced straps 13 and 14 extend over the back of the wrist so that the fastenings 16 and 17 can mate with the fastenings 19 and 20 on the member 24. As so worn, the rigid reinforcement 31 braces the hand and wrist to prevent backward wrist movement during bowling. The large cushioning pad 34 insures that the device is comfortable to wear and that nothing digs into the hand of the user. Also, the strip of resilient material 50 cushions the edge of the wrist support body that extends from adjacent the proximal end of the index finger over the crotch of the thumb and alongside the base of the thumb to the heel of the palm.
The pad 58, as the wrist support is worn, fills in the space at the palm of the hand where it is slightly cupped by the gripping of the bowling ball. The pad 58, therefore, occupies the space between the palm of the hand and the bowling ball and enhances the control of the ball during bowling. The contour of the pad enables it to do an effective job so that the hand assumes a natural position without interference from the pad.
The relationship between the pad and the hand can be seen in FIG. 8 in which the pad 58 is shown on the palm of the hand in the position it assumes when the wrist support is in place. The rounded edge 64 is located below the fingers approximately at the position where the hand bends at the knuckles, following the natural curvature of the hand. The taper to the edge 64 assures that there is not too much bulk from the pad adjacent the fingers. The short straight edge 63 is positioned generally parallel to the side edge 67 of the hand, and again the smooth taper to this portion of the pad 58 avoids interference to the movement of the hand at this location. The edge 62 angles down at the base of the thumb, and the edge 59 extends along where the hand bends below the thumb to the juncture with the edge 60 at the corner 61. At the latter location, the hand bends to form a V-shaped recess as the bowling ball is gripped, so the pad corresponds to the contour assumed by the hand. Thus, the pad 58 follows the natural configuration of the hand and permits normal hand movement in the act of bowling.
Another advantage arises from the fact that the pad 58 is smaller in lateral dimension than the pocket that receives it. This permits the pad to be shifted around within the pocket, so that the user of the wrist support may select the proper location of the pad to fit his anatomy. Once in this location, the pad does not tend to shift its position, because it is frictionally retained by the walls of the pocket. The opening to the pocket along the edge 46 faces the inside of the pad where the portion of the body 10 at the seams 53, 54 and 55 is bent around the edge of the hand opposite from the thumb, and is completely covered when the wrist support is worn. This facilitates retention of the pad and improves the appearance of the wrist support.
The foregoing detailed description is to be clearly understood as given by way of illustration and example only, the spirit and scope of this invention being limited solely by the appended claims.
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This invention provides a bowler's wrist support that includes a flexible body adapted to be wrapped around the hand and wrist with straps to hold it in position. A rigid reinforcement may be included to prevent bending of the wrist. The body includes a pocket within which fits a pad which is positioned at the palm of the hand when the device is worn. The pocket is larger than the pad, so that the pad may be moved around to the optimum position. The contour of the pad follows the shape of the hand so as to not interfere with movement of the hand or to cause discomfort.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2007-329243, filed Dec. 20, 2007, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor memory device.
2. Description of the Related Art
A single transistor DRAM (Dynamic Random Access Memory) using an FBC (Floating Body Cell) has so far been known as a node for storing data. In such single transistor DRAM, the FBC is formed on an SOI (Silicon On Insulator) wafer having a thin semiconductor layer formed on a support substrate with an insulating layer called a BOX (Buried Oxidation) layer formed therebetween.
The single transistor DRAM, when the transistor is of an N-channel type, stores data by utilizing the variation of the threshold value of the transistor depending on the number of holes confined and accumulated in the body of the transistor surrounded by a source region and a drain region and electrically floated.
Writing data is performed by selecting the gate voltage to operate the transistor in such a way that hole-electron pairs are formed in larger number than the holes removed.
Erasing data is performed by selecting the gate voltage to operate the transistor in such a way that holes are removed at a higher rate than that at which hole-electron pairs are formed.
However, a single transistor DRAM using FBC as a node for storing data receives a smaller amount of signals as compared to a DRAM using a capacitor as a node for storing data. Therefore, the single transistor DRAM using FBC has a problem of having a low signal margin, resulting in a low writing speed.
In this regard, a single transistor DRAM having improved reading and writing speeds has been known (refer to, for example, the specification of U.S. Pat. No. 6,861,689).
The single transistor DRAM disclosed in the specification of U.S. Pat. No. 6,861,689 includes, between the drain region and the body, a region, which aids in impact ionization and thus electron/hole pair formation during writing, that is the same conductivity type as the body but of a higher concentration than the body.
The single transistor DRAM includes, adjacent to the source region and to the body, a region, which aids in diode current during erase, that is the same conductivity type as the source region but of a lower concentration than the source region.
However, the single transistor DRAM disclosed in the specification of U.S. Pat. No. 6,861,689 has a problem of having a complicated structure and increasing the number of processes of forming a region having a concentration higher than that of the body and a region having a concentration lower than that of the source region.
As a result, there are problems of reducing the productivity and increasing the production cost of the semiconductor memory device.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is provided a semiconductor memory device comprising a cell transistor, the cell transistor including: a gate electrode film formed on a semiconductor film with a gate insulating film therebetween, the semiconductor film formed on a main surface of a support substrate with an insulating film therebetween; and a drain region and a source region formed so as to sandwich the gate electrode film in a gate length direction, and the cell transistor having a larger border length between the drain region and the gate electrode film contiguous to each other than a border length between the source region and the gate electrode film contiguous to each other.
According to another aspect of the present invention, there is provided a semiconductor memory device comprising a memory cell array including cell transistors arranged in matrix, each of the cell transistors including: a gate electrode film formed on a semiconductor film with a gate insulating film therebetween, the semiconductor film formed on a main surface of a support substrate with an insulating film therebetween; and a drain region and a source region formed so as to sandwich the gate electrode film in a gate length direction, and each of the cell transistors having a smaller border length between the drain region and the gate electrode film contiguous to each other than a border length between the source region and the gate electrode film contiguous to each other, wherein in a first direction of the matrix, each adjacent two of the cell transistors are arranged so as to share one of the drain region and the source region, and in a second direction perpendicular to the first direction, cell transistors being adjacent to each other and sandwiching an element separation region are arranged in such a way that the drain region of one cell transistor and the source region of another cell transistor face each other.
According to another aspect of the present invention, there is provided a semiconductor memory device comprising: a support substrate; an insulating film formed on the support substrate; a semiconductor film formed on the insulating film; a gate insulating film formed on the semiconductor film; a gate electrode film formed on the gate insulating film; and a source region and a drain region formed in the semiconductor film so as to sandwich the gate insulating film in a gate length direction, the source and drain regions contacting the insulating film at the bottom surface, and the semiconductor memory device storing data corresponding to the amount of charges accumulated in the semiconductor film surrounded by the insulating film, the gate insulating film, and the source and drain regions and electrically floated, wherein a border length between the source region and the gate insulating film contiguous to each other is different from a border length between the drain region and the gate insulating film to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A , 1 B and 1 C show the semiconductor memory device according to embodiment 1 of the present invention and FIG. 1A is a plan view of the semiconductor memory device, FIG. 1B is a cross-sectional view taken along line A-A of FIG. 1A when viewed in an arrow direction and FIG. 1C is a cross sectional view taken along line B-B of FIG. 1A when viewed in an arrow direction.
FIGS. 2A and 2B show operation of the semiconductor memory device according to embodiment 1 of the present invention and FIG. 2A is a plan view of the semiconductor memory device, FIG. 2B is a cross-sectional view of the semiconductor memory device.
FIGS. 3A , 3 B and 3 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 4A , 4 B and 4 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 5A , 5 B and 5 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 6A , 6 B and 6 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 7A , 7 B and 7 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 8A , 8 B and 8 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 9A , 9 B and 9 C sequentially show processes of manufacturing the semiconductor memory device according to embodiment 1 of the present invention.
FIGS. 10A , 10 B and 10 C show another semiconductor memory device according to embodiment 1 of the present invention and FIG. 10A is a plan view of the semiconductor memory device, FIG. 10B is a cross sectional view taken along line C-C of FIG. 10A when viewed in an arrow direction and FIG. 10C is a cross sectional view taken along line D-D of FIG. 10A when viewed in an arrow direction.
FIGS. 11A , 11 B and 11 C show the semiconductor memory device according to embodiment 2 of the present invention and FIG. 11A is a plan view of the semiconductor memory device, FIG. 11B is a cross-sectional view taken along line E-E of FIG. 11A when viewed in an arrow direction and FIG. 11C is a cross-sectional view taken along line F-F of FIG. 11A when viewed in an arrow direction.
FIGS. 12A and 12B show an operation of the semiconductor memory device according to embodiment 2 of the present invention and FIG. 12A is a plan view of the semiconductor memory device and FIG. 12B is a cross-sectional view of the semiconductor memory device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, the embodiments of the present invention will be described below.
Embodiment 1
The semiconductor memory device according to the present embodiment will be described with reference to FIGS. 1 and 2 . FIG. 1 shows a semiconductor memory device. FIG. 1A is a plan view of the semiconductor memory device. FIG. 1B is a cross-sectional view taken along line A-A of FIG. 1A when viewed in an arrow direction. FIG. 1C is a cross-sectional view taken along line B-B of FIG. 1A when viewed in an arrow direction. FIG. 2 shows operation of the semiconductor memory device. FIG. 2A is a plan view of the semiconductor memory device. FIG. 2B is a cross-sectional view thereof.
As shown in FIGS. 1A , 1 B and 1 C, a semiconductor memory device 10 according to the present embodiment includes a cell transistor 18 being a single transistor DRAM. The cell transistor 18 has a gate electrode film 15 formed on a semiconductor film 13 with a gate insulating film 14 therebetween, the semiconductor film 13 formed on the main surface of a support substrate 11 with an insulating film 12 therebetween, and a drain region 16 and source region 17 formed so as to sandwich the gate electrode film 15 in a gate length direction. In the cell transistor 18 , a border length Wd between the drain region 16 and the gate electrode film 15 contiguous to each other is longer than a border length Ws between the source region 17 and the gate electrode film 15 contiguous to each other.
Furthermore, the semiconductor memory device 10 includes a sidewall film 19 formed on the side surface of the gate electrode 15 , a silicide film 20 formed on the gate electrode 15 , a silicide film 21 formed on the drain region 16 and the source region 17 , a contact plug 23 connecting the source region 17 to a source line 22 via the silicide film 21 , a contact plug 25 (via) connecting the drain region 16 to a bit line 24 via the silicide film 21 , a word line (not shown) connected to the gate electrode film 15 via the silicide film 20 , and an interlayer insulating film 26 covering the cell transistor 18 .
The drain region 16 and the source region 17 of the cell transistor 18 are formed so as to extend from the surface of the semiconductor film 13 to the insulating film 12 .
The cell transistor 18 operates as a complete depletion type MOS transistor because the thickness of the semiconductor film 13 on the insulating film 12 is small.
The cell transistors 18 are arranged in matrix to construct a memory cell array.
Each adjacent two of the cell transistors 18 are arranged so as to share one of the drain region 16 and the source region 17 in a first direction X of the matrix.
The adjacent cell transistors 18 sandwiching an element separation region (STI: Shallow Trench Isolation) 27 are arranged in such a way that the drain region 16 of one cell transistor 18 and the source region 17 of another cell transistor 18 are opposite to each other in a second direction Y perpendicular to the first direction X of the matrix.
The source regions 17 , of the cell transistors 18 , obliquely adjacent to each other with respect to the first direction X are commonly connected to an angled source line 22 arranged in stripes via the contact plugs 23 .
The support substrate 11 is, for example, a p-type silicon substrate. The insulating film 12 is, for example, a silicon oxide film having a thickness of about 10 to 30 nm. The semiconductor film 13 is, for example, a p-type silicon film having a thickness of about 20 to 50 nm.
The support substrate 11 , the insulating film 12 , and semiconductor film 13 form an SIMOX (Separation by Implanted Oxygen) wafer produced by, for example, deeply implanting oxygen ions in a silicon substrate and heat-treating the silicon substrate at high temperature to form an oxide film at a certain depth from the surface of the silicon substrate and by eliminating defects caused on the surface layer.
FIGS. 2A and 2B show operation of writing data “1” in the cell transistor 18 of the semiconductor memory device 10 . FIG. 2A is a schematic plan view of a cell transistor. FIG. 2B is a cross-sectional view in the gate length direction.
As shown in FIGS. 2A and 2B , data “1” is written in the cell transistor 18 in the following manner. The source line 22 is connected to a reference potential (GND), and the bit line 24 is then connected to the first positive voltage power source. Subsequently, the second positive voltage is applied to a word line. Consequently, the cell transistor 18 a is turned on, and a channel current flows.
At this time, electrons are accelerated by an electric field generated by the first positive voltage, and collide against impurity atoms in the drain region 16 . The electrons colliding against impurity atoms cause the impurity atoms to be ionized, resulting in an impact ionization phenomenon wherein electron-hole pairs are formed.
Generated holes 40 rush from the drain region 16 into the channel region 41 of FBC. The holes 40 rushing into the channel region 41 are attracted to the insulating film 12 because the insulating film 12 is negatively charged, and the holes 40 accumulates near the interface of the insulating film 12 in the channel region 41 , resulting in the creation of hole accumulation region.
This changes the threshold of the cell transistor 18 a , thus causing the cell transistor 18 a to be in a state where data “1” is written therein.
The border length Wd between the drain region 16 and the gate electrode 15 contiguous to each other is then set large. Therefore, the amount of the impact-ionized holes 40 is increased. Thus, a large amount of holes 40 can rush from the drain region 16 into the channel region 41 .
As a result, the amount of signals is increased, and thus a signal margin is improved. Consequently, a writing speed can be improved.
Furthermore, the border length Wd between the drain region 16 and the gate electrode 15 contiguous to each other is set small. Therefore, the resistance of the source region 17 is increased. Consequently, the holes 40 rushing from the drain region 16 into the channel region 41 can be restrained from penetrating the source region 17 .
As a result, it is possible to suppress the malfunction (referred to as “1” disturb) where a data “0” state is rewritten to a data “1” state when the cell transistor 18 b is in the data “0” state, due to the holes 40 penetrating the source region 17 and entering the channel region 41 of the adjacent cell transistor 18 b
Furthermore, the holes 40 in the holes accumulation region 42 are restrained from leaking to the source region 17 by the resistance of the source region 17 . Accordingly, the data is held for a longer time period, and thus the power necessary for refresh can be reduced.
The border length Wd between the drain region 16 and the gate electrode 15 contiguous to each other and the border length Ws between the source region 17 and the gate electrode film 15 a contiguous to each other only need to be within a range of length providing a desired characteristics and are not particularly limited.
For example, the ratio of the length Wd to the length Ws is appropriately about 1.5 to 2 times in consideration of the integration degree and the obtained effect.
A method of manufacturing the semiconductor memory device 10 will then be described with reference to FIGS. 3 to 9 . In each figure, a symbol “A” after a figure number represents a plan view. A symbol “B” represents a cross-sectional view taken along line A-A of FIG. 3A when viewed in an arrow direction. A symbol “C” represents a cross-sectional view taken along line B-B of FIG. 3A when viewed in an arrow direction.
As shown in FIGS. 3A , 3 B and 3 C, an SOT wafer 50 including the semiconductor film 13 formed on the support substrate 11 with the insulating film 12 therebetween is firstly prepared.
As shown in FIGS. 4A , 4 B and 4 C, a silicon nitride film 51 is then formed on the semiconductor film 13 by, for example, a CVD (Chemical Vapor Deposition) method.
Subsequently, a resist film 52 having an opening 52 a corresponding to an insulating separation region is formed on the silicon nitride film 51 by use of a photolithography method.
As shown in FIGS. 5A , 5 B and 5 C, the silicon nitride film 51 is then anisotropic etched using the resist film 52 as a mask by use of the RIE (Reactive Ion Etching) method.
Then, after the resist film 52 is removed, the semiconductor film 13 and the insulating film 12 are sequentially anisotropic etched using the silicon nitride film 51 as a mask to form a separating groove 53 .
As shown in FIGS. 6A , 6 B and 6 C, a silicon oxide film is subsequently formed on the entire surface of the support substrate 11 by a CVD method, for example. An excessive silicon oxide film is then removed by use of the CMP (Chemical Mechanical Polishing) method. Then, a silicon oxide film is embedded in the separating groove 53 . Consequently, an STI 27 is formed.
As shown in FIGS. 7A , 7 B and 7 C, the STI 27 is then etched back by use of the RIE method so as to have the same thickness as the semiconductor film 13 . Subsequently, the silicon nitride film 51 is removed by a wet etching method.
As shown in FIGS. 8A , 8 B and 8 C, the gate electrode 15 is formed on the semiconductor film 13 with the gate insulating film 14 therebetween by a known method. The drain region 16 and the source region 17 are formed so as to sandwich the gate electrode 15 in a gate length direction.
To be specific, the gate insulating film 14 is formed on the semiconductor film 13 by use of a thermal oxidation method. A polysilicon film is formed on the gate insulating film 14 by a CVD method. Then, the gate electrode film 15 is formed by use of a photolithography method.
Then, in order to reduce a contact resistance, the silicide film 20 is formed on the gate electrode 15 , and the silicide film 21 is formed in the drain region 16 and the source region 17 . The silicide films 20 and 21 are for example a tungsten silicide (WSi) film.
Next, the side wall film 19 is formed on the side wall of the gate electrode 15 by use of the CVD or the RIE method. The drain region 16 and the source region 17 are formed in a self-aligning manner on the side wall film 19 by use of an ion implantation method
After that, an interlayer insulating film 26 a is formed on the cell transistor 18 . A contact hole (not shown) is formed in a position corresponding to the silicide film 21 of the source region 17 . A conductive material is embedded in the contact hole to form the contact plug 23 .
Likewise, a contact hole (not shown) is formed in a position corresponding to the silicide film 21 of the drain region 16 . A conductive material is embedded in the contact hole to form the contact plug 25 .
Then, as shown in FIGS. 9A , 9 B and 9 C, the source regions 17 , of the cell transistors 18 , obliquely adjacent to each other with respect to the first direction X are commonly connected to the angled source line 22 arranged in stripes via the contact plugs 23 . A connection electrode 30 having a cross-sectional area larger than that of the contact plug 25 is also formed on the contact plug 25 exposed from the interlayer insulating film 26 a in parallel to the formation of the source line 22 .
Next, an interlayer insulating film (not shown) is formed on the cell transistor 18 including the source line 22 while a contact hole (not shown) is formed in a position corresponding to the connection electrode 30 of the interlayer insulating film. A conductive material is embedded in the contact hole to form the contact plug 31 . The drain regions 16 of cell transistors 18 adjacent to each other in the first direction X are connected to the bit line 24 (not shown) via the contact plugs 25 and 31 and the connection electrode 30 .
The above process provides a semiconductor memory device 10 including a memory cell array in which: the cell transistors 18 shown in FIG. 1 are arranged in matrix, the cell transistors adjacent to each other are arranged so as to share the drain region 16 and the source region 17 in the first direction X of the matrix, the adjacent cell transistors 18 sandwiching the STI 27 are arranged in such a way that the drain region 16 of one cell transistor 18 and the source region 17 of another cell transistor 18 are opposite to each other in a second direction Y perpendicular to the first direction X of the matrix.
As described above, the semiconductor memory device 10 according to the present embodiment includes the cell transistor 18 , formed on the semiconductor film 13 formed on the support substrate 11 with the insulating film 12 therebetween, having a larger border length Wd between the drain region 16 and the gate electrode film contiguous to each other than a border length Ws between the source region 17 and the gate electrode film 15 contiguous to each other.
Furthermore, the cell transistors 18 are arranged in matrix in such a way that the drain region 16 and the source region 17 of the adjacent cell transistors 18 sandwiching the STI 27 in the second direction Y are opposite to each other. The source regions 17 , of the cell transistors 18 , obliquely adjacent to each other with respect to the first direction X is commonly connected to the angled source line 22 arranged in stripes.
As a result, an impactization coefficient is increased and the amount of signals is increased. A signal margin is therefore improved. Consequently, a writing speed can be improved.
Furthermore, the resistance of the source region 17 is increased. Accordingly, the holes 40 coming from the channel region 41 into the source region 17 cannot enter the channel region 41 of the adjacent cell transistor 18 b . Consequently, “1” disturb can be suppressed.
Even if the border length Wd between the drain region 16 and the gate electrode film 15 contiguous to each other and the border length Ws between the source region 17 and the gate electrode film 15 contiguous to each other are different from each other, an integration degree can be increased. Therefore, there is an advantage that the chip size of a semiconductor memory device 10 can be reduced.
Modification can be made only by changing patterns of the drain region 16 , source region 17 and the source line 22 . Hence, a small number of processes are necessary to manufacture the semiconductor memory device 10 having a single transistor DRAM.
Therefore, the semiconductor memory device 10 having a high performance single transistor DRAM can be obtained.
Here, the case where the source line 22 is of angled stripe-type is described, while a zigzag source line may be used.
FIG. 10 shows another semiconductor memory device according to the present embodiment. FIG. 10A is a plan view of the semiconductor memory device. FIG. 10B is a cross-sectional view taken along line C-C of FIG. 10A when viewed in an arrow direction. FIG. 10C is a cross-sectional view taken along line D-D of FIG. 10A .
That is to say, as shown in FIGS. 10A , 10 B and 10 C, in a semiconductor memory device 60 , the source regions 17 of the adjacent cell transistors 18 sandwiching the STI 27 in the second direction Y are commonly connected via the contact plugs 23 to a source line 61 extending zigzag along the second direction Y.
In the present embodiment, the case where the support substrate 11 , the insulating film 12 and the semiconductor film 13 form an SIMOX wafer is described, while a bonded substrate produced by bonding two silicon substrates with an oxide film in between and grinding one of the two substrates into a thin film may be used.
The case where the cell transistor 18 is of N-channel type is described, while the same is true for the case where a cell transistor is of P-channel type. In this case, the conductivity types of a semiconductor film, a drain region and source region are inverted, and electrons are accumulated in a channel region.
A case where the support substrate 11 is a p-type silicon substrate 11 is described, while a silicon germanium (SiGe) substrate, a germanium (Ge) substrate and other compound semiconductor substrate may be used.
The case where the gate insulating film 14 is a silicon oxide film is also described, while a film having a dielectric constant larger than that of the silicon oxide film, such as a silicon oxynitride film (SiON), a hafnium oxide film (HfO 2 ), a hafnium silicon oxide film (HfSiO), a hafnium silicon oxynitride film (HfSiON), a hafnium aluminium oxide film (HfAlO), or a hafnium aluminium oxynitride film (HfAlON), may be used.
For example, a hafnium silicon oxynitride film (HfSiON) can be formed by forming a hafnium silicon oxide film (HfSiO 4 ) on the p-type silicon substrate 11 by use of a MOCVD method and then heat-treating the film in an ammonia (NH3) atmosphere or a nitrogen plasma atmosphere.
Embodiment 2
A semiconductor memory device according to an embodiment 2 of the present invention will be described with reference to FIGS. 11 and 12 . FIG. 11 shows a semiconductor memory device. FIG. 11A is a plan view of the semiconductor memory device. FIG. 11B is a cross-sectional view taken along line E-E of FIG. 11A when viewed in an arrow direction. FIG. 11C is a cross-sectional view taken along line F-F of FIG. 11A when viewed in an arrow direction. FIG. 12 shows the operation of a semiconductor memory device. FIG. 12A is a plan view of the semiconductor memory device. FIG. 12B is a cross-sectional view thereof.
In the present embodiment, the same components as in the above embodiment 1 are given the same symbols. The descriptions of the same components are omitted, while different components will be described.
The difference of the present embodiment from embodiment 1 lies in the fact that a border length between the drain region and the gate electrode film contiguous to each other is smaller than a border length between the source region and the gate electrode film contiguous to each other. That is, in embodiment 1, it is an object to provide a semiconductor memory device suitable to suppress “1” disturb by making larger the border length between the drain region and the gate electrode film contiguous to each other than the border length between the source region and the gate electrode film contiguous to each other. With semiconductor memory devices, suppressing the malfunction (referred to as “0” disturb) where a data “1” state is rewritten to a data “0” state is sometimes required rather than suppressing “1” disturb. As described above, an object of embodiment 2 to be described below is to provide a semiconductor memory device suitable for suppressing “0” disturb by making smaller a border length between the drain region and the gate electrode film contiguous to each other than a border length between the source region and the gate electrode film contiguous to each other.
That is, as shown in FIGS. 11A , 11 B and 11 C, a semiconductor memory device 70 according to the present embodiment includes a cell transistor 73 . The cell transistor 73 has a gate electrode film 15 formed on a semiconductor film 13 with a gate insulating film 14 therebetween, the semiconductor film 13 formed on the main surface of a support substrate 11 with an insulating film 12 therebetween, and a drain region 71 and source region 72 formed so as to sandwich the gate electrode film 15 in a gate length direction. In the cell transistor 73 , the border length Wd between the drain region 71 and the gate electrode film 15 contiguous to each other is smaller than the border length Ws between the source region 72 and the gate electrode film 15 contiguous to each other.
The cell transistors 73 are arranged in matrix. The cell transistors 73 adjacent to each other are arranged so as to share the drain region 71 and the source region 72 in the first direction X of the matrix. The adjacent cell transistors 73 sandwiching the STI 27 are arranged in the second direction Y perpendicular to the first direction X in such a way that the drain region 71 of one cell transistor 73 and the source region 72 of another cell transistor 73 are opposite to each other.
FIG. 12 shows operation where data “0” is written in the cell transistor 73 a , having data “1” already written, of the semiconductor memory device 70 .
As shown in FIGS. 12A and 12B , when writing data “0” in the cell transistor 73 a , the source line 22 is connected to a reference potential (GND), the bit line 24 is connected to a negative potential and a positive voltage is applied to a word line.
At this time, holes accumulated in the holes accumulation region 42 near the interface of the insulating film 12 rush from the channel region 41 into the drain region 71 . Accordingly, the holes accumulation region 42 disappears.
This changes the threshold of the cell transistor 73 a , thus causing the cell transistor 73 a to be in a state where data “0” is written therein.
Then, the border length Wd between the drain region 71 and the gate electrode film 15 contiguous to each other is set small. Accordingly, the side wall capacity C of the drain region 71 is reduced. Consequently, a writing speed can be improved.
Furthermore, the resistance of the drain region 71 is increased, and hence, holes 40 rushing from the channel region 41 into the drain region 71 can be restrained from penetrating the drain region 71 and entering the channel region 41 of the cell transistor 73 b.
Consequently, when the adjacent cell transistors 73 b are in a data “0” state, “0” disturb can be suppressed.
The border length Wd between the drain region 71 and the gate electrode 15 contiguous to each other and the border length Ws between the source region 72 and the gate electrode film 15 contiguous to each other only need to be within a range of length providing a desired characteristics and are not particularly limited.
For example, the ratio of the length Wd to the length Ws is appropriately about 1.5 to 2 times in consideration of the integration degree and the obtained effect.
As described above, the semiconductor memory device 70 according to the present embodiment includes the cell transistor 73 in which the border length Wd between the drain region 71 and the gate electrode film 15 contiguous to each other is smaller than the border length Ws between the source region 72 and the gate electrode film 15 contiguous to each other.
As a result, the side wall capacity of the drain region 71 is reduced. Accordingly, a writing speed can be improved. Furthermore, the resistance of the drain region 71 is increased. Consequently, “0” disturb can be suppressed.
Therefore, the semiconductor memory device 10 having a high performance single transistor DRAM can be obtained.
Here, the case where the source line is the angled source line 22 arranged in stripes is described, while a zigzag source line 61 may be used.
Having described the embodiments of the invention referring to the accompanying drawings, it should be understood that the present invention is not limited to those precise embodiments and various changes and modifications thereof could be made by one skilled in the art without departing from the spirit or scope of the invention as defined in the appended claims.
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A semiconductor memory device comprising: a support substrate; an insulating film formed on the support substrate; a semiconductor film formed on the insulating film; a gate insulating film formed on the semiconductor film; a gate electrode film formed on the gate insulating film; and a source region and a drain region formed in the semiconductor film so as to sandwich the gate insulating film in a gate length direction, the source and drain regions contacting the insulating film at the bottom surface, and the semiconductor memory device storing data corresponding to the amount of charges accumulated in the semiconductor film surrounded by the insulating film, the gate insulating film, and the source and drain regions and electrically floated, wherein a border length between the source region and the gate insulating film contiguous to each other is different from a border length between the drain region and the gate insulating film to each other.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process of preparing expandable styrene polymer of controlled particle size.
2. Description of the Background
In the preparation of expandable polystyrene by aqueous suspension polymerization, a relatively broad particle size spectrum is obtained. About 90% of the particles are in the range between 0.5 and 2.0 mm, with a maximum between 0.7 and 1.0 mm.
Different particle fractions have different applications. Thus, fine material is employed in the packaging sector, while coarse material is used primarily in the building sector in the manufacture of insulation, footstep insulation and the like products.
Market requirements are constantly changing. It is therefore desirable to control the particle size distribution of expandable polystyrene during polymerization without endangering suspension stability. The only possibility known to date for control is the qualitative and quantitative variation of the suspending agent composition as described in German Offenlegungsschrift 331,569, German Offenlegungsschrift 331,570, JA 945 248 and German Offenlegungsschrift 3,728,044. Influencing the particle size distribution in a controlled manner during suspension polymerization of styrene is not possible in these processes; the amount of suspending agent must be redetermined for each subsequent batch. Establishing coarse particle sizes in a controlled manner leads again and again, in the critical polymerization range of 120 to 180 min, to instabilities, which are counteracted by premature restabilization. However, this generally results in increased internal water contents and a very broad particle size spectrum with the particulate material containing a large amount of fine material.
The reason for the occurrence of instabilities and poor reproducibility are likely attributable, inter alia, to the characteristics of the particle size development during the suspension polymerization. The initially very fine particles grow only insignificantly in the first 120 minutes of polymerization time. Thereafter, a drastic growth in particle size occurs within a short time of 120 to 180 min until the desired final particle size is reached at the settling point. At the settling point, the styrene conversion is about 70%. The viscosity of the particles at this point in time is so high that virtually no coalescence occurs and formation of further particles by subdivision take place. In other words, the particles retain their identity. Immediately before the settling point, the suspension is relatively unstable and the tendency to cream increases with decreasing amount of suspending agent. Furthermore, this course of particle size development results in poor reproducibility of the batches.
An alternative is seed polymerization. A completely polymerized particle of a defined size is taken and a certain amount of organic phase is metered and disclosed in European Patent 102,655; U.S. Pat. No. 1,54,184; French Patent 2,238,717; French Patent 2,238,718; German Offenlegungsschrift 2,338,133. This process makes it possible to influence the particle size during polymerization by means of the amount of organic phase metered in. However, seed polymerization requires the presence of a seed particle free of coating agent. This preparation necessitates a separate polymerization process and hence reduces the space/time yield. Homogeneous distribution of the subsequently delivered organic phase requires a very slow metering rate. Otherwise, undesirable formation of further particles, particularly as fine material occurs. A need therefore continues to exist for a styrene suspension polymerization process which provides greater control of polymer particle size distribution. cl SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a process for controlling the particle size during suspension polymerization which can be conducted in a stable manner in the critical range and by means of which a coarse final particle size can be achieved.
Briefly, this object and other objects of the present invention as hereinafter will become more readily apparent can be attained by a process for preparing expandable polystyrene of controlled particle size by polymerizing styrene and optionally polymerizable comonomers in a stirred aqueous suspension in the presence of monomer-soluble free radical initiator and dispersant to the extent that at least 70%, based on the total monomer, of the monomers are polymerized in the aqueous suspension initially to a conversion of at least 70% by weight, and then adding the remaining monomer, initiator and optional copolymerizable monomer and additives to the polymerization medium over one to three hours.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has now been surprisingly found that by the process of the invention the particle size distribution of the polymer particles is no longer controlled by the amount of suspending agent. Instead, a fine and hence stable particle size is established, at a high level of suspending agent by the settling point of the particles at 70% styrene conversion at about 180 min reaction time. The suspensions formulation is identical to the standard formulation for styrene polymerization normally employed. The particle development takes place relatively slowly up to the settling point and there is no dramatic particle growth. If the mixture were allowed to continue polymerizing as normally done with standard formulations, an undesirable very fine polymer particle size would be obtained. The desired final particle size is established by subsequent metering in of further organic phases. The in-flowing organic phase diffuses into the stable polymer particles already present. This leads to continuous increase in particle size. Formation of further particles is undesirable because they lead to an increase in the fine particle fraction of the particulate product. The metering rate should therefore be chosen so that, as far as possible, no free styrene droplets are present in the suspension. A further criterion determining rate of metering in of organic phase is the settling point of the particles. The residual styrene content should always be ≦30% by weight. In this way, the particles retain their identity and the suspension cannot become unstable.
Upon the conclusion of the metering of organic phase, the suspension polymerization is continued in the conventional manner. The normal polymerization cycle is interrupted virtually only when organic phase is metered in. The associated increase in the cycle time is, however, largely compensated by the increase in the ratio of organic phase to aqueous phase and hence in the yield.
U.S. Pat. No. 4,137,388, JP 62 053 306 and JP 5393/6 disclose the subsequent metering in of organic phase. However, this measure has served only to improve the processing properties, i.e., the effect on the molecular weight distribution or to improve the optical properties of the product. In contrast to the present process, in the publications cited above, metering in is not carried out at a certain metering rate which keeps the residual styrene content constant. This makes control of particle size impossible.
In the process according to the present invention, 70 to 90%, preferably 80 to 90%, of the amount of styrene to be polymerized and optionally comonomers, in which one or more water-insoluble initiators are dissolved, are dispersed in about the same amount of water while stirring. The amount and type of polymerization initiators are matched with the polymerization temperature in such a way that the final conversion is as complete as possible and the molecular weight of the polymer has the desired values. For stabilization of the dispersed particles, organic or inorganic dispersants are added to the reaction mixture. This mixture is heated to the polymerization temperature at about 90° C. and then styrene is polymerized to a conversion level of 70% in about 180 min reaction time, generally in the range from 120 to 210 minutes. Thereafter, the residual styrene which is about 10 to 30% of the total amount of styrene employed, which contains initiator and dispersant, is metered into the reaction mixture over the course of 1 to 3 hours, preferably 1 to 2 hours. The metering rate should be chosen so that the residual monomer content is always less than or equal to 30% by weight.
After subsequent metering of the organic phase, the mixture is polymerized to completion.
Metering in of a 20% strength by weight organic phase over the course of 2 hours after a reaction time of 180 min has proved optimum with regard to the target objective of an increase in particle size.
For the preparation of the expandable styrene polymers the monomer employed is styrene or a monomer mixture containing at least 50% by weight of styrene. Examples of suitable comonomers include α-methylstyrene, styrenes halogenated in the nucleus, acrylonitrile, esters of acrylic and methacrylic acid with alcohols having 1 to 8 carbon atoms and N-vinyl compounds such as N-vinylcarbazole.
The suspension polymerization is carried out at temperatures of 80° to 130° C. It is initiated in a conventional manner using one or more free radical-forming substances, examples being tert-butyl benzoate, tert-butyl peroctoate, di-tert-butyl peroxide, dibenzoyl peroxide and mixtures thereof. Organic protective colloids such as polyvinyl alcohol, polyvinylpyrrolidone, polyvinylpyrrolidone copolymers and hydroxyalkylcelluloses, or mineral suspending agents, such as finely divided tricalcium phosphate and barium phosphate, or mixtures of organic protective colloids and mineral suspending agents may be used in a known manner as suspension stabilizers.
The blowing agent for the polymer beads can be added during or after polymerization, depending on the process. However, addition of blowing agent is not possible before the end of metering in of organic phase.
The blowing agents used are the known low-boiling, merely swelling, liquid hydrocarbons such as pentane or hexane, cycloaliphatic hydrocarbons such as cyclohexane, and halohydrocarbons such as dichlorodifluoromethane or 1,2,2-trifluoro-1,1,2-trichloroethane, and mixtures of these compounds. The amount of blowing agent employed ranges from 3 15% by weight, preferably between 5 and 8% by weight, based on the styrene polymer.
The expandable styrene polymers may contain the conventional flameproofing agents such as organic halogen compounds, in particular bromine compounds. These include particularly completely or partially brominated oligomers of butadiene or of isoprene having a mean degree of polymerization of 2 to 20, for example 1,2,5,6- tetrabromocyclooctane, 1,2,5,6,9,10-hexabromocyclodecane or brominated polybutadiene having a degree of polymerization of, for example, 3 to 15. The organic halogen compounds are present in the expandable styrene polymer in amounts of 0.4 to 3% by weight. In addition to the flame-retardant halogen compounds, it is possible to use the known synergistic agents in conventional amounts, preferably organic peroxides, in particular those having a half life of at least two hours at 373°K. If desired, the halogen compounds can also be used in a known manner in amounts of 0.05 to 1% by weight in order to improve the minimum residence time.
The expandable styrene polymers may furthermore contain additives, such as dyes, fillers and stabilizers. After their preparation, they are present in bead form and have a particle diameter of between 0.5 and 2.0 mm.
Styrene polymers are further expanded by conventional methods, in the pre-expanded state, by heating in molds which are not gas-tight, and are sintered to give foamed articles which correspond in their dimensions to the inner cavity of the molds used.
Having now generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and ar not intended to be limiting unless otherwise specified.
EXAMPLE 1
50 kg of water together with 76.4 g of hydroxyethylcellulose, 191 g of tricalcium phosphate and 5.1 g of EDTA as a suspending medium are introduced into a 150 1 reactor. 50 kg of styrene which contains 203.6 g of benzoyl peroxide and 127.3 g of tert-butyl perbenzoate are added. The mixture is heated to 90° C. while stirring and is kept at this temperature for 3 hours. Thereafter, a further 10.2 kg of styrene which contains 40.8 g of benzoyl peroxide and 25.5 g of tert-butyl perbenzoate are metered in within 2 hours. After the end of the metering in of organic phase, stabilization is subsequently effected with 25.5 g of polyvinyl alcohol.
A total of 3.7 kg of pentane is then added over the course of 1 hour while simultaneously heating the mixture to 110° C. After a polymerization time of a further 5 hours, the suspension is discharged and the polymer is filtered off, dried and sieved.
______________________________________Yield: 65.0 kgK value: 56.8Monomeric styrene: 0.12% by weightBlowing agent content: 6.68% by weightWater content: 0.08% by weightParticle size distribution:>2.5 >2.0 >1.6 >1.25 >1.0 >0.9 >0.8 >0.63 >0.5mm mm mm mm mm mm mm mm mm3.1% 13.0% 22.1% 36.8% 11.0% 6.9% 2.2% 3.6% 0.8%Fine material: 0.5%______________________________________
EXAMPLE 2
The reaction conditions and reaction temperature are as described in Example 1, except that 0.1% of polyvinyl alcohol is used instead of the hydroxyethylcellulose and the tricalcium phosphate.
______________________________________Yield: 65.0 kgK value: 56.3Monomeric styrene: 0.10% by weightBlowing agent content: 6.42% by weightWater content: 0.24% by weightParticle size distribution:>2.5 >2.0 >1.6 >1.25 >1.0 >0.9 >0.8 >0.63 >0.5mm mm mm mm mm mm mm mm mm5.1% 13.5% 20.2% 35.6% 14.8% 9.6% 0.6% 0.4% 0.4%Fine material: 0.2%______________________________________
COMPARATIVE EXAMPLE 1
The reaction conditions and the reaction temperatures are as described in Example 1, except that there is no subsequent metering of some of the organic phase.
______________________________________Yield: 55 kgK value: 54.0Monomeric styrene: 0.29% by weightBlowing agent content: 6.16% by weightWater content: 0.11% by weightParticle size distribution:>2.5 >2.0 >1.6 >1.25 >1.0 >0.9 >0.8 >0.63 >0.5mm mm mm mm mm mm mm mm mm2.6% 3.2% 3.2% 8.7% 11.3% 17.8% 13.5% 28.4% 8.4%Fine material: 2.9%______________________________________
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit or scope of the invention as set forth herein.
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Expandable styrene polymer of controlled particle size is prepared by polymerizing styrene and optionally polymerizable comonomers in a stirred aqueous suspension in the presence of monomer-soluble free radical initiator and dispersant to the extent that at least 70%, based on the total monomer, of the monomers are polymerized in the aqueous suspension initially to a conversion of at least 70% by weight; and then adding the remaining monomer, initiator and optional copolymerizable monomer and additives to the polymerization medium over one to three hours.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. patent application Ser. No. 13/531,880 filed Jun. 6, 2012, which is a Continuation of U.S. patent application Ser. No 13/315,465 filed Dec. 9, 2011, which is a Continuation of U.S. patent application Ser. No. 13/102,000 filed May 5, 2011, which is a Continuation of U.S. patent application Ser. No. 11/277,339 filed Mar. 23, 2006, now U.S. Pat. No. 8,172,683, issued on May 8, 2012, which is a Continuation of U.S. patent application Ser. No. 10/751,006 filed Dec. 31, 2003, now U.S. Pat. No. 7,762,885, issued Jul. 27, 2010, which is a Continuation of U.S. patent application Ser. No. 09/433,523 filed Nov. 3, 1999, now U.S. Pat. No. 6,758,755, issued Jul. 6, 2004, which is a Continuation-In-Part of U.S. application Ser. No. 09/040,654, filed Mar. 17, 1998, now U.S. Pat. No. 6,007,426, issued Dec. 28, 1999, which is a Continuation of U.S. patent application Ser. No. 08/746,755, filed on Nov. 14, 1996, now U.S. Pat. No. 5,816,918, issued Oct. 6, 1998, which are all incorporated herein by reference in their entirety.
FIELD
[0002] This invention generally relates to a network gaming system and more particularly pertains to a method and system for storing and updating the account information for a plurality of users on a database server.
BACKGROUND
[0003] Traditional gaming environments have conventionally been restricted to bars, arcades, homes, and other public and private establishments. Outside such gaming environments, players have been commonly restricted to playing board games, local computer games, TV-supported video games, etc. However, with the widespread use of standardized large-scale wide area networks such as the Internet and World Wide Web in recent years, players of video and computer games at home are offered an environment to access numerous games and compete with each other. A player can connect a home computer, video game console, set top box, or other device to the Internet using telephone lines, cable TV lines, or other connections to the home. The player can thus play games offered to the player from a remote server or other source. The player can also compete or otherwise interact in a game with hundreds or even thousands of other players who are also connected to the Internet.
[0004] However, although a wide array of options are available for home game players, players typically cannot play games from home to receive prizes. Players may often desire to receive a prize after playing a game or participating in a tournament, but no standardized prize redemption system is provided to home players. Any administrator of such a prize redemption system faces problems when attempting to organize ticket winnings and offer prizes at ticket costs adjusted for a desired profitability.
[0005] One problem with the network games of the prior art is that maintaining a redemption system can be very involving for an entity which maintains a web site, to the point of being burdensome. For example, operators must maintain a system of prize tracking and delivery for a large pool of users. Requiring even greater maintenance is the setting and adjustment of prize credit costs or prices of the prizes. The operator must determine how many prize credits are awarded, on average, by each game on the network and then determine the price of each prize in terms of prize credits and in view of a desired profitability level.
[0006] There is thus a need for an effective system of enabling prize redemption with games which are distributed, executed, and managed over a wide area network.
SUMMARY
[0007] This summary is provided to describe certain aspects of embodiments of the invention. It is not intended to show the essential features of the invention nor is it intended to limit the scope of the claims.
[0008] The invention includes a method for providing a game interface for a multi-player game accessible over a wide area network by a plurality of users. This method comprises transmitting an identification of a user over a wide area network to a database server; retrieving a number of units associated with the user from the database server; executing a game on a display; indicating on the display the number of units associated with the user; updating on the display the number of units granted to the user based on a game activity of the user; depicting a link on the display for allowing use of the units by the user; and deducting from the number of units the specified member of units responsive to the use of the units by the user.
[0009] The invention includes a user interface through which a user at a client interacts in a multi-player game accessible over a wide area network by a plurality of users. This user interface comprises a display with a log-in area to facilitate transmitting an identification of a user over a wide area network to a database server wherein responsive to a log-in by the user the user interface causes a number of units associated with the user to be retrieved from the database server; a game window on the display for displaying the multi-player game; a first status area on the display indicating the number of units associated with the user wherein the first status area updates to display the number of units granted to the user based on a game activity of the user; a link on the display for allowing use of the units by the user and wherein the first status area is updated by deducting from the number of units the specified number of units responsive to the use of the units by the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other advantages of the present invention will become apparent to those skilled in the art after reading the following descriptions and studying the various figures of the drawings.
[0011] FIG. 1 is a schematic diagram of a wide area network which interconnects a plurality of game apparatuses for facilitating a prize redemption system in accordance with one embodiment of the present invention;
[0012] FIG. 2 is a block diagram of various components used in one of the game apparatuses of FIG. 1 ;
[0013] FIG. 3 is a general functional diagram of the prize redemption system of FIG. 1 in accordance with one embodiment of the present invention;
[0014] FIG. 4 is a functional diagram illustrating various interfaces accessed during the course of use of the present invention in addition to underlying supporting components of such interfaces;
[0015] FIG. 4A is a functional diagram illustrating the operation of the prize database server of the present invention;
[0016] FIG. 5 is a schematic diagram illustrating various software components of one of the game apparatuses of the present invention and further multiple servers associated therewith;
[0017] FIG. 6 is a flowchart illustrating various operations associated with the present invention;
[0018] FIG. 7 illustrates the process of the present invention by which the player registration operation 602 of FIG. 6 is executed;
[0019] FIG. 8 illustrates the process of the present invention by which the purchase game credits operation 604 of FIG. 6 is executed;
[0020] FIG. 9 illustrates the process of the present invention by which the play games operation 608 of FIG. 6 is executed;
[0021] FIG. 10 illustrates the process of the present invention by which the error handling operation 610 of FIG. 6 is executed;
[0022] FIG. 11 illustrates the process of the present invention by which the awarding prizes operation 612 of FIG. 6 is executed;
[0023] FIG. 11A illustrates a method of the present invention for determining payment for participating in a network gaming tournament;
[0024] FIG. 12 illustrates the process of the present invention by which the awarding prizes operation 614 of FIG. 6 is executed;
[0025] FIG. 13 is an illustration of a graphical user interface of the present invention; and
[0026] FIG. 14 is a flowchart illustrating the acts involved with an advertisement feedback aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 1 is a schematic diagram of the present invention which is adapted for allowing redemption of prizes won while playing games on a plurality of networked game apparatuses. As shown in FIG. 1 , a wide area network 100 , i.e. the Internet, interconnects a plurality of game apparatuses 102 for facilitating a prize redemption system. Such game apparatuses 102 are each adapted for displaying a user interface which in turn allows a user to play a plurality of games. Also included is a prize database server 104 , adapted for connecting to the game apparatuses 102 via the wide area network 100 for communication via a protocol such as TCP/IP or IPX. As an option, the prize database server 104 may also function at least in part as a game apparatus 102 .
[0028] In use, a user identification code is received by the prize database server 104 from the game apparatuses 102 that corresponds to the user. After play of a game is complete, an indication of an outcome of the game is also received by the prize database server 104 . The prize database server 104 also tracks a number of prize credits awarded the user based on the outcome of the present game and/or previous games. Further, the prize database server 104 functions to allow redemption of the prize credits for a prize.
[0029] With continuing reference to FIG. 1 , at least some of the game apparatuses 102 include dedicated game units 106 which are commonly used in combination with televisions or are portable in nature for the sole purpose of playing various games. Such dedicated game units 106 may include a NINTENDO, SEGA or SONY game unit or a game implemented on a personal digital assistant such as a PALM PILOT.
[0030] In one embodiment, the dedicated game units 106 each include a modem to connect with the wide area network for communication purposes. In the alternative, the dedicated game units may each include a removable cartridge 108 which may or may not contain one or more specific games, and also allow storage of information, i.e. an identification code and an indication of an outcome of the game. Such cartridges 108 may further be adapted for being releasably received in a specially-adapted port such as a DEXDRIVE connected to a computer which is in turn connectable with the wide area network 100 for communication purposes. In the case of a personal digital assistant such as a PALM PILOT, a HOTSYNC module may be used to communicate information with the computer.
[0031] In another embodiment, at least some of the game apparatuses 102 include desktop or laptop computers 110 each having a modem to connect with the wide area network 100 for communication purposes. In still yet another embodiment, at least some of the game apparatuses 102 include servers 112 for allowing communication with a plurality of computers 110 via the wide area network 100 .
[0032] As an option, some of the game apparatuses may include stand-alone units capable of printing prize credits in the form of tickets, coupons, magnetically readable cards, cards with barcodes, or any other type of “smart” card which may be redeemable at the site of the game apparatus. More information on such game apparatuses may be had by reference to U.S. Pat. No. 5,292,127, by Kelly et al. which is hereby incorporated by reference herein in its entirety. It should be noted that the various aforementioned game apparatuses may be used in any combination.
[0033] FIG. 2 is a schematic diagram of one of the aforementioned computers 110 . As shown, input devices 200 may be used by a player or user to provide input to the game unit to influence game events during a game process and to achieve one or more predetermined goals or tasks for scoring points and winning prizes or other types of awards. The input devices 200 can also be used to select prizes within the redemption system of the present invention. Alternatively, separate input controls can be used for the prize functions of the game unit.
[0034] Player input typically includes game commands provided by controlling devices such as buttons, keyboard, dials, joystick controls, touch screen, track ball, mouse, gun device, steering wheel, foot pedals, speech input through a microphone, or any other input used in playing a game and providing selections. For example, the player can move a joystick to control a graphical object displayed on a video screen. Each type of user input can provide a particular game command to the computer, and the computer interprets the commands and influences game states and game events in the game process accordingly.
[0035] With continuing reference to FIG. 2 , the computer 110 receives signals and commands from the player input devices 200 and translates/interprets those signals and commands so that the game process can be updated. The computer 110 preferably includes a microprocessor 202 , random access memory (RAM) 204 , read-only memory (ROM) 206 , and input/output (I/O) 210 . Microprocessor 202 can be any processor or controller with features sufficient to control the game apparatus. For example, a suitable microprocessor 202 for many mechanical game applications is the Intel 8031 8 -bit microprocessor, which includes eight data lines and sixteen address lines. Alternatively, more powerful microprocessors, such as Pentium-class/Power PC class microprocessors, or specialized graphical or digital signal processors, can be used. Microprocessor 202 executes a process, described by software instructions stored in memory, which recognizes a game command from player input devices 200 . The software instructions can be stored in a “computer readable medium”, which, by way of example, includes memory such as RAM and ROM, magnetic disks, magnetic tape, optically readable media such as CD ROMs, semiconductor memory such as memory chips or PCMCIA cards, etc. In each case, the medium may take the form of a portable item such as a small disk, diskette, cassette, memory module, etc., or it may take the form of a relatively larger or immobile item such as a hard disk drive.
[0036] Microprocessor 202 is coupled to RAM 204 by a data (D)/address (A)/control (C) bus 208 to permit the use of the RAM 204 for scratch-pad memory and other functions during a game process. ROM 306 is preferably an erasable, programmable read-only memory (EPROM) that contains the start-up instructions and operating system for the microprocessor 202 . Methods for coupling RAM 204 and ROM 206 to the microprocessor 202 by bus 208 including data, address, and control lines are well-known to those skilled in the art.
[0037] I/O 210 includes buffers, drivers, ports, registers, and other analog and/or digital circuitry to interface inputs and outputs with the bus 208 . Game output devices 212 and input devices 200 can be coupled to I/O 210 . For example, a display screen can be coupled to I/O 210 so that the microprocessor or another video processor can control the display of images on the display screen, as is well known to those skilled in the art.
[0038] The computer can include plug-in interface cards such as video cards, 3 -D graphics cards, sound cards, controller cards, etc. Standard peripherals can be coupled to the I/O 210 as input devices 200 and output devices 212 , such as a CD-ROM drive, storage device (floppy disk drive, hard disk drive, etc.), PCMCIA card, printer, stylus and tablet, microphone for voice recognition, camera, or communication device.
[0039] FIG. 3 is a functional diagram illustrating an overview of the interaction among various users, computers, servers, business entities, etc. during the course of use of the present invention. As shown, in one embodiment, a user utilizes a game apparatus, i.e. computer, for directly or indirectly accessing a server which provides a plurality of games in operation 300 . In one embodiment, the user may access the game server via any particular related or unrelated hosting web site. Next, in operation 302 , the user logs on, purchases credits (optional), and plays a game provided by the server. During the course of the game, any prize credits earned are deposited in an account of the user, as indicated in operation 304 .
[0040] With continuing reference to FIG. 3 , the user is notified of any prize credits that may have resulted from the play of the game, as indicated in operation 306 . Thereafter, in operation 308 , the user may again use the game apparatus to access the prize database server which may or may not be separate from the game server. An account of the user is then checked to verify a current number of prize credits available. See operation 310 . Then, in operation 312 , the game database orders any prizes selected by the user from a prize vendor. The prize is then delivered to the user in operation 314 . In the case where a prize credit that represents a specific prize is awarded in operation 316 , the prize database server does not require any selection prior to ordering in operation 312 .
[0041] Any monetary gain resulting from the method of the present invention may be distributed in various ways. For example, an owner of a hosting web site may be compensated for providing access to the games via the hosting web site. Note operation 318 . Further, a developer of the games may be compensated in operation 320 . The prize vendor may also receive funds for cost of prizes, shipping, handling, etc. in operation 322 .
[0042] FIG. 4 illustrates a functional diagram illustrating some of the user interfaces, supporting software, and hardware associated with an alteration of the flowchart in FIG. 3 . In terms of hardware, a server 400 is shown to include software having a game settings cartridge 402 , an advertising cartridge 404 , and a prize redemption cartridge 406 . It should be understood that any of the foregoing cartridges may be executed from separate servers.
[0043] In use, a user interface 405 , i.e. web page, of a hosting web site allows access to a game interface 407 via the game settings cartridge 402 of the server 400 . In contrast to operation 302 of the method of FIG. 3 , the present alternate method does not require the user to log on or purchase credits. Instead, funding is afforded by advertising that is provided during the course of the game by way of the advertising cartridge 404 . Upon winning a number of prize credits, the user is then forwarded to a prize redemption interface 409 governed by the prize redemption cartridge 406 .
[0044] When access is gained to the prize redemption interface 409 , the user is required to log on via a log-on interface 411 , unless, of course, the user is already logged on. Thereafter, a confirmation interface 410 is displayed for indicating that the prize has been delivered. As an option, a “cookie” may be placed on the computer of the user in operation 412 .
[0045] FIG. 4A is a general functional diagram illustrating the operation of the prize database server of the present invention. Irrespective of whether the present invention is implemented in the manner shown in FIG. 3 or FIG. 4 , or any other manner, the prize database server may carry out fundamental operations. In particular, the prize database server is adapted for allowing redemption of prizes resulting from playing games on a plurality of networked game apparatuses.
[0046] To accomplish this, the prize database server is capable of connecting to the game apparatuses via a wide area network, i.e. the Internet, or any other communication system in operation 450 . Upon the connection being established, the prize database server receives a user identification code from the game apparatuses that corresponds to the user in operation 452 . Also received is an indication of an outcome of a game or games upon the user playing the game(s). Note operation 454 . The prize database server also tracks a number of prize credits awarded the user based on the outcome of the game in addition to allowing redemption of the prize credits for a prize, as indicated in operations 456 and 458 , respectively.
[0047] FIG. 5 illustrates software that may be resident in one of the game apparatuses mentioned hereinabove. Client-side software 501 is shown to include an activator module 500 , a communicator module 502 , and a buffer module 504 which are adapted to interface with a game module 506 , a modem 508 , and internal storage 510 among other components of the game apparatus. Together, the foregoing software components constitute an application program interface (API) that may be accessed via a C++ dll for Win32 games and obfuscated Java class(es) for Java applet games.
[0048] Also shown is server-side software 512 . The server-side software is shown to include a secure credit card transaction module 514 , a shopping module 516 , an advertising module 518 , a redemption module 520 , and a payment server 522 which may be interconnected with any of the game apparatuses via a web server 524 and an associated firewall 526 . A plurality of supporting servers 528 may also be included per the desires of the user.
[0049] In order for the process of FIG. 3 to be effectively carried out, variables, or game settings, must be transmitted to the game apparatuses from the server and further identification codes and game outcomes must be transmitted to the server from the game apparatuses.
[0050] Examples of the game settings include a table of prize credits awarded in terms of various game outcomes possible on the game. For instance, 10 prize credits may be awarded for every 1000 points earned during play of the game. Yet another example of game settings may include the enabling or disabling of various features of the game based on the geographic location of the user as indicated by the identification code. It should be noted that the transmission of the identification codes and game outcomes to the game server is critical for tracking the prize credits awarded a user when prize redemption is desired. Further examples of game settings, identification codes, and other information that may be exchanged for various purposes will be set forth hereinafter in greater detail.
[0051] To accomplish the foregoing exchange of information, the activator module 500 is adapted to interface with the game module 506 and request information from the communicator module 502 as needed. At the time of each request, the activator module 500 identifies the game module 506 to the communicator module 502 for purposes that will soon become apparent later. As such, the activator module 500 is specifically tailored for use with the corresponding game. For security purposes, additional information relative to the game developer may be stored on the game server.
[0052] The communicator module 502 in turn make numerous calls for information from the server. Such calls are made over the modem. In order to accommodate situations where a connection cannot be made with the game server or a connection is lost temporarily, various features are afforded. First, upon the receipt of information from the server resulting from a call, such information is stored in internal storage which may constitute any type of memory. As such, when a connection to the server cannot be made, the game settings may be retrieved directly from the internal storage. Further, the communicator module 502 may be adapted to manually or automatically connect with the server periodically or on any other time frame for synchronization purposes.
[0053] Since the present invention may be used with many types of games and communication with the game server may sometimes be compromised, it is preferred that a minimum amount of calculations be performed on the game apparatus itself. Instead, information is received from the game apparatus by way of the API, calculated by the game server, and transmitted back to the game apparatus. Further, the communicator module 502 may be capable of requesting core assets from the game server for storage on the client computer. Such core assets may be used universally with any type of game and include universal graphics, playing cards, sound effects, mah-jongg tiles, sound effects, graphics, etc. The core assets would only need to be downloaded once and may be updated, deleted or supplemented as needed.
[0054] The calls that may be executed by the API in order to communicate necessary information will now be discussed. Such function may actually include a plurality of URL-based calls. The calls may correctly format the data, connect to the server, send information to the game server using secure sockets layer (SSL) and then correctly format the return code and any data that was returned to it from the server. The communication layer is responsible for formatting parameters and for maintaining as many internal variables as possible. This shields the game module 506 from continuously having to pass the same parameters. The game module 506 is responsible, however, for appropriately handling return codes returned from the server.
[0055] Some examples of calls will now be set forth:
[0056] getGameSettings: This function takes a few different forms. First, if it is called from a Java applet game, then it is safe to assume the player is connected to a network, i.e. the Internet, in which case it is safe to retrieve game settings from the game server regardless if the game is being played in a demonstration (play-for-fun) mode or a pay-to-play mode. Any other kind of game requires default game settings to be used if in the demonstration mode. Any game in the pay-to play mode assumes it is safe to query the server to get game settings. The data is specific to each game and is returned in the form of name-value pairs (e.g. “PointsLevell=10”). The game apparatus is responsible for extracting the value for each known piece of data. This call is also used to validate the game version. Games are not allowed to continue if they are not the latest version. This helps to ensure reliable redemption play.
[0057] beginGame: The present call may or may not be available in games played in the demonstration mode. With this call, the server is given the number of credits to be played and attempts to debit the player's account. Prior to doing so, however, the server determines whether the player has any specific business rules that prevent him from playing. When the player has been successfully validated and his account has been debited, the server adds a row to a table in a database indicating that he has started the game, and then returns the appropriate return code to the game apparatus.
[0058] endGame: The present call may or may not be available in games played in the demonstration mode. The present call is sent to the prize database server to provide game data including end time and score. This data is used to update the database row that was added when the game was started. The score is fed into the points-to-prize credits conversion table to determine if any award should be given. The present call also prompts the prize credits in the player's account to be appropriately changed.
[0059] getNextInstaPrizes: The present call may or may not be available in games played in the demonstration mode. The present call is sent to the prize database server to obtain a description and unique prize ID of the next specific prize. The redemption engine on the server generates this data. All next specific prizes are predetermined based on the previous prize and reside locally on the game apparatus. The server notes the prize ID in order to validate against the wonInstaPrize call.
[0060] wonInstaPrize: The present call may or may not be available in games played in the demonstration mode. The present call is used when a specific prize is won at which time the prize ID of the specific prize is sent to the server for validation within the redemption cartridge. This affects at least one of three occurrences: If game credits were won, such game credits are added to the account of the player. If prize credits were won, such prize credits are added to the account of the player. If merchandise has been won, such merchandise is added to the player's shopping cart. Procurement is delayed until the player checks-out.
[0061] getAvailableCredits: The present call may or may not be available in games played in the demonstration mode. In use, this call is used prior to each game as a way of displaying to the player a number of credits that are available.
[0062] canPlay: The present call may or may not be available in games played in the demonstration mode. This call serves as a separate function to check business rules preventing game play (parental controls, bad account, available credit, etc.)
[0063] getAdvertisements: This call may be available in the demonstration mode depending upon the game platform. The present call serves to retrieve the latest advertisements which are to be played. This may be accomplished by calling the advertisement in the form of an advertisement ID and checking to see if the appropriate advertisement has already been downloaded. If the appropriate advertisement has not already been downloaded, default advertisements are used that were downloaded previously during which downloading begins to obtain the latest advertisements while the player is playing the game or browsing a related site.
[0064] postGameStatus: The present call sets a persistent game state in the event of a failure of the game apparatus, connection loss, etc.
[0065] getGameStatus: This call gets the persistent data (see postGameStatus) from the game apparatus.
[0066] getErrors: The present call retrieves any error information that was generated during use of the game apparatus.
[0067] In terms of security, the various variables that are passed may be named in a counter-intuitive, obfuscated manner. For example, a variable relating to a personal identification code may be named “prize credits awarded.” Further, digital signing may be employed where feasible. Even if security is breached, the present invention inherently prevents significant fraud since the value of prize credits awarded is always a fraction of the value of game credits required to play the game. In addition to the foregoing features, when requests start flooding the server from one particular location, the present invention may lock out all future requests from that location.
[0068] FIG. 6 illustrates a functional diagram showing the various aspects of the method associated with use of the present invention. The various operations shown in the functional diagram of FIG. 6 include a player registration operation 602 , a purchase game credits operation 604 , a select game operation 606 , a play game operation 608 , an error handling operation 610 , an award prizes operation 612 , and a prize redemption operation 614 . It should be noted that the foregoing functional aspects of the present invention may be carried out in any order or not at all.
[0069] For example, in demonstration mode, the purchase game credits operation 604 is not necessary and the awarding prizes and prize redemption operations 612 and 614 are optional. Further, the player registration operation 602 is only necessary if the prize redemption operation 614 is executed. Still yet, the select games operation 606 is required only if multiple games exist and the error handling operation 610 is optional.
[0070] FIG. 7 illustrates the process of the present invention by which the player registration operation 602 of FIG. 6 is carried out. Player registration may be executed at any time by the prize database server or not at all in some embodiments where a game is being played in demonstration mode. In one embodiment, player registration is required only upon redemption of prize credits for prizes. In such embodiment, the registration process makes it clear that in the event the user does not register, the user forfeits any prize credits that have been won.
[0071] When registration is required, unregistered players are provided a registration link in operation 702 . Such link affects the display of an interface such as a web page which prompts the user to create a personal user name, or user identification code, and a password. Note operation 704 . Further, the registration interface requires entry of minimal necessary information such as a name and an e-mail address. Optional information such as demographics, game preferences, etc. may also be entered if desired by the user. It is then determined if the necessary information has been entered and is complete in decision 706 . Upon entry of at least the necessary information, a confirmation may be sent to the user in operation 708 .
[0072] At any time, the user may update any of the foregoing profile information. As an option, the user may be precluded from altering the user identification code for security purposes. As a further option, a hint may be provided in order to facilitate remembering the user identification code and/or the password.
[0073] In one embodiment, a person registering, or a primary account holder, may establish a plurality of secondary accounts for secondary account holders. Such feature allows a parent to assume a primary account holder role and control various aspects of the secondary account holders who may include children of the parent. Examples of aspects which may be varied independently or simultaneously for each player include a duration or specific range of time a secondary account holder may play games, a dollar amount of game credits that can be purchased in a specified amount of time, and/or the types of games that may be played. The control of the type of game permitted to be played may be based on a current game industries rating system.
[0074] In addition to limiting the ability of the secondary account holders to use the present invention, the primary account holders are also given exclusive authority to modify and/or delete a current account, and transfer game credits, prize credits, and prizes to and from the various secondary accounts. This allows pooling of prize credits for obtaining desired prizes, etc. In order to add secondary accounts, a primary account holder may be required to enter at least one valid credit card number as a way to establish eligibility. It should be noted that a credit card may not be used to create two separate main accounts during use of the present invention. Further, game credits, prize credits, and prizes may not be transferred between main account holders to inhibit fraud.
[0075] FIG. 8 illustrates the process of the present invention by which the purchase game credits operation 604 of FIG. 6 is carried out. Such game credits are used to play games in order to win prize credits. It should be noted that in some embodiments, purchase of game credits is unnecessary due to the presence of advertisements or because the game is merely being played in a demonstration mode.
[0076] The process of FIG. 8 begins by determining whether the player is registered in decision 800 . If not, the player registration operation 602 (see FIG. 7 ) is executed. Once it is ascertained that registration is complete, the purchase of the game credits is permitted in operation 804 .
[0077] Upon purchase, the game credits are automatically stored under the corresponding account in operation 806 . The system may have the capability to provide a non-linear purchasing scale, giving players incentives to purchase larger quantities of credits at a lower per unit cost. For example, when purchasing credits the player might be offered 10 game credits for $1.00, 30 game credits for $2.50, 60 game credits for $4.75, and 120 games for $8.50.
[0078] While the prize database server handles all of dollar-to-game credit conversion, the conversion factors may be also dictated by managers of the game apparatuses. When a player makes a purchase request, the prize database server validates the account and check business rules to verify that the user is qualified to make the purchase. In the event that a user is either restricted by parental controls or his or her account has been flagged, the user may be notified of such with the appropriate messages on how to correct the situation, i.e. contacting support personnel.
[0079] The prize database server may also be designed to support “incentive suppliers.” Entities which desire to provide free game plays to their customers may present various customers with a URL and a key code to be able to use a predetermined amount of game credits. The customer, or user, would then go to the URL, enter the key code, and receive a predetermined number of free game credits. In the present embodiment, the incentive supplier would be responsible for all costs related to the key codes that are distributed.
[0080] In operation 606 of FIG. 6 , a selection of a game to be played occurs. Two optional types of games that are available include games played in exchange for payment and free games including games played in a demonstration mode. The payment games require the prior execution of operations 602 and 604 of FIG. 6 . In the case of free games, however, player registration in operation 602 may be delayed until prize redemption is required.
[0081] The free games may include games supported by Java Applets, ShockWave, Flash, etc. without communication of identification codes or the like. Further free games may be created to entice users to register with the prize database server. It should be noted that free games may award only a limited amount of prize credits, if any. As an option, the free games may only simulate winning In any case, the user may be required to register before a prize is redeemable after which future prize credits awarded to the registered use may be limited or prevented. Further, the free games may be supported by advertising.
[0082] Payment games may be supported by Java Applets, ShockWave, Flash, Windows95/98/2000, macros, etc. It is imperative that it is understood that payment games may include any type of advertising-supported game or a game that is supported by any type of compensation scheme. In one embodiment, the payment games may be played in a tournament mode. Ideally, tournament games present all tournament players with the same exact game settings so that all players have the same odds. In one type of tournament game, a duration-type game, a variable number of games are to be played in a fixed amount of time.
[0083] In each of the previous embodiments, the games may include a “game of skill” that requires a predetermined goal, task, or objective for a game to be accomplished in a skilful manner such that an outcome of the game is determined primarily by the amount of skill of the player. The greater the player's skill, the closer or more easily a desired goal in the game can be reached by the player. Points associated with the predetermined goals or objectives can be added to a game score such that a higher game score, on average, indicates a greater amount of skill by the player. In the alternative, the games may include a “game of chance” where the outcome of the game is determined primarily on chance. It should be noted that games of chance may be restricted based on an age of the user and/or a geographic location where the user resides.
[0084] FIG. 9 illustrates the process of the present invention by which the play games operation 608 of FIG. 6 is carried out. As shown, the prize database server is adapted for receiving a plurality of identification codes in operation 900 . For example, a site code may be received which is representative of a web site, or game apparatus, which is supporting a game. In addition to the site identification code, a game identification code, a user identification code, a prize credit identification code, a mode identification code, or any other type of identifier may be received by the prize database server.
[0085] As an option, the prize or any other feature associated with the present invention may be determined based on any of the foregoing identification codes. Further, other aspects of the present invention may be specifically tailored for a particular profile. For example, the cost of game credits, a prize, a name, a number or value of the prize credits awarded, advertising, sounds, graphics, and/or limited access may be altered based on any of the aforementioned identifiers. In each of the foregoing cases, such tailored aspects may be handled by the game server.
[0086] One objective of the use of identifiers is to allow for partnerships, especially between the prize database server and other game servers. One game server, for example, may allow all its players to play a specific game for free thus modifying the value of credits, but only for that particular site. Accordingly, each game server may have settings specific to that site and thus when a player launches a game, the prize database server must know the originating location of the game in order to return the appropriate game settings. In addition, players will be able to register with the prize database server at partner game servers, or sites. Further, the interfaces provided by the prize database server may be modified in accordance with the interface of the partner game servers. This creates the perception that a user is still interfacing with the partner game server when actually he or she is interfacing with the prize database server. As an option, activity for all players may be maintained for each of the game servers as a way to track site traffic and thus be able to pay commissions of the game credits revenue, sale advertising, and collect advertising revenue.
[0087] In addition to facilitating partnerships, the identifiers may be used to control the experiences of particular users. As mentioned earlier, an age of the user or account status, i.e. secondary account holder, may affect the user's ability to perform various functions of the present invention. Further, the user identification code may be used to indicate a location of the user. This may be accomplished by referencing registration information of the user or tracking an IP address by which the user has gained access to the server. Given the identity of such geographic location, the present invention may preclude access to certain games in accordance with local jurisdiction laws. This may be particularly beneficial in the case of “games of chance” as discussed hereinabove. It should be noted that alternate game settings may be changed for each particular jurisdiction.
[0088] Upon the receipt of the identification codes, it is then determined in decision 902 whether a current version of the game is present and valid. If the current version is unacceptable, an installer may be executed in operation 904 . Such installer may be downloaded from the prize database server and subsequently executed on the game apparatus.
[0089] When it is verified that the current version of the game on the game apparatus is valid, advertisement software may be executed. Prior to execution, however, the advertisement software may be identified in operation 906 after which it is determined in decision 908 whether a version of the advertisement software is present and valid. If not, the advertisement is updated in operation 910 by downloading, etc. Finally, the game is executed in operation 912 .
[0090] Advertising software may be executed between or during games. Such advertisements can include still shots, animation, movies, sound, etc. Advertisements sponsored by companies, prize providers, game providers, or other sources can be displayed and, in another aspect of the present invention, can be directly related to prize or game information. For example, a sponsor may have contributed to prizes available to players on the advertising game apparatus, so that the advertisement has a direct relation to prizes and can thus increase the effectiveness of such advertising. A sponsor might also supply free games for players in exchange for displaying advertisements, or may simply pay the game or prize database server for advertising time. Still yet, a player can play an advertiser-sponsored game and directly win an advertiser's prize if a task is accomplished. Thus, using the linked advertising and prize redemption system disclosed herein, multiple revenue streams from advertisers are offered to a game operator and also offer the sponsors more effective advertising.
[0091] FIG. 10 illustrates the process of the present invention by which the error handling operation 610 of FIG. 6 is carried out. Error handling is executed upon a loss of connection between the prize database server and the desktop or laptop computer, as determined by decision 1000 . If a loss of connection is detected, the game parameters in the prize database server will not have had the chance to be updated at game end-time. As such, in order to compensate the user, a predetermined number of game or prize credits may be awarded to the user in operation 1006 .
[0092] Since awarding game or prize credits in response to connection loss may provide an incentive for intended connection loss during game play, certain precautions are necessary. In one embodiment, a method may be implemented for tracking players who regularly ‘drop’ connections. The software on the game apparatus, i.e. the communicator module, may try to solve the problem when communication is re-established, but if it cannot fix the problem, the player may be given the opportunity to play the game again for free as long as they have not exceeded a predetermined maximum number of free game or prize credits. Such predetermined maximum number of free games may be established in predetermined time intervals, i.e. 10 credits/month, to limit the negative effects of fraud.
[0093] In the event that a user has exceeded the predetermined maximum number of free games in decision 1002 , the user may be notified and given a customer service number to call in operation 1004 . Customer service will have the ability to give the user some more credits on a discretionary basis. Once connection has been re-established, the communicator module will update the server with any data cached prior to the connection loss.
[0094] In the awarding prizes operation 612 of FIG. 6 , prizes of various types may be awarded. The term “prize”, as used herein, is intended to generically refer to any merchandise, souvenir, food item, game credits or other physical goods or services which can be offered to players of redemption games and which may have value other than as a medium of exchange for use in the gaming environment. A radio, stuffed animal, toy model, coupon for monetary value outside the gaming environment, gift certificate, cash, and free games to be played on game apparatus are all examples of “prizes.” A prize might also be a promotional coupon or cash prizes, which can encourage players to return to the current gaming environment more quickly in the future.
[0095] “Prize credits” differ from a “prize” since they can be used to redeem other types of prizes. In one embodiment, the prize credits that are awarded represent a type of universal currency that may be used for prize redemption purposes. In use, prizes may be made available for various amounts of the universal prize credits.
[0096] The amount of prize credits awarded to the player may be based upon a game score or other result of a game process. In addition, special or progressive goals may be achieved by the player to win an additional or specified number of universal prize credits. In the preferred embodiment of the redemption system, “prize credits” are used as a medium of conversion from game score to prize value.
[0097] As an option, specific prize credits may be awarded which may be redeemed for specific prizes awarded to the user. Specific prize credits are to be distinguished from the universal credits described above. A “specific prize” or “instant prize,” as referred to herein, is a particular prize or type of prize that a player can be directly and immediately awarded and, in most cases, can immediately receive due to a particular winning result on a game apparatus. A “specific prize credit,” as referred to herein, is thus an electronic voucher that can be exchanged for the specific prize only.
[0098] The prize credits, as described hereinabove, may be awarded by any one of various methods. In the case of the specific prize credit, the same may be downloaded prior to beginning play of the game. This prevents complications if a connection with the prize database server is lost during play. Further, such feature allows the player to know the prize(s) at stake prior to play for legal purposes, and also allows the specific prize credit to be immediately displayed upon being awarded without delay due to downloading. As an option, the specific prize credit may even be displayed during play prior to being awarded for enticement purposes.
[0099] In another embodiment, an ordered list of specific prize credits may be displayed during play. Ideally, such list of specific prize credits may be generated based on business rules on a periodic, i.e. 24 hours, basis. Such business rules may include a current total number of specific prize credits a current player has been rewarded in the past, a desired payout percentage, a current average number of game credits that the current player spends per game, a current total number of specific prize credits available, and a value of game credit. It should be noted that the foregoing business rules may vary based on other factors such as a web site through which the game was accessed, a profile of the player, etc. If such information is not available for any reason, the present invention may employ default values to generate the appropriate specific prize credits. Additional information on such business rules may be had by reference to U.S. Pat. No. 5,292,127, by Kelly et al. which is incorporated herein by reference.
[0100] In yet another embodiment, a “frenzy” is afforded by listing a plurality of specific prize credits along with a current number of such specific prize credits that are remaining, or have not yet been awarded. Rules governing how the specific prize credits are awarded in the present mode are similar to those discussed previously. However, the types and number of specific prize credits awarded are predetermined. It should be noted that when the quantity of any given specific prize credits reaches zero, such specific prize credit may remain on the list but will graphically indicate that it is no longer available.
[0101] As an option, the previous embodiment may be modified by increasing the variety and/or number of specific prize credits under certain circumstances. This number may be increased based on the amount of times a particular game is played, the number of times that different games are played, or by achieving a game-related goal, thus affording a “frenzy”-type situation.
[0102] In still yet another embodiment, the prize credits may be awarded in a “progressive” manner. In such embodiment, each user contributes to a collective progressive pool. The progressive pool, for example, can be incremented with every game credit spent on any game apparatus, incremented based on an amount of advertisement impressions that are served (ideal for when advertiser is paying or supporting the progressive score), automatically incremented over time at regular or random intervals, manually incremented by an operator of the prize database server, calculated in real-time, etc. The progressive pool is accumulated from the current and previous games that have been played on any linked game apparatus. In one embodiment, the increment rate of the progressive pool can be determined independent of the number of players playing or advertisements viewed.
[0103] The first player that achieves a predetermined progressive goal on any of the linked game apparatuses wins the progressive prize credits pool, where the progressive amount of prize credits is added to that player's prize credits count. It should be noted that a progressive bonus number of prize credits may also be awarded in lieu of a bonus score, thereby avoiding the need for conversion. Once the progressive bonus score is won, the process is restarted at a default value for continued play. Progressive goals, scores, and bonus apparatuses are described in additional detail in U.S. Pat. No. 5,292,127, by Kelly et al. which is hereby incorporated by reference herein in its entirety.
[0104] FIG. 11 illustrates the process of the present invention by which the awarding prizes operation 612 of FIG. 6 is carried out in order to contend with the possibility of losing a connection with the prize database server. Specifically, FIG. 11 illustrates the process associated with awarding a progressive score or prize credit amount.
[0105] As shown in FIG. 11 , prior to the beginning of each game, information including a current progressive prize credit or score amount is retrieved along with a current predetermined increment rate from the server in operations 1100 and 1102 . During use, the progressive prize credit or score amount is periodically incremented at the increment rate in operation 1104 for the duration of the game.
[0106] During the course of the game, the current prize credit or score amount may be displayed, as indicated in operation 1106 . If the player achieves the high score or some other related goal, all of the current progressive prize pool or score amount is awarded the user. At the end of the game in operation 1108 , information including the current prize credit or score amount is sent to a host server for redemption purposes. By downloading both an increment rate and a progressive prize credit or score amount, communication with the server need only be established once at the beginning of the game.
[0107] In one embodiment, a particular method may be used to calculate a dynamic progressive score increment rate during the course of the game. In such embodiment, a calculation is made periodically to determine the current increment rate which is, in turn, used to calculate the current progressive pool that is to be displayed. In one embodiment, such calculation may be carried out every 2 minutes. It should be noted that the increment rate reflects the amount of time required for the progressive prize credit pool to be incremented by one prize credit, e.g., a prize credit is incremented every 1.824 seconds.
[0108] To calculate the current increment rate, a current total number of games played is first determined. The current total number of games increments each time a game is begun at a certain site on the network and in a certain mode, i.e. progressive mode, tournament, etc. Next, a previous total number of games is subtracted from the current total number which, of course, will be larger. The previous total number of games is the total number of games that was retrieved when the increment rate was last calculated. Thereafter, a difference between the current total number of games played and the previous total number of games played is multiplied by a prize credit fraction that determines a desired pay-out of the progressive game, thus rendering a prize credit increment product.
[0109] Next, an amount of time that has elapsed since the last calculation of the increment rate is determined by subtracting a last counter read time from a current time. This elapsed time is then converted into milliseconds and divided by the prize credit increment product. This renders the current increment rate.
[0110] In another embodiment, a client computer may store a time when the player achieves the high score or other related goal. Subsequently, upon reconnection with the host server, information including such time may be communicated thereto. This time may then be used in conjunction with tables on the host server that have different progressive scores based on different times and dates. For example, as time progresses from a designated start time of the progressive scoring, the amount of the awarded progressive score increases.
[0111] Further information including a cap or maximum progressive score may be retrieved from the host server prior to the game or any other time to prevent such score from exceeding a predetermined amount. In the alternative, such information may be stored and utilized on the host server. These features aid in preventing fraudulent activity.
[0112] As an option, the games may be played in a tournament-type fashion. During tournament play, various user may play against each other. To ensure fairness, various aspects of the games played may be maintained constant. For example, in the case of card games, the electronic virtual playing deck may be made to deliver similar results in the games of each of the players. To enhance tournament play, top scores of tournament players may be tracked over a period of time for the purpose of awarding a particular prize pool or a portion thereof to the highest score, etc. More information on tournament play may be had by reference to U.S. Pat. No. 5,292,127, by Kelly et al. which is hereby incorporated by reference herein in its entirety.
[0113] FIG. 11A illustrates a method of the present invention for determining payment for participating in a network gaming tournament. As shown, a plurality of networked game apparatuses are first provided in operation 1150 for allowing games to be played by a plurality of players in a tournament. Such game apparatuses allow the play of games in exchange for game credits, or rely on funding provided by advertisers or the like.
[0114] After the play of game(s) during a tournament, an indication of an outcome, i.e. score, of at least one game played by each of the players is then received in operation 1152 . Such outcome may be manually sent by the player, or automatically sent. Based on a sum of the outcomes of the games of all of the players, a total amount of prize credits or prizes is determined in operation 1154 . It should be noted that the game apparatuses are already equipped with the ability to convert between outcomes of the games and a number of appropriate prize credits or prizes. Such ability is necessary for the games to be played during non-tournament play.
[0115] Subsequently, a first portion of the total amount of prize credits or prizes is partitioned for payment for participation in the tournament, and a second portion of the total amount of prize credits or prizes is awarded to one or more winning players based on the outcome of the at least one game thereof. Note operations 1156 and 1158 . As an option, a first predetermined part of the second portion may be allocated for a first winner, a second predetermined part of the second portion may be allocated for a second winner, and so on.
[0116] In one embodiment, at least one winning player may be indicated on a list accessible on a site on the network. Such list may be updated upon receiving an indication of an outcome of at least one game played by another one of the players. This process may continue until all of the outcomes are received. As an option, a notice may be sent to at least one player each time the list is updated. Such notice, i.e. e-mail, may be given only to those players whose winnings are affected, or anybody desired.
[0117] In another embodiment, the total amount of prize credits or prizes may be determined by receiving a total sum of outcomes of the games for each of the players. Such total sum may then be divided by a number of the games played by each player. Such process renders an average outcome value per game for each player. The total amount of prize credits or prizes may be then determined based on a sum of the average values of the players. For additional incentive purposes, each of the players may be awarded a predetermined number of prize credits or prizes irrespective of an outcome of the games.
[0118] It should be noted that the game experience of each of the players may be set to be the same. Further, the network gaming system may tailor the experience upon each game. In a trivia game example, the network gaming system may track each time a tournament trivia game is played. Thereafter, each consecutive time the trivia game is played, a different line of questions may be provided. In operation, all players in the tournament may be given the same set of questions depending on whether it is their first, second, third, etc. entry. After the database of questions is exhausted, the questions may be “wrapped back” around to the first set of questions.
[0119] FIG. 12 illustrates the process of the present invention by which the prize redemption operation 614 of FIG. 6 is carried out. In order to accomplish this, the prize database server is adapted for displaying at least one prize redemption interface page in operation 1200 to allow redemption of the prize credits. As an option, the user interface of the game apparatuses may include a link to the prize redemption interface page of the prize database server.
[0120] Once the prize redemption interface page, or “shopping center”, has been accessed, the user is required to register in operation 602 (see FIG. 7 ) if it is determined that he or she is not already registered in decision 1202 . After an identity of the user is verified, selection of a desired prize may be executed in operation 1204 . In the case where the prize credit is a specific prize credit which corresponds with an undesired prize, the user may have the option of replacing the specific prize credit with universal prize credits. Upon selection of the desired prize, shipping information may be verified in operation 1206 . Subsequently, the prize may be delivered by any capable means and the account of the user may be adjusted to reflect the current available prize credits accordingly. Note operation 1208 . It should be noted that user registration may not be required for merely browsing the prize redemption interface page.
[0121] In an alternate embodiment, a user may elect for the prize database server to automatically deliver a prize corresponding to any specific prize credit awarded. In such case, the prize database server may use the player's default account settings for shipping. During the course of delivery, the users may receive emails indicating that a delivery has been confirmed and also when the prize is to be shipped. As an option, the user may be notified of a back-order.
[0122] In addition to the foregoing capabilities, the prize redemption interface page and prize database server may include a virtual shopping cart function, a checkout capability, shipping address modification module, etc. If the virtual shopping cart function is employed, any specific prize credit that is awarded may be immediately deposited therein. At any desired time, prizes depicted on the prize redemption interface page may be added and removed. Optionally, the prize redemption interface page may display advertisements, notification of specials, legal disclaimers, etc.
[0123] FIG. 13 is a graphical user interface 1300 for allowing play of a game that is “prize-enabled” in accordance with the present invention. As shown, a frame 1302 is shown to include a first display 1304 for depicting a current amount of available credits of a particular user based on the user identification code. A second display 1306 is provided for depicting a number of prize credits that are currently awarded to the user. Also positioned on the frame 1302 is a third display 1308 for indicating either a point-to-prize credit conversion table, a list of possible prizes, or a list of high scores.
[0124] The frame 1302 is also equipped with links including a select game link 1310 for allowing selection of a game to play and buy credits links 1312 , 1313 for purchasing additional game credits. Upon selection of either the select game link 1310 or the buy credits links 1312 , 1313 , both the user identification code and the site identification code is transmitted to the prize database server for the reasons set forth earlier. Shop links 1314 , 1316 are also provided for linking to the prize redemption user interface of the prize database server. Upon selection of one of the shop links 1314 , 1316 , a site identification code is transmitted in order to allow the prize redemption user interface to be equipped with specifically tailored insignias and other “look and feel” features.
[0125] With continuing reference to FIG. 13 , a start button 1318 may be included to execute the game that is currently selected. A display bar 1320 may also be shown for advertisement, informative, or any other purposes. Further, a member link 1322 and a help link 1324 may be included for providing various miscellaneous services. Positioned in the frame is a game interface 1326 that is to be executed. Ideally, the game is configured with dynamic HTML.
[0126] FIG. 14 illustrates an optional advertisement feedback capability of the present invention. Such feature is adapted for reporting interest in an advertisement displayed during use of a network system, and in particular, a network gaming system of the present invention. This system enables a provider of the network gaming system to focus advertising towards particular users of the network system and also report the interest shown by particular users towards particular advertisers and advertisements.
[0127] As shown in FIG. 14 , the advertisement feedback system of the present invention stores user profiles of a plurality of users of a network system in operation 1400 . After a user logs onto the network system in operation 1402 , an advertisement by a sponsor of the network system is displayed on a visual display of the particular user in operation 1404 .
[0128] In response to an action by the user, the network system sends the particular user's profile to the sponsor. Note operation 1406 . The user profile may contain a great deal of previously collected information. Thus, this system allows a network system provider to strategically pass on a wealth of marketing information of the users of the network system. As an option, the method by which the marketing information is delivered may be selected by the user and may include modes of communication such as electronic mail, ground mail, etc. This selection may be effected during log-on, registration, or at any other time. Also, the user may be connected to a site on the network associated with the advertisers upon a user selecting, or “clicking” on the advertisement. If the marketing information is sent by a network provider, the advertiser may be informed of the delivery of the appropriate information.
[0129] The advertisement may relate to an offered prize or a particular game capable of being played on the network gaming system. As an option in this network gaming system embodiment, the user profile of the user may be sent to the advertiser as a result of the user being awarded a prize.
[0130] In one embodiment, the user action may occur while the advertisement is being displayed. As one option for this embodiment, the user action may comprise the user actually selecting the displayed advertisement. This way, the provider has a way to identify immediate user interest in a particular advertisement. With such an embodiment, the network system provider is able to easily relay user interest in a particular sponsor at the time that the user actually experiences the sponsor's advertisement. This embodiment also provides a way for a network system provider to determine which advertisements their users are more interested in. With this information, the provider is then able to arrange and time the display of advertisements in an manner to optimize the effectiveness of the advertisements towards the users of the network system.
[0131] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of a preferred embodiment should not be limited by any of the above described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
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A method and interface for a network gaming system is disclosed. The invention includes a method for providing a game interface for a multi-player game accessible over a wide area network by a plurality of users. This method comprises transmitting an identification of a user over a wide area network to a database server; retrieving a number of units associated with the user from the database server; executing a game on a display; indicating on the display the number of units associated with the user; updating on the display the number of units granted to the user based on a game activity of the user; depicting a link on the display for allowing use of the units by the user; and deducting from the number of units the specified member of units responsive to the use of the units by the user.
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BACKGROUND OF THE NEW VARIETY
The present invention relates to a new and distinct variety of nectarine tree, which will hereinafter be denominated varietally as "Santa Maria", and, more particularly, to a nectarine tree which produces freestone fruit which are mature for commercial harvesting and shipment approximately July 21 to August 3 in the San Joaquin Valley of central California, and which is further distinguished in that the fruit are of large size with a bright red blush coloration and excellent flavor and flesh characteristics.
ORIGIN AND ASEXUAL REPRODUCTION OF THE NEW VARIETY
The present variety of nectarine tree was discovered by the applicant in his orchard which is located near Sanger in the central San Joaquin Valley of California. The applicant discovered the new variety in 1983 as an open pollinated seedling of the unpatented "Larry's" nectarine tree (unpatented). The seedling of the instant invention was discovered on the applicant's Ranch No. 11 on Goodfellow Avenue near Sanger, Calif.
In the month of September, 1983, the applicant asexually reproduced the seedling of the new variety by grafting four trees to the new variety using buds from the parent seedling of the new variety. The asexually reproduced trees of the new variety were grown on the Gong Ranch of the applicant near Sanger, Calif. Over the years thereafter, the applicant closely observed the asexually reproduced trees of the instant invention and confirmed that they were in all respects identical to the parent tree of the new variety.
SUMMARY OF THE NEW VARIETY
The "Santa Maria" nectarine tree is characterized as to novelty by producing freestone fruit late in the season which are large in size exhibiting a bright red blush coloration and with excellent flavor and flesh characteristics. The fruit produced by the "Santa Maria" nectarine tree are ripe for commercial harvesting and shipment approximately July 21 to August 3 in the San Joaquin Valley of central California. The new variety is most closely similar to the "Fantasia" nectarine tree (unpatented) which is believed to be the latest high volume freestone nectarine tree grown in California. All high volume nectarines maturing after the "Fantasia" nectarine tree are of the clingstone type. The date of maturity for the "Fantasia" nectarine tree in 1990 grown in Sanger-Reedley fruit district of central California was July 6 to July 19. For the new variety, the date of maturity was July 21 to August 3 in the same fruit growing district, or approximately two weeks after the "Fantasia" nectarine tree.
In addition to the later date of maturity, the fruit of the new variety excels in comparison with the fruit of the "Fantasia" nectarine tree in several respects. The fruit of the new variety has a brighter red blush coloration in comparison with the more dull orange-red blush coloration of the "Fantasia" nectarine tree. Also, the percentage of blush present on the fruit of the new variety is greater than that found on the fruit of the "Fantasia" nectarine tree. With respect to the firmness of the fruit, the new variety possesses a firmer flesh quality than the fruit of the "Fantasia" nectarine tree and is less prone to tip softening or tip "slipskin" which can be a substantial problem with the fruit of the "Fantasia" nectarine tree.
Furthermore, with regard to production, in many years the "Fantasia" nectarine tree displays a substantial preharvest fruit drop. This drop can occur after thinning has been completed up to two weeks before harvest and usually results in reduced yields. No such drop has been observed with the new variety, giving it the advantage of a greater yield potential over the "Fantasia" nectarine tree.
Lastly, the flavor and quality of the fruit of the new variety is outstanding. Its high solids and intense flavor are a substantial improvement over the very average flavor characteristics of the fruit of the "Fantasia" nectarine tree.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a color photograph of mature fruit of the new variety including a first specimen so positioned as to show the base end portion thereof; a second shown in side elevation; a third so positioned as to show the apex end portion thereof; and a fourth sectioned and laid open to show the stone in position in one of the sections and to expose the pit well of the other of the sections; and representative foliage of the new variety.
DETAILED DESCRIPTION
Referring more specifically to the pomological details of this new and distinct variety of nectarine tree, the following has been observed under the ecological conditions prevailing at the orchard of origin which is located near Sanger, Calif. All major color code designations are by reference to the Dictionary of Color, by Maerz and Paul, published in 1950. Common color names are also occasionally employed.
TREE
Generally: Hardy.
Figure.--Upright to upright-spreading with eventual form and density determined by pruning.
Productivity.--Productive.
Regularity of bearing.--Regular.
Trunk:
Size.--Average in diameter.
Surface texture.--Average in comparison with other common nectarine varieties.
Color.--Grey-brown (7-C-9).
Lenticels -- numbers.--Numerous present on trunk surface.
Lenticels -- size.--Large. The lenticel openings are surrounded by light hazel-brown (13-J-9) callous tissue.
Branches:
Size.--Average.
Surface texture.--Average.
Color -- one year of age or older wood.--Light brown (7-C-10).
Color -- immature branches.--Light green (21-L-5) with shoots exposed to direct sunlight displaying reddish pigmentation.
Surface texture -- immature growth.--Smooth.
LEAVES
Size:
Generally.--Large. Leaf measurements have been taken from leaves growing near midpoint of vigorous upright current season's growth.
Average length.--18.4 cm (4.674 inch), including the petiole.
Average width.--4.5 cm (1.143 inch).
Form: Lanceolate with acuminate leaf apex. The apex is often slightly twisted to one side.
Color:
Upwardly disposed surface.--Deep green (24-E-8).
Downwardly disposed surface.--Lighter grey-green (23-J-3).
Leaf vein.--Color of midvein on lower leaf surface is a light green-yellow (20-G-2).
Marginal form:
Generally.--Crenate, often doubly so at mid-leaf. Individual crenations are low and moderately broad.
Leaf margin: Moderately undulate.
Petiole:
Size.--Medium.
Length.--Average 11.5 mm (0.4527 inches).
Thickness.--Average 2.0 mm (0.0787 inches).
Color.--Light green (20-I-2).
Stem glands:
Form.--Most glands present are of reniform type.
Position.--Most commonly, 3 to 5 glands are present with 2 to 4 found on the petiole.
Pattern.--In alternate position and an additional 1 to 2 percent on the base of the leaf margin. Substantial variation exists. Globose glands are occasionally present, but only on the petiole.
Color.--Shiny light green (18-K-3) when young, darkening and deteriorating with age.
Stipules: Two moderately large stipules present, but they are early deciduous.
Length.--8 mm (0.3149 inches) to 10 mm (0.3937 inches).
Color.--Light green (18-K-4) when young, darkening substantially with age.
Form.--Serrate.
FLOWERS
Bloom quantity: Abundant. Most commonly 2 flower buds are present per node.
Flower buds:
Size.--Medium.
Form.--Conic.
Bud scales: Covered with a moderately long, grey pubescence.
Color.--Light chestnut brown (Rustic Brown 7-H-11).
Flowers:
Generally.--Large and showy in form.
Size:
Diameter.--Average 39 mm (1.535 inches) when fully expanded.
Date of full bloom: March 1 in 1991. The bloom timing is considered average to slightly early in relation to other common commercial nectarine cultivars.
Petal:
Number.--Five.
Color.--Pink (1-D-1) with darker shades of pink (1-F-1) basally and very dark pink (1-G-2) on the claw.
Form.--Generally ovate.
Length.--Averages 19.5 mm (0.7677 inches).
Width.--Averages 16.2 mm (0.6377 inches).
Petal claw.--Relatively short, broad and truncate. The petals are slightly cupped inwards.
Margins.--Slightly undulate.
Apex.--Rounded with no tip.
Pedicel:
Generally.--Glabrous.
Color.--Shiny medium green (18-L-5).
Length.--Short, averaging 2.0 mm (0.0787 inches).
Thickness.--Averages 2.0 mm (0.0787 inches).
Nectaries:
Color.--Bright orange (9-J-10).
Anthers:
Size.--Average.
Color.--Tan (9-G-3) ventrally and red streaked (Withered Rose 5-J-10) dorsally.
Pollen: Abundant.
Color.--Yellow (10-L-3).
Stamens:
Filament color.--Very light pink (1-B-1) when young, darkening to a light violet color (2-F-3) when fully mature.
Length.--13 mm (0.5118 inches) to 14.5 mm (0.5708 inches), about equal with the pistil at full maturity.
Pistil: Glabrous.
Color.--Very light green (18-J-2).
Length.--16.5 mm (0.6496 inches) including the ovary when fully extended.
FRUIT
Maturity when described: Ripe for commercial harvesting and shipment approximately July 21 to August 3 near Sanger, Calif. in 1990.
Size:
Generally.--Uniform, large in size.
Average diameter in the axial plane.--78 mm (3.070 inches) to 82 mm (3.228 inches).
Average diameter in the suture plane.--72 mm (2.834 inches) to 78 mm (3.070 inches).
Average cheek diameter.--72 mm (2.834 inches) to 75 mm (2.952 inches).
Form:
Uniformity.--Uniform.
Lateral.--Slightly ovate to an irregular oval.
Axial.--Globose to oval.
Suture:
Generally.--A broad, rather shallow but distinct depression from apex to base, more distinct apically. The suture usually takes on the general color of the adjacent skin area, but the general color is overlain with some very thin multiple striping in various shades of red, most commonly a dark Korean red (5-J-11). The thin striping is only present along the ventral suture area. A distinct depression is evident on the dorsal side of the apex and over the dorsal apical shoulder.
Ventral surface:
Generally.--Rounded and moderately lipped, especially apically. One side of the fruit usually protrudes more than the other, especially in the upper apical shoulder area.
Stem cavity:
Generally.--Moderately small in size.
Width.--Averages 24 mm (0.9448 inches) to 27 mm (1.062 inches).
Depth.--Averages 12 mm (0.4724 inches) to 14 mm (0.5511 inches).
Length.--25 mm (0.9842 inches) to 29 mm (1.141 inches).
Shape.--Oval to almost globose. The basal shoulders of many fruit show an indentation mark where the fruit was pressed against the bearing branch.
Base:
Form.--Slightly truncate. Base angle can be somewhat variable, but most frequently is slightly oblique to the fruit axis.
Apex:
Shape.--Apex form is generally rounded, but apex height can be variable. At times a low tip is present, higher than the apical shoulders. The tip can also, however, be in a depressed form, lower than the apical shoulders and recessed into the suture groove.
Pistil point:
Form.--Variable in form, from perfectly apical to quite oblique.
Stem:
Length.--Medium to slightly short from 10 mm (0.3937 inches) to 12 mm (0.4724 inches).
Thickness.--Average, from 3.5 mm (0.1377 inches) to 4.0 mm (0.1574 inches).
Color.--Light green (20-K-6).
Skin:
Thickness.--Average.
Texture.--Tenacious to flesh at commercial maturity. Glabrous with a bright, glossy finish.
Tendency to crack.--None observed.
Blush color.--Variable, covering from 25 to 60 percent of the fruit surface. Blush pattern is generally a solid washed form, overlain with some color streaking and dappling. Blush color occurs within a range from a medium Canna antique red (4-J-11) to a darker Egyptian red (6-L-11), including a range of intensities in between. Most blushed areas are overlain with a dark red (5-K-11) dappling and/or striping.
Ground color.--Light yellow (10-K-3) to yellow-green (18-J-1).
Flesh color.--Interior coloration of the flesh is a clear light yellow (10-J-2).
Stone cavity -- color.--Dark red (6-J-11) on the walls of the cavity and radiating inward into the flesh 5 mm (0.1960 inches) to 8 mm (0.3149 inches). A moderate amount of white callous tissue is present on the walls of the stone cavity.
Flavor.--Outstanding, mild.
Aroma.--Slight.
Texture.--At commercial maturity, the flesh is firm and crisp.
Fibers -- numbers.--Moderate of medium length, light colored fibers are present.
Ripening.--Ripens evenly.
Eating quality.--Excellent.
Stone:
Attachment.--Full freestone.
Fibers -- numbers.--Few and relatively short. Most are attached basally.
Size.--Medium.
Size -- length.--38.2 mm (1.503 inches).
Size -- width.--24.6 mm (0.9685 inches).
Size -- thickness.--17.8 mm (0.7007 inches).
Form -- generally.--Variable, from a long oval to slightly obovate.
Apex -- shape.--Acute in form with usually a sharp acuminate tip.
Color -- dry.--Medium brown (7-E-11). Moderate amount of callous tissue is present, usually attached within the stone pits, especially laterally.
Base -- shape.--Broad and truncate in form. Base angle variable but most often very slightly oblique to the stone axis.
Sides -- generally.--Variable, from equal to slightly unequal in size.
Surface.--Moderately rough with deep grooves over the apical shoulders laterally, and substantially grooved basally and also along the basal portion of the dorsal suture. Deep pits are present laterally at mid-stone.
Ventral edge.--Rather broad, especially at mid-suture. Several low, thick wings are present along the ventral suture, converging apically.
Dorsal edge.--A wide groove is usually present extending from the base to 9 mm (0.3543 inches) to 13 mm (0.511 inches) above the base. The groove becomes narrow at mid dorsal suture, and the ridges subtending the groove become raised and are irregularly cut with cross grooves at mid-stone. The apical shoulder of the dorsal edge is moderately eroded with the shoulder taking on a concave appearance.
Hilum.--Large and substantially eroded. Generally oval in form.
Tendency to split.--None observed.
Use: A late season fresh market nectarine for both local market and long distance shipping.
Although the new variety of nectarine tree possesses the described characteristics noted above as a result of the growing conditions prevailing near Sanger, Calif. in the central part of the San Joaquin Valley of California, it is to be understood that variations of the usual magnitude and characteristics incident to changes in growing conditions, irrigation, fertilization, pruning and pest control are to be expected.
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A new and distinct variety of nectarine tree which is somewhat remotely similar to the "Fantasia" nectarine tree (unpatented) in producing freestone fruit, but from which it is distinguished in that the fruit are mature for harvesting and shipment approximately two weeks after the fruit produced by the "Fantasia" nectarine tree and wherein the fruit has a brighter red blush coloration, firmer flesh and enhanced flavor and quality than the fruit of the "Fantasia" nectarine tree.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of Korean Patent Application No. 10-2010-0063132 filed in the Korean Intellectual Property Office on Jun. 30, 2010, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a device and a method for controlling a compressor of vehicles. More particularly, the present invention relates to a device and a method for controlling a compressor of vehicles which improves fuel efficiency by accumulating a cold air energy when a speed-reducing condition occurs and using the accumulated cold air energy when a release condition occurs.
[0004] 2. Description of the Related Art
[0005] Recently, countries tighten exhaust regulations and fuel efficiency regulations so as to retard progress of global warming and to prepare depletion of petroleum resources. In order to enhance fuel efficiency, improvement of auxiliary machinery including a powertrain is required. An air conditioning system including an air conditioner is one of such auxiliary machinery.
[0006] Such the air conditioning system includes a compressor. The compressor selectively receives an engine torque transmitted through a pulley by engaging or disengaging operation of an electric clutch and compresses a cooling medium flowing in from an evaporator. After that, the compressor flows the cooling medium out to a condenser. Various types of compressors exist, and compressors of variable-capacity type are widely used for vehicles.
[0007] According to the compressor of variable-capacity type, a pressure control valve changes pressure of the cooling medium based on a load, and thereby, an angle of an inclined plate can be controlled. If the angle of the inclined plate is changed, stroke of a piston changes, and accordingly, discharge flux of the cooling medium can also be controlled.
[0008] A great amount of driving torque is required for operating the compressor. Particularly, since the compressor receives the driving torque by the pulley connected to a crankshaft of an engine through a belt, the compressor is operated according to an engine speed irrelevant to a target cooling performance. In addition, since occupants operate the air conditioning system for their comfort, the compressor may operate excessively and fuel efficiency may be deteriorated. These problems mainly occur when acceleration or deceleration.
[0009] The information disclosed in this Background section is only for enhancement of understanding of the general background of the invention and should not be taken as an acknowledgement or any form of suggestion that this information forms the prior art already known to a person skilled in the art.
SUMMARY OF THE INVENTION
[0010] Various aspects of the present invention have been made in an effort to provide a device and a method for controlling a compressor of vehicles having advantages of improving fuel efficiency as a consequence that a cold air energy is accumulated by increasing an operation of the compressor when a speed-reducing condition occurs, and the accumulated cold air energy is used when a release condition occurs.
[0011] A device for controlling a compressor of vehicles according to various aspects of the present invention may include a sensor module including a cabin temperature sensor detecting a cabin temperature of the vehicle, an outdoor temperature sensor detecting an outdoor temperature of the vehicle, an evaporator temperature sensor detecting a temperature of a cooling medium in an evaporator (evaporator temperature), a vehicle speed sensor detecting a vehicle speed, and a brake sensor detecting an operation of a brake pedal, an injector injecting a fuel for driving the vehicle, an air conditioning system including a condenser condensing and liquefying the cooling medium, an evaporator evaporating the liquefied cooling medium, the compressor compressing the cooling medium, a temperature control door controlling a temperature of an air flowed in a cabin of the vehicle, an intake door selectively flowing an inner air or an outer air in the cabin of the vehicle, and a blower blowing the air to the intake door, and a controller controlling operations of the injector and the air conditioning system, wherein the controller accumulates a cold air energy by increasing an operation of the compressor in a case that a speed-reducing condition occurs, and the air conditioning system uses the accumulated cold air energy by decreasing the operation of the compressor in a case that a release condition occurs.
[0012] The controller may increase the operation of the compressor until the evaporator temperature reaches a first target temperature in a case that the speed-reducing condition occurs.
[0013] The controller may control the temperature control door to raise the temperature of the air supplied to the cabin in a case that the evaporator temperature is lower than a second target temperature during increasing the operation of the compressor.
[0014] The controller may decrease the operation of the compressor until the evaporator temperature is higher than or equal to an allowable temperature in a case that the release condition occurs.
[0015] The controller may control the temperature control door to lower the temperature of the air supplied to the cabin in a case that the evaporator temperature is higher than a second target temperature during decreasing the operation of the compressor.
[0016] Control of the temperature control door by the controller may include control of the intake door through which the inner air or the outer air selectively flows in the cabin and control of blowing speed of the blower.
[0017] The controller may increase the operation of the compressor according to a target increasing rate of the operation of the compressor in a case that the evaporator temperature is higher than or equal to the allowable temperature.
[0018] The controller may increase the operation of the compressor until the operation of the compressor reaches a target operation of the compressor.
[0019] The controller may control the temperature control door to lower the temperature of the air supplied to the cabin in a case that the evaporator temperature is higher than the second target temperature during increasing the operation of the compressor.
[0020] Control of the temperature control door by the controller may include control of the intake door through which the inner air or the outer air selectively flows in the cabin and control of blowing speed of the blower.
[0021] A method for controlling a compressor of vehicles according to other aspects of the present invention may include a) determining whether a speed-reducing condition occurs, b) determining, in a case that the speed-reducing condition occurs, whether an evaporator temperature is higher than a first target temperature, c) increasing, in a case that the evaporator temperature is higher than the first target temperature, an operation of the compressor based on a difference between the evaporator temperature and the first target temperature, d) determining whether the evaporator temperature is lower than a second target temperature during increasing the operation of the compressor, and e) raising the temperature of the air supplied to the cabin by controlling the temperature control door in a case that the evaporator temperature is lower than the second target temperature.
[0022] The speed-reducing condition may occur when a driving condition of an engine is a fuel cut state, or when a vehicle speed is faster than a predetermined vehicle speed and a brake is operated.
[0023] The method may further include g) determining whether a release condition occurs, wherein the steps b) to e) are repeated in a case that the release condition does not occur at the step g).
[0024] In a case that the evaporator temperature is lower than or equal to the first target temperature at the step b) or the release condition occurs at the step g), the method may further include h) determining whether the evaporator temperature is lower than an allowable temperature, i) decreasing, in a case that the evaporator temperature is lower than the allowable temperature, the operation of the compressor based on a difference between the evaporator temperature and the allowable temperature, j) determining whether the evaporator temperature is higher than the second target temperature, and k) lowering, in a case that the evaporator temperature is higher than the second target temperature, the temperature of the air supplied to the cabin by controlling the temperature control door, the intake door, and the blower.
[0025] The intake door may be controlled based on a difference between a cabin temperature and an outdoor temperature or the outdoor temperature, and the blower may be controlled based on an inner air ratio at the step k).
[0026] The steps h) to k) may be repeated, in a case that the evaporator temperature is lower than or equal to the second target temperature at the step j) or the step k) is performed.
[0027] In a case that the evaporator temperature is higher than or equal to the allowable temperature at the step h), the method may further include l) increasing the operation of the compressor according to a target increasing rate of the operation of the compressor, m) determining whether the operation of the compressor is lower than a target operation of the compressor, n) determining, in a case that the operation of the compressor is lower than the target operation of the compressor, whether the evaporator temperature is higher than the second target temperature, and o) lowering, in a case that the evaporator temperature is higher than the second target temperature, the temperature of the air supplied to the cabin by controlling the temperature control door, the intake door, and the blower.
[0028] The intake door may be controlled based on the difference between the cabin temperature and the outdoor temperature or the outdoor temperature, and the blower may be controlled based on the inner air ratio at the step o).
[0029] The steps l) to o) may be repeated, in a case that the evaporator temperature is lower than or equal to the second target temperature at the step n) or the step o) is performed.
[0030] Controlling the compressor may be finished when the operation of the compressor reaches the target operation of the compressor at the step m).
[0031] The methods and apparatuses of the present invention have other features and advantages which will be apparent from or are set forth in more detail in the accompanying drawings, which are incorporated herein, and the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is a block diagram of an exemplary device for controlling a compressor of vehicles according to the present invention.
[0033] FIG. 2 is a graph explaining the spirit of the present invention.
[0034] FIG. 3 is a flowchart of a method for controlling an exemplary compressor of vehicles according to the present invention.
[0035] FIG. 4 is a graph showing an exemplary relation between an operation of a compressor and a temperature difference.
[0036] FIG. 5 is a graph showing an inner air ratio according to a temperature difference.
[0037] FIG. 6 is a graph showing a blower speed respectively at an outer air mode, a partial inner air mode, and an inner air mode.
[0038] FIG. 7 is a graph showing an exemplary operation of a compressor to time.
DETAILED DESCRIPTION
[0039] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0040] As shown in FIG. 1 , a device for controlling a compressor of vehicles according to various embodiments of the present invention includes a sensor module 10 , a control portion 20 , an actuator 30 , an air conditioning system 40 , and an injector 50 .
[0041] The sensor module 10 includes a cabin temperature sensor 11 , an outdoor temperature sensor 13 , an evaporator temperature sensor 15 , a vehicle speed sensor 17 , and a brake sensor 19 . Additionally, the sensor module 10 further includes sensors for shifting (e.g., a throttle position sensor, an engine speed sensor, and so on) and/or sensors for controlling an engine (e.g., an exhaust temperature sensor, an oxygen sensor, and so on).
[0042] The cabin temperature sensor 11 detects a cabin temperature of the vehicle and transmits a signal corresponding thereto to the control portion 20 .
[0043] The outdoor temperature sensor 13 detects an outer temperature of the vehicle and transmits a signal corresponding thereto to the control portion 20 .
[0044] The evaporator temperature sensor 15 detects a temperature of a cooling medium passing through an evaporator and transmits a signal corresponding thereto to the control portion 20 .
[0045] The vehicle speed sensor 17 detects a vehicle speed from a rotation speed of a wheel and transmits a signal corresponding thereto to the control portion 20 .
[0046] The brake sensor 19 detects an operation of a brake pedal and transmits a signal corresponding thereto to the control portion 20 .
[0047] The control portion 20 is electrically connected to the sensor module 10 so as to receive signals corresponding to values detected by the sensor module 10 , and controls the injector 50 and the air conditioning system 40 based on the signals. Various control units such as a transmission control unit controlling a transmission of the vehicle, an engine control unit controlling the engine, and an air conditioning system control unit controlling the air conditioning system 40 may be used in the vehicle, and the control portion 20 in this specification includes all the control units used in the vehicle. Particularly, it is to be understood that the control portion 20 includes all the control portions suitable to perform a method for controlling a compressor according to various embodiments of the present invention.
[0048] The actuator 30 is electrically connected to the control portion 20 and operates the air conditioning system 40 and/or the injector 50 according to a control signal transmitted from the control portion 20 . A solenoid device may be used as the actuator 30 , and the control signal may be a duty signal applied to the solenoid device.
[0049] The air conditioning system 40 includes all the devices used for warming, ventilating, and cooling the cabin of the vehicle. Concretely, the air conditioning system 40 includes a condenser 41 , an evaporator 43 , a compressor 45 , a temperature control door 47 , an intake door 48 , and a blower 49 . The air conditioning system 40 may include various components which are not described in this specification.
[0050] The condenser 41 condenses and liquefies the cooling medium, the evaporator 43 evaporates the liquefied cooling medium, and the compressor 45 compresses the cooling medium.
[0051] In addition, the temperature control door 47 controls a temperature of an air supplied to the cabin of the vehicle by mixing a warm air with a cool air, the intake door 48 controls an inner air, an outer air or a mixture of the inner and outer airs to flow in the cabin of the vehicle, the blower 49 blows the air toward the intake door.
[0052] Such an air conditioning system 40 is well known to a person of an ordinary skill in the art, and a detailed description thereof will be omitted.
[0053] The injector 50 injects a fuel so as to drive the vehicle (particularly, the engine).
[0054]
10
[0055] A solid line in FIG. 2 represents an operation (load) of the compressor and a fuel consumption according to the prior arts, and a dotted line represents an operation (load) of the compressor and a fuel consumption according to various embodiments of the present invention.
[0056] If a speed-reducing condition of the vehicle (particularly, fuel cut condition) occurs, the fuel consumption is quickly reduced and the operation of the compressor is gradually reduced according to the conventional arts. On the contrary, if a release condition occurs, the fuel consumption is quickly increased and the operation of the compressor is maintained as a predetermined operation.
[0057] According to the spirit of the present invention, fuel consumption is quickly reduced but the operation of the compressor is gradually reduced after being quickly increased if the speed-reducing condition of the vehicle occurs. That is, if the speed-reducing condition of the vehicle occurs, the operation of the compressor is increased so as to accumulate cold air energy. After that, if the release condition occurs, the fuel consumption is increased a little and the operation of the compressor is reduced quickly. That is, the air conditioning system 40 is operated by the cold air energy accumulated when the vehicle slows down. Therefore, fuel consumption for operating the air conditioning system 40 is reduced.
[0058] Finally, if the accumulated cold air energy is used up, the fuel consumption and the operation of the compressor are controlled through the same way as the conventional art.
[0059] A method for controlling a compressor for vehicles realizing the spirit of the present invention will be described with reference to FIG. 3 to FIG. 7 .
[0060] As shown in FIG. 3 , in a state that the vehicle runs, the control portion 20 controls the cabin temperature of the vehicle at a step S 110 . At this state, the control portion 20 determines whether the speed-reducing condition occurs at a step S 120 . The speed-reducing condition occurs when a fuel cut state occurs or the brake pedal is operated in a state that the vehicle speed is faster than a predetermined vehicle speed. Herein, the occurrence of fuel cut state is decided by a signal corresponding to a fuel injection amount received from the injector 50 . On the contrary, it may be determined based on the signal transmitted to the sensor module 10 whether a predetermined occurrence condition of the fuel cut state is satisfied. Meanwhile, if the vehicle speed is lower than the predetermined vehicle speed, a regenerable kinetic energy is small. Therefore, if the operation of the compressor is increased, the fuel injection amount also increases. Therefore, it may be set that the speed-reducing condition for performing the method for controlling the compressor according to various embodiments of the present invention is satisfied only when the brake pedal operates in the state that the vehicle speed is faster than the predetermined vehicle speed. The predetermined vehicle speed may be 20-40 km/h.
[0061] If the speed-reducing condition does not occur at the step S 120 , the control portion 20 continues the control of the cabin temperature at the step S 110 .
[0062] If the speed-reducing condition occurs at the step S 120 , the control portion 20 determines whether the evaporator temperature is higher than a first target temperature at a step S 130 . Herein, the evaporator temperature represents a temperature of the cooling medium passing through the evaporator 43 . The first target temperature is a temperature (0-4° C.) where the evaporator begins to be frozen. The reason why the first target temperature is set as described above is to increase the operation of the compressor as much as possible before the evaporator is frozen. If the evaporator is frozen, heat-exchanging efficiency is lowered and fuel efficiency is actually deteriorated.
[0063] If the evaporator temperature is lower than or equal to the first target temperature at the step S 130 , the operation of the compressor cannot be increased. Thus, the method according to various embodiments of the present invention proceeds to a step S 180 .
[0064] If the evaporator temperature is higher than the first target temperature at the step S 130 , the control portion 20 increases the operation of the compressor at a step S 140 . The operation of the compressor, as shown in FIG. 4 , is increased based on a difference between the evaporator temperature and the first target temperature. That is, the increase amount of the operation according to the temperature difference is defined in a map. Herein, it is exemplary shown that the operation amount is proportional to the temperature difference, but the spirit of the present invention is not limited to this.
[0065] Meanwhile, in a case that the operation of the compressor is increased, the control portion 20 may decide that a load of the vehicle increases and may increase a fuel injection amount of the injector 50 . Thereby, the fuel efficiency may be deteriorated. Therefore, in a case that the operation of the compressor is increased because of the occurrence of the speed-reducing condition, the increase of the fuel injection amount is prohibited.
[0066] After that, the control portion 20 determines whether the evaporator temperature is lower than a second target temperature at a step S 150 . Generally, if the evaporator temperature is lowered, the temperature of the air supplied to the cabin is also lowered. Thereby, comfort of the cabin may be deteriorated. Therefore, if the evaporator temperature is lower than the second target temperature at the step S 150 , the control portion 20 controls the temperature control door 47 to compensate an excessive decrease in the cabin temperature at a step S 160 . That is, a cold air supplied to the cabin is warmed up by a heater or is mixed with a warm air passing through the heater such that the air with suitable temperature should be supplied to the cabin. Such a temperature control door 47 is controlled based on a difference between the temperature of the air supplied to the cabin at the step S 110 and a current temperature of the air supplied to the temperature control door 47 . After that, the control portion 20 proceeds to a step S 170 .
[0067] If the evaporator temperature is higher than or equal to the second target temperature at the step S 150 , the control portion 20 does not control the temperature control door 47 but proceeds to the step S 170 .
[0068] The control portion 20 determines whether the release condition occurs at the step S 170 . The release condition may be satisfied when the speed-reducing condition is not satisfied. If the release condition does not occur at the step S 170 , the control portion 20 continuously performs the steps S 130 to S 170 , repeatedly. That is, the control portion 20 continues to increase the operation of the compressor so as to accumulate the cold air energy. If the release condition occurs at the step S 170 , the control portion 20 proceeds to the step S 180 . In this case, since the release condition occurs, the control portion 20 uses the accumulated cold air energy.
[0069] At the step S 180 , the control portion determines whether the evaporator temperature is lower than an allowable temperature. The allowable temperature means an evaporator temperature corresponding to the temperature of the air required for maintaining the comfort of the cabin. If the operation of the compressor is decreased after the release condition occurs, the temperature of the air supplied to the cabin is raised. At this time, the operation of the compressor should be increased so as to lower the temperature of the air supplied to the cabin. Therefore, the operation of the compressor is decreased until the evaporator temperature reaches the allowable temperature. Therefore, the evaporator temperature is higher than or equal to the allowable temperature at the step S 180 , the control portion 20 proceeds to a step S 220 . On the contrary, if the evaporator temperature is lower than the allowable temperature at the step S 180 , the control portion 20 decreases the operation of the compressor at a step S 190 . The operation of the compressor is decreased based on a difference between the evaporator temperature and the allowable temperature (refer to FIG. 4 ).
[0070] After that, the control portion 20 determines whether the evaporator temperature is higher than the second target temperature at a step S 200 . If the operation of the compressor is decreased, the temperature of the air supplied to the cabin is raised. Therefore, if the evaporator temperature is higher than the second target temperature at the step S 200 , the control portion 20 controls the temperature control door 47 , the intake door 48 , and the blower 49 so as to suppress a rise of the temperature of the air supplied to the cabin at a step S 210 . That is, the temperature control door 47 is controlled based on the difference between the temperature of the air supplied to the cabin at the step S 110 and the current temperature of the air supplied to the temperature control door 47 . The intake door 48 , as shown in FIG. 5 , is controlled based on a difference between the cabin temperature and the outdoor temperature or the outdoor temperature. A speed of the blower 49 , as shown in FIG. 6 , is controlled based on an inner air ratio (a ratio of the inner air to the air supplied to the cabin).
[0071] Explaining concretely, the temperature control door 47 is controlled to lower the temperature of the air supplied to the cabin. For this purpose, a ratio of the inner air and the outer air is controlled through the intake door 48 , and speeds of the inner air and the outer air are controlled through the blower 49 .
[0072] If the evaporator temperature is lower than or equal to the second target temperature at the step S 200 , the control portion 20 continuously performs the steps S 180 to S 200 , repeatedly.
[0073] Steps S 220 to S 250 are steps for preparing a normal operation of the compressor 45 after the accumulated cold air energy is used up. If the evaporator temperature is higher than or equal to the allowable temperature at the step S 180 , the temperature of the air supplied to the cabin is higher than that of the air required for maintaining the comfort of the cabin. In this case, the temperature of the air supplied to the cabin is lowered by raising the operation of the compressor to a target operation of the compressor and the cabin temperature control is performed normally. At this time, if the operation of the compressor is raised quickly, the injection amount of the fuel increases. Therefore, the operation of the compressor is gradually increased so as to prevent the fuel efficiency and the comfort from being deteriorated.
[0074] For this purpose, the control portion 20 increases the operation of the compressor according to a target increasing rate of the operation of the compressor at the step S 220 . The target increasing rate of the operation of the compressor, as shown in FIG. 7 , is calculated according to a target position of the temperature control door 47 and a reference target increasing rate of the operation of the compressor. The target increasing rate of the operation of the compressor A rate is represented as a dotted line in a right graph in FIG. 7 . That is, assuming that a distance from a predetermined position of the temperature control door when the outdoor temperature is 0° C. to the target position of the temperature control door is α and a distance from the predetermined position of the temperature control door when the outdoor temperature is 0° C. to a minimum position of the temperature control door is β, the target increasing rate of the operation of the compressor A target is calculated from a following equation.
[0000] A target =A rate *(α/β) Eq. (a)
[0075] The reference target increasing rate of the operation of the compressor A rate represents an increasing rate of the operation of the compressor used for increasing the operation of the compressor at a normal state. Since the operation of the compressor is increased according to the target increasing rate of the operation of the compressor A target that is lower than the reference target increasing rate of the operation of the compressor in various embodiments of the present invention, the operation of the compressor may be prevented from being increased quickly. Therefore, deterioration of the fuel efficiency may be prevented.
[0076] After performing the step S 220 , the control portion 20 determines whether the operation of the compressor is lower than the target operation of the compressor at the step S 230 . That is, it is determined whether the operation of the compressor reaches the target operation of the compressor. If the operation of the compressor reaches the target operation of the compressor at the step S 230 , the control portion 20 finishes the method for controlling the compressor according to various embodiments of the present invention and returns to the step S 110 . If the operation of the compressor is lower than the target operation of the compressor at the step S 230 , the control portion 20 determines whether the evaporator temperature is higher than the second target temperature at the step S 240 .
[0077] If the evaporator temperature is lower than or equal to the second target temperature at the step S 240 , the control portion 20 continuously performs the steps S 220 to S 240 , repeatedly.
[0078] If the evaporator temperature is higher than the second target temperature at the step S 240 , the control portion 20 controls the temperature control door 47 , the intake door 48 , and the blower 49 so as to suppress the rise of the temperature of the air supplied to the cabin at the step S 250 . Since the step S 250 is the same as the step S 210 , a detailed description thereof will be omitted.
[0079] As described above, a cold air energy may be accumulated according to the present invention by suppressing an increase in an injection amount of a fuel when decelerating and increasing an operation of a compressor. Since the cold air energy accumulated as described above is used when the deceleration is released, fuel efficiency may improve.
[0080] Since the operation of the compressor is controlled such that the evaporator is lowered to a temperature where the evaporator begins to be frozen, accumulating efficiency of the cold air energy can be maximized. In addition, since the operation of the compressor is increased under the condition that the evaporator is not frozen, heat-exchanging efficiency may increase.
[0081] Further, since the temperature control door is controlled such that a temperature of air supplied to a cabin is prevented from being lowered as the evaporator temperature is lowered, comfort of the cabin may be maintained.
[0082] The foregoing descriptions of specific exemplary 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 teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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A method for controlling a compressor of vehicles improves fuel efficiency by accumulating a cold air energy when a speed-reducing condition occurs and using the accumulated cold air energy when a release condition occurs. A device for controlling a compressor of vehicles may include a sensor module including a cabin temperature sensor detecting a cabin temperature of the vehicle, an outdoor temperature sensor detecting an outdoor temperature of the vehicle, an evaporator temperature sensor detecting a temperature of a cooling medium in an evaporator (evaporator temperature), a vehicle speed sensor detecting a vehicle speed, and a brake sensor detecting an operation of a brake pedal, an injector injecting a fuel for driving the vehicle, an air conditioning system including a condenser condensing and liquefying the cooling medium, an evaporator evaporating the liquefied cooling medium, the compressor compressing the cooling medium, a temperature control door controlling a temperature of air flowing into a cabin of the vehicle, an intake door selectively distributing an inner air or an outer air into the cabin of the vehicle, and a blower blowing the air to the intake door, and a controller controlling operations of the injector and the air conditioning system, wherein the controller accumulates a cold air energy by increasing an operation of the compressor in a case that a speed-reducing condition occurs, and the air conditioning system uses the accumulated cold air energy by decreasing the operation of the compressor in a case that a release condition occurs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a mechanical seal device with an improved sealing ability and an easy installation of a shaft sleeve. More particularly, the invention relates to a mechanical seal device which retains a relative pressure difference in fluid pressure of a sealed fluid chamber, an intermediate chamber and a buffer fluid chamber to enhance its sealing ability.
2. Description of the Related Art
There has been a mechanical seal device as a relative art of the present invention, as shown in FIG. 3 . FIG. 3 shows a half sectional view of the shaft seal device.
In FIG. 3 , a shaft seal device 100 is disposed between the inner diameter surface of a housing 160 and the outer diameter surface of a rotary shaft 150 . This shaft seal device is a tandemly configured mechanical seal device. This tandem type mechanical seal device comprises a contacting type mechanical seal device 101 in the region of sealed process fluid and a non-contact type mechanical seal device disposed in the atmospheric region.
In the contacting type mechanical face seal 101 , a rotary seal ring 102 and a stationary seal ring 103 are disposed adjacent and opposite to each other. The rotary seal ring 102 and the stationary seal ring 103 make a sealing contact at respective sealing faces 104 and 105 wherein the rotary seal ring 102 is fixedly connected to one of split parts comprising a second shaft sleeve 141 and the mating stationary seal ring 103 is fixedly connected to a second seal cover 131 . The sealing faces 104 , 105 are elastically pressed against each other by springs 107 which are disposed on the back face 106 of the stationary seal ring 103 . In addition, the pressure exerted on the back face 106 by the sealed process fluid pushes the sealing face 104 against the sealing face 105 . An O-ring 108 is disposed on the inside diameter surface of the stationary seal ring 103 which determines the pressure area of the back face 106 .
In the non-contact type mechanical seal device 110 , a second rotary seal ring 111 and a second stationary seal ring 115 make a sealing contact at a second sealing face with spiral grooves 113 and a second sealing face 112 , respectively. Contact between the second sealing face with spiral grooves 113 and the second sealing face 112 is further reinforced by a spring 116 and the pressure of purge gas exerted on a back face 117 of the stationary seal ring 115 . The pressure area of the back face 117 is determined by an O-ring 119 which is disposed in the inner annular groove of the back face 117 . The second stationary seal ring 115 is axially movable relative to a first seal cover 132 so that the second sealing face 112 is sufficiently biased by the spring 116 against the second sealing face with spiral grooves 113 .
The rotary seal ring 111 fits over a first shaft sleeve 140 and is retained between a third shaft sleeve 142 and the mating part of the split parts of the second sleeve 141 .
The flange of the first sleeve 140 engages a step of a rotary shaft 150 . The first sleeve 140 fixates the second sleeve 141 and the second rotary seal ring by means of the third sleeve 142 . Furthermore, a lock nut 143 engages a screw thread 144 prepared on the rotary shaft 150 so as to prevent the first sleeve 140 and the third sleeve 142 from moving in an axial direction. These three sleeves, 140 , 141 , 142 , are separated parts and five O-rings 146 are installed for the sake of sealing
A seal cover fixedly connected to the housing 160 is comprised of a first seal cover 131 and a second seal cover 132 . The seal covers 131 and 132 are fixedly held between a step of the housing 160 and a presser cover 133 . The seal covers 131 and 132 have a passage 121 to feed a purge gas into an intermediate chamber C′. Pressure of the purge gas is set lower than the pressure of the sealed process fluid.
The shaft seal device 100 constructed accordingly has to be able to retain the primary seal ring 102 and the secondary seal ring 111 so that they are free to rotate. Therefore, it is not only that the first, the second, and the third sleeves 140 , 141 , 142 become large in size, but that they have to be separable. Being separable parts then necessitates as many as five O-rings 146 . This in turn yields a mass increase of the first, the second and the third sleeves, which requires a large diameter of the rotary shaft 150 to assure a high speed rotating motion. In addition, the tandem configuration of the mechanical seal device leads to a large axial length.
Since the pressure of the intermediate chamber C′ is lower than the pressure of the sealed process fluid, there may be a leakage of the sealed process fluid into the intermediate chamber. Also the mechanical seal device 110 residing in the atmospheric region is a non-contact type, therefore the purge gas may leak to the atmospheric region. Accordingly, there remain problems in the seal performance of the shaft seal device 100 .
The present invention is introduced to resolve the above mentioned problems. A primary technical goal which this invention tries to achieve is to collect the sealed process fluid with no leakage to the atmospheric region by enhancing the seal performance of the seal parts against the atmosphere region.
Another goal is to collect all the leaking fluid into the intermediate chamber without further leaking to the atmospheric region by means of the pressure of the intermediate chamber not only being set lower than the pressure of the sealed fluid but also being set lower than the pressure of the buffer fluid chamber.
Yet another goal is to fixate sleeves without use of fitting devices, to reduce the weight of the sleeves and their fitting devices, to achieve a high-speed rotating motion of the rotary shaft, and to reduce a production cost by decreasing the number of parts as the result of a weight reduction of the sleeves.
SUMMARY OF THE INVENTION
A primary object of the present invention is to resolve the above mentioned technical problems, and a solution to such problems is embodied as follows.
A preferred embodiment of a shaft seal device constructed in accordance with the principles of the present invention is a mechanical seal device with a sealed process fluid being sealed between the inner surface of a housing and a rotary shaft retained within the housing, the shaft seal device comprising a stationary seal ring and a rotary seal ring, the stationary seal ring sealingly fixed to the housing being axially biased by a spring and having a primary sealing face on one end whose other back face being pressurized by the sealed process fluid, the rotary seal ring fixedly connected to a sleeve being disposed in the sealed process fluid side relative to the stationary seal ring and having a secondary sealing face adjacent the primary sealing face, an end face of the sleeve engaging a shoulder of the rotary shaft which is disposed in the sealed process fluid side relative to the stationary seal ring, the end face having an inner surface diameter which is larger than the inner diameter of the back face of the stationary seal ring pressurized by the sealed process fluid.
In a shaft seal device as an embodiment of the present invention, the sealed process fluid exerts a larger force to the back face of the stationary seal ring than to the end face of the sleeve, therefore enabling the sleeve to engage the shoulder of the rotary shaft. Accordingly, the sleeve does not require a fitting device for fixing and thinning the wall thickness of the sleeve results in a reduction in weight. As a consequence, omitting fitting devices and thinning the sleeve yields a reduction in the total size of the mechanical seal device. The reduction in weight then makes it easy for the mechanical seal device to undergo a high speed rotating motion.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a half cut-away sectional view showing one preferred embodiment of a mechanical seal device of the present invention.
FIG. 2 is an enlarged sectional view of a portion of the mechanical seal device shown in FIG. 1 .
FIG. 3 is a half cut-away sectional view of a mechanical seal device according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Described below is details of the figures of a preferred embodiment of a shaft seal device constructed in accordance with the principles of the present invention. All the figures explained below are constructed according to actual design drawings with accurate dimensional relations.
FIG. 1 shows a half cross sectional view of a mechanical seal device in accordance with the present invention. FIG. 2 is a cross sectional view enlarging a sealed fluid region HP of FIG. 1 .
In FIG. 1 and FIG. 2 , a mechanical seal device 1 is disposed between the inner surface of a housing 60 and a rotary shaft 50 . The mechanical seal device 1 mainly comprises a stationary seal ring 3 and a rotary seal ring 10 .
The stationary seal ring 3 is retained in an annular groove of a seal cover 30 so as to move freely in an axial direction. In the back face 5 of the stationary seal ring 3 , multiple biasing springs are disposed concentrically and equally spaced apart. A primary O-ring 19 made of rubber is disposed between a circumferential surface of the annular groove and an inner diameter surface of the stationary seal ring 3 . By use of the primary O-ring 19 , the sealed process fluid exerts pressure upon a surface radially extending from the inner diameter of the primary O-ring 19 to the outer diameter surface of the stationary seal ring 3 . The pressure area of the surface becomes equal to the area of a back face upon which the sealed process fluid and the biasing spring 4 exert pressure to thrust forward the stationary seal ring 3 .
This stationary seal ring 3 is retained such that a cavity 7 and a primary lock pin 15 inserted into the cavity 7 prevents the ring 3 from rotating, and a sealing face 6 resides on a front surface of the stationary seal ring 3 opposite to the back face 5 .
In a rotary seal ring 10 disposed against the stationary seal ring 3 , a sealing face 16 is disposed in such a way that the face 16 forms a sealing contact with the sealing face 6 . The rotary seal ring 10 fitted over the rotary shaft 50 is constructed so as to rotate with the shaft 50 by means of an anti-rotation mechanism in which a protruding drive pin 44 is inserted to a lock bore 12 . A secondary O-ring 47 is disposed between the two fit surfaces of the rotary seal ring 10 and the shaft sleeve 40 so as to achieve a sealing contact between the rotary seal ring 10 and the shaft sleeve 40 .
The rotary shaft 50 has a shoulder 52 in the sealed fluid region HP. A secondary lock pin 53 is fixedly connected adjacent the shoulder 52 of the rotary shaft 50 . A diameter surface in which the secondary lock pin 53 is fixed forms a fit surface 51 . The rotary shaft 50 is made smaller in diameter in an atmospheric region LP.
The shaft sleeve 40 fitted over the rotary shaft 50 is made large in wall thickness in the sealed fluid region HP, and an end face 42 of the sleeve 40 is formed at the interface where the sleeve engages the shoulder 52 of the rotary shaft 50 .
Inside the neighborhood of the end face 42 of the shaft sleeve 40 is formed a primary inner diameter surface 41 fitted over the fit surface 51 . A third O-ring 56 is disposed between the fit surface 51 and the primary inner diameter surface 41 . The third O-ring 56 provides a sealing between the fit surface 51 and the primary inner diameter surface 41 . Furthermore, a tapered shoulder is disposed inside the sleeve 40 between the primary inside diameter surface 41 and a secondary inner diameter surface 41 A, and an auxiliary through passage 45 is formed in the tapered shoulder. A fourth O-ring 57 is disposed in the atmospheric side LP of the tapered shoulder between the shaft sleeve 40 and the rotary shaft 50 . In case of a leakage of the sealed process fluid from the third O-ring 56 , the fourth O-ring 57 hinders further leakage such that the leaked fluid is guided to flow into an intermediate chamber B via the auxiliary through passage 45 .
A symmetrically opposite pair of a first seal part 20 A and a second seal part 20 B are disposed inside a buffer fluid chamber C which resides inside the seal cover 30 fixed to the housing 60 as well as toward the atmospheric side of the cover 30 . The first seal part 20 A and the second seal part 20 B are segment seals. In addition, multiple biasing springs are disposed concentrically and equally spaced apart between the first seal part 20 A and the second seal 20 B. The springs 24 impinge upon the first seal 20 A and the second seal part 20 B in axially opposite directions so that a first sealing face 21 A of the first seal part 20 A makes a sealing contact with the mating face of the seal cover 30 while a second sealing face 21 B of the second seal part 20 B makes a sealing contact with the mating seal cover face of a segmented seal cover 39 .
Garter springs 24 and 25 engage outside diameter surfaces of the first seal part 20 A and the second seal part 20 B, respectively, and the first seal part 20 A and the second seal part 20 B being comprised of concentrically and equally spaced segments are fastened radially inward against the rotary shaft 50 . The first seal part 20 A and the second seal part 20 B form a good seal with the rotary shaft 50 by an inner diameter sealing face 22 A of the first seal part 20 A and an inner diameter sealing face 22 B of the second seal part 20 B, respectively. The first seal 20 A and the second seal 20 B are retained by respective lock pins 26 fixedly connected to the seal cover 30 . The buffer fluid chamber C is enclosed by the first seal part 20 A and the second seal part 20 B accordingly.
Segmented seal cover 39 fitted over the seal cover 30 in the atmospheric region LP is retained within the seal cover 30 by means of a snap ring 27 . The snap ring 27 engages an annular groove disposed in the seal cover 30 . A locating snap ring 49 disposed in the atmospheric side LP of the shaft sleeve 40 engages an annular groove 48 of the shaft sleeve 40 in a disconnectable manner. The snap ring 49 is disposed in such a way that not only the mechanical shaft seal 2 but also the first seal part 20 A and the second seal part 20 B are retained together between the seal cover 30 and the shaft sleeve 40 . Therefore, the snap ring 49 can be removed from the sleeve 40 after the completion of assembly.
Once the mechanical seal device 1 is installed in a hydraulic machine, even after the snap ring 49 is removed from the shaft sleeve 40 , the pressure of the sealed process fluid firmly thrusts the sleeve 40 against the shoulder 52 of the rotary shaft 50 because the pressure area of the back face 5 of the stationary seal ring 3 is larger than the pressure area of the end face 42 of the shaft sleeve 40 . The press contact state is explained by the fact that an inner diameter D of the primary inside diameter surface 41 of the shaft sleeve 40 is set larger than an inner diameter d of the back face 5 of the stationary seal ring 3 , and that a pressure exerted to the portion of the back face 5 in accordance with the diameter difference D-d causes the shaft sleeve 40 to be pressed against the shoulder 52 of the rotary shaft 50 .
The seal cover 30 engages the housing 60 and is retained within the housing 60 by fixedly connecting a flange 70 A of a retainer ring 70 to the housing 60 by means of screw bolts 71 . Disposition of the seal cover 30 can be achieved by holding the right side end face of the cover 30 by the retainer ring 70 as seen in the figure, and does not require the left side end face of the cover 30 to be engaged by a step shoulder. This relation holds from the aforementioned relationship of counter pressures one of which is the pressure exerted to the back face 5 of the stationary seal ring 3 and the other of which is the pressure exerted onto the end face 42 .
Intermediate chamber B is disposed between a pair of the seal parts 20 A and 20 B and the mechanical shaft seal 2 for the inner diameter surface of the seal cover 30 which fits over the housing 60 . A drain passage 38 disposed in the seal cover 30 is a through hole connected to the intermediate chamber B. The drain passage 38 is directly connected to a drain hollow 62 via an annular cavity 34 . A device to process hazardous gases such as ethylene gas or propylene gas is disposed at the outlet of the drain hollow 62 . Pressure of the intermediate chamber B is set lower than that of a sealed fluid chamber A.
Furthermore, a circulation passage 32 is disposed in the seal cover 30 so as to cool off the mechanical shaft seal 2 by circulating the fluid such as oil from the sealed fluid chamber A. The circulation passage 32 is directly connected to a passage hollow 61 via an annular cavity 33 . A dam 58 is disposed in the outer circumferential region of the mechanical shaft seal 2 to circulate along the sealing face 6 of the mechanical shaft seal 2 and the mating sealing face 16 . The seal cover 30 and the retainer ring 70 are connected by screw bolts 72 .
Buffer fluid passage 37 disposed in the seal cover 30 directly connects the buffer fluid chamber C and a buffer fluid hollow 63 via an annular cavity. Pressure of the buffer fluid chamber C is set higher than that of the intermediate chamber B.
As a consequence, a relation of the internal pressures of the sealed fluid chamber A, the intermediate chamber B, and the buffer fluid chamber C is represented by A>B and C>B. Therefore, the sealed process fluid is ejected from the drain passage 38 without leaking through the first seal part 20 A and the second seal part 20 B disposed in the buffer fluid chamber C. Fluid leaked from the sealed fluid chamber A also is ejected from the drain passage 38 .
Next described is another form of a preferred embodiment in accordance with the present invention.
A mechanical seal device 1 as a second preferred embodiment of the present invention is to seal a sealed process fluid by being disposed between the inner circumferential surface of a housing 60 and a rotary shaft 50 retained inside the inner circumferential surface of the housing, being comprised of a mechanical shaft seal 2 , a buffer fluid chamber C, seal parts 20 A, 20 B, and an intermediate chamber B, the mechanical shaft seal 2 being disposed between the housing 60 and a shaft sleeve 40 fitted over the rotary shaft 50 so as to seal the sealed process fluid, the buffer fluid chamber C being constructed between the housing 60 and the shaft sleeve 40 in the opposite side of the sealed fluid region with respect to the mechanical shaft seal 2 and being connected to a buffer fluid passage 37 , the seal parts 20 A, 20 B to seal a gap between the shaft sleeve 40 and the housing 60 inside the buffer fluid chamber C, the intermediate chamber B being disposed between the mechanical shaft seal 2 and the seal parts 20 A, 20 B and being connected to a drain passage 38 , the buffer fluid pressure inside the buffer fluid chamber C being set higher than the fluid pressure inside the intermediate chamber B.
The mechanical seal device 1 as the second preferred embodiment of the present invention can prevent a sealed process fluid inside the intermediate chamber B from leaking to an atmospheric region because of the pressure inside the buffer fluid chamber C being set higher than the pressure of the intermediate chamber B.
A mechanical seal device 1 as a third preferred embodiment of the present invention is constructed in such a way that the pressure of a sealed process fluid is lower than the fluid pressure in an intermediate chamber B while the pressure in an intermediate chamber B being higher than the fluid pressure in a buffer fluid chamber C.
In the mechanical seal device 1 as the third preferred embodiment of the present invention, even if the seal of the mechanical shaft seal 2 is broken, a harmful sealed process fluid is effectively prevented from leaking to an atmospheric region by being ejected from the intermediate chamber B to a collecting device through a drain passage 38 because of the pressure inside the intermediate chamber B being set lower than the pressure of the sealed fluid chamber A.
A mechanical seal device 1 as a fourth preferred embodiment of the present invention has a disconnectable snap ring disposed near the end face of a shaft sleeve to engage a split seal cover for retaining seal parts and the snap ring is removed after the mechanical seal device is installed to the shaft sleeve.
In the mechanical seal device 1 as the fourth preferred embodiment of the present invention, the shaft sleeve does not require fitting devices for retaining respective seal parts, therefore the sleeve 40 can be made light and slim. Furthermore, a rotary shaft and the sleeve do not need to fit over each other in an atmospheric region, therefore the rotary shaft can be made small in diameter. Consequently, the reduction in weight makes it possible for the rotary shaft to rotate fast. Also energy consumption can be saved for driving the rotary shaft.
Mechanical seal devices in accordance with the present invention are expected to be able to effective in the following merits.
In a mechanical seal device 1 in accordance with the present invention, a sealed process fluid exerts more pressure to the back face of a stationary seal ring 3 than to the end face 42 of a shaft sleeve 40 , therefore the sleeve 40 can be engaged to a shoulder 52 of a rotary shaft 50 . Accordingly, the sleeve 40 does not require a fitting device for fixing and thinning the wall thickness of the sleeve results in a reduction in weight. As a consequence, omitting fitting devices and thinning the sleeve 40 yields a reduction in the total size of the mechanical seal device. The reduction in weight then makes it easy for the mechanical seal device 1 to undergo a high speed rotating motion
In addition, leakage of the sealed process fluid from the intermediate chamber B to the atmospheric region can be prevented due to the fact that the pressure inside the buffer fluid chamber C is set higher than the pressure of the intermediate chamber B.
Even in the case of a seal failure of the mechanical shaft seal 2 , since the pressure of the intermediate chamber B is lower than the pressure of the sealed fluid chamber A, the leaked hazardous fluid is effectively caught and ejected from the intermediate chamber B to a collection device through the drain passage 38 without leaking to the atmospheric region HP
Having described specific embodiments of the invention, however, the descriptions of these embodiments do not cover the whole scope of the present invention nor do they limit the invention to the aspects disclosed herein, and therefore it is apparent that various changes or modifications may be made from these embodiments.
The technical scope of the invention is specified by the claims.
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A primary object of the present invention is to achieve a high sealing performance, to collect hazardous gas contained in a sealed process fluid, and to realize an easy disposition of a mechanical seal device. A typical configuration is that the end face of a shaft sleeve engages a rotary shaft by a step shoulder of the shaft which is disposed in the sealed fluid side relative to the stationary seal ring, and that the inner diameter of the end face is set larger than the inner diameter of the sealed fluid pressure surface on the back face of the stationary seal ring. This construction makes it easy to dispose a mechanical seal device and with this mechanical seal device, the sealed process fluid is securely sealed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to novel liquid-crystalline compounds useful as electrooptical display elements.
2. Description of the Prior Art
Liquid crystals which have currently been broadly used as display elements are nematic liquid crystals. When the methods of display are roughly classified, TN type (twisted nematic type), DS type (dynamic scattering type), DAP type (electric field-controlling birefringence type), PC type (cholesteric-nematic phase-transition type), GH type using dichromatic dye (guest-host type), etc. are representative. Smectic liquid crystals have so far been not broadly employed for practical uses, but it is possible to add them to nematic liquid crystals depending on their compatibility with nematic liquid crystals, to thereby improve their characteristic properties, and further, in recent years, since it has become possible to display large capacity informations by way of a matrix display utilizing a electrothermo-optic effect, their practical use has been hurried up. Furthermore a display method according to which the response speed is higher than that of TN type has been actively developed. As to liquid-crystalline materials currently used for these dispaly elements, none of single compounds cannot endure practical use as regards their various characteristic properties i.e. liquid-crystalline temperature range, actuation voltage, response performance, etc.; thus it is the present status that compounds which endure practical use have been obtained by blending several kinds or in some case, about 20 kinds of liquid-crystalline compounds.
In particular, liquid-crystalline display elements have recently been also used for cars, etc., and those which can be used within a broader temperature range and also have a higher response speed have been needed. In order that such liquid-crystalline compositions are composed, higher temperature liquid-crystalline compounds (i.e. those of which the liquid-crystalline temperature range has a higher upper limit) and lower viscosity liquid-crystalline compounds are indispensable as their components. Usually, the former higher temperature liquid-crystalline compounds have intrisically a higher viscosity, while the latter lower viscosity liquid-crystalline compounds such as those expressed by the formulas ##STR4## have no satisfactorily low viscosity, and also they usually have their liquid-crystalline temperature range on the lower side of such ranges to function so as to reduce the liquid-crystalline temperature range of the whole of the composition whereby their amount added is restricted. Thus, compounds having a lower viscosity and also a liquid-crystalline temperature range as high as possible have been desired.
The object of the present invention is to provide compounds which are useful as a lower viscosity liquid-crystalline component of which such liquid-crystalline compositions are partly composed.
SUMMARY OF THE INVENTION
The present invention resides in the following two aspects:
1. Liquid-crystalline compounds expressed by the general formula ##STR5## wherein ##STR6## and R 1 and R 2 each represent an alkyl group of 1 to 8 carbon atoms.
2. Liquid-crystalline compounds expressed by the general formula ##STR7## wherein R 1 and R 2 each represent an alkyl group of 1 to 8 carbon atoms.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Among the compounds expressed by the formula (I), those wherein ##STR8## i.e. those expressed by the general formula ##STR9## (wherein R 1 and R 2 each are as defined above) are nematic liquid-crystalline compounds.
On the other hand, those wherein ##STR10## in the general formula (I) i.e. those expressed by the general formula ##STR11## (wherein R 1 and R 2 each are as defined above) and those expressed by the general formula (II) are mainly smectic liquid-crystalline compounds.
In general, the compounds of the present invention, considering their low viscosity, are liquid-crystalline compounds having a high clearing point (N-I point or S-I point) and also a superior stability. Further, the compounds of the present invention alone cannot be practically used as a liquid crystal for display elements, but since they are superior in the compatibility with other liquid-crystalline compounds, they are used in admixture with such other liquid-crystalline compounds as biphenyl, ester, azoxy, cyclohexanecarboxylic acid ester, phenylpyrimidine, phenylcyclohexane, phenylmetadioxane liquid crystals or the like. Further, since the compounds of the present invention are superior in the response performance, particularly in the steepness property (sharpness of voltage rise) and also little in the temperature-dependency of drive voltage, they are useful as a constituent component for multiplexing drive.
Now, a prior art will be referred to wherein compounds having a similar structure to that of the compounds of the formula (II) of the present invention are disclosed. European patent application laid-open No. 58,981 (filed on Feb. 22, 1982; laid-open on Sept. 1, 1982) is directed to a very broad range of liquid-crystalline compounds containing --CH 2 O-- group. These compounds may include formally the compounds of the formula (II) of the present invention, but the specification of the prior art does not disclose at all not only values of physical properties of compounds corresponding to the compounds of the formula (II) of the present invention but also even the names of the compounds. As for compounds which are structurally similar to those of the formula (II) of the present invention, there are shown values of physical properties of compounds expressed by the following formulas (P) and (Q): ##STR12## wherein R 1 and R 2 each represent an alkyl group of 1 or 2 carbon atoms. Namely the compounds of the formula (II) have two cyclohexane rings, whereas in the prior art European patent application laid-open No. 58,981, one of two six-member rings is benzene ring. The compounds of the formulas (P) and (Q) are far different from those of the formula (II) of the present invention in practical physical properties. Namely the compounds of the formula (II) have a preferable liquid-crystalline temperature range including room temperature as shown in Table 3 of Examples described later, whereas the compounds of the formulas (P) and (Q) have a N-I point as extremely low as -20° to -70° C., excluding only one exception of 7° C., as shown in Tables 1 and 2 of the specification; thus they exhibit practically a different effectiveness from that of the compounds of the formula (II) of the present invention.
Next, the preparation of the compounds of the present invention will be described.
First as to the preparation of the compounds of the formula (I), a 4-(trans-4'-alkylcyclohexyl)benzoic acid prepared by a known method is refluxed with a small amount of concentrated sulfuric acid in an aliphatic alcohol to obtain a compound of the formula (I a ) i.e. an alkyl ester of a 4-(trans-4'-alkylcyclohexyl)benzoic acid, while similarly a trans-4-(trans-4'-alkylcyclohexyl)cyclohexanecarboxylic acid is refluxed with a small amount of concentrated sulfuric acid in an aliphatic alcohol to obtain a compound of the formula (I b ) i.e. an alkyl ester of a trans-4-(trans-4'-alkylcyclohexyl)cyclohexanecarboxylic acid.
Further, the compounds of the formula (II) of the present invention can be prepared through the following steps: ##STR13##
First, a trans-4-(trans-4'-alkylcyclohexyl)cyclohexanecarboxylic acid (III) prepared by a known method is heated under reflux with a small amount of sulfuric acid in methyl alcohol to obtain a trans-4-(trans-4'-alkylcyclohexyl)cyclohexanecarboxylic acid methyl ester (IV) which corresponds to a compound of the above formula (I b ) wherein R 2 is CH 3 . This compound (IV) is reduced with a reducing agent such as lithiumaluminum hydride (LiAlH 4 ) to obtain a compound (V) which is then reacted with p-toluenesulfonyl chloride in dry pyridine to obtain a compound (VI) which is then reacted with an alcoholate to obtain an objective compound of the formula (II).
The preparation and properties of the compounds of the present invention and the use thereof as a liquid-crystalline material will be described in detail by way of Examples.
EXAMPLE 1
Preparation of trans-4-(trans-4'-propylcyclohexyl)cyclohexanecarboxylic acid methyl ester (a compound of the formula (I a ) wherein R 1 is C 3 H 7 and R 2 is CH 3 ).
Methyl alcohol (200 ml) and conc. sulfuric acid (15 ml) were added to trans-4-(trans-4'-propylcyclohexyl)cyclohexanecarboxylic acid (68.2 g, 0.27 mol) and the mixture was heated under reflux for 4 hours, followed by cooling, adding water (200 ml) and toluene (100 ml), transferring the resulting mixture to a separating funnel, three times washing the foluene layer with water (each time 100 ml), distilling off toluene, adding ethyl alcohol (40 ml) to the residue, recrystallizing, filtering off and drying to obtain the objective trans-4-(trans-4'-propylcyclohexyl)cyclohexanecarboxylic acid methyl ester (65 g) (yield: 90.2%).
This product had a melting point (C-N point) of 34.2° C. and a clearing point (N-I point) of 62.8° C., and its values of elemental analysis well accorded with the calculated values as follows:
______________________________________ Calculated values (%)Observed values (%) (as C.sub.17 H.sub.30 O.sub.2)______________________________________C 76.61 76.64H 11.30 11.35______________________________________
EXAMPLES 2˜9
Example 1 was repeated except that trans-4-(trans-4'-propylcyclohexyl)cyclohexanecarboxylic acid or in place thereof, trans-4-(trans-4'-alkylcyclohexyl)cyclohexanecarboxylic acids having other alkyl groups were reacted with methyl alcohol or other aliphatic alcohols to obtain compounds of the formula (I b ). Their physical properties are shown in Table 1 together with those of the compound of Example 1.
TABLE 1______________________________________In the Phase transition point (°C.)formula (I.sub.b) C-S S-N C-N S-I N-IExample R.sub.1 R.sub.2 point point point point point______________________________________2 C.sub.2 H.sub.5 CH.sub.3 -- -- 21.5 -- 19.6 (C-I point)1 C.sub.3 H.sub.7 CH.sub.3 -- -- 34.2 -- 62.83 C.sub.3 H.sub.7 C.sub.2 H.sub.5 20.1 -- -- 57.9 --4 C.sub.3 H.sub.7 C.sub.3 H.sub.7 24.4 -- -- 53.5 --5 C.sub.4 H.sub.9 CH.sub.3 34.9 52.0 -- -- 62.96 C.sub.5 H.sub.11 CH.sub.3 40.3 56.9 -- -- 77.07 C.sub.5 H.sub.11 C.sub.2 H.sub.5 23.1 -- -- 80.6 --8 C.sub.5 H.sub.11 C.sub.3 H.sub.7 34.9 -- -- 78.6 --9 C.sub.7 H.sub.15 CH.sub. 3 52.0 71.9 -- -- 79.9______________________________________
EXAMPLE 10
Preparation of 4-(trans-4'-pentylcyclohexyl)benzoic acid methyl ester (a compound of the formula (I a ) wherein R 1 is C 5 H 11 and R 2 is CH 3 ).
Methyl alcohol (50 ml) and conc. sulfuric acid (4 ml) were added to 4-(trans-4'-pentylcyclohexyl)benzoic acid (13.8 g, 0.05 mol) and the mixture was heated under reflux for 4 hours, followed by cooling, adding water (20 ml) and toluene (30 ml), transferring the resulting mixture to a separating funnel, three times washing the toluene layer with water (each time 20 ml), distilling off toluene, recrystallizing the residue from ethyl alcohol, filtering off and drying to obtain the objective 4-(4'-trans-pentylcyclohexyl)benzoic acid methyl ester (12.1 g) (yield: 83.6%). The product had a melting point (C-I point) of 54.2° C. and its mixture with trans-4-pentyl-1-(4-cyanophenyl)cyclohexane was measured to obtain a N-I point of 48° C. as extrapolated. The values of elemental analysis of this compound well accorded with calculated values as follows:
______________________________________ Calculated values (%)Observed values (%) (as C.sub.19 H.sub.28 O.sub.2)______________________________________C 79.10 79.12H 9.75 9.78______________________________________
EXAMPLES 11-18
Example 10 was repeated except that 4-(trans-4'-pentylcyclohexyl)benzoic acid or in place thereof, 4-(trans-4'-alkylcyclohexyl)benzoic acids having other alkyl groups were reacted with methyl alcohol or other aliphatic alcohols to obtain other compounds of the formula (I a ). Their physical properties are shown in Table 2 together with those of the compound of Example 10.
TABLE 2______________________________________ Phase transition point (°C.)In the formula (I.sub.a) C-I N-IExample R.sub.1 R.sub.2 point point______________________________________11 C.sub.3 H.sub.7 CH.sub.3 39.9 (35.0)12 C.sub.3 H.sub.7 C.sub.2 H.sub.5 Room temp. (-18.0)* or lower13 C.sub.3 H.sub.7 C.sub.3 H.sub.7 Room temp. (-22.0)* or lower10 C.sub.5 H.sub.11 CH.sub.3 54.2 (48)14 C.sub.5 H.sub.11 C.sub.2 H.sub.5 Room temp. (16.1)* or lower15 C.sub.5 H.sub.11 C.sub.3 H.sub.7 Room temp. (22.5)* or lower16 C.sub.7 H.sub.15 CH.sub.3 42.5 52.217 C.sub.7 H.sub.15 C.sub.2 H.sub.5 Room temp. (21.0)* or lower18 C.sub.7 H.sub.15 C.sub.3 H.sub.7 Room temp. (12.5)* or lower______________________________________ Symbol * indicates extrapolated values of N-I point by way of mixing of the respective compounds with ##STR14##
EXAMPLE 19
Preparation of trans,trans-4-propyl-4'-methyloxymethylbicyclohexane (a compound of the formula (II) wherein R 1 is C 3 H 5 and R 2 is CH 3 )
First step:
The process is all the same as that of Example 1 as described above.
Second step:
Dry tetrahydrofuran (THF) (440 ml) was added to lithiumaluminum hydride (7.0 g, 0.188 mol) and the mixture was vigorously agitated, followed by dropwise adding thereto a solution obtained by dissolving trans-4-(trans-4'-propylcyclohexyl)cyclohexanecarboxylic acid methyl ester obtained at the first step (i.e. in Example 1) (65 g, 0.244 mol) in THF (65 ml), at a reaction temperature kept at 20° C. or lower, thereafter heating the mixture up to 55° C., reacting for 2 hours, cooling, adding ethyl acetate (13 ml) and water (100 ml) and then a 18% aqueous solution of sulfuric acid (400 ml), to give an organic layer and an aqueous layer separated from each other, adding heptane (200 ml), transferring the mixture to a separating funnel, washing with water (500 ml), further washing with a 2% aqueous solution of sodium carbonate (500 ml), further washing with water till the aqueous layer became neutral, distilling off heptane, THF, etc. under reduced pressure, recrystallizing the product remaining in the kettle from ethyl alcohol (100 ml), filtering off crystals and drying to obtain a compound of the formula (V) (49.3 g) which had a melting point of 125.8°˜126.9° C.
Third step:
The compound of the formula (V) (49.2 g, 0.268 mol) was dissolved in dry pyridine (100 ml) and dry toluene (240 ml) and the solution was cooled down to 5° C. or lower, followed by dropwise adding to this solution a solution obtained by dissolving p-toluenesulfonic acid chloride (42 g, 0.216 mol) in dry toluene (70 ml), in small portions, so that the reaction temperature could not exceed 10° C., followed by removing the cooling bath, stirring at room temperature for 4 hours, adding water (100 ml) and toluene (300 ml), stirring, transferring the mixture to a separating funnel, twice washing the toluene layer with a 6N-HCl aqueous solution (100 ml), once washing with water (200 ml), further twice with a 2N-NaOH aqueous solution (100 ml), 4 times washing with water (200 ml), distilling off toluene under reduced pressure, recrystallizing the resulting crystals from ethyl alcohol (200 ml), filtering off crystals and drying to obtain a compound of the formula (VI) (54 g) having a melting point of 94.8°˜95.8° C.
Fourth step:
Slices of metallic sodium (1.8 g, 0.080 mol) were portionwise added to methyl alcohol (50 ml) agitated at room temperature to prepare sodium methoxide. After the metallic sodium slices disappeared, a solution obtained by dissolving the compound of the formula (VI) (24 g, 0.061 mol) obtained at the third step in dry toluene (50 ml) was gradually added through a dropping funnel so as to keep the inner temperature in the range of 50° to 60° C., followed by refluxing for 4 hours, cooling, adding water (20 ml), transferring the mixture to a separating funnel, washing the toluene layer with water till the aqueous layer became neutral, distilling off toluene under reduced pressure, distilling under reduced pressure, to collect a fraction having a boiling point of 113°˜117° C./1.5 mmHg, recrystallizing crystals of this fraction from ethyl alcohol (15 ml), filtering off crystals and drying to obtain the objective compound, trans,trans-4-propyl-4'-methyloxymethylbicyclohexane (12 g). This product exhibited a smectic phase and a nematic phase and had a melting point (C-S point) of 44.8° C., a S-N point of 51.0° C. and a clearing point (N-I point) of 52.0° C. Its values of elemental analysis well accorded with calculated values as follows: T1 ? Calculated values (%)? Observed values (%)? (as C 17 H 32 O)? C 80.86 80.88 H 12.75 12.78?
EXAMPLES 20˜27
Example 19 was repeated except that trans-4-(trans-4'-propylcyclohexyl)cyclohexane carboxylic acid or other trans-4-(trans-4'-alkylcyclohexyl)cyclohexane carboxylic acids were used and at the fourth step, methyl alcohol or other aliphatic alcohols were used to obtain compounds of the formula (II). Their physical properties are shown in Table 3 together with those of the compound of Example 19.
TABLE 3______________________________________In the Phase transition point (°C.)Formula (II) C-S S-N S-I N-IExample R.sub.1 R.sub.2 point point point point______________________________________20 C.sub.2 H.sub.5 CH.sub.3 -14 -- 37 --19 C.sub.3 H.sub.7 CH.sub.3 44.8 51.0 -- 52.021 C.sub.3 H.sub.7 C.sub.2 H.sub.5 5.8 -- 52.4 --22 C.sub.3 H.sub.7 C.sub.3 H.sub.7 14.0 -- 43.3 --23 C.sub.4 H.sub.9 CH.sub.3 -21.6 -- 61.9 --24 C.sub.5 H.sub.11 CH.sub.3 19.6 -- 73.4 --25 C.sub.5 H.sub.11 C.sub.2 H.sub.5 -14.8 -- 75.4 --26 C.sub.5 H.sub.11 C.sub.3 H.sub.7 14.3 -- 69.3 --27 C.sub.7 H.sub.15 CH.sub.3 27.8 -- 70.3 --______________________________________
In addition, the melting points of the compounds of the formulas (V) and (VI) as intermediates obtained at the second and third stages are shown in Table 4.
TABLE 4______________________________________ Melting points of Melting points of compounds of compounds ofR.sub.1 formula (V) (°C.) formula (VI) (°C.)______________________________________C.sub.2 H.sub.5 116.7˜120.3 84.9˜87.1C.sub.3 H.sub.7 125.8˜126.9 94.8˜95.8C.sub.4 H.sub.9 132.6˜133.4 87.8˜89.9C.sub.5 H.sub.11 128.7˜130.0 91.0˜94.3C.sub.7 H.sub.15 119.5˜120.8 85.6˜87.1______________________________________
EXAMPLE 28 (USE EXAMPLE 1)
A liquid-crystalline composition (A) consisting of
______________________________________ ##STR15## 21 parts by weight, ##STR16## 28 parts by weight and ##STR17## 21 parts by weight,______________________________________
had a nematic liquid-crystalline temperature range (MR) of -3° to +52.5° C., a viscosity at 20° C. (η 20 ) of 23 cp, a dielectric anisotropy Δε of 11.3 (ε.sub.∥ =16.2, ε.sub.⊥ =4.9) and an optical anisotropy Δn of 0.120. When this composition was sealed in a TN cell of 10 μm thick, the resulting threshold voltage and saturation voltage were 1.5 V and 2.2 V, respectively. When the compound of Example 6 (15 parts) and that of Example 8 (15 parts), each as one of the compounds of the present invention, were added to the above composition, the resulting liquid-crystalling composition had a MR of -3° to +53.3° C., a η 20 of 20.5 cp, a Δε of 7.9 (ε.sub.∥ =12.5, ε.sub.⊥ =4.6) and a Δ.sub. n of 0.096, and when it was sealed in the same cell as the above, the resulting threshold voltage and saturation voltage were 1.65 V and 2.2 V, respectively. Further when the sharpness i.e. the ratio of saturation voltage to threshold voltage before the addition of the compounds of the present invention was compared with that after the addition, the property was improved from 1.47 up to 1.33.
EXAMPLE 29 (USE EXAMPLE 2)
To the liquid-crystalline composition (A) used in Example 28 were added the compound of Example 9 (20 parts) and that of Example 25 (10 parts), each as one of the compounds of the present invention. The resulting liquid-crystalline composition had a MR of -10° C. or less to +52.2° C., a η 20 of 17 cp and a Δε of 7.6 (ε.sub.∥ =11.8, ε.sub.⊥ =4.2), and when this composition was sealed in the same cell as the above-mentioned, the resulting threshold voltage and saturation voltage were 1.61 V and 2.33 V, respectively.
EXAMPLE 30 (USE EXAMPLE 3)
A liquid-crystalline composition consisting of
______________________________________ ##STR18## 27 parts by weight, ##STR19## 9 parts by weight, ##STR20## 28 parts by weight and ##STR21## (compound of Example 19) 36 parts by______________________________________ weight
was prepared. This liquid-crystalline composition was a nematic one having a N-I point as high as 85.4° C. and nevertheless a viscosity as extremely low as 15.4 CPS (20° C.) and also a high response speed. In addition when this composition was sealed in the same cell as in Example 29 and the cell was driven, the resulting threshold voltage and saturation voltage were 2.7 V and 3.8 V, respectively.
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Compounds useful as lower viscosity liquid-crystalline components of which liquid-crystalline compositions are partly composed are provided, which compounds are
liquid-crystalline compounds expressed by the general formula ##STR1## wherein ##STR2## and R 1 and R 2 each represent an alkyl group of 1 to 8 carbon atoms, or
liquid-crystalline compounds expressed by the general formula ##STR3## wherein R 1 and R 2 each represent an alkyl group of 1 to 8 carbon atoms.
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FIELD OF THE DISCLOSURE
[0001] The subject disclosure generally relates to the field of coiled tubing and coiled tubing applications in hydrocarbon wells. More particularly, the subject disclosure relates to reducing residual bending and fatigue of coiled tubing.
BACKGROUND OF THE DISCLOSURE
[0002] Coiled tubing refers to metal piping, used for interventions in oil and gas wells and sometimes as production tubing in depleted gas wells, which comes spooled on a large reel. Coiled tubing operations typically involve at least three primary components. The coiled tubing itself is disposed on a reel and must, therefore, be dispensed onto and off of the reel during an operation. The tubing extends from the reel to an injector. The injector moves the tubing into and out of the wellbore. Between the injector and the reel is a tubing guide or gooseneck. The gooseneck is typically attached or affixed to the injector and guides and supports the coiled tubing from the reel into the injector. Typically, the tubing guide is attached to the injector at the point where the tubing enters. As the tubing wraps and unwraps on the reel, it moves from one side of the reel to the other (side to side).
[0003] Residual bend exists in every coiled tubing string. During storage and transportation, a coiled-tubing string is plastically deformed (bent) as it is spooled on a reel. During operations, the tubing is unspooled (bent) from the reel and bent on the gooseneck before entering into the injector and the wellbore. Residual bending is one of the technical challenges for coiled tubing operations and originates from the spool of the coiled tubing on the reel. Although the reel is manufactured in a diameter as large as possible to decrease the residual bending incurred on the coiled tubing, the maximum diameter of many reels is limited to several meters due to storage and transportation restrictions.
[0004] Coiled tubing is susceptible to a condition known as helical buckling of the tubing which leads to lockup. Residual bending of the coiled tubing increase the susceptibility of the coiled tubing to helical buckling and lockup. As the coiled tubing goes through the injector head, it passes through a straightener; but the tubing retains some residual bending strain corresponding to the radius of the spool. That strain gives the tubing a helical form when deployed in a wellbore and can cause it to wind axially along the wall of the wellbore like a long, stretched spring. Ultimately, when a long enough length of coiled tubing is deployed in the well bore, frictional forces from the wellbore wall rubbing on the coiled tubing cause the tubing to bind and lock up, thereby stopping its progression. Lock up limits any further progression as the coiled tubing cannot be pushed further by a force applied at the surface. (Lubinski, A., Althouse, W. S., and Logan, J. L., “Helical Buckling of Tubing Sealed in Packers,” SPE 178, 1962). Such lock up limits the use of coiled tubing as a conveyance member for logging tools in highly deviated, horizontal, or up-hill sections of wellbores. Therefore, reducing the residual bending of the coiled tubing before the coiled tubing is placed into the wellbore can increase the extended reach of the coiled tubing (Zheng, A. and Adnan, S., “The Penetration of Coiled Tubing with Residual Bend in Extended-Reach Wells,” SPE 95239, 2007). Residual bending also decreases the fatigue life for coiled tubing, therefore, reducing residual bending will thus increase the fatigue life of coiled tubing (Bhalla, K., “Coiled Tubing Extended Reach Technology,” SPE 30404, 1995). Fatigue failure of coiled tubing is a serious concern because of plastic deformation caused by repeated bending on the reel and gooseneck.
[0005] Coiled tubing passing downward (generally running-in hole) undergoes at least three straining events: 1) as the coiled tubing is straightened upon leaving the reel and on approach to the gooseneck; 2) as the coiled tubing is curved over the gooseneck; and 3) as the coiled tubing is straightened on its way from the gooseneck to the injector head. Similarly, coiled tubing passing upward (generally pulling-out-of-hole) undergoes at least three straining events: 1) as the coiled tubing is extracted from the wellbore and curved over the gooseneck; 2) as the coiled tubing is straightened upon leaving the gooseneck and on approach to the reel; and 3) as the coiled tubing is being curved onto the reel. These strains in coiled tubing may cause residual bend in the tubing which may prevent it from straightening properly in the borehole or rolling properly on the reel.
[0006] Residual bending is reduced by the straightener. The straightener applies compressive forces around the coiled tubing before the coiled tubing is placed into the wellbore, straightening the coiled tubing and reducing some of the residual bending in the coiled tubing. However, the tubing retains some residual bending. Furthermore, the straightener is unable to reduce fatigue of the coiled tubing or elongate the life cycle of the coiled tubing.
[0007] Mueller et al, (U.S. Pat. No. 5,291,956) proposes a method for reducing the residual bending using a pulley. However, the pulley has a diameter near to the diameter of the reel and occupies additional space for the coiled tubing unit.
[0008] The presently disclosed subject matter addresses the problems of the prior art by addressing residual bending and fatigue of the coiled tubing. The presently disclosed subject matter reduces residual bending and fatigue of the coiled tubing, which assists in extending the maximum reach of the coiled tubing in the wellbore and the life cycle of the coiled tubing respectively.
SUMMARY OF THE DISCLOSURE
[0009] In view of the above there is a need for an improved mechanism which reduces residual bending in coiled tubing. Further there is a need for an improved mechanism to reduce fatigue of the coiled tubing and elongate the life cycle. The subject technology accomplishes these and other objectives. The subject disclosure provides a method of reducing residual bending and fatigue in the coiled tubing by utilizing a reel and gooseneck. The subject disclosure discloses a gooseneck that provides an opposite bending moment to reduce the residual bending in the coiled tubing as a result of the reel. Further, the subject disclosure discloses a gooseneck having an adjustable radius during the coiled tubing operations which optimizes the residual bending reduction process. The subject disclosure also discloses a heating and cooling module. The heating and cooling modules are attached to the gooseneck and are utilized to increase the efficiency of the residual bending process and reduce fatigue of the coiled tubing.
[0010] In accordance with an embodiment of the subject disclosure, an apparatus for reducing residual bending in coiled tubing is disclosed. A gooseneck is positioned to receive the coiled tubing from the coiled tubing reel and once positioned reverse bends the coiled tubing to an extent sufficient to remove residual bend resulting from the coiled tubing being coiled on the reel.
[0011] In accordance with a further embodiment of the subject disclosure, a method for reducing residual bend from a reel is disclosed. A gooseneck is positioned to reverse bend the coiled tubing sufficiently to remove residual bend resulting from the coiled tubing being coiled on the reel.
[0012] Further features and advantages of the subject disclosure will become more readily apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0013] FIG. 1 shows the coiled tubing operating environment for the subject disclosure;
[0014] FIG. 2 represents a coiled tubing unit having a hydraulically operated tubing reel and shows the bending events that coiled tubing undergoes while moving from the coiled tubing reel to the main injector;
[0015] FIG. 3 illustrates one embodiment of the subject disclosure;
[0016] FIG. 4 illustrates a second embodiment of the subject disclosure;
[0017] FIG. 5 illustrates the embodiment of FIG. 1 with a heating and cooling module;
[0018] FIG. 6 illustrates the embodiment of FIG. 2 with a heating and cooling apparatus;
[0019] FIG. 7 illustrates a gooseneck having an adjustable radius of curvature; and
[0020] FIG. 8 is the bending moment M—curvature 1/ρ curve of coiled tubing under elastically-perfectly plastic deformation.
DETAILED DESCRIPTION
[0021] Embodiments of the present technology comprise a reel and a gooseneck which significantly reduce residual bending of the coiled tubing.
[0022] In FIG. 1 the operating environment of the subject disclosure is shown. Coiled tubing operation comprises a truck 103 and/or trailer 109 that supports power supply 105 and tubing reel 107 . An injector unit head 111 feeds and directs coiled tubing 113 from the tubing reel into the subterranean formation. The configuration of FIG. 1 shows a horizontal wellbore configuration which supports a coiled tubing trajectory 115 into a horizontal wellbore 117 . The subject disclosure is not limited to a horizontal wellbore configuration but may also be used in vertical and deviated wells, both on land and offshore. Downhole tool 119 is connected to the coiled tubing, as for example, to conduct flow or measurements, or perhaps to provide diverting fluids.
[0023] FIG. 2 depicts a coiled tubing assembly 211 . The coiled tubing assembly 211 is composed of coiled tubing 203 , reel 201 and a gooseneck 205 . When the coiled tubing assembly is run into the wellbore the coiled tubing 203 spooled onto the reel 201 is unwound first and then delivered through a levelwind assembly 212 and a coiled tubing brake 214 in a controllable way. The coiled tubing spooled on the reel 201 is plastically deformed, resulting in residual bending in the coiled tubing. The forces and strains placed upon coiled tubing when it is used in a coiled tubing unit 211 are apparent from viewing FIG. 2 . Coiled tubing undergoes numerous bending events each time it is run into and out of a wellbore. Coiled tubing 203 is straightened when it emerges from the reel by way of the levelwind assembly 212 . A levelwind assembly for a coiled tubing reel guides coiled tubing onto a reel when the coiled tubing is removed from an oil or gas well and guides coiled tubing from the reel when the coiled tubing is injected into an oil or gas well. Levelwind assemblies are known to those skilled in the art. One such levelwind assembly is describe in U.S. Pat. No. 6,264,128, entitled “Levelwind Assembly for Coiled Tubing Reel”, incorporated herein in its entirety by reference. Coiled tubing brake 214 on the levelwind assembly 212 is shown. The coiled tubing 203 is guided by the gooseneck 205 , and is straightened as it goes into the injector head 207 for entry into the wellbore. Of course, each bending event is repeated in reverse when the tubing is later extracted from the wellbore. These bending events weaken the tubing each time it is used, and tubing use must be monitored. Tubing is discarded when it has been used beyond an acceptable safety limit as indicated by reaching predicted fatigue limits. The coiled tubing, typically made of steel, is plastically deformed every time it is spooled off the reel, bent over the gooseneck, straightened through the chains, and in the reverse process. It is known that the fatigue resistance of steel is severely degraded when it is plastically deformed. Residual bending in the coiled tubing 203 is not reduced when the coiled tubing 203 is guided by the gooseneck 205 . When the coiled tubing 203 slides through the injector head 207 , the injector head 207 exerts a compressive force around the coiled tubing which straightens the coiled tubing. Finally, after the coiled tubing is straightened by the injector head 207 , the residual bending in the coiled tubing 209 is reduced before the coiled tubing 209 is run into the wellbore.
[0024] FIG. 3 show a reel 301 of coiled tubing 305 stored on a drum in a clockwise direction 309 . As the coiled tubing 305 slides through the gooseneck 303 the coiled tubing 305 unwinds in a counter-clockwise direction 311 , and continues unwinding in a counter-clockwise direction 311 as it is placed into a wellbore (not shown). The reel 301 spooled with coiled tubing 305 rotates in a clockwise direction 309 while the coiled tubing 305 is guided by the gooseneck 303 in a counter-clockwise direction 311 when the coiled tubing is run into a wellbore. Once the coiled tubing 305 leaves the reel 301 , the residual bending existing in the coiled tubing 305 is compensated by an opposite bending moment exerted by the gooseneck 303 and the residual bending in the coiled tubing 307 is reduced. The opposite bending moment means the sign of the bending moment M is different, i.e. clockwise or anti-clockwise. Once the coiled tubing 305 has travelled through the gooseneck 303 , residual bending in the coiled tubing 305 will be significantly reduced. Residual bending of the coiled tubing is significantly reduced as a result of the reverse unwinding of the coiled tubing, in this instance in a counter-clockwise direction. The radius profile of the gooseneck 303 is adjustable during the coiled tubing operation for optimal reduction of residual bending.
[0025] FIG. 4 shows a reel 401 of coiled tubing 403 stored on a drum in a counter-clockwise direction 411 . The reel 401 spooled with coiled tubing 403 rotates in a counter-clockwise direction 411 and the coiled tubing is guided by a first section of the gooseneck 409 in the same counter-clockwise direction when running the coiled tubing into well. A second section of the gooseneck 407 enables rotation of the coiled tubing in a clockwise direction 415 . The coiled tubing 403 enters a first section 409 of the gooseneck in a counter-clockwise direction 413 . The gooseneck further comprises a second section 407 . The coiled tubing 403 enters in a clockwise direction 415 into the second section 407 of the gooseneck. The residual bending existing in the coiled tubing 403 is compensated by an opposite bending moment exerted by the second section 407 of the gooseneck on the coiled tubing 403 and the residual bending in the coiled tubing 405 is reduced. Once the coiled tubing moves through the second section 407 of the gooseneck the residual bending in the coiled tubing 403 will be significantly reduced. The radius profile of the second section 407 of the gooseneck is adjustable for optimal reduction of residual bending.
[0026] FIG. 5 illustrates the schematic of FIG. 3 further comprising a heating and cooling module. FIG. 5 depicts a reel 505 of coiled tubing 507 stored on a drum in a clockwise direction 513 . A heating module 503 is attached to the gooseneck 501 and a cooling module 509 surrounds the coiled tubing 507 . The heating module 503 heats the coiled tubing 507 and enables the residual bending reduction process in a high temperature. In certain non-limiting examples the temperature may reach 600° C. A high temperature increases the efficiency of reducing residual bending and reducing fatigue of the coiled tubing 507 . The cooling module 509 controls the temperature of the coiled tubing 507 ensuring the high temperature is in an area close to the gooseneck 501 . Thus, the cooling module 509 confines the high temperature of the coiled tubing 507 to a region close to the gooseneck 501 .
[0027] FIG. 6 illustrates the schematic of FIG. 4 further comprising heating and cooling modules. FIG. 6 depicts a reel 609 of coiled tubing 613 stored on a drum in a counter-clockwise direction 615 . A heating module 603 is attached to a second section 603 of gooseneck and a cooling module 605 surrounds the coiled tubing 613 on either end of the gooseneck 601 . Similar to the embodiment of FIG. 5 the heating module 603 heats the coiled tubing 605 and enables the residual bending reduction process in a high temperature. A high temperature increases the efficiency of reducing residual bending and reducing fatigue of the coiled tubing 605 . The cooling module 605 controls the temperature of the coiled tubing 605 ensuring the high temperature is in an area close to the second section 611 of the gooseneck. Thus, the cooling module 605 confines the high temperature of the coiled tubing 613 to a region close to the area of the second section 611 of the gooseneck.
[0028] The configuration of the gooseneck 303 and the second section of the gooseneck 407 are adjustable during an individual coiled tubing operation or multiple coiled tubing operations. For the individual coiled tubing operation, the configuration of the gooseneck 303 or 407 changes as different locations of the coiled tubing are guided by the gooseneck 303 or 407 . The magnitude of the residual bending of the coiled tubing varies depending on the location of the coiled tubing on the reel. The coiled tubing spooled on the outside of the reel experiences less plastic deformation than the coiled tubing spooled on the inner side of the reel. The radius of curvature of the gooseneck 303 or 407 may be adjusted from a large curvature to a smaller curvature as more coiled tubing is unwound from the reel when the coiled tubing is run into the wellbore.
[0029] For the multiple coiled tubing operations, the configuration of the gooseneck 303 or 407 changes as the diameter of the reel changes. The magnitude of the residual bending of the coiled tubing varies depending on the diameter of the reel. The coiled tubing spooled on large reels experiences less plastic deformation than the coiled spooled on smaller reels. The radius of curvature of the gooseneck 303 or 407 is adjusted to a larger radius if the coiled tubing is spooled on a larger reel. The radius of curvature of the gooseneck 303 or 407 is adjusted to a smaller radius if the coiled tubing is spooled on a smaller reel.
[0030] FIG. 7 schematically illustrates a gooseneck 701 with an adjustable radius of curvature. The gooseneck has the largest radius of curvature when segment 714 , segment 715 , segment 716 , and the plurality of other segments (not listed) are expanded. Joint 713 is fixed on the segment 714 . Joint 705 and joint 709 are fixed on the gooseneck base 703 . When the radius of curvature of the gooseneck decreases, segment 715 collapses into segment 714 . At the same time, upper supporting arms 711 rotate around joint 713 and lower supporting arms 707 rotate around joint 705 and joint 709 to achieve a new balanced position. When the radius of curvature of the gooseneck further decreases, segment 716 also collapses into segment 714 , upper arms 711 and lower arms 707 change their positions accordingly, to a different balanced position. One skilled in the art will appreciate that adjusting the radius of curvature can be accomplished using many other techniques known to those skilled in the art and not described in the subject disclosure.
[0031] The significance of the residual bending can be described quantitatively by using bending strain. The maximum magnitude of the bending strain ε max in a given pipe cross-section usually occurs on the outside of the pipe. The radius of the reel is ρ 0 and the coiled tubing outside diameter is D o . When the number of the loops of the coiled tubing spooled on the reel is n, the curvature ρ of the coiled tubing of the i th loop is:
[0000] ρ=β 0 +i·D o ( i= 1, 2 . . . n ) (1)
[0000] The relationship between the maximum bending strain ε max , curvature 1/ρ, and the pipe outside diameter D o is:
[0000] |ε max |=|( D o /2)(1/ρ)| (2)
[0000] As can be seen from Eq. (2), the residual bending is significant when the pipe outside diameter D o is large and the radius ρ is small. As can be seen from Eq. (1), the radius ρ is small when the radius of the reel ρ o is small and the number of the loops n is small.
[0032] FIG. 8 depicts the bending moment M—curvature (ρ) of a pipe undergoing a series of deformations. In a non-limiting example this pipe may be a portion of coiled tubing. The material is assumed to be elastically-perfectly plastic. In a first deformation from A to B the pipe undergoes linear elastic bending. Further bending from B to C results in deformation which is elastic-plastic, this means that some parts of a cross-section are deforming plastically and some parts of a cross-section are deforming elastically. The deformation from A to C may be representative of placing a straight coiled tubing string onto a reel. The pipe unloads elastically from C-D, the curvature at D would be the residual bend if no further deformation occurred e.g. if a coiled tubing was unwound from the reel without a straightening process. If the pipe is then straightened, the deformation will unload elastically from D to E and then elastically-plastically from E to F. At F, the pipe will be straight. If the pipe then unloads elastically, it will proceed from F to G and have a residual bend shown by the curvature at G. If the pipe is then reverse-bent, the deformation will proceed from F to G′, with further elastic-plastic deformation. Upon unloading elastically from G′, the pipe returns to the initial state A with no residual bend, providing G′ has been selected appropriately. In one non-limiting example G′ would be estimated by reverse bending to the same curvature as seen at G, i.e. reverse bending by the same amount as the residual curvature if in the absence of the reverse bend operation.
[0033] Reverse bending may also occur elsewhere in the coiled tubing e.g. injector. Although the embodiments of the subject disclosure have been described with respect to coiled tubing, the mechanisms disclosed may reduce residual bending of tubing in general.
[0034] While the subject disclosure is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the subject disclosure should not be viewed as limited except by the scope and spirit of the appended claims.
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The subject disclosure provides a reel and a gooseneck which significantly reduce residual bending of the coiled tubing. The subject disclosure discloses a gooseneck that provides reverse bending forces to reduce the residual bending as a result of the reel. Further, the subject disclosure discloses a gooseneck having an adjustable radius during the coiled tubing operations which optimizes the residual bending process. The subject disclosure also discloses a heating and cooling module. The heating and cooling modules are attached to the gooseneck and are used to reduce fatigue of the coiled tubing and elongate the life cycle of the coiled tubing.
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FIELD OF THE INVENTION
The field of the present invention pertains to computer implemented graphics. More particularly, the present invention pertains to a method and system for efficiently simplifying 3D tetrahedral models used in 3D volumetric representations.
BACKGROUND OF THE INVENTION
Computer graphics are being used today to perform a wide variety of tasks. Many different areas of business, industry, government, education, entertainment, and most recently, the home, are tapping into the enormous and rapidly growing list of applications developed for today's increasingly powerful computer devices. Graphical user interfaces have replaced textual interfaces as the standard means for user computer interaction.
Graphics have also become a key technology for communicating ideas, data, and trends in most areas of commerce, science, and education. Until recently, real time user interaction with three dimensional (3D) models and pseudo-realistic images was feasible on only very high performance workstations. These workstations contain dedicated, special purpose graphics hardware, and are typically very expensive. The spectacular progress of semiconductor fabrication technology has made it possible to do the same real time 3D animation, with color shaded images of complex objects, described by thousands of polygons, on rendering subsystems of only a few chips. The most recent and most powerful workstations are capable of rendering completely life-like, realistically lighted, 3D scenes.
In a 3D computer generated image, objects are typically described by data models. These models store descriptions of “primitives” (usually mathematically described polygons and polyhedra) that define the shape of the object, the object attributes, and the connectivity and positioning data describing how the objects fit together. The component polygons and polyhedra connect at common edges defined in terms of common vertices and/or enclosed volumes.
There are primarily two techniques used in 3D modeling; surface geometry modeling, and volumetric modeling. Surface geometry modeling is the more common of the two techniques. As is well known, in surface geometry modeling, primitives are used to define the surface of an object (e.g., a polygon mesh approximating the shape of the surface of an object). The polygons are textured, Z-buffered, and shaded/illustrated onto an array of pixels, creating a realistic 3D image. Volumetric modeling is the less common of the two techniques. Volumetric modeling is considerably more complex than surface geometry modeling.
The volumetric modeling, or volumetric representation of objects is typically specified in terms of a set of 3D “volumetric primitives”, which include tetrahedra, blocks, cylinders, cones, spheres etc., and a set of Boolean operators, for example union, intersection and difference. In typical applications, the volumetric primitive descriptions can be much more complex, including for example, ellipsoidal shapes or other “quadric” descriptions (e.g., quadratic descriptions which consists of a second order surface with variable parameters). The volumetric modeling of complex objects is used to implement volume visualization applications.
Volume visualization is widely recognized as one of the best ways of understanding increasingly large and complex data sets, such as for example, large and complex sets of observed or simulated scientific and engineering data. The more advanced volume visualization techniques, for example, present an entire data set at once and take advantage of the innate capabilities of the human visual system to distinguish depth and recognize patterns, trends, and anomalies in complex visual environments. Such volume visualization techniques often present data with a minimum of preprocessing and enable users to interpret that data by applying their own knowledge of the scientific or engineering processes that underlie it. Hence, for example, by magnifying the human intelligence applied to the interpretation process, volume visualization allows scientists and engineers to create better solutions faster and at lower cost than ever possible before.
To achieve its best results, volume visualization requires accurate, high fidelity volume after representation of objects. Many such objects require the generation of smooth surfaces, curves, and internal and external features. To realistically generate a real-world object, various subdivision or tessellation algorithms have been developed.
The tessellation/subdivision algorithms are generally a set of geometry based rules for increasing the number of primitives used to model an object. A computer system implements these rules in the process of computing the tessellation, using the rules to manipulate the primitives of the model. A complex volumetric representation can include many hundreds of thousands of primitives.
For example, in a typical tessellation technique, the primitives comprising a volumetric model (e.g., tetrahedra) are each divided into a plurality of “daughter” to primitives. The daughter primitives share most of the characteristics of the “parent” primitive, however, their position and orientation in 3D space is influenced by the position and orientation of neighboring daughter primitives. The nature and degree of this influence is implementation specific, i.e., particular tessellation algorithms cause differing effects. Tessellation algorithms determine the placement of the vertices and edges of the daughter primitives. In so doing, a typical tessellation algorithm utilizes not only information regarding the parent primitive, but also information regarding the connectivity of the parent primitive with its neighboring primitives. The tessellation algorithm places and connects the daughter primitives in 3D space such that the primitive mesh becomes a smoother, less geometrically aliased representation of the real life object being modeled.
There exists several problems, however, with increasing the number primitives used to model volumetric 3D objects. One problem is the fact that increasing the number primitives in a model greatly increases the computational load on the computer system. In performing volumetric tessellation processing, the computer system needs to perform geometric manipulations on each of the primitives comprising the model, which can lead to severe computational loads. These computational loads often slow the graphics processing speed of the computer system. In addition to the computational loads caused by performing the tessellation itself, the computer system has a finite amount of memory space. Each primitive in the model has a number of attributes which need to be stored, e.g., the coordinates of each of the vertices of the primitive, the connective relationship of the primitive in relation to its neighbors, the orientation of the primitive in 3D space, and the like. Volumetric tessellation also reduces the number of objects a computer system can simultaneously store and manipulate, volumetric tessellation processing geometrically increases the number of primitives in a modeled object. The lack of memory resources is often a limiting factor in the graphics process. Hence, all though it is desirable to model an object with a large number of primitives in order to reduce geometric aliasing, increasing the number of primitives greatly stresses the computational resources of the computer system.
Thus, many applications require that some form of simplifying transformation be applied to a tetrahedral tessellation to facilitate easier manipulation by the computer system. For example, many adjacent cells of an “over-tessellated” object can be collapsed to decrease the cell count (e.g., two adjacent primitives can often be collapsed into one reducing the minimal cell count from 10 to 5). Similarly, certain types of sub-volumes clipped to arbitrary densely tessellated surfaces (e.g., horizon surfaces in seismic data interpretation) can result in prohibitively large number of cells and may have to be simplified in order to facilitate further manipulation. As another example, the creation of multi-resolution models of volumetrically defined objects can also require smooth transformation between various tetrahedral decompositions. Such models can be used to improve rendering performance for large volumetric models of large complex data sets, or, for example, to facilitate hierarchical collision detection. Finally, combined with multi-resolution handing of large textures, tetrahedral mesh simplification can be used as an effective model compression technique and an aid for progressive transmission.
Thus, what is required is a method and system for efficiently implementing the simplification of a complex volumetric representation. What is required is a system for efficiently simplifying a tessellated volumetric model. The system should be able to reduce the number primitives used in a volumetric representation without causing excessive geometric aliasing. The system should be able to transform a tetrahedral volumetric representation to facilitate the operation of subsequent simplification algorithms. The system of the present invention provides a novel solution to the above requirements.
SUMMARY OF THE INVENTION
The present invention provides a method and system for efficiently implementing simplification algorithms for complex volumetric representations. The system of the present invention efficiently simplifies a tessellated volumetric model. The system of the present invention is able to reduce the number primitives used in a volumetric representation without causing excessive geometric aliasing. Additionally, the system of the present invention is able to transform a tetrahedral volumetric representation to facilitate the operation of subsequent simplification algorithms.
In one embodiment, the present invention is implemented as a computer implemented method for efficient simplification of tetrahedral meshes used in 3D volumetric representations, as performed in a 3D graphics computer system. The 3D graphics computer system implements a method for manipulating a volumetric model of a 3D object to simplify the volumetric model by reducing the number of primitives within the volumetric model. To implement the method, the computer system accesses a volumetric model of a 3D object. The 3D object is modeled using a large number of volumetric primitives. After accessing, the volumetric model is analyzed to identify a plurality of sets of adjacent primitives within the model for processing. For each set of identified adjacent primitives, the set of primitives is transformed within the volumetric model to facilitate the simplification of the model. The resulting transformed set of primitives are then stored. This process is carried through to completion, until the entire volumetric model has been processed. The resulting transformed volumetric model is then output for further processing or manipulation.
In this manner, the 3D graphics computer system is able to transform a tetrahedral volumetric representation of a 3D object or scene to facilitate the operation of subsequent simplification algorithms. The specific transformation process used on the sets of adjacent primitives can be based on adaptive subdivision, geometry decimation, sampling, or similar procedures.
Embodiments of the transformation processing apply one or more specific type of local transformation (e.g., as performed on adjacent sets of primitives). Such local transformations include, for example, Face Swap, Face Split, Edge Collapse, Vertex Split, Half-Edge Collapse, Vertex Insertion, Vertex Deletion. Additionally, the transformation process may be deterministic or stochastic, algorithmic or heuristic. Further, the end result of the transformation process may or may not preserve volumetric model topology. Various refinements of the transformation process can be implemented based on various topological, geometric, or per-vertex property preserving criteria. In addition to outputting the resulting transformed volumetric model, various error metrics can also be output.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
FIG. 1 shows a diagram of a 3D graphics computer system 100 in accordance with one embodiment of the present invention.
FIG. 2 shows a diagram of two sets of adjacent primitives a volumetric model in accordance with one embodiment of the present invention as used in a face swap transform.
FIG. 3 shows a flow chart of the steps of a face swap transform process in accordance with one embodiment of the present invention.
FIG. 4 shows a diagram of two sets of adjacent primitives of a volumetric model in accordance with another embodiment of the present invention as used in a face split transform.
FIG. 5 shows a flow chart of the steps of a face split transform process in accordance with one embodiment of the present invention.
FIG. 6 shows a diagram of two sets of adjacent primitives of a volumetric model in accordance with another embodiment of the present invention as used in an edge collapse transform.
FIG. 7 shows a flow chart of the steps of an edge collapse transform process in accordance with one embodiment of the present invention.
FIG. 8 a diagram of two sets of adjacent primitives of a volumetric model in accordance with another embodiment of the present invention as used in a half edge collapse transform.
FIG. 9 shows a flow chart of the steps of a half edge collapse transform process in accordance with one embodiment of the present invention.
FIG. 10 shows a diagram of a set of adjacent primitives of a volumetric model wherein the operation of an edge collapse transform in accordance with one embodiment can result in the collapse of all the primitives of the set.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be obvious to one skilled in the art that the present invention may be practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the present invention.
The present invention is a method and system for efficient simplification of tetrahedral meshes used in 3D volumetric representations. The method and system of the present invention efficiently implements simplification algorithms for complex volumetric representations. The system of the present invention efficiently simplifies a tessellated volumetric model and is able to reduce the number primitives used in the model without causing excessive geometric aliasing. Additionally, the system of the present invention is able to transform a tetrahedral volumetric representation, by for example changing the aspect ratio of selected primitives in the representation, to facilitate the operation of subsequent simplification algorithms. The present invention and its benefits are described in greater detail below.
Notation and Nomenclature
Some portions of the detailed descriptions which follow are presented in terms of procedures, logic blocks, processing, and other symbolic representations of operations on data bits within a computer memory. These descriptions and representations are the means used by those skilled in the data processing arts to most effectively convey the substance of their work to others skilled in the art. A procedure, logic block, process, step, etc., is here, and generally, conceived to be a self-consistent sequence of steps or instructions leading to a desired result. The steps are those requiring physical manipulations of physical quantities. Usually, though not necessarily, these quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a computer system. It has proven convenient at times, principally for reasons of common usage, to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like.
It should be borne in mind, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise as apparent from the following discussions, it is appreciated that throughout the present invention, discussions utilizing terms such as “swapping” or “processing” or “splitting” or “subdividing” or “storing” or “outputting” or “collapsing” or the like, refer to the action and processes of a computer system (e.g., computer system 100 of FIG. 1 ), or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.
Computer System Environment
Referring now to FIG. 1, a diagram of a 3D graphics computer system 100 in accordance with one embodiment of the present invention is shown. Computer system 100 depicts a basic implementation of a computer system in accordance with the present invention. Computer system 100 includes a bus 101 for transmitting digital information between the various parts of the computer system. One or more microprocessors 102 are coupled to bus 101 for processing information. The information along with the instructions of how the information is to be processed are stored in a hierarchical memory system comprised of mass storage device 107 , read only memory 106 , and main memory 104 . Mass storage device 107 is used to store large amounts of digital data. The mass storage device 107 can consist one or more hard disk drives, floppy disk drives, optical disk drives, tape drives, CD ROM drives, or any number of other types of storage devices having media for storing data digitally. A read only memory (ROM) 106 is used to store digital data of a permanent basis, such as instructions for the micro-processors. Main memory 104 is used for storing digital data on an intermediate basis. Main memory 104 can be dynamic random access memory (DRAM).
Computer system 100 includes a 3D graphics rendering subsystem 111 . Processor 102 provides the graphics subsystem 111 with graphics data, such as drawing commands, coordinate vertex data, and other data related to an object's geometric position, color, texture, shading, and other surface parameters. As with typical graphics subsystems, the object data is processed by graphics subsystem 111 in multiple stages (e.g., geometry processing, rasterization/scan conversion, etc.).
Several other optional devices may also be coupled to system 100 . For example, an alphanumeric keyboard 122 is used for inputting commands and other information to processor 102 . Another type of user input device is cursor control device 123 (a mouse, trackball, joystick, and the like) used for positioning a movable cursor and selecting objects on a computer screen. Another device which ay be coupled to bus 101 is a hard copy device 124 (e.g., a laser printer) for printing data or other information onto a tangible medium. Additionally, a sound recording or voice device option 125 can be coupled to the system 100 to provide multimedia capabilities.
Transformation Processing
As described above, the present invention is a method and system for efficient simplification of tetrahedral meshes used in 3D volumetric representations. Embodiments of the present invention function in part by efficiently implementing simplification algorithms for complex volumetric representations. In so doing, the complex volumetric representations are made less complex, including fewer primitives, allowing the computer system to manipulate and further process them more readily. Embodiments of the present invention function by efficiently simplifying complex volumetric models, such as, for example, a tessellated volumetric model of a real world object (e.g., a human organ imaged during a CT scan) to reduce the number primitives used in the model. The overriding goal of the simplification is to achieve this reduction without causing excessive geometric aliasing. For example, the volumetric model should be simplified (e.g., the number of comprising primitives reduced) while retaining as much information as possible. Additionally, embodiments of the present invention function in part by transforming tetrahedral volumetric representations, by for example changing the aspect ratio of selected primitives in the representation, to facilitate the operation of different types of subsequent simplification algorithms. Many of these algorithms perform in a significantly different manner where the aspect ratio and/or other characteristics of the representation are different.
Referring now to FIG. 2, a diagram of two sets of adjacent primitives 201 and 202 of a volumetric model in accordance with one embodiment of the present invention is shown. FIG. 2 shows the operation of a “face swap” transform process of the present embodiment. The set of adjacent primitives 201 show a configuration before a transformation process of the present embodiment is executed. The set of adjacent primitives 202 show the primitives after the transformation has been executed. Sets 201 and 202 comprise a portion of an overall volumetric representation (e.g., a volumetric model including many thousands of primitives).
The face swap transform of the present embodiment changes the orientation of tetrahedra in the set while maintaining the same number of tetrahedra. Set 201 includes 8 tetrahedra. After the face swap transformation, set 202 also includes 8 tetrahedra.
In this case, the effect of the face swap transformation is to exchange the face shared by tetrahedra 210 and 211 . In set 201 , tetrahedra 210 and 211 share a face 205 . This face is identified and deleted. Concurrently, a new face is introduced, face 206 . The effect of the deletion of face 205 and the introduction of face 206 is shown in set 202 of FIG. 2 . Face swaps within sets that would cause face intersections are prevented. With the face swap transform, the number of tetrahedra comprising the overall volumetric representation remains unchanged. This transform technique is well suited for reconfiguring representations for a more uniform internal construction.
It is usually advantageous to have a more uniform internal construction of a volumetric representation due to the fact that the uniformity aids the operation of any other subsequent simplification or manipulation algorithms. For example, face swap transformations as depicted in FIG. 2 can have the effect of changing the aspect ratio of certain tetrahedra within the model. Certain optimization and/or simplification algorithms function more efficiently with tetrahedra having a more regular, more uniform aspect ratio (e.g., as where tetrahedra are more even in length as opposed to being “long and skinny”).
FIG. 3 shows a flow chart of the steps of a face swap transform process 300 in accordance with one embodiment of the present invention. The steps of process 300 depict the face swap local transformation process as performed on set 201 of FIG. 2 .
Process 300 (e.g., the face swap transformation) begins in step 301 , where the volumetric model (e.g., a volumetric representation) is accessed by computer system 100 for processing. In step 302 , sets of adjacent primitives within the model are defined. Then particular sets are selected for face swap transformation processing. In step 303 , for each particular set selected for processing, a face between two adjacent primitives (e.g., tetrahedra) within the set is selected. In step 304 , the selected face between the two adjacent primitives is deleted. Then, in step 305 , a new face having a new orientation is inserted to replace the deleted face. As described above, the insertion of the new face has the effect of changing the aspect ratio of the two adjacent primitives. In step 306 , the reconfigured set is stored in the model, thereby updating the model. And in step 307 , after all the particular sets selected for processing have been transformed, the updated model is ready for subsequent simplification and/or optimization processing.
Referring now to FIG. 4, a diagram of two sets of adjacent primitives 401 and 402 of a volumetric model in accordance with another embodiment of the present invention is shown. FIG. 4 shows the operation of a “face split” transform process of the present embodiment. The set of adjacent primitives 401 show a configuration before the face split transformation process of the present embodiment is executed. The set of adjacent primitives 402 show the primitives after the transformation has been executed. As with sets 201 and 202 of FIG. 2, sets 401 and 402 comprise a portion of an overall volumetric representation.
The face split transform of the present embodiment increases the number of cells (e.g., tetrahedra) in each set of adjacent primitives by 2. Set 401 includes 8 tetrahedra. After the face split transformation, set 402 includes 10 tetrahedra. The face split transformation of the present embodiment functions by identifying an internal face between two tetrahedra, in this case tetrahedra 410 and 411 and inserting a new diagonal face to yield four tetrahedra 420 - 423 . The original two tetras are split into four, increasing the number of cells by two.
A goal of the face split transformation process of the present embodiment is to reconfigure the internal construction of a volumetric representation for a more uniform internal construction. Hence, as with the face swap embodiment described in the discussion of FIG. 2, the face split embodiment of FIG. 4 can produce a more advantageous uniform internal construction of a volumetric representation due to the fact that the uniformity aids the operation of any other subsequent simplification or manipulation algorithms. However, the face split transformation of the present embodiment actually increases the number of tetrahedra in the representation as opposed to keeping a same number of tetrahedra as with the face split transformation embodiment.
The face split transformation of the present embodiment depicted in FIG. 4 has the effect of changing the aspect ratio of the tetrahedra within the model. As described above, certain optimization and/or simplification algorithms function more efficiently with tetrahedra having a more regular, more uniform aspect ratio. Hence, even though the number of tetrahedra increases with set 402 , set 402 can be more easily simplified since the tetrahedra are of a more desirable aspect ratio.
FIG. 5 shows a flow chart of the steps of a face split transform process 500 in accordance with one embodiment of the present invention. The steps of process 500 depict the face split local transformation process as performed on set 401 of FIG. 4 .
Process 500 (e.g., the face split transformation) begins in step 501 , where the volumetric model (e.g., a volumetric representation) is accessed by computer system 100 for processing. In step 502 , sets of adjacent primitives within the model are defined. Then particular sets are selected for face split transformation processing. In step 503 , for each particular set selected for processing, a face between two adjacent primitives (e.g., tetrahedra) within the set is selected. In step 504 , a new diagonal face, having a diagonal orientation with respect to the selected face from step 503 , is inserted. As described above, the insertion of the new diagonal face has the effect of splitting the two adjacent primitives into four, each having a different aspect ratio than the original two adjacent primitives. In step 505 , the reconfigured set is stored in the model, thereby updating the model. And in step 506 , after all the particular sets selected for processing have been transformed, the updated model is ready for subsequent simplification and/or optimization processing.
Referring now to FIG. 6, a diagram of two sets of adjacent primitives 601 and 602 of a volumetric model in accordance with another embodiment of the present invention is shown. FIG. 6 shows the operation of an “edge collapse” transform process of the present embodiment. The set of adjacent primitives 601 show a configuration before the edge collapse transformation process of the present embodiment is executed. The set of adjacent primitives 602 show the primitives after the transformation has been executed. As with sets 201 and 202 of FIG. 2, sets 601 and 602 comprise a portion of an overall volumetric representation.
The edge collapse transform of the present embodiment decreases the number of cells (e.g., tetrahedra) in each set of adjacent primitives by one or more. Set 601 includes 8 tetrahedra. After the edge collapse transformation, set 602 includes 7 tetrahedra. The edge collapse transformation of the present embodiment functions by identifying an internal face 605 between two tetrahedra, in this case tetrahedra 610 and 611 and deleting that face, thereby collapsing the two tetrahedra 610 and 611 into a single tetrahedral 620 . The edge collapse transform is implemented in part by selecting an edge of a tetrahedral (e.g., tetrahedral 610 ) of the set 201 and equating one of the vertices of the edge with the other, collapsing the edge as the result. The original two tetrahedra 610 and 611 are collapsed into one tetrahedral 620 .
As with the face swap and the face split transformations, a goal of the edge collapse transformation process of the present embodiment is to reconfigure the internal construction of a volumetric representation to aid the performance of subsequent simplification/optimization algorithms. However, as opposed to the face swap embodiment described in the discussion of FIG. 2 and the face split embodiment of FIG. 4, the edge collapse transform of the present embodiment can produce a simpler internal construction of a volumetric representation due to the fact that the operation of the edge collapse transform results in a representation having fewer primitives. Thus, even though the subsequent operation of certain optimization and/or simplification algorithms function more efficiently, the execution of the edge collapse transform itself results in more simple representation having fewer primitives.
It should be noted that a variation of the edge collapse transform is the “vertex split” transform. The vertex split transform is an inverse operation of the edge collapse transform, where a single vertex is expanded into an edge forming additional cells. The vertex split variation can be used in those cases where a more favorable internal configuration of the volumetric representation would result.
FIG. 7 shows a flow chart of the steps of an edge collapse transform process 700 in accordance with one embodiment of the present invention. The steps of process 700 depict the edge collapse local transformation process as performed on set 601 of FIG. 6 .
Process 700 (e.g., the edge collapse transformation) begins in step 701 , where the volumetric model (e.g., a volumetric representation) is accessed by computer system 100 for processing. In step 702 , sets of adjacent primitives within the model are defined. Then particular sets are selected for edge collapse transformation processing. In step 703 , for each particular set selected for processing, an edge of one primitive (e.g., tetrahedral) within the set is selected. In step 704 , the selected edge of the primitive is collapsed by moving one vertex of the edge to the same location as the other vertex of the edge (e.g., identifying one vertex to be the other). As described above, the collapsing of the edge of the primitive has the effect of collapsing two adjacent primitives into one, thereby reducing the number of primitives in the set by one. In step 705 , the reconfigured set is stored in the model, thereby updating the model. And in step 706 , after all the particular sets selected for processing have been transformed, a determination is made as to whether the updated model requires additional simplification and/or optimization processing. If additional simplification and/or optimization is required, process 700 proceeds to step 707 and then step 708 , else, process 700 proceeds directly to step 708 as shown. As described above, the edge collapse transformation results in a more simple model having fewer primitives. However, additional simplification and/or optimization processing can still be performed, for example, as dictated by the particular requirements of the user.
Referring now to FIG. 8, a diagram of two sets of adjacent primitives 801 and 802 of a volumetric model in accordance with another embodiment of the present invention is shown. FIG. 8 shows the operation of a “half edge collapse” transform process of the present embodiment. The set of adjacent primitives 801 show a configuration before the half edge collapse transformation process of the present embodiment is executed. The set of adjacent primitives 802 show the primitives after the transformation has been executed. As with sets 201 and 202 of FIG. 2, sets 801 and 802 comprise a portion of an overall volumetric representation.
The half edge collapse transformation is analogous to the edge collapse transformation. The half edge collapse transformation of the present embodiment differs, however, in that instead moving one vertex of a selected edge onto the other, both vertices of the selected edge are moved towards a center (or some other point) of the edge. Hence, the result of the half edge collapse transform is the collapsing of three tetrahedra 810 , 811 , and 812 into two tetrahedra 810 and 812 (e.g., thereby eliminating tetrahedral 811 ). Half edge collapse transforms are well suited for creating smoothly varying representations since the distortion of the sets of adjacent primitives tends to be less pronounced.
As with the other embodiments (e.g., face swap, face split, etc.), a goal of the half edge collapse transformation process of the present embodiment is reconfiguration of volumetric representations for better performance of subsequent simplification/optimization algorithms. However, as with the edge collapse embodiment described in the discussion of FIG. 6, the half edge collapse transform of the present embodiment can produce a simpler internal construction of a volumetric representation due to the fact that a representation having fewer primitives results. Thus, even though the subsequent operation of certain optimization and/or simplification algorithms function more efficiently, the execution of the half edge collapse transform itself results in more simple representation having fewer primitives.
FIG. 9 shows a flow chart of the steps of a half edge collapse transform process 900 in accordance with one embodiment of the present invention. The steps of process 900 depict the half edge collapse local transformation process as performed on set 801 of FIG. 8 .
Process 900 (e.g., the half edge collapse transformation) begins in step 901 , where the volumetric model (e.g., a volumetric representation) is accessed by computer system 100 for processing. In step 902 , sets of adjacent primitives within the model are defined. Then particular sets are selected for half edge collapse transformation processing. In step 903 , for each particular set selected for processing, an edge of one primitive (e.g., tetrahedral) within the set is selected. In step 904 , the selected edge of the primitive is collapsed by moving both vertices of the edge to a point near the center of the edge. As described above, the half edge collapsing the primitive has the effect of collapsing three adjacent primitives into two, reducing the number of primitives in the set by one. In step 905 , the reconfigured set is stored in the model, thereby updating the model. And in step 906 , after all the particular sets selected for processing have been transformed, a determination is made as to whether the updated model requires additional simplification and/or optimization processing. If additional simplification and/or optimization is required, process 900 proceeds to step 907 and then step 908 , else, process 900 proceeds directly to step 908 as shown. As with the edge collapse transformation, the half edge collapse transformation results in a more simple model having fewer primitives. However, additional simplification and/or optimization processing can still be performed.
Referring now to FIG. 10, a diagram of a set of adjacent primitives 1001 of a volumetric model is shown. FIG. 10 shows a case where the operation of an edge collapse transform in accordance with one embodiment can result in the collapse of all the primitives of set 1001 . FIG. 10 depicts a vertex 1010 that is shared by all tetrahedra within set 1001 . Where an edge collapse transformation is performed, by moving the location of vertex 1010 to the location of vertex 1011 (as shown by arrow 1015 ), edge between vertices 1010 and 1011 collapses, resulting in the collapse of all tetrahedra in the set 1001 .
Thus, as depicted in FIG. 10, it should be noted that in certain situations several tetrahedra can be eliminated by a single edge collapse transform. This is unlike a polygonal edge collapse (e.g., as in surface geometry representations), where in the case of well formed manifold polygon meshes, such operations tend to remove at most two polygons. This is due to the fact that, in volumetric representations, the edge being collapsed can be a member of several tetrahedral faces, each of which gets collapsed, causing collapse of additional tetrahedra. For example, FIG. 10 shows collapsing an edge between vertices 1010 and 1011 . This results in the collapse of four cells, because the vertex involved in the edge being collapsed was shared by each of them. Therefore, a single edge collapse operation can have fairly drastic consequences. For example, collapsing an axial edge a “cone” of tetrahedral primitives can cause all the tetrahedra in the cone to collapse. Accordingly, the operation of the edge collapse and half edge collapse transformations of the present invention should be configured to take this characteristic into account.
Thus, the method and system of the present invention efficiently implements simplification algorithms for complex volumetric representations. The system of the present invention efficiently simplifies a tessellated volumetric model and is able to reduce the number primitives used in the model without causing excessive geometric aliasing. Additionally, the system of the present invention is able to transform a tetrahedral volumetric representation, by for example changing the aspect ratio of selected primitives in the representation, to facilitate the operation of subsequent simplification algorithms.
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. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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In a 3D graphics computer system, a method and system for efficient simplification of tetrahedral meshes used in 3D volumetric representations. The 3D computer system implements a method for manipulating a volumetric model of a 3D object to simplify the volumetric model by reducing the number of primitives within the volumetric model. To implement the method, the computer system accesses a volumetric model of a 3D object. The 3D object is modeled using a large number of volumetric primitives. After accessing, the volumetric model is analyzed to identify a plurality of sets of adjacent primitives within the model for processing. For each set of identified adjacent primitives, the set of primitives is transformed within the volumetric model to facilitate the simplification of the model. The resulting transformed set of primitives are then stored. This process is carried through to completion, until the entire volumetric model has been processed. The resulting transformed volumetric model is then output for further processing or manipulation.
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This application is a continuation-in-part of the application, filed Feb. 20, 1996, entitled LOOSE-FILL INSULATION HAVING IRREGULARLY SHAPED FIBERS, which is a continuation of Ser. No. 08/309,698, filed Sep. 21, 1994 now abandoned, which was a continuation-in-part of Ser. No. 08/148,098, filed Nov. 5, 1993 now U.S. Pat. No. 5,431,992.
BACKGROUND OF THE INVENTION
The present invention relates to loose-fill or blowing wool insulation for sidewall or attic installation, and more particularly to a blended loose-fill insulation which utilizes irregularly-shaped glass fibers and provides improved coverage and reduced convection.
The use of glass fiber blowing wool or loose-fill insulation is well-known and increasing in popularity. Loose-fill insulation is preferred by many contractors because it can be easily and quickly applied in both new construction as well as in existing structures. Further, loose-fill insulation is a relatively low cost material.
As the name implies, loose-fill insulation is not Breed into a blanket or batt prior to installation. Rather, the product is generally installed by pneumatically blowing the loose-fill insulation into the desired area. Accordingly, loose-fill fiberglass insulation in an unconstrained space, such as an attic, is not as compacted as blanket insulation, occupying a greater volume than an equivalent amount of blanket insulation. As a result, the thermal conductivity or k value of loose-fill insulation in current use is generally higher than that of blanket insulation. That is, loose-fill insulation currently used in the industry does not inhibit the conduction of heat as well as blanket insulation. To compensate for the higher conductivity of loose-fill, it is applied in greater depth than blanket insulation to achieve an equivalent R-value.
Furthermore, in many applications, increased insulation depth is either not possible or impractical. For example, in sidewall installation, the depth (or in this instance the thickness of the wall) is limited by standard wall thicknesses such as 3.5 inches (8.9 cm) for a 2×4 (5×10 cm) wall or 5.5 inches (14 cm) for a 2×6 (5×15.2 cm) wall. To compensate for such thickness limits, a higher density loose-fill must be employed. In other words, more glass must be blown into the same mount of space. Also, in practice it has remained quite difficult to uniformly blow the required higher densities into the confined spaces of sidewalls.
When designing loose-fill or blown insulation products of glass fibers, the ideal insulation would have uniform spacing and density once installed. That is, the final product would preferably be free of gaps, spaces or voids between fibers. Insulation is basically a lattice for trapping air between the fibers and thus preventing movement of air. The lattice also retards heat transfer by scattering radiation. A more uniform spacing and density of the insulation would minimize air movement under extreme cold conditions and maximize scattering and, therefore, would have greater insulating capability.
Traditional loose-fill or blown insulation comprises traditional, straight, short fibers. Baits of traditional bindered or unbindered glass fibers are cut, milled, or otherwise formed into nodules, and then compressed and bagged for shipment. Upon installation, the compressed loose-fill is added to the hopper of a blowing machine where the loose-fill is mechanically opened and broken into smaller portions. However, after being blown into position, numerous small gaps or voids remain between the blown portions of insulation. These voids raise the thermal conductivity of the insulation, requiring more glass to be employed to achieve a specified insulating value.
While lighter density loose-fill insulating materials have been developed, a problem with convection within the body of the material occurs under extreme cold temperatures which adversely affects the R-value. For example, primarily straight bindered fibers of loose-fill insulation may be comprised of 1/2" milled nodules which are relatively large and very low in density. As a result, when the nodules are spread out or blown into place, there are voids in the interstices between the nodules which allow some convection of cold air.
Accordingly, a need exists for an improved loose-fill insulating material with a uniform volume filling nature and to an insulating material which provides good coverage and thermal efficiency when blown.
SUMMARY OF THE INVENTION
These needs are met by the present invention in which an improved loose-fill or blowing insulation is provided which is comprised of a blend of first and second insulating materials. The insulating materials are comprised of groups of fibers which differ in size such that one of the groups of fibers is larger than the other groups of fibers. When the insulation is installed, the larger groups of fibers provide high coverage and the smaller groups of fibers fill the voids between the larger groups. Thus, the blended insulation product of the present invention provides substantially uniform coverage upon installation and reduces or substantially eliminates convection of air.
According to one aspect of the present invention, a loose-fill insulation product is provided comprising a blend of a first insulating material comprised of a first series of three-dimensional groups of fibers having a first size and density and a second series of three-dimensional groups of fibers having a second size and density, where the groups of fibers of the second size are smaller than the groups of fibers of the first size. The density of the second series of groups of fibers is preferably greater than the density of the first series of the groups of fibers. However, it should be appreciated that the density of the first series of groups of fibers may be greater than the density of the second series of groups of fibers.
In addition, the fibers of at least one of the first or second insulating materials are irregularly-shaped glass fibers, wherein each fiber is comprised of two distinct glass compositions with different coefficients of thermal expansion. The irregularly-shaped glass fibers used in the present invention are preferably binderless, i.e., the binder materials comprise less than or equal to 1% by weight of the product. It should be noted that the term "binder" is not meant to include materials added for dust suppression or lubrication.
In a preferred embodiment of the invention, the three-dimensional groups of fibers comprise nodules, where the size of the nodules for the first series of fibers is at least 1/2 inch in at least one of the length, height and width directions, and the size of the nodules for the second series of fibers is less than 1/2 inch in the length, width and height directions.
For purposes of the present invention, the term nodules is meant to encompass groups of fibers which have been cut or milled to form three-dimensional shapes having either a uniform or nonuniform configuration, and having dimensions of generally less than about 1 inch. Where the fibers have been cut by a cubing device or a chopping device, the nodules are of a substantially uniform shape and size, while fibers which have been milled tend to form nodules having a more nonuniform shape and size.
The nodules of the irregularly-shaped fibers of the present invention, when blended with another group of fibers, tend to open up (i.e., expand in size) and assume the form of wisps which function to fill the voids between adjacent nodules.
In one embodiment of the invention, both of the first and second insulating materials comprise irregularly-shaped glass fibers, and the fibers of the first insulating material have been coated with a lubricant. The groups of fibers which have been coated with the lubricant are larger in size, while the uncoated groups of fibers of the second insulating material are smaller and more dense. In this embodiment, the weight ratio of the first insulating material to the second insulating material is from about 80:20 to 20:80, and more preferably, from about 50:50.
In another embodiment of the invention, the first insulating material comprises single-glass fibers and the second insulating material comprises irregularly-shaped glass fibers. In this embodiment, the groups of single-glass fibers are larger in size than the groups of irregularly-shaped fibers. The irregularly-shaped glass fibers may optionally be coated with a lubricant. In this embodiment, the weight ratio of the first insulating material to the second insulating material is about 80:20 to 20:80.
Preferably, at least a portion of the fibers of the first and second insulating materials are coated with a dust suppressant, anti-static agent, or both. The dust suppressant or anti-static agent may comprise mineral oil, a quaternary ammonium salt, or combinations thereof.
The present invention also provides a method of making the blended loose-fill insulation product comprising the steps of providing a first insulating material comprised of a first series of three-dimensional groups of fibers having a first size and density, providing a second insulating material comprised of a second series of three-dimensional groups of fibers having a second size and density, with the groups of fibers of the second size being smaller than the groups of fibers of the first size. The fibers of at least one of the first or second insulating materials are irregularly-shaped glass fibers. The first and second insulating materials are then blended together.
The method may also include the step of coating the fibers of the blend with a dust suppressant, anti-static agent, or both as described previously.
Where both the first and second insulating materials comprise irregularly-shaped fibers, an alternative method for making the blended loose-fill insulation product comprises the steps of forming irregularly shaped fibers, intermittently applying a lubricant to the fibers, and cutting or milling the fibers into groups of fibers, where a first group of fibers is coated with the lubricant and a second group is not coated with the lubricant. By applying the lubricant in this manner, the resulting insulation comprises a blend of lubricated and unlubricated fibers, where the lubricant functions to control the size and density of the nodules.
Upon handling and installation of the insulation, the smaller sized groups of fibers fill existing voids between the larger sized groups of fibers, providing a substantially uniform coverage and reduction in convection. When blown into an unconstrained area, the blended loose-fill insulation product of the present invention preferably has a thermal conductivity or k value of between about 0.25 to 0.50 Btu in/hrft 2 ° F. (0.036 to 0.072 Watts/m° C.) at a density of 0.45 to 2.00 pcf (7.2 to 32.0 Kg/m 3 ). The installed density of the insulation product is preferably between about 0.50 to 1.00 pcf(8.0 to 16.0 Kg/m 3 ).
When blown into a sidewall, the installed density of the insulation product is preferably between about 1.0 to 2.0 pcf(16.0 to 32.0 Kg/m 3 ).
Accordingly, it a feature of the present invention to provide a loose-fill insulation comprising a blend of first and second insulating materials having groups of fibers of different sizes and densities which include irregularly-shaped fibers, and to a loose-fill insulation which provides improved uniform coverage and thermal efficiency upon installation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic view in elevation of a process by which the loose-fill insulation of the present invention may be produced.
DETAILED DESCRIPTION OF THE INVENTION
The blended loose-fill insulation of the present invention provides several advantages over the prior art loose-fill insulation which is typically comprised of large, low density nodules. While such nodules provide good coverage, due to their large size, when the insulation is blown into an attic or wall, voids or gaps remain between the pieces of insulation, thereby substantially reducing the insulation's ability to retard heat flow or convection.
The present invention, however, provides a blend of nodules which differ in size and density such that the larger sized nodules provide good coverage while the smaller sized nodules fill the voids between the large nodules. Thus, the present invention provides insulation which allows better coverage and which reduces or substantially eliminates convection problems.
The irregularly-shaped fibers used in the blended insulation product of the present invention can be produced from a rotary fiber forming process as shown in FIG. 1. The irregularly-shaped fibers are dual-glass fibers, i.e. each fiber is composed of two different glass compositions. Such fibers are disclosed in the copending parent application entitled LOOSE-FILL INSULATION HAVING IRREGULARLY SHAPED FIBERS, filed Feb. 20, 1996, and Houpt et al, U.S. Pat. No. 5,431,992, the disclosures of which are hereby incorporated by reference.
The dual-glass compositions of the present invention preferably comprise a high-borate, low-soda lime-aluminosilicate composition as one glass and a high-soda, low-borate lime-aluminosilicate composition as the other glass, which satisfy all constraints necessary for a successful irregularly-shaped fiber. Other known glass compositions may also be used. A wide range of proportions of the amounts of the two glasses may exist in the various irregularly-shaped glass fibers.
Preferably, the coefficients of thermal expansion of the glasses, as measured on the individual glasses by standard rod techniques, differ by at least 2.0 ppm/° C. The dual-glass fibers have a curvilinear nature due to this difference in thermal expansion coefficients. An irregularly-shaped fiber of the invention differs from a helical fiber in that the rotation of the fiber is not constant, but rather varies irregularly both in direction (clockwise and counter-clockwise) and in magnitude. Thus, each irregularly-shaped fiber is twisted in a unique way. No two fibers are exactly alike. The fiber's irregular nature allows the irregularly-shaped glass fibers to stand apart from one another and achieve a uniform volume filling nature.
By uniform volume filling, it is meant the fibers have a desire to spread out and fill the entire volume available to them in a uniform manner when blown. A more uniform volume filling nature allows a more efficient use of glass fibers to resist the convective flow of heat. Thus, by combining nodules of irregularly-shaped fibers with different sized nodules of irregularly-shaped or standard insulation fibers, excellent coverage and minimization of convection are achieved as the gaps or voids between the larger nodules are filled in by the smaller nodules of the insulation.
Referring now to FIG. 1, streams 13 of two distinct molten glass compositions are supplied from furnaces 10 via forehearths 12 to fiberizers 14. Veils of irregularly-shaped glass fibers 18 produced in fiberizers 14 are blown downward by means of blowers 22 and collected on a conveyor 16 to form a fibrous blanket 20. As the fibers are blown downward and cool, they assume their irregular shape.
In the embodiment where both the first and second insulating materials comprise the irregularly-shaped fibers, the fibers may be coated after being formed by applying a lubricant intermittently to the fibers as the fibers 18 are blown downward. To accomplish this, rings or series of nozzles 17 are positioned around the veil of fibers which supplies a lubricant from source 15 to the fibers. The supply of lubricant is controlled by a rotary valve 21, which regulates the amount of lubricant and length of time it is applied to the fibers. By opening and closing valve 21 intermittently, different sections of the fibers become coated while other sections remain uncoated. A suitable lubricant for use in the present invention is available from Henkel under the designations Emerlube™ or Emerest™. Preferably, the lubricant is applied to the fibers at a rate of between about 0.05% to 0.30% by weight, and more preferably, about 0.10% by weight.
After the lubricant is applied and the fibers are collected on the conveyor to form a shaped fibrous blanket 20, the blanket is then fed through a cutting or milling device (not shown) where the blanket is preferably cut or milled into nodules of approximately the same size. The insulation may be cut or milled using conventional milling, cubing or chopping equipment. A suitable milling device is available from Jeffrey Manufacturing. A suitable cubing device is disclosed in the copending parent application entitled LOOSE-FILL INSULATION HAVING IRREGULARLY SHAPED FIBERS, filed Feb. 20, 1996. A preferred chopping device is available from Owens Corning (#775) which utilizes a helical Chevron cutter head.
In an alternative embodiment, the lubricant may be applied to an entire tow of irregularly-shaped fibers as they are formed. In a separate process, a second tow of irregularly-shaped fibers may be formed without the application of the lubricant. The two sets of fibers may then be subsequently cut or milled and then blended together.
In another embodiment of the invention, the first insulating material comprises irregularly-shaped fibers and the second insulating material comprises single-glass fibers. In this embodiment, the second insulating material preferably comprises a standard insulating material, i.e., an insulating material comprising primarily straight, single-glass fibers. Suitable standard insulating materials include ADVANCED THERMACUBE PLUS™, THERMAGLAS™, and STANDARD BLEND™, all available from Owens Corning. Such single-glass fibers are generally not uniform in volume filling, but when blended with the irregularly-shaped fibers of the present invention, the gaps or voids between the various large nodules of standard insulation are filled in by the smaller nodules or wisps of the irregularly-shaped fibers. Thus, while the single-glass fibers and the irregularly-shaped fibers of the present invention may be cut or milled to almost the same size, when blended together, the nature of the irregularly-shaped fibers is to open up and spread out such that the smaller wisps of irregularly-shaped fibers fill in the voids between the nodules of the single-glass fibers.
In this embodiment, the irregularly-shaped fibers may or may not be coated with a lubricant, depending on the desired application.
Once the groups of fibers are cut or milled, the different sized nodules are blended together, compressed and bagged for shipment. If desired, the blend of fibers is sprayed with a dust suppressant and/or an anti-static agent after cutting. Preferably, the dust suppressant is a mineral oil, quaternary ammonium salt or combinations thereof. If a quaternary ammonium salt is employed, the dust suppressant/anti-static agent is preferably is a modified fatty dimethyl ethylammonium ethosulfate. Suitable quaternary ammonium salts are disclosed in U.S Pat. No. 4,555,447 to Sieloff et al, the disclosure of which is herein incorporated by reference. To aid in coating ability, the quaternary ammonium salt may be mixed with a non-ionic lubricant material. A suitable dust suppressant/anti-static agent is available under the tradename MAZON JMR-1 and is available from PPG Industries, Inc. in Pittsburgh, Pa. The dust suppressant/anti-static agent may be applied by traditional means such as dilution with water, followed by spraying onto the cut loose-fill insulation.
Once at the installation site, the blended loose-fill insulation of the present invention may be unpackaged and installed by hand or preferably by blowing. Where the insulation is blown, the insulation is added to the hopper of a standard blowing device and blown into position, thereby expanding and recovering in the process. Blowing can be performed with any conventional blowing technology known in the art.
Once blown, the insulation provides a uniform volume filling, i.e., the voids between the larger nodules are filled in by the smaller nodules. The uniform volume filling nature of a insulating material may be additionally indicated by measuring thermal conductivity. Building insulation products are quantified by their ability to retard heat flow. Resistance to heat flow or R value is the most common measure of an insulation product's ability to retard heat flow from a structure. R-value is defined by the equation: R value=t/k, where R-value is resistance to heat flow in hrft 2 ° F./Btu (m 2 ° C./Watt); t is recovered thickness in inches; and k is thermal conductivity in Btu in/hrft 2 ° F. (Watt/m° C.).
Thermal conductivity or k value is a measure of a material's ability to conduct heat. Thus, the lower a material's k value the better that material is as an insulator. The more uniform the lattice of the material, the greater that material's insulation ability. Thus, thermal conductivity can be a measure of the uniform volume filling nature of the insulation material. When blown into an unconstrained area, the loose-fill insulation of the present invention has a k value ranging from about 0.25 to 0.50 Btu in/hr 2 ° F. (0.036 to 0.072 Watt/m° C.) at a density of from 0.45 to 2.0 pcf(7.2 to 32.0 Kg/m 3 ).
In order that the invention may be more readily understood, reference is made to the following examples, which are intended to be illustrative of the invention, but are not intended to be limiting in scope.
EXAMPLE 1
A blended loose-fill insulation product was prepared in accordance with the present invention using one bag of Miraflex™ fibers (Owens Corning) which had been treated with lubricant during formation, and one bag of Miraflex™ fibers which had not been coated with lubricant during formation. The densities of the two materials were 0.33 pcf and 1.02 pcf, respectively. The treated fibers were approximately 1/2-3/4 inch in size, while the untreated fibers ranged from 1/8-1/4 inch in size. The bag weights were 24.10 and 25.10 lbs., respectively, so the mix was very close to a weight ratio of 50:50. The two bags were hand mixed in a hopper and sprayed with a dust suppressant/anti-static agent available from PPG Industries, Inc. under the tradename MAZON JMR-1. The material was blown at a rate of 12.62 lb/min. The blown density and coverage (based on 8 3/4" blown thickness), and dust levels are shown below in Table I. The dust level was determine used Owens Corning test method D04A.
______________________________________ Density Coverage Dust (pcf) (sq. ft.) (gm/35 lb. bag)______________________________________Miraflex ™ 0.487 98.56 0.914(with lubricant)/Miraflex ™(without lubricant)______________________________________
EXAMPLE 2
A loose-fill insulation product was produced using a blend of Miraflex™ fibers which were cut using a cubing device and oversprayed with an anti-static agent and a light-weight oil, and standard loose-fill insulating material. The standard loose-fill was coated with an anti-static agent prior to blending with the Miraflex™ fibers. The Miraflex™ and standard fibers were mixed in a hopper and blown at a rate of 15.47 lb/min and a thickness of 8 3/4".
The results are shown below in Table II.
TABLE II______________________________________ Density Coverage Dust (pcf) (sq. ft.) (gm/35 lb. bag)______________________________________Miraflex ™/ 0.53 89.58 0.754Standard insulation______________________________________
After blowing it was observed that the standard loose-fill insulation remain more compressed and in a larger, denser form while the Miraflex™ fibers opened and wisps could be observed in and around the standard insulation.
EXAMPLE 3
Two blends of standard insulating fibers and Miraflex™ fibers were produced in which the first blend comprised about 80% SR/HT standard insulation and 20% Miraflex™, and the second blend comprised about 80% RA23 and 20% Miraflex™ fibers. The materials were nonuniform in the hopper, but blew to a very homogeneous material in the attic. The results after blowing to a thickness of 8 3/4" are shown below.
TABLE 3______________________________________ Blow Density Coverage Dust rate (pcf) (sq. ft.) (gm/35 lb. bag) (lb/min.)______________________________________80/20 0.731 65.63 1.373 20.10SR/HT/Miraflex ™80/20 1.064 45.12 0.569 22.63RA23/Miraflex™______________________________________
Having described the invention in detail and by reference to the preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention which is defined in the appended claims.
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A loose-fill insulation product is provided which is formed from a blend of first and second insulating materials having three-dimensional groups of fibers of different sizes and densities. At least one of the insulating materials is comprised of irregularly-shaped glass fibers comprised of two distinct glass compositions. When blended with the fibers of a standard insulation or with other irregularly-shaped fibers of different sizes, the resulting loose-fill insulation product shows improved coverage and thermal efficiency.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 08/378,009 filed Jan. 25, 1995, now U.S. Pat. No. 5,858,170. This application claims priority of Swedish application 9404299-1 filed Aug. 12, 1994.
FIELD OF THE INVENTION
The present invention relates to a method for pressurized peroxide bleaching and, more specifically, to a method for carrying out pressurized peroxide bleaching safely, i.e. to a method in association with pressurized peroxide bleaching which is intended to eliminate possible risks of injury to personnel or of damage of a mechanical nature.
DESCRIPTION OF THE RELATED ART
Our own patent SE-C-500616 has previously disclosed a method for carrying out pressurized peroxide bleaching of pulp at a consistency exceeding 8%, in a bleaching vessel designed for pressures greater than atmospheric pressure, with the pulp being fed to the vessel by means of a pump and heated to a temperature exceeding 90° C. and being bleached with peroxide using a quantity exceeding 5 kg/BDMT.
As the peroxide decomposes, oxygen gas is formed. If the discharge from an above-described bleaching vessel is suddenly halted, the pressure in the reactor will increase gradually due to decomposition of the peroxide and the formation of oxygen gas. The risk therefore exists that a bleaching vessel of this type, or surrounding equipment, reach, once the stoppage has continued for a period of time, a pressure which exceeds its permitted pressure limit.
SUMMARY OF THE INVENTION
An object of the present invention is to create a safety system which eliminates the risk of reaching the above-mentioned forbidden pressure limit within the vessel or any part of its surrounding equipment. Due to the nature of the milieu, i.e., a fibre-containing suspension, such a system cannot be secured using mechanical safety valves since, once such a valve has been used once, fibres will inevitably have become located between the cone and the seat of the valve, resulting in malfunction.
The object of the present invention is achieved using a method wherein, upon plugging or power failure, measures are taken, essentially without using mechanical safety valves, which prevent the pressure in the bleaching vessel, or an affiliated part, from exceeding a certain set point.
A further aspect of the invention is that the pump (2) which feeds pulp to the beaching vessel is shut off when the pressure in the bleaching vessel exceeds a desired first set point, preferably approximately 0.55 MPa overpressure, ±0.05 MPa.
A further aspect of the invention is a bypass conduit which links the pump (2) to the bleaching vessel (1) and which is opened by means of a valve (H) when the pump (2) stops.
A further aspect of the invention is that the pulp is heated in a mixer (3) arranged between the pump (2) and the bleaching vessel (1) and that the supply of steam, by means of a valve (B), and also the supply of other possible fluids such as oxygen gas, to the mixer (3) is interrupted when the pressure in the bleaching vessel exceeds a desired first set point, preferably 0.55 MPa overpressure ±0.05 MPa.
A further aspect of the invention is that a safety valve (A) opens a connection to a lower pressure, preferably atmospheric pressure, for a pipe conduit which runs between the valve (B), at the mixer (3), and the valves (E) and (D) when the pressure in the reactor exceeds a desired set point, preferably approximately 0.05 MPa higher than the said first set point.
A further aspect of the invention is that a valve (C), which is arranged at the discharge end of the bleaching vessel (1), opens a second connection to an outlet pipe (4) from the vessel (1) when the pressure in the vessel (1) exceeds a certain third set point, preferably about 0.1 MPa greater than the said first set point, which valve (C) preferably shuts again when the pressure falls back below the said set point.
A further aspect of the invention is that the bleaching vessel (1) is arranged with a discharge scraper (5) and that the said valve (C) is arranged, preferably directly on the vessel (1) without any space in between, so that the scraper (5) cleans in front of this valve (C), thereby eliminating the risk of a pulp plug being formed.
A further aspect of the invention is that the distance between the valve cone and the outer edge of the scraper is less than 300 mm, preferably 200 mm, and more preferably 100 mm.
A further aspect of the invention is that the bleaching vessel (1) is equipped with a rupture disc (9) which opens towards lower pressure at a pressure inside the vessel which exceeds the said first set point, preferably by 0.15 MPa overpressure.
A further aspect of the invention is that the outlet conduit (4) leads to a standpipe (6) which is arranged with a spillway (7) which preferably opens out in an area which is at least in part enclosed by a wall (8) which is impervious to liquid.
BRIEF DESCRIPTION OF THE FIGURES
The invention will be elucidated in more detail below with reference to the attached figures in which: FIG. 1 shows a preferred embodiment for arranging a safety system in association with a pressurized peroxide bleaching vessel, and FIG. 2 shows a preferred detailed embodiment for the discharge end of such a vessel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 accordingly shows a preferred embodiment of a system according to the invention. A pressurized peroxide vessel (1), which is filled hydraulically, normally operates at a pressure, half-way up the vessel, of about 3-5 bar. The pressure is maintained with the aid of a medium-consistency pump (2) which thus feeds the pulp to the bleaching vessel (1). Between the pump (2) and the bleaching vessel (1) there is a mixer (3) which, in order to raise the temperature of the pulp, is fed with steam, preferably medium-pressure steam, so that the temperature of the pulp in the preferred case exceeds 100° C. In certain cases (for example, in order to increase the pressure or to prevent so-called "condensate bangs"), it is desirable also to supply oxygen gas to the mixer (3). The peroxide is preferably supplied to the pulp either prior to or at the pump (2). Very effective bleaching of the pulp is achieved due to the high temperature and the high pressure in the reactor.
The pulp is discharged, using a scraper (5) (see FIG. 2), from the top of the vessel (1) and is conveyed via a conduit (4) into a so-called standpipe (6) in which the pulp is "degassed". The standpipe (6) is additionally arranged with a spillway (7) which opens into an area which is at least in part enclosed by a wall (8) which is impervious to liquid.
In order to operate this reactor safely, there are arranged a number of valves etc., the most important functions of which are given below. Between the pump (2) and the mixer (3) there is a shut-off valve (G) which is normally open. A valve (H), which is normally closed, is arranged in a bypass conduit which circumvents the mixer (3). One (or two) valve(s) (B), which is/are normally open, is/are arranged in the main conduit for supplying steam and oxygen gas. That side of the valve(s) (B) which is not in contact with the mixer side can be brought into contact with atmospheric pressure by opening valve (A), which is normally closed. In addition, valves (E) and (D) are present for regulating the flow of steam and of oxygen gas, respectively. A valve (F), which can be shut off manually, is arranged at the bottom of the reactor. An additional conduit (10) is arranged at the top of the reactor, which conduit links the top of the reactor with the outlet pipe (4) when a safety valve (C) opens. In addition, two pressure sensors (1, PZ) and (2, PZ) are arranged at the top of the reactor. In cases where it is desired, a "rupture disc" (9) is also arranged at the top of the reactor.
According to the preferred embodiment, the reactor is constructed for a maximum pressure of 0.7 MPa overpressure at the top at a temperature of 180° C. The preferred safety system functions as follows. At a first set point, 0.55 MPa overpressure, which is thus then measured by one of the independent pressure sensors, the MC pump is stopped, and the valves for the supply of steam and, where appropriate, oxygen gas, (E) and (D), respectively, are closed, as is the valve (B) as well. This therefore ensures that no additional oxygen or steam will be supplied to the mixer (3). The valve (B) is equipped with a spring for closing the valve.
At a second set point, 0.6 MPa overpressure, the valve (A) opens so that the volume in the pipe between the regulating valves for oxygen gas and steam and the valve(s) (B) can be ventilated. The valve (A) is equipped with a spring in order to open.
At a third pressure level, 0.65 MPa overpressure, the valve (C) at the top of the reactor opens fully, thereby connecting this additional conduit (10) to the outlet pipe (4). The valve (C) is arranged with a spring for the opening function.
If the electricity supply were completely cut off, and if there were no reserve system, such as, for example, air, the safety valve (C) would open and pulp would flow out in an unregulated manner if no preventive measures were taken. In order to avoid this happening, the safety valve (C) can be connected to a prioritized electrical circuit and/or to an auxiliary system, for example an air system. If there is no such auxiliary system, the valve can be connected to an air tank having a nonreturn valve. This tank must be able to accommodate the volume which is required for ensuring at least ten actuations of the valve (C). The solenoid which acts on the safety valve can be operated by the power back-up system for the instrumentation.
It is important that the connecting conduit in which the valve (C) is located is made as short as possible in order to avoid a drop in pressure.
In certain cases, as has already been mentioned, the reactor is arranged with a rupture disc, which preferably has a rupture value of 0.7 MPa. A temperature sensor is preferably installed in the pipe downstream of the rupture disc, which sensor can be used to indicate that the disc is ruptured and provide a signal which shuts off the pump (2).
According to a preferred embodiment, a position sensor is present which senses whether the manual valve (F) is shut or being shut and which then shuts off the pump (2).
FIG. 2 shows that the different valves for discharging pulp (the outflow control valve 11, the safety valve C and an additional control valve (12) for opening an additional discharge outlet are arranged so that the discharge scraper (5) cleans in front of these valves as it rotates. To avoid the possibility of pulp plugs building up, the valves are arranged directly on the vessel. According to a preferred embodiment, the distance between cones of the valves and scraper end must not exceed 200 mm and the outer edge of the scraper blade should be shaped so that it sweeps past the whole of the inlet to each opening which leads to a valve or the like.
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Apparatus for safely carrying out pressurized peroxide bleaching of pulp in a bleaching vessel at a consistency exceeding 8%, the bleaching vessel designed for at least 0.5 MPa overpressure, with the pulp being pumped to the bleaching vessel through a mixer at a temperature exceeding 90° C., wherein a bypass conduit is provided to bypass the mixer and wherein a valve is provided in the bleaching vessel, the valve opening when the pressure in the bleaching vessel or an affiliated part thereof reaches a first set point.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority based on U.S. patent application Ser. No. 60/339,218 entitled Push-Button Quick-Change Spool System For Fishing Reel, filed Dec. 10, 2001, the disclosure of which is incorporated here by reference in its entirety.
BACKGROUND
The present invention relates to fishing reels.
Conventional fishing reels include a spool for holding the fishing line. It is often desirable for a user to change the line on the spool to a line of different strength, length, or type, depending on changing conditions, weight of bait or lures, and size of fish being sought.
With conventional spinning reels, there are two primary ways in which the user can change fishing line on the spool. One method involves manually removing the old line from a fixed spool, tying on the new line, and then winding the new line onto the spool with the reel. A second method involves buying a spare spool and winding a different line on the spare spool. To change lines, the user removes the original spool from the reel and installs the spare spool.
A variety of methods are employed for attaching a spool to a fishing reel. One conventional method of attaching the spool to the reel is threading. Internal threads located in the spool interface with the externally threaded support shaft of the reel. Installation of the spool requires many rotations to achieve full engagement. Likewise, removal of the spool is accomplished through twisting the spool, relative to the reel, through many rotations. Moreover, the drag (on fishing reels with an adjustable drag feature) must be set very tight in order to disengage the threads. The spool itself is generally a complicated, expensive part to manufacture.
SUMMARY
The present invention provides methods and apparatus for a quick-change spool system.
In general, in one aspect, a method for providing a spool system includes providing a plurality of spools each having a fishing line. The method includes providing a spool base configured for receiving any one of the plurality of spools, the spool base being further configured for coupling to a support shaft of a reel body.
In general, in another aspect, a quick-change spool system includes one or more spools, each spool including a cavity in which there are one or more mounting features. Mounting features can include detents and recesses. The system includes a spool base configured for detachably coupling with a spool support shaft of a fishing reel body, the spool base including a member configured for mating with the cavity of one of the spools. The system includes a retaining mechanism that includes one or more spring-loaded catches. The catches can be keys. A catch is shaped such that the catch depress when the member of the spool base is being inserted into the cavity of one of the spools and, furthermore, extend to engage the mounting feature when the member of the spool is fully inserted into the cavity, thereby capturing and fixedly mounting the spool.
In general, in another aspect, a spool system includes a spool base configured for detachably coupling with a spool support shaft of a fishing reel body. The spool base includes a member configured for mating with a cavity of each of one or more spools, each cavity including one or more mounting features. The member includes one or more spring-loaded catches that are shaped such that the catches depress when the member of the spool base is being inserted into the cavity of one of the spools and, furthermore, extend to engage the mounting feature when the member of the spool is fully inserted into the cavity.
In general, in another aspect, a spool system includes one or more spools. Each spool includes a cavity configured to received a member of each of one or more spool bases. Each cavity includes one or more mounting feature. The member includes one or more spring-loaded catches that are shaped such that the catches depress when the member of the spool base is being inserted into the cavity of one of the spools and, furthermore, extend to engage the mounting feature when the member of the spool is fully inserted into the cavity. Each of the spool bases is configured for detachably coupling with a spool support shaft of a fishing reel body.
In general, in another aspect, the quick-change spool system includes a spool base and a spool. The spool base is configured to be detachably coupled to a fishing reel body. The spool is configured to be detachably coupled to the spool base. Furthermore, the spool, the spool base, or both the spool and the spool base can be configured so that the spool can be quickly and easily coupled with and removed from the spool base.
In one implementation, the spool is compact and can be quickly removed from the spool base by a push of a button. The button actuates a mechanism that releases the spool. The mechanism can also act to couple the spool to the spool base. The mechanism can be spring loaded so that coupling does not require pushing the button. The mechanism can be spring loaded so that decoupling does not require pushing the button.
The invention can be implemented to realize one or more of the following advantages. As discussed, the user of a fishing reel often desires to change the type, color, or strength of fishing line on the reel. A quick-change spool system allows the user to quickly change line through the use of multiple spools that have different types of lines. Different lines can be pre-wounded onto different spools. To change a line, one would have to simply change spools.
The changing of spools is achieved with utmost simplicity. Installation of a spool can be accomplished with axial insertion of the spool onto a spool base. The spool, the spool base, or both can include features to guide the spool into correct orientation for engagement with the spool base. That is, the quick-change spool system can be self-aligning and, thus, facilitate installation. Completion of installation can be felt and heard by the user as a spring-clip engages to hold the spool in place. In one implementation, the normal force of multiple splines interlocking with multiple rabbets prevents rotation of the spool relative to the spool base with great structural integrity. Removal of the spool is easy and intuitive. The user need only press a button, placed in obvious view on top of the spool assembly and pull the spool axially away from the reel. If a user attempts to forcibly pull off the spool without pressing the button, the spring-clip will disengage without failure. The change operation can generally be a one handed operation.
A spool can be configured to be coupled with different spool bases. Each of the different spool bases can be configured to be detachably coupled to different types of reel bodies. For example, the same spool can be coupled with a spool base configured to be coupled with a bottom drag reel body and also with a top drag reel body. A spool base can be configured to be coupled with different types of spools.
A spool can be an assembly that includes a line holding member (spool proper) and a line retainer. This line retainer acts to secure the line when the spool is not in use. This line retainer can be manufactured in a variety of dimensions so as to accommodate line of various diameters. In one implementation, this line retainer can be constructed as special geometry molded into the spool. In another implementation, this line retainer can be constructed with a rubber overmold onto the molded spool. In another implementation, this line retainer can be constructed as a detachable piece of plastic or rubber. In a further implementation, this detachable plastic or rubber line retainer can be manufactured in a variety of colors so as to differentiate spools carrying various weights and grades of line. In a further implementation, this detachable plastic or rubber line retainer can be manufactured in a variety of colors so as suit the taste of the user.
A spool can be an assembly that includes a line cartridge and a cap. The line cartridge can be easy to manufacture and can be made available, pre-wound with a variety of line-types, for the great convenience of fishermen utilizing this system. The pre-wound line cartridges can be factory wound at the appropriate tension to reduce line problems such as line tangles and breakage. The pre-wound line cartridges can be disposable, offering advantages such as removal of the need for a user to manually load fishing lines.
A line cartridge can be configured to be coupled with different spool bases. A spool base can also be configured to be coupled with different line cartridges.
The details of one or more implementations of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show one implementation of a quick-change spool system.
FIGS. 2A-2C show a front view of the implementation with two projected cross-sectional views.
FIGS. 3A and 3B illustrate how to install a spool assembly to a threaded support shaft of a fishing reel.
FIG. 4 shows how to place a spool onto the spool assembly.
FIGS. 5A and 5B show how the spool can be removed.
FIGS. 6A and 6B show an alternative implementation.
FIG. 7 shows a base of the alternative implementation.
FIGS. 8A-8C show implementations designed for a top drag reel body.
FIG. 9 shows an implementation that includes self-guiding features for coupling a spool to a spool base.
FIGS. 10A-10F show an implementation that includes a line retainer.
FIG. 11 shows a method for providing a quick-change reel system.
Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
A quick-change spool system includes one or more spool bases and one or more spools. The system can optionally include one or more reel bodies. In general, a reel body includes a handle mechanically coupled to a spool support shaft. Cranking the handle causes the spool support shaft to oscillate axially and rotate about its longitudinal axis.
A spool base is configured to be detachably coupled to a reel body, usually to the spool support shaft of the reel body. Any mechanism can be used to detachably couple the spool base to the reel body. For example, fasteners such as screws can be used. A single spool base can be configured to be detachably coupled to different reel bodies. Different spool bases can be configured to be detachably coupled with the same reel body. A spool base can be configured to be detachably coupled with different reel bodies. In one implementation, the system includes adaptors for coupling a particular spool base to different reel bodies.
A spool base can be configured to receive one or more spools. The system includes a quick-change mechanism. Specifically, either the spool base, the spool, or both the spool and the spool base can be configured so that so that the spool can be quickly and easily coupled with and removed from the spool base. Alternatively, the system can further include components that provide mechanism for coupling spools to the spool base as described. The components can be considered to be part of the spool base, the spool, or both. A spool base can be configured to detachably couple with different spools. A spool can be configured to be coupled with different spool bases.
Generally, the spools hold fishing lines. Different ones of the one or more spools can hold different types of fishing lines. The fishing lines can be pre-wounded onto the spools (e.g., such as a factory loaded spool). Optionally, one or more of the spools hold a fishing line that is different from fishing lines on other spools. Optionally, the spools are disposable.
The spool can be an assembly that includes a cap and a line cartridge, which holds a fishing line. In this case, the system can include multiple cartridges each having pre-loaded fishing lines (e.g., such as a factory loaded cartridge). Optionally, one or more of the cartridges hold a fishing line that is different from fishing lines on other cartridges. Optionally, the cartridges are disposable.
An Implementation
The following reference numbers are associated with elements shown in FIGS. 1A, 1 B, 2 A, 2 B, 3 A, and 3 B.
11 base
12 spring-clip
13 button
14 hub
15 line-retainer
16 spool
17 screws
21 base assembly
22 fishing reel (partial)
23 threaded support shaft
FIGS. 1A and 1B show one implementation of the system. The implementation shown includes a base 11 , a spring-clip 12 , a button 13 , a hub 14 , a line-retainer 15 , a spool 16 , and three screws 17 . The spring-clip 12 is fabricated from hardened stainless steel. The line-retainer 15 can be made of a soft material such as silicone or urethane, with a durometer of approximately 60 Shore A. The base 11 , button 13 , hub 14 , spool 16 are made from plastic or an aluminum alloy and can be machined, injection-molded, or die-cast. The base 11 includes a thread insert on the center axis of its cylindrical body and specified to match the reciprocating, threaded shaft of a popular rear-drag fishing reel. The hub 14 has three holes, which are arranged such as to mate to the three holes through the base 11 and tapped such as to accept the three screws 17 .
FIGS. 2A-2C show a front view and two cross-sections of the implementation described above. As seen in section A—A, (FIG. 2 B), the screws 17 fasten through base 11 into hub 14 , capturing spring-clip 12 and button 13 . Spool 16 mates to base 11 and is retained axially by the three detents of spring-clip 12 acting on the ramped upper surfaces of the spool's 16 three internal splines. The splines mate with rabbets in hub 14 , as illustrated in section C—C (FIG. 2 C). Line-retainer 15 is pressed into the u-shaped recess of spool 16 such that three detents in the u-shaped recess of spool 16 match three recesses in the line-retainer 15 , acting to position and retain line retainer 15 .
Operation
FIGS. 3A & 3B illustrate how to install the base assembly 21 , without the spool 16 , to the threaded support shaft 23 of fishing reel 22 . As shown, base 11 of base assembly 21 threads on to the threaded support shaft 23 of the fishing reel.
FIG. 4 shows how to place a spool 16 onto the spool assembly 21 . The user aligns the three internal splines of spool 16 with the three rabbets in hub 14 . The spool 16 is then slid axially onto the assembly, snapping into place as the detents of spring-clip 12 catch over the ramped splines of spool 16 .
FIGS. 5A and 5B show how the spool 16 can be removed. The user presses button 13 as shown in FIG. 5A while lifting off spool 16 , as shown in FIG. 5 B. If the user attempts to forcibly remove the spool 16 without pressing button 13 , spring-clip 12 will release without failure.
The user can keep any number of pre-wound spools on hand, each loaded with fishing line of varying specification. Thus, it becomes simple and convenient to change lines. When a spool is not in use, the loose end of line can be inserted into the jaws of the line-retainer 15 and held in place.
An Alternative Implementation
The following reference numbers are associated with elements shown in FIGS. 6A, 6 B, and 7 .
31 base
36 line-cartridge
37 top-flange
41 lower-assembly
42 cartridge-assembly
As shown in FIGS. 6A and 6B, the spool 16 can be an assembly that includes a line cartridge 36 and cap 37 . These two parts can mate in a toothed interface, forming an upper-assembly 42 . The line cartridge 36 is designed to maximize manufacturability; it can be injection-molded from an inexpensive polymer. Cap 37 includes internal spline geometry identical to that of spool 16 . Cap 37 can be either injection-molded from a hard polymer or die-cast from a metal alloy.
FIG. 7 shows how the base 31 can be slightly modified to accept line-cartridge 36 while maintaining a similar exterior profile of the spool assembly 21 .
Operation-Alternative Implementation
The line-cartridge 36 and top-flange 37 slide together axially, the smooth inner cylindrical surface of 36 mating tightly to the cylindrical outer barrel of 37 . The two parts mesh in a toothed interface, which prevents rotation of the line-cartridge.
As shown in FIG. 7, the assembly 42 functions in the same manner as the spool 16 as it mates to the lower-assembly 41 . The alternative implementation provides line cartridges that are easy to manufacture, inexpensive, and, thus, can be disposable.
Other Alternative Implementations
The above implementations describe a system for coupling with a bottom drag reel. However, the system is not limited to these types of reels. For example, the system can be coupled to a top drag reel. In general, the spool support shaft of a top drag reel penetrates a spool of the reel. The top drag is typically provided by a screw mechanism that, when tightened down, increases the resistance in the rotation of the spool. To accommodate the top drag, the spool base and spool can include apertures so that the spool support shaft can penetrate through these components and be coupled to the top drag.
FIGS. 8A and 8B show one implementation that can be used with a top drag reel. FIG. 8B shows a cross section of the system shown in FIG. 8 A. In this implementation, the top drag also acts as a spool release. Other implementations of the system need not incorporate this feature. That is, the drag adjustment knob can, but need not, act as a spool release. As shown, a spool release 802 that also acts as a top drag, when depressed, can cause a clip 804 to bend away from a clip detent 806 , thus releasing a spool 808 from a spool base 810 . When sufficient force is used to pull the spool 808 away from the spool base 810 , the clip 804 can bend away from the clip detent 806 to release the spool, even when the drag adjustment knob/spool release button is not depressed. Sufficient force includes force sufficient to overcome the forced exerted by the clip against the clip detent. The amount of sufficient force can be varied by using different clips. FIG. 8C shows another implementation designed for a top drag reel body.
In one implementation, the spool, the spool base, or both can include features to guide the spool into correct orientation for engagement with the spool base. That is, the quick-change spool system can be self-aligning and, thus, facilitate installation. FIG. 9 shows an implementation that includes a self-aligning feature. As shown, the wide and curved openings of each rabbet of the spool base 902 , e.g., opening 904 , can receive and guide a mating spline of the inside surface of the spool cavity into a correct orientation. Alternatively, other guiding features can be included. For example, the splines can be shaped to guide the spool to a correct orientation.
In yet another implementation, the system includes a line retainer. The line retainer holds the end of a fishing line and keeps the line from unwrapping. The retainer can reduce instances of line tangles, especially when the spool is removed from the spool base. The line retainer can be made of a soft material that has a high coefficient of friction such as, for example, double-shot rubber (chemically sympathetic rubber such as Kraton), that is molded directly onto the spool. Alternatively, the line retainer can be otherwise implemented, one example of which is shown in FIGS. 10A-10F. The line retaining feature, in this implementation, includes a pocket 1002 at the base of a spool 1004 and also a retainer 1006 made of soft rubber or plastic that holds fishing lines well and accommodates various line diameters. To secure a line, one folds the retainer 1006 around the end of a line and then inserts the retainer into the pocket.
There can be multiple retainers having, for example, different materials and colors. The different color retainers can, for example, allow a user to distinguish between spools (which can then be mass-produced from the same color of plastic) to indicate the line weight and style on the spool. The retainer can be taken out and replaced (when it becomes worn or if, for example, one prefers a certain color or decide to wind a different line on the spool).
A Method for Providing a Quick-Change Spool System
As shown in FIG. 11, an entity such as a retailer or a manufacturer provides one or more spools (step 1102 ). The spools can hold fishing lines of various sorts. In implementations when the spool includes a line cartridge, the line cartridges hold the fishing line. The spools or line cartridges can be provided pre-loaded with fishing lines, removing the need for the user to wind a fishing line onto a reel. In one implementation, the fishing lines are machine loaded onto the cartridges at an appropriate tension so as to reduce the probability of line problems such as line breaks and line tangles. Optionally, the pre-loaded cartridges are disposable. Thus, when a fishing line is worn, the user simply disposes the cartridge of the worn line and inserts a new cartridge having a new line pre-loaded to reduce line problems.
The entity can manufacture and sell the spools. Alternatively, the entity can license the manufacture and sales of the spools and collect royalties.
The entity provides one or more spool bases (step 1104 ). The spool base can be configured to receive different spools. A spool can be configured to be detachably coupled with different spools bases. The spool base can be configured to be detachably coupled to different reel bodies. Optionally, the entity can provide adapters that couple a particular spool base to different reel bodies.
The entity can manufacture and sell the spools base. Alternatively, the entity can license the manufacture and sales of the spool base and collect royalties.
Optionally, the entity can provide a reel body (step 1106 ). The reel body includes a spool support shaft that can be coupled with the spool base. Optionally, the entity can provide any combination of the reel body, spool base, spools, and line cartridges as a kit.
The invention has been described in terms of particular embodiments. Other implementations are within the scope of the following claims. For example, the steps of the invention can be performed in a different order and still achieve desirable results. Any mechanism can be used to detachably couple the spool base to the reel body. Any mechanism can be used to detachably couple any one of the spools to the spool base. Any mechanism can be used to detachably couple a cartridge to a spool base. The system can be used with different types of reels, such as, for example, top drag reels and bottom drag reels. The mechanism for detachably coupling the spool base to the reel body and the mechanism for detachably coupling a cartridge to the spool base can be different. The components can be manufactured from different materials and not just those examples described. The system can include one or more adapters for detachably coupling a particular spool base with different reel bodies. The retaining mechanisms described, including the clip 804 shown in FIG. 8, can be implemented for use with either a top reel body or bottom drag reel body. Similarly, the guide features a line retainer mechanisms described can be implemented for use with either a top reel body or bottom drag reel body. Mounting features can include recesses, detents, as well as any other features that can operate to detachably couple a spool to a spool base. Catches can include spring clips, spring-loaded keys, as well as other features that can operate to detachably couple a spool to a spool base.
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Methods and apparatus implementing a quick-change spool system. A quick-change spool system includes one or more spools, each spool including a cavity in which there are one or more recesses. The system includes a spool base configured for detachably coupling with a spool support shaft of a fishing reel body, the spool base including a member configured for mating with the cavity of one of the spools. The system includes a retaining mechanism that includes one or more spring-loaded keys that are shaped such that the keys depress when the member of the spool base is being inserted into the cavity of one of the spools and, furthermore, extend to engage the recesses when the member of the spool is fully inserted into the cavity.
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CROSS REFERENCE TO RELATED DOCUMENTS
This application is a divisional of U.S. patent application Ser. No. 10/961,732, filed on Oct. 7, 2004 and issued as U.S. Pat. No. 7,253,709.
BACKGROUND
1. Technical Field
The present disclosure relates generally to switches. More particularly, this disclosure relates to microfabricated electromechanical switches having a spring-loaded latching mechanism.
2. Description of Related Art
Switch networks are found in many systems application. For example, in satellite systems, switch networks are essential for routing matrices and redundancy systems. Future satellite systems will not only require larger switch routing networks, but also increased functionality for network-centric operations. These new capabilities will includes spacecraft reconfiguration for beam switching, beam shaping, and frequency agility. Thus, it is expected that satellites will require an increasing number of switches in their payloads.
In many cases, these switches need to be latching, that is, once they are actuated they will remain in a desired state even after the actuation energy source is removed. Some of the applications where latching switches are important are ultra-reliable networks where power interruptions could create a problem, such as satellite or Unmanned Air Vehicles, or networks where supplied power is limited, like in small mobile platforms that run on batteries. Current latching switch technology typically relies on magnetic or motor drives to change switch states. These switches, typically fabricated using coaxial conductors or metallic waveguide, generally work very well. However, most of the applications listed above would benefit from size and weight reduction since the mechanical latching switches currently in use tend to be larger and heavier than desired. Semiconductor switches, such as made using PIN diodes and FET switches, are small, but they typically cannot latch in multiple states without a constant energy source.
Radio Frequency (RF) Micro Electro-Mechanical System (MEMS) switches are known in the art to have small size and weight and are also known to provide desirable performance in the radio frequency and microwave spectrums. Several types of MEMS switches are well-known in the art. For example, U.S. Pat. No. 5,121,089 issued Jun. 9, 1992 to Larson discloses a microwave MEMS switch. The Larson MEMS switch utilizes an armature design. One end of a metal armature is affixed to an output line, and the other end of the armature rests above an input line. The armature is electrically isolated from the input line when the switch is in an open position. When a voltage is applied to an electrode below the armature, the armature is pulled downward and contacts the input line. This creates a conducting path between the input line and the output line through the metal armature. This switch requires a constant voltage to maintain the switch in a closed state.
As another example, U.S. Pat. No. 6,046,659 of Loo et al. discloses methods for the design and fabrication of non-latching single pole single throw MEMS switches. U.S. Pat. No. 6,046,659 is incorporated herein by reference in its entirety. FIG. 1 shows a top view of a MEMS switch 10 according to Loo et al, which provides single pole single throw switching between an input line 20 and an output line 18 .
FIGS. 2A and 2B are side-elevational views of the MEMS switch 10 . FIG. 2A shows the switch 10 in the open position and FIG. 2B shows the switch 10 in the closed position. Beam structural material 26 is connected to a substrate 14 through a fixed anchor via 32 . A suspended armature bias electrode 30 is nested within the structural material 26 and electrically accessed through a bias line 38 at an armature bias pad 34 . A conducting transmission line 28 is at the free end of the beam structural layer 26 and is electrically isolated from the suspended armature bias electrode 30 by the dielectric structural layer 26 . Contact dimples 24 of the transmission line 28 extend through and below the structural layer 26 and define the areas of metal contact to the input and output lines 20 and 18 , respectively. A substrate bias electrode 22 is below a suspended armature bias electrode 30 on the surface of the substrate 14 . When a voltage is applied between the suspended armature bias electrode 30 and the substrate bias electrode 22 , an electrostatic attractive force will pull the suspended armature bias electrode 30 as well as the attached armature 16 towards the substrate bias electrode 22 . The contact dimples 24 touch the input line 20 and the output line 18 , so the conducting transmission line 28 bridges the gap between the input line 20 and the output line 18 , thereby closing the MEM switch.
Loo et al. generally describe a surface micromachined device. That is, layers are deposited on top of a substrate, and then one or more of the layers is etched away to release the moving parts of the switch 10 . As described in Loo et al., the parts of the switch generally comprise gold (or gold alloys) for the switch contacts, silicon dioxide for the one or more layers etched away (i.e., the sacrificial layers), and silicon nitride for the beam structural layer. However, the Loo switch generally requires a voltage to be applied to keep the switch in a closed state.
An example of a latching micro switch is described in U.S. Pat. No. 6,496,612 issued Dec. 17, 2002 to Ruan et al. Ruan et al. describe a switch having a cantilever to switch between an open state and a closed state. To operate as a latching switch, a permanent magnet is used to maintain the cantilever in an open state or a closed state. However, the use of a permanent magnet may result in a switch that is bigger and/or heavier than desired. Further, the placement of the permanent magnet further complicates the manufacture of the switch, increasing the cost of the switch.
Another example of a latching switch is described by Xi-Qing Sun, K. R. Farmer and W. N. Carr in “A Bistable Micro Relay Based on Two-Segment Multimorph Cantilever Actuators,” The Eleventh Annual International Workshop on Micro-electro Mechanical Systems, 1998, MEMS 98 Proceedings, Jan. 25-29, 1998, pp. 154-159. Sun et al. describe a latching switch mechanism that uses two metals to create stresses in opposite directions along a cantilever beam. RF contacts can be moved by controlling the stress on the two segments electrostatically to lengthen or shorten the length of the cantilever along the substrate so that the contact can be moved from one RF line to another. The fabrication of the switch disclosed by Sun et al. may be complicated since two different metals are required. Further, the latching force is on a direction that may ultimately pull the metal bar from the cantilever.
Therefore, there is a need in the art for small, lightweight latching switch that does not require a constantly applied external voltage or magnetic source to stay latched in a selected state.
SUMMARY
Embodiments of the present invention provide for a method and apparatus for switching that is latchable. An embodiment of the present invention comprises a RF MEMS metal contact electrostatically actuated latching switch. According to embodiments of the present invention, a cantilever arm is provided that can be moved into orthogonal directions for latching and unlatching. That is, in one orientation, the cantilever arm may be moved in both a horizontal direction and a vertical direction.
Embodiments of the present invention may have a latching structure that essentially comprises a metalized angular mortise and tenon structure. The mortise and tenon structure may be provided by etching a substrate to provide a dovetail structure at the edges of the etched portions of the substrate. The etched edge of the substrate then forms the mortise. The end of the cantilever arm is fabricated to form the tenon. In a latched state, the tenon portion of the cantilever arm fits within the mortise portion of the substrate.
According to some embodiments of the present invention, movement in orthogonal directions may be provided by a combined comb-drive actuator structure and parallel plate actuator structure to move a cantilever arm prior to latching or unlatching. The comb-drive actuator structure provides the capability to move the cantilever arm parallel to the substrate surface. The parallel plate actuator structure provides the capability to move the cantilever arm vertically in a manner similar to that described above for the Loo switch.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages will become more apparent from a detailed consideration of the invention when taken in conjunction with the drawings described below. However, this invention may be embodied in many different forms and should not be construed as limited to the embodiments depicted in the drawings or described below. Further, the dimensions of certain elements shown in the accompanying drawings may be exaggerated to more clearly show details. The present invention should not be construed as being limited to the dimensional relations shown in the drawings, nor should the individual elements shown in the drawings be construed to be limited to the dimensions shown.
FIG. 1 (prior art) is a top view of a prior art RF MEMS switches.
FIG. 2A (prior art) shows a cross-sectional view of the switch in FIG. 1 in an open position.
FIG. 2B (prior art) shows a cross-sectional view of the switch in FIG. 1 in a closed position.
FIG. 3 shows a top view of a switch according to an embodiment of the present invention.
FIG. 4 shows a side view of the switch shown in FIG. 3 .
FIG. 5 illustrates the steps for latching the switch.
FIG. 6 illustrates the components used for calculating the force to laterally move the switch beam illustrated in FIGS. 4 and 5 .
FIG. 6A shows a close-up view of a pair of the interdigitated fingers shown in FIG. 6 .
FIGS. 7A-7H show steps of a fabrication process for one embodiment according to the present invention.
FIGS. 8A-8D show steps of a fabrication process of an alternative embodiment according to the present invention.
DETAILED DESCRIPTION
It should be appreciated that the particular embodiments shown and described herein are examples of the invention and are not intended to otherwise limit the scope of the present invention in any way. Indeed, for the sake of brevity, conventional electronics, manufacturing, MEMS technologies and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail herein. Furthermore, for purposes of brevity, embodiments of the invention are frequently described herein as pertaining to a micro electromechanical switch for use in electrical or electronic systems. It should be appreciated that many other manufacturing techniques could be used to create the embodiments described herein. Further, the embodiments according to the present invention would be suitable for application in electrical systems, optical systems, consumer electronics, industrial electronics, wireless systems, space applications, or any other application. Moreover, it should be understood that the spatial descriptions (e.g. “above”, “below”, “up”, “down”, etc.) made herein are for purposes of illustration only, and that embodiments of the present invention may be spatially arranged in any orientation or manner.
A top view of an embodiment of a switch 100 according to the present invention is shown in FIG. 3 . FIG. 4 presents a side view of the switch 100 along the center line 4 . The switch 100 comprises a switch beam 150 disposed on a substrate 101 . The substrate 101 preferably comprises semi-insulating GaAs with a {100} crystallographic orientation. A portion of the substrate 101 is etched away to provide an etched region 103 in the substrate 101 . If the substrate 101 comprises GaAs, the substrate is preferably etched away with an acidic H 2 O 2 solution. A property of this etching solution on the preferred orientation of GaAs is that the wall of the etched GaAs is undercut from the surface to provide a dovetail structure 105 as shown in FIG. 4 .
The switch beam 150 is preferably disposed above the etched region 103 . For ease of understanding, the switch 100 can be considered as comprising four parts. The first portion consists of the switch beam 150 , a beam electrode 156 and a substrate electrode 158 . The switch beam 150 preferably comprises at least two structural layers 151 , 152 and one or more metal layers 153 . The at least two structural layers 151 , 152 preferably comprise silicon nitride and the one or more metal layers 153 preferably comprise gold, each 1-2 μm in width. The structural layers 151 , 152 may comprise dielectric materials other than silicon nitride. However, such other dielectric materials should be easily deposited and patterned and have good resistance to the final release etch of the sacrificial layer, discussed below. Silicon nitride is preferred, since it is a material that is commonly used in the semiconductor industry. Materials other then gold, such as aluminum, may be used for the one or more metal layers 153 .
As shown in FIG. 4 , the one or more metal layers 153 are configured to provide the beam electrode 156 on or in the switch beam 150 . FIG. 4 shows two structural layers 151 , 152 and a metal layer 153 sandwiched between them. It is preferred that the metal layer 153 be disposed between the upper structural layer 151 and the lower structural layer 152 , so that the structure is more symmetric and less prone to stress caused by thermal expansion mismatch. However, if a thick structure is required, more structural layers 151 , 152 and/or metal layers 153 can be deposited. Further, alternative embodiments may have only the upper structural layer 151 or the lower structural layer 152 .
The beam electrode 156 and the substrate electrode 158 are used to create an electrostatic field to pull the switch beam down 150 . The actuation voltage may be applied to the substrate electrode through substrate electrode actuation pads 159 . The beam electrode 156 may be connected through the switch beam 150 and a spring section 160 (discussed below) to ground pads 157 . Upon application of a voltage to the substrate electrode actuation pads 159 , the beam electrode 156 will be attracted to the substrate electrode 158 , causing the switch beam 150 to move towards the substrate 101 .
The next part of the switch 100 is where the RF signal is switched. It includes the tip 161 of the switch beam 150 , which comprises a conducting material. Preferably, the conducting material is gold. A metalized mortise 163 is disposed on the dovetail structure 105 formed by the etching of the substrate 101 . The mortise 163 preferably comprises gold that is sputtered on and under the overhanging dovetail structure 105 . Input 167 and output 169 RF lines are disposed on the substrate 101 . The input 167 and output 169 RF lines may be sputtered down and then plated to the desired thickness. A gap 165 in the metalized mortise 163 separates the input 167 and output 169 RF lines. It is preferred that the tip 161 and mortise 163 comprise gold, but other metals or conducting materials that do not easily oxidize may also be used.
The third part of the switch 100 is a switch beam spring 170 . The switch beam spring 170 comprises one or more cross beams 171 , 173 attached to switch beam anchors 175 . The switch beam anchors 175 comprise posts disposed on the substrate 101 . In equilibrium, the spring beam 150 is disposed such that the tip 161 of the switch beam 150 extends beyond the mortise 163 , as shown in FIG. 4 . The switch beam spring 170 is preferably fabricated from the same structural layers 151 and metal layers 153 that the switch beam 150 is fabricated from. Therefore, the switch beam spring preferably comprises one or more layers of silicon nitride and one or more layers of gold. A metal line 177 is attached from ground actuation pads 157 , along one of the cross beams 173 , and to the metal layer 153 configured to provide the beam electrode 156 .
The fourth part of the switch 100 is one or more comb-drive actuators 180 consisting of pairs of interdigitated fingers 181 . The fingers 181 preferably comprise the same structural layers 151 and metal layers 153 that the switch beam 150 is fabricated from. One side of the comb-drive actuator 180 is anchored to the substrate 101 by comb actuator posts 188 . One side of the interdigitated fingers 181 are electrically connected to comb-drive actuation electrode pads 187 through the comb actuator posts 188 by metal lines and vias. The other side of the interdigitated fingers 181 is attached to the switch beam spring 170 . The other side of the interdigitated fingers 181 is electrically connected to the ground actuation pads 157 by the metal line 177 .
The steps for latching the switch 100 are described below and are also shown in FIG. 5 . Assume the switch is in the equilibrium position shown in FIG. 4 . As shown in FIG. 4 , the tip 161 of the switch beam 150 is above the metalized mortise 163 . First, a voltage V L is applied to the comb-drive actuator 180 . The electrostatic force between the interdigitated fingers 181 pulls the switch beam spring 170 and switch beam 150 toward the comb actuator posts 188 , as shown by the arrow 501 in FIG. 5 . The switch is fabricated such that the application of voltage V L will result in the tip 161 of the switch beam 151 being pulled behind the metalized mortise 163 . Then a voltage V T is applied between beam electrode 156 and the substrate electrode 158 , which causes the switch beam 150 to be pulled down, as shown by arrow 502 in FIG. 5 . The switch beam 150 should then rest against the substrate 101 and/or the substrate electrode 158 . The comb-drive actuation voltage V L is then removed, and the switch beam spring 170 relaxes toward lateral equilibrium, as shown by arrow 503 in FIG. 5 . It is prevented from reaching equilibrium when the tip 161 of the switch beam 150 hits the metalized mortise 163 . The metal-metal contact of the tip 161 of the switch beam 150 and the metalized mortise 163 causes the RF lines 167 , 169 to be electrically connected, hence the switch 100 is closed. The contact force of the switch beam 150 to the metalized mortise 163 is maintained even when the pull down voltage V T is removed, and the shape of the metalized mortise 163 keeps the switch 100 latched into position.
To unlatch the switch, the voltage V L is again applied to the comb-drive actuator 180 . The tip 161 of the switch beam 150 will slide out of the metalized mortise 163 , and, because the pull-down voltage is not present, the switch beam 150 will pop up. Removal of the comb-drive actuation voltage then puts the switch beam 150 back into equilibrium where it originated. The gap 165 between the RF lines 167 , 169 is now not connected, so the switch 100 is open.
The viability of this switch can be demonstrated by simple calculations. FIG. 6 illustrates the dimensions of various components used in the calculation of the comb-drive actuator force versus voltage. The calculations discussed below were made based on the use of a pair of interdigitated fingers 181 , as shown in FIG. 6 and shown in a close-up and three-dimensional view in FIG. 6A . The height of each of the interdigitated fingers 181 (i.e. the width of each finger in a direction perpendicular to the surface of the substrate) is assumed to be 5 μm. MEMS switches using a trilayer of silicon nitride/gold/silicon nitride, such as the switch disclosed in U.S. Pat. No. 6,046,659, may have structures with thicknesses of 5 μm. Therefore, the assumption for a similar height for the interdigitated fingers 181 is considered reasonable. The gap between each interdigitated finger 181 is also assumed to be 5 μm.
The formula for the attractive force along the horizontal direction (i.e., the X direction shown in FIG. 5 ) is:
F x = 0.5 ɛ o V 2 ( H Z ) N
where H is the finger height and Z is the finger gap. V is the applied voltage and ∈ 0 is the electric permittivity. N is the number of interdigitated finger surface pairs. If V=50 V and N=201, the force is F x =5.5×10 −5 Newtons. The number of interdigitated finger pairs used for the calculation is considered reasonable, since comb-drive actuators are known in the art that use more than this number.
The lateral displacement may also be determined by reviewing the geometry of the structure depicted in FIG. 5 . The switch spring is assumed to be made of silicon nitride, with an elastic modulus of 3×10 11 Newtons/m 2 . The nitride spring is 400 μm long and 2 μm wide. The lateral displacement may be found by the following equation
x= 0.625 F x L 3 E −1 H −1 D −3
where L is the length of the switch spring, D is the width of the switch spring, and H is the height of the switch spring (the same as for the comb-drive fingers). With the values given, it is found that x=18.2 μm, which should be more than enough to pull the end of the spring beam behind the mortise.
The processing of the switch is slightly modified from the current processing practice. The only fabrication differences from the current practice are 1) the first etching step to create the mortise and tenon by etching GaAs to the desired depth, and 2) the dimple etching step is not needed. The layer thickness may be varied depending upon the required latching forces and desired comb-drive actuator voltages. Additional layers of gold and nitride may also be added to build up the height of the comb-drive fingers to reduce the needed voltage. The use of sputtered gold insures that metal coats the edges of the mortise 163 .
FIGS. 7A-7H illustrate the manufacturing processes embodying the present invention used to fabricate the switch 100 of FIGS. 3 and 4 . FIGS. 7A-7H present a profile of the switch taken along the section line 4 - 4 of FIG. 3 . As shown in FIG. 7A , the process begins with a substrate 101 . In a preferred embodiment, GaAs with a {100} crystallographic orientation is used as the substrate. Other materials may be used, however, such as InP, ceramics, quartz or silicon. The substrate is chosen primarily based on the technology of the circuitry the MEMS switch is to be connected to so that the MEMS switch and the circuit may be fabricated simultaneously. For example, InP can be used for low noise HEMT MMICS (high electron mobility transistor monolothic microwave integrated circuits) and GaAs is typically used for PHEMT (pseudomorphic HEMT) power MMICS.
FIG. 7B shows a profile of the switch 101 after the etched region 103 is formed. The etch may be performed with acidic (H 2 SO 4 or HCl)/hydrogen peroxide etch solutions. As indicated above, the substrate preferably comprises GaAs with a {100} crystallographic orientation, since this facilitates the formation of the dovetail structure 105 that facilitates latching.
FIG. 7C shows the deposition of metal for the substrate electrode 158 and the metalized mortise 163 . FIG. 7C also shows the deposition of metal on the substrate to form an electrical contact 198 between one side of the interdigitated fingers 181 and the comb-drive actuation electrode pads 187 . The metal layer may be deposited lithographically using standard integrated circuit fabrication technology, such as resist lift-off or resist definition and metal etch. In the preferred embodiment, gold (Au) is used as the primary composition of the metal layer. Au is preferred in RF applications because of its low resistivity. In order to ensure the adhesion of the Au to the substrate, a 900 angstrom layer of gold germanium is deposited, followed by a 100 angstrom layer of nickel, and finally a 1500 angstrom layer of gold. The thin layer of gold germanium (AuGe) eutectic metal is deposited to ensure adhesion of the Au by alloying the AuGe into the semiconductor similar to a standard ohmic metal process for any III-V MESFET or HEMT.
Next, as shown in FIG. 7D , a support layer 210 is placed on top of the deposited metal and the substrate 101 including the etched region 103 . The support layer 210 typically comprises SiO 2 , which may be sputter deposited or deposited using PECVD (plasma enhanced chemical vapor deposition). The support layer 210 is preferably planarized after being deposited by chemical-mechanical planarizing. Other materials besides SiO 2 may be used as a sacrificial layer 210 . The important characteristics of the sacrificial layer 210 are a high etch rate, good thickness uniformity, and conformal coating by the oxide of the metal already on the substrate 210 . The thickness of the oxide partially determines the thickness of the switch opening, which is critical in determining the voltage necessary to close the switch as well as the electrical isolation of the switch when the switch is open. The sacrificial layer 210 will be removed in the final step to release the switch beam 150 as shown in FIG. 7 h.
Another advantage of using SiO 2 as the support layer 210 is that SiO 2 can withstand high temperatures. Other types of support layers, such as organic polyimides, harden considerably if exposed to high temperatures. This makes the polyimide sacrificial layer difficult to later remove. The support layer 210 is exposed to high temperatures when the silicon nitride for the structural layers 151 , 152 is deposited, as a high temperature deposition is desired when depositing the silicon nitride to give the silicon nitride a lower HF etch rate.
FIG. 7E shows the fabrication of the lower structural layer 152 . The lower structural layer 152 and the upper structural layer 151 (discussed below) are the supporting mechanism of the switch beam 150 and are preferably made out of silicon nitride, although other materials besides silicon nitride may be used. Silicon nitride is preferred because it can be deposited so that there is neutral stress in the structural layers 151 , 152 . Neutral stress fabrication reduces the bowing that may occur when the switch is actuated. The material used for the structural layers 151 , 152 must have a low etch rate compared to the support layer 210 so that the structural layers 151 , 152 are not etched away when the support layer 210 is removed to release the switch beam 150 .
FIG. 7E also shows the etching of the structural layer 152 and the support layer 210 to form recesses 212 for vias for the interdigitated fingers 181 and to provide the comb actuator posts 188 . Those skilled in the art will understand that recesses may also be formed at this step in the process for the switch beam anchors 175 and for vias to provide electrical contact to the other side of the interdigitated fingers 181 . However, these other recesses are not shown in FIG. 7E , due to the cross-section depicted. The structural layer 151 and the support layer 210 may also be etched at this time to form a recess 214 into which metal for the tip 161 will be deposited. The structural layer 152 and the support layer 210 are patterned and etched using standard lithographic and etching processes.
As shown in FIG. 7F , another metal layer 153 is deposited onto the structural layer 152 and into the recesses 212 , 214 . This second metal layer forms the beam electrode 158 . Metal deposited in this step may also form the tip 161 and portions of the interdigitated fingers 181 . In the preferred embodiment, the second metal layer is comprised of a sputter deposition of a thin film (200 angstroms) of Ti followed by a 1000 angstrom deposition of Au. The second metal layer should be conformal across the wafer and acts as a plating plane for the Au. The plating is done by using metal lithography to open up the areas of the switch that are to be plated. The Au is electroplated by electrically contacting the membrane metal on the edge of the wafer and placing the metal patterned wafer in the plating solution. The plating occurs only where the membrane metal is exposed to the plating solution to complete the electrical circuit and not where the electrically insulating resist is left on the wafer. After 2 microns of Au is plated, the resist is stripped off of the wafer and the whole surface is ion milled to remove the membrane metal. Some Au will also be removed from the top of the plated Au during the ion milling, but that loss is minimal because the membrane is only 1200 angstroms thick.
FIG. 7G shows the deposition of the second structural layer 151 . As shown, the second structural layer 151 covers the second metal layer 153 in the area of the beam electrode 156 and also fills in additional portions of the recess 212 to form the comb actuator posts 188 . The second structural layer 152 may also be deposited at this time to form the switch beam anchors 175 (not shown in FIG. 7G ). The second structural layer 151 is then lithographically defined and etched to complete the formation of the switch beam spring 170 and the comb-drive actuators. Finally, as shown in FIG. 7H , the support layer 210 is removed to release the switch beam 150 .
If the support layer 210 comprises of SiO 2 , then it will typically be wet etched away in the final fabrication sequence by using a hydrofluoric acid (HF) solution. The etch and rinses are preferably performed with post-processing in a critical point dryer to ensure that the switch beam 150 does not come into contact with the substrate 101 when the support layer 210 is removed. If contact occurs during this process, device sticking and switch failure are likely. Contact is prevented by transferring the switch from a liquid phase (e.g. HF) environment to a gaseous phase (e.g. air) environment not directly, but by introducing a supercritical phase in between the liquid and gaseous phases. The sample is etched in HF and rinsed with DI water by dilution, so that the switch is not removed from a liquid during the process. DI water is similarly replaced with ethanol. The sample is transferred to the critical point dryer and the chamber is sealed. High pressure liquid CO 2 replaces the ethanol in the chamber, so that there is only CO 2 surrounding the sample. The chamber is heated so that the CO 2 changes into the supercritical phase. Pressure is then released so that the CO 2 changes into the gaseous phase. Now that the sample is surrounded only by gas, it may be removed from the chamber into room air.
The fabrication of an alternative embodiment according to the present invention is depicted in FIGS. 8A-8D . As indicated above, it is preferred that the fingers of the interdigitated fingers 181 have a thickness of at least 5 μm so that the lateral electrostatic voltage V L is kept to around 50V or less. However, as discussed above and shown in FIG. 7F , the metal for the interdigitated finger 181 can be deposited at the same time as the metal for the beam electrode 156 . If the metal layer for the beam electrode 156 is 5 μm, the switch beam will become thicker and may become stiffer and more difficult to pull down. Hence, the process shown in FIGS. 7A-7H , may require one to choose between a lower lateral electrostatic voltage V L and a higher transition voltage V T between the beam electrode 156 and the substrate electrode 158 , or a higher lateral electrostatic voltage V L and a lower transition voltage V T . FIGS. 8A-8D depict the fabrication of an embodiment in which the interdigitated fingers 181 may have a different thickness than the beam electrode 156 .
FIG. 8A depicts a process step similar to that shown in FIG. 7F , in which metal is deposited to form the beam electrode 156 and the tip 161 . However, in this step, the metal for the interdigitated fingers is not yet deposited. FIG. 8B depicts another metal deposition step, in which the gold (or other electrically conductive material) for the interdigitated fingers is deposited with a metal layer thicker than that used to form the beam electrode 156 . As discussed above, a preferred thickness for the interdigitated fingers is 5 μm. FIGS. 8C and 8D depict process steps similar to those depicted in FIGS. 7G and 7H , in which the upper structural layer 151 is deposited and patterned and the support layer 210 is removed to release the switch beam 150 . As shown in FIG. 8D , the metal layer 153 for the interdigitated finger 181 is thicker than the metal layer 153 for the beam electrode 156 .
As can be surmised by one skilled in the art, there are many more configurations of the present invention that may be used other than the ones presented herein. It is therefore intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it be understood that it is the following claims, including all equivalents, that are intended to define the scope of this invention.
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Disclosed are methods for fabricating a micro-electro-mechanical switch. The switch has a cantilever arm disposed on a substrate that can be moved in orthogonal directions for latching and unlatching. For latching, the cantilever arm is moved back by a comb-drive actuator and then pulled down by electrodes disposed on the substrate and the cantilever arm. The comb-drive actuator switch is then released and the cantilever arm moves forward to be captured by a dove-tail structure on the substrate. When the voltage is removed, the cantilever arm is held in place by the dove-tail structure. The switch is unlatched by actuating the comb-drive actuator to move the cantilever arm away from the dove-tail structure. The cantilever arm will then pop up once it is released from the dove-tail structure.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is generally related to the area of optical systems and devices. In particular, the invention is related to method and apparatus for combining multiple signals as depolarized output.
2. The Background of Related Art
In optical communication applications, wider spectrums are often used, thus a single light source is not sufficient to cover the entire application demanded spectrum. A typical scenario is the so-called fiber-to-the-home (FTTH) applications where optical signals are needed and defined in a broad spectrum from 1260 nm to 1625 nm range. However, even the super luminescence light-emitting diode (SLED) can only cover <80 nm of spectrum and thus several of them are needed to provide a wide enough spectrum light source.
FIG. 1A shows a prior art approach 100 of combing multiple wavelength spectra light sources (e.g., four wavelengths λ 1 , λ 2 , λ 3 , and λ 4 light sources) by using two stages of couplers (also referred to as 2×1 couplers), wherein the first stage of couplers 102 and 104 each combine two light sources, the second stage combines the outputs from the first stage. Because each stage causes 50% loss in power, accordingly, FIG. 1B shows a 6 dB loss in the curve of the combined output 108 .
FIG. 2A shows another prior art approach 200 of combing multiple wavelength spectra light sources (e.g., four wavelengths λ 1 , λ 2 , λ 3 , and λ 4 light sources) by using two WDM filters 202 and 204 and a coupler 206 , wherein two WDM filters 202 and 204 combine λ 1 , λ 2 , λ 3 , and λ 4 light sources and output two combined light sources that are coupled together by the coupler 206 . As shown in FIG. 2B , the total power loss is around 4 dB as the WDM filters 202 and 204 are typically less than 1 dB in power loss.
It is known in the art that the cost of a WDM filter is a lot more expensive than that of a coupler, but using couplers would introduce more power loss. Furthermore, all these prior arts are limited to providing only one output port and discard or waste other outputs. For many practical manufacturing and other applications where several users need such power light sources, multiple of these devices are needed. Thus there is need for a design that captures all or part of the wasted powers to recycle them for multiple identical output port light source applications, in addition to other benefits and advantages to be appreciated described herein.
SUMMARY OF THE INVENTION
This section is for the purpose of summarizing some aspects of the present invention and to briefly introduce some preferred embodiments. Simplifications or omissions may be made to avoid obscuring the purpose of the section. Such simplifications or omissions are not intended to limit the scope of the present invention.
The present invention is related to designs of optical devices for combining optical signals or sources at different wavelengths to generate depolarized outputs combining the optical signals. According to one aspect of the present invention, an optical apparatus comprises N different inputs, each having a wavelength and a combining mechanism receiving the N different inputs and combining the N different inputs to produce N outputs, each of the outputs being coupled to a series of optical recirculation depolarizers to produce combined and depolarized outputs.
In another aspect of the present invention, the different inputs are respectively depolarized first before being coupled to the combining mechanism. Depending on implementation, the combining mechanism may be implemented with couplers arranged in various structures.
The present invention may be implemented as an apparatus or a part of a system. According to one embodiment, the present invention is an optical apparatus comprising: N different inputs, each having a wavelength and depolarized via to a series of optical recirculation depolarizers; and a combining mechanism receiving the N different inputs and combining the N different inputs to produce N outputs, each of the outputs being coupled to another series of optical recirculation depolarizers to produce combined and depolarized outputs.
There are numerous benefits, features, and advantages in the present invention. These benefits, features, and advantages of the present invention will become apparent upon examining the following detailed description of an embodiment thereof, taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other 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. 1A shows a prior art approach of combing multiple wavelength spectra light sources (e.g., four wavelengths λ 1 , λ 2 , λ 3 , and λ 4 light sources) by using two stages of couplers (also referred to as 2×1 couplers);
FIG. 1B shows a 6 dB loss in the curve of a combined output from FIG. 1A ;
FIG. 2A shows another prior art approach of combing multiple wavelength spectra light sources (e.g., four wavelengths λ 1 , λ 2 , λ 3 , and λ 4 light sources) by using two WDM filters and a coupler;
FIG. 2B shows a total power loss is around 4 dB as the WDM filters are typically less than 1 dB in power loss;
FIG. 3A shows a four-port directional coupler that is also denoted as a 2×2 coupler and considered as a simplest coupler;
FIG. 3B shows a design of using four couplers in combining four different wavelengths λ 1 , λ 2 , λ 3 , and λ 4 (light sources) to produce four combined and polarized light sources;
FIG. 3C shows a 2×3 or 3×2 coupler that may combine two inputs into three outputs or three outputs to two inputs;
FIG. 3D shows the use of the 3×2 couples with 2×2 couples to combine five inputs to generate five outputs, each producing a combination of these five inputs;
FIG. 3E shows the use of four of 3×2 couples to combine six inputs to generate six outputs, each producing a combination of these six inputs;
FIG. 4 shows another embodiment of having four inputs, each depolarized first via a series of optical recirculation depolarizers;
FIG. 5 shows a sandwiched structure that embeds two stages of couplers in a series of depolarizers;
FIG. 6A and FIG. 6B show respectively two possibilities, respectively referred to as inner cross-over structure and outer cross-over structure;
FIG. 7 shows an embodiment based on 2×2 couplers with 50% coupling ratio; and
FIGS. 8A , 8 B, 8 C and 8 D show, respectively, four possible configurations that are formed by changing the two inputs and two outputs of the couplers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will become obvious to those skilled in the art that the present invention may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring aspects of the present invention.
Reference herein to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the order of blocks in process flowcharts or diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention.
Embodiments of the present invention are discussed herein with reference to FIGS. 3-8 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments.
FIG. 3A shows a four-port directional coupler 300 that is also denoted as a 2×2 coupler and considered as a simplest coupler. A light arrives for instance at port A and is split between port C and D. In the most common case, 50% of the light power will go in C and D.
FIG. 3B shows a design of using four couplers in combining four different wavelengths λ 1 , λ 2 , λ 3 , and λ 4 (light sources) to produce four combined and polarized light sources. Using two stages of couplers 302 , 304 , 306 and 308 , the four different wavelength light sources are combined. In operation, the first stage including two couplers 302 and 304 outputs λ 1 +λ 2 , λ 1 +λ 2 , λ 3 +λ 4 and λ 3 +λ 4 combined signals that are coupled to a second stage including two couplers 306 and 308 . The second stages outputs four substantially similar combined signals λ 1 +λ 2 +λ 3 +λ 4 .
The combined signals are then coupled to a series of optical recirculation depolarizers. In one embodiment, each of the depolarizers is formed from optical fibers (e.g., single mode fiber optic cables) and a coupler (e.g., a fused single mode fiber coupler). Each fiber coupler has an input pair of fibers and an output pair of fibers. One of the output fibers is coupled to one of the input fibers to form a recirculation loop. The recirculation loop allows a degree of polarization in the output beam to be varied across a wide spectrum of values. Further, the amount of the circulated output is controlled (e.g., from 33%˜66%). Details of such depolarizers are described in U.S. Pat. No. 5,933,555 which is hereby incorporated by reference.
As shown in FIG. 3A , using 2×2 optical couplers instead of 2×1 couplers in 2 stages, equal power level and equal spectra outputs can be generated. Thus, there are four outputs available, each is coupled to a series of optical recirculation depolarizers to produce a depolarized output.
Many applications for broad-band light sources are in testing areas. Not only are the power levels important, but also the polarization uniformity is critical for many of these applications. The so-called polarization dependent loss (PDL) is the power level difference between two orthogonal polarization states of the same light source. Many of such light sources use super luminescence light emitting diode (SLED) which is a light emitting device similar to laser diode in the sense that their power output are much stronger than that of the pure LED due to the use of some levels of lasing gains in LED. Thus these SLEDs typically have some level of polarization preferences. The use of them directly may cause testing inaccuracy by PDL. Thus, in addition to the strong combined spectra and power, it is also ideal for the broad-band source to be polarization independent. The inclusion of the optical recirculation depolarizers makes the broad-band source fairly polarization free.
FIG. 3C shows a 2×3 or 3×2 coupler that may combine two inputs into three outputs or three outputs to two inputs. FIG. 3D shows the use of the 3×2 couples with 2×2 couples to combine five inputs to generate five outputs, each producing a combination of these five inputs. FIG. 3E shows the use of four of these 3×2 couples to combine six inputs to generate six outputs, each producing a combination of these six inputs.
FIG. 4 shows another embodiment 400 of having four inputs, each depolarized first via a series of optical recirculation depolarizers 402 . The outputs from the depolarizers are then coupled to the two stages of couplers 404 . Two couplers in the second stage output four depolarized combined signals, each having the combined wavelengths (e.g., λ 1 +λ 2 +λ 3 +λ 4 ).
FIG. 5 shows a sandwiched structure 500 that embeds the two stages of couplers 502 in the depolarizers. Specifically, FIG. 5 shows four input signals are depolarized first, the outputs therefrom are coupled to the couplers 502 . The output from the couplers 502 are further depolarized by one or more of the depolarizers.
As far as the couplers are concerned, there are also ways to combine two inputs. FIG. 6A and FIG. 6B show respectively two possibilities, respectively referred to as inner cross-over structure and outer cross-over structure. Beside using the above described combination of a spectrum combiners (e.g., couplers) and separate depolarizers, 2×2 couplers may be used to serve the same purpose of the spectrum combining function and depolarizing function in a more integrated way. FIG. 7 shows an embodiment 700 based on 2×2 couplers with 50% coupling ratio. Various 2×2 couplers are formed to provide inner and outer feed-back loops, the depolarizing functions are thus achieved through feed-forward lines from other 2×2 couplers. The first group 702 including 16 couplers form a basic unit, this unit can be cascaded further to further perform spectrum combination and depolarization.
By changing the two inputs and two outputs of the couplers, there may be four possible configurations, respectively labeled and shown in FIGS. 8A , 8 B, 8 C and 8 D. More specifically, with inner and outer feed-back loops formed by various 2×2 couplers, the depolarizing functions are achieved through feed-forward lines from other 2×2 couplers. The 16 couplers in any of the four configurations in FIGS. 8A , 8 B, 8 C and 8 D can be used as a basic unit and they can be cascaded either directly or mixed in such cascade to further perform spectrum combination and depolarization. The more stages used, the larger the loss but the better the depolarized light outputs.
It should be noted that the current invention is largely described in terms of four inputs with four different wavelengths to generate four combined depolarized outputs. Those skilled in the art shall understand that given a number of inputs and outputs, it is not difficult to figure out the number of stages or couplers that are needed to produce the outputs. For example, when there are four inputs, there need two stages, each includes two couplers. Logically, when there are N inputs, there will be N/2 stages, each includes N/2 couplers.
The present invention has been described in sufficient details with a certain degree of particularity. It is understood to those skilled in the art that the present disclosure of embodiments has been made by way of examples only and that numerous changes in the arrangement and combination of parts may be resorted without departing from the spirit and scope of the invention as claimed. For example, a single port 602 is shown in FIG. 6 , there may be multiple ports, each of the ports is structured similar to those ports 604 . Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description of embodiments.
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The present invention is related to designs of optical devices for combining optical signals or sources at different wavelengths to generate depolarized outputs combining the optical signals. According to one aspect of the present invention, an optical apparatus comprises N different inputs, each having a wavelength and a combining mechanism receiving the N different inputs and combining the N different inputs to produce N outputs, each of the outputs being coupled to a series of optical recirculation depolarizers to produce combined and depolarized outputs.
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TECHNICAL FIELD OF THE INVENTION
The present invention is directed, in general, to power conversion and, more specifically, to a system and method for limiting overshoot in a voltage and current control circuit.
BACKGROUND OF THE INVENTION
Increased power density is a continuing goal of modern power supply design. High power density is particularly crucial in applications wherein the allocated space for the power supply relative to the power output is restricted. In addition to being highly compact, the power supply must also be efficient to limit heat-creating power dissipation. An illustrative application for a high density power supply is a power supply module employing a battery reserve system or battery plant in a central office of a telecommunications network.
A power supply module that provides power to a battery plant in a telecommunications network may employ a convection-cooled rectifier. Conventionally, the rectifier consists of two power stages including a power factor correction section and an isolated DC/DC converter. The rectifier should be designed to achieve low total harmonic distortion, high power factor and high efficiency. Any number of topologies may be employed in the two stages of the rectifier. For instance, a boost topology with lossless snubber circuit and a power factor enhancement circuit may be employed for the power factor correction section of the rectifier. A zero-voltage switching full-bridge phase-shifted topology may be employed for the isolated DC/DC converter.
As previously mentioned, one of the challenges in the design of a power supply, especially in a natural convection-cooled rectifier, is the thermal management therein. One solution to the thermal management challenge is to design a higher efficiency rectifier. Not only may the area of the silicon forming the power semiconductors of the rectifier be increased to reduce losses therethrough, but the components, power stages and control of the rectifier should be augmented to optimize the overall efficiency thereof. In conjunction therewith, the physical arrangement of the power dissipating components should be addressed to minimize the thermal cross coupling and maximize the convection cooling within the rectifier.
Another important factor in the design of high power density power supplies is the functional demands on the output of the device (e.g., rectifier). Moreover, the control scheme designated to regulate to rectifier should be flexible in nature to accommodate the fluctuations in the operation of the rectifier in an adequate period of time. For instance, when employed in a battery plant for a telecommunications system, the rectifiers regulate the plant voltage to a programmable constant value (i.e., a float value) when the batteries are fully charged. However, this value may vary depending on the battery characteristics and the surrounding environment (e.g., temperature). As a result, the rectifiers may be required to provide minimal current or full-load current during the float mode of operation.
In the event of a loss of primary power, the battery reserve system is employed to provide power to the telecommunications equipment. To maintain a state of readiness, the battery reserve system must be preserved in a fully-charged and operational condition at all times. Therefore, when the primary power is operational, the rectifiers are employed to simultaneously recharge the plant batteries and provide power to the system load. During the recharging process (i.e., when the battery voltage is less than the float value) the rectifiers function as a programmable regulated current source to control the recharging rate of the batteries. As the batteries in the plant approach a full charge, the rectifiers transition from regulating current to regulating voltage.
While the float and charge modes are the predominant modes of operation for the rectifier associated with a battery plant, the rectifier also endures other operating conditions. For instance, activating a rectifier when the power module is operating is essentially a no-load turn-on condition because the rectifier is incapable of providing source current to the load until its voltage output exceeds the voltage of the plant. Additionally, activating a rectifier in an installation without reserve battery units and without other non-active rectifiers coupled to the bus may provide a capacitive load from the other rectifiers on the bus. Also, the rectifier may also be subject to a short-circuiting condition. The rectifier is therefore subject to a wide range of operating conditions and should be capable of operating under any combination of rated output voltage (e.g., from zero to maximum rating) and output current (e.g., from zero to current limit).
Accordingly, what is first needed in the art is a recognition that electronic components (e.g., power components such as a rectifier) are subject to a wide range of real world operating conditions and that precise control of the components to react to the variations in those conditions promptly (i.e., without needless time delays) is necessary. Further, what is needed is a system and method for controlling the components by decreasing a slew rate time delay associated therewith and thereby smoothing transitions between or among separate control loops in a multiple loop controller, and especially for a battery plant rectifier.
SUMMARY OF THE INVENTION
To address the above-discussed deficiencies of the prior art, the present invention provides a control circuit for, and method of, alternately controlling one of at least two controllable characteristics of a controlled circuit. The circuit includes: (1) a first control subcircuit having a first error amplifier for developing a first control signal as a function of a first controllable characteristic of the controlled circuit, (2) a second control subcircuit for developing a second control signal as a function of a second controllable characteristic of the controlled circuit, (3) an OR circuit for selecting which of the first control signal and the second control signal is to control the controlled circuit and (4) an overshoot limiting circuit for establishing a feedback loop around the first error amplifier as a function of a voltage present in the OR circuit while the second control signal controls the controlled circuit, the feedback loop preventing a saturation of the first error amplifier and thereby reducing a slew rate time delay when the first control signal is selected to control the controlled circuit.
Thus, the present invention provides a saturation and slew rate control scheme that is useful for controlled circuits that vary widely in their output characteristics. For the purposes of the present invention, the overshoot limiting circuit closes a loop around a portion of the control circuit in response to a characteristic in the circuit. More specifically, the overshoot limiting circuit establishes a feedback loop around the first or second control subcircuit as a function of a voltage in the OR circuit. Of course, the control circuit may be modified such that the overshoot limiting circuit responds to other characteristics (e.g., a sensed current) and still be within the broad scope of the present invention.
In an alternative embodiment of the present invention, the first control subcircuit further has a first sense amplifier, coupled to the first error amplifier, for sensing the first controllable characteristic. In a related embodiment, the second control subcircuit further has a second sense amplifier, coupled to a second error amplifier, for sensing the second controllable characteristic. Those of skill in the art are familiar with sense amplifiers and their use in control circuits.
In an alternative embodiment of the present invention, the OR circuit is a diode OR circuit. Those of skill in the art are familiar with diode OR circuits and their use in multi-loop control circuits. Further, those of skill in the art are familiar with alternative selection circuits that can function to advantage with the present invention.
In an alternative embodiment of the present invention, the first characteristic is an output voltage of the controlled circuit. In a related embodiment, the second characteristic is a load current of the controlled circuit. The first or the second characteristics could be variations in voltage or current or changes in rates of variations of such voltage or current. The first or the second characteristics could be temperature, frequency, wavelength, variations thereof or changes in rates of variations thereof. Those of skill in the art are familiar with the various characteristics that may be desired to be controlled, depending upon the particular application.
The present invention further contemplates a complete battery plant rectifier, including: (1) a power input that receives input AC power, (2) at least one switch couplable to said power input for switching said input AC power, (3) a rectifier that rectifies the switched AC power to produce a DC power, (4) a filter that filters the DC power to produce an output DC power to charge a battery and (4) a rectifier control circuit that alternately controls one of an output voltage and a load current of the battery plant rectifier. The rectifier control circuit includes: (a) a voltage control subcircuit having a voltage sense amplifier for sensing the output voltage and a voltage error amplifier that develops a voltage control signal as a function of the output voltage, (b) a current control subcircuit having a current sense amplifier for sensing the load current and a current error amplifier that develops a current control signal as a function of the load current, (c) a diode OR circuit that selects which one of said voltage control signal and the current control signal is to control the battery plant rectifier, (d) a voltage control signal overshoot limiting circuit for establishing a feedback loop around the voltage error amplifier as a function of a voltage present in the diode OR circuit while the current control signal controls the battery plant rectifier and (e) a current control signal overshoot limiting circuit for establishing a feedback loop around the current error amplifier as a function of the voltage present in the diode OR circuit while the voltage control signal controls the battery plant rectifier, the feedback loops around the voltage and current error amplifiers preventing a saturation and thereby reducing a slew rate time delay when the diode OR circuit switches between the voltage control signal and the current control signal.
In this more specific embodiment, the first control subcircuit is termed a "voltage control subcircuit," being so directed to controlling the output voltage of the battery plant rectifier. Further, the second control subcircuit is termed a "current control subcircuit," being so directed to controlling the load current of the battery plant rectifier.
Alternatively, in this more specific embodiment of the present invention, the feedback loops around the voltage and current error amplifiers limit the voltage and current control signals to a diode forward bias voltage above the voltage present in the diode OR circuit. Typically, the diode forward bias voltage is about 0.6 volts, resulting in a nearly nonexistent slew rate time delay.
Alternatively, in this more specific embodiment of the present invention, the feedback loops around the voltage and current error amplifiers each include a differential amplifier having inputs coupled across a diode in the diode OR circuit. The differential amplifiers sense the voltage across the associated diode and establish the appropriate feedback loop as a function thereof.
Alternatively, in this more specific embodiment of the present invention, the diode OR circuit comprises diodes coupling outputs of the voltage and current error amplifiers to a control input of the rectifier.
Alternatively, in this more specific embodiment of the present invention, the voltage control signal overshoot limiting circuit is disabled while the voltage control signal controls the battery plant rectifier and the current control signal overshoot limiting circuit is disabled while the current control signal controls the battery plant rectifier. Disabling the limiting circuit when its associated control signal is selected and in control of the battery plant rectifier prevents the limiting circuit from substantially interfering with the operation of the associated control circuit.
Alternatively, in this more specific embodiment of the present invention, the battery plant rectifier further comprises a plurality of chargeable batteries coupled to the battery plant rectifier to receive the filtered output DC power. Those of skill in the art will readily perceive other useful environments and applications for the control circuit and battery plant rectifier of the present invention.
The foregoing has outlined, rather broadly, preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.
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 a schematic diagram of a multiple loop controller having a prior art diode-based overshoot limiting circuit;
FIG. 2 illustrates a schematic diagram of a multiple loop controller including an embodiment of an overshoot limiting circuit according to the present invention; and
FIG. 3 illustrates a block diagram of a battery plant rectifier, including the multiple loop controller of FIG. 2, for providing charge power to one or more batteries.
DETAILED DESCRIPTION
Referring initially to FIG. 1, illustrated is a schematic diagram of a multiple loop controller 100 having a prior art diode-based overshoot limiting circuit. The multiple loop controller 100 includes two similar sections. The first section, including a first amplifier A1 and a second amplifier A2, is an output voltage control circuit. The output voltage V out of a rectifier (not shown) provides an input signal to the first amplifier (e.g., a differential remote sense amplifier) A1. The output of first amplifier A1 feeds the second amplifier (e.g., a voltage error amplifier) A2. A reference voltage V ref is the output voltage reference. The second section of the multiple loop controller 100, including a third amplifier A3 and a fourth amplifier A4, embodies the output current control circuit. Analogous to the first section, an output current signal V s provides an input signal to the third amplifier (e.g., a differential current remote sense amplifier) A3. An output of third amplifier A3 feeds the fourth amplifier (e.g., a current error amplifier) A4. A reference current I ref is the output current reference voltage. The outputs of the second and fourth amplifiers A2, A4 are diode OR-ed with a first diode or second diode D1, D2, respectively, in such a manner that the amplifier (either the second or fourth amplifier A2, A4) with the lowest output voltage controls the peak current control ("PCC") power stage 110.
A limitation with the present control scheme is that the error amplifier (e.g., the fourth amplifier A4) that is not controlling the PCC power stage 110 tends to saturate towards the positive rail. As a result, when the inactive error amplifier (the fourth amplifier A4) seizes control of the control loop 100, its output voltage slews from the rail voltage to the control voltage level of the other error amplifier (e.g., the second amplifier A2). Depending on circuit parameters, the slew time delay can be as long as tens of milliseconds. Unfortunately, a circuit time delay, of even a few milliseconds, can be detrimental because of the excessive output currents or voltages resulting from rapid load transients (such as a short circuit or load dump). A different manifestation of this limitation occurs when a rectifier in a battery plant (not shown) is hovering at a threshold between output voltage control and output current control. A rectifier with a slow transitional time can oscillate as the two control loops alternately seize and lose control of the output.
A frequently employed solution to the aforementioned limitations is to couple a diode-based overshoot limiting circuit (including a first diode D3 and second diode D4 for the second amplifier A2 and fourth amplifier A4, respectively) in parallel with the feedback components of the second and fourth amplifier A2, A4 to clamp the output voltage to a level lower than the rail. For a power supply with a fixed output voltage and a fixed current limit, this may be an adequate solution, but for a rectifier with a wide range of output voltage control and an output current control, the prior art diode-based overshoot limiting circuit is not an adequate solution because of the large signal fluctuations for the error signals of the two loops.
Turning now to FIG. 2, illustrated is a schematic diagram of a multiple loop controller 200 including an embodiment of an overshoot limiting circuit according to the present invention. Analogous to the multiple loop controller 100 of FIG. 1, the multiple loop controller 200 includes an output voltage control circuit or first control subcircuit (including a first amplifier A1 and a second amplifier A2) 210 and an output current control circuit or second control subcircuit (including a third amplifier A3 and a fourth amplifier A4) 220. Referring to the output voltage control circuit 210, an output voltage V out of a rectifier (for instance) provides an input signal to the first amplifier (e.g., a differential remote sense amplifier) A1. The output of first amplifier A1 feeds the second amplifier (e.g., a voltage error amplifier) A2. A reference voltage V ref is the output voltage reference. Referring now to the output current control circuit 220, an output current signal V s provides an input signal to the third amplifier (e.g., a differential current remote sense amplifier) A3. An output of third amplifier A3 feeds the fourth amplifier (e.g., a current error amplifier) A4. A reference current I ref is the output current reference voltage. The outputs of the second and fourth amplifiers A2, A4 are diode OR-ed (a diode OR circuit 230) including a first diode or second diode D1, D2, respectively, in such a manner that the amplifier (either the second or fourth amplifier A2, A4) with the lowest output voltage controls a peak current control ("PCC") power stage 210. In contrast to the multiple loop controller 100 of FIG. 1, the multiple loop controller 200 includes overshoot limiting circuits 240, 250 establishing a feedback loop with first and second feedback loop amplifiers A5, A6 around the second and fourth amplifiers A2, A4, respectively.
Again, due to the OR-ing of the first and second diodes D1, D2, the amplifier (either the second or fourth amplifier A2, A4) with the lowest output voltage controls the PCC power stage 210. As a result, when the second amplifier A2 is controlling the output, the first diode D1 is conducting. Moreover, because the first feedback loop amplifier A5 is configured as a unity gain differential amplifier with its output referenced to the reference voltage V ref , the output voltage of the first feedback loop amplifier A5 is approximately 0.6 volts negative with respect to the reference voltage V ref when the first diode D1 is conducting. As a result, a third diode D3 incurs a negative bias thereby effectively disconnecting the loop including the first feedback loop amplifier A5. In other words, when the second amplifier A2 is in control, the first feedback loop amplifier A5 has no effect.
When the output current control circuit is controlling, the output of second amplifier A2 tends to saturate towards the positive rail thereby reverse biasing the first diode D1. As the voltage on the cathode of first diode D1 increases, the output voltage of the first feedback loop amplifier A5 increases until the third diode D3 begins to conduct thereby closing the feedback loop of the first feedback loop amplifier A5 around the second amplifier A2. Due to the high DC gain from the cathode of third diode D3 to the output of second amplifier A2, the reverse bias voltage across the first diode D1 is approximately 0.6 volts DC leading to an output voltage of about 0.6 volts DC above the reference voltage V ref . The differential voltage is then adequate to forward bias the third diode D3. As a result, the output of second amplifier A2 is about 0.6 volts DC more positive than the control voltage V err established by the output current control circuit 220. In an analogous manner, the output of the fourth amplifier A4 will be about 0.6 volts DC more positive than the control voltage V err when the output voltage control circuit 210 is in control. During the transition between control loops, the inactive amplifier (either the second or fourth amplifier A2, A4) has a much improved slew rate time delay because the inactive amplifier changes at about 0.6 volts or less to obtain control of the PCC power stage 210.
Turning now to FIG. 3, illustrated is a block diagram of a battery plant rectifier 300, including the multiple loop controller 200 of FIG. 2, for providing charge power to one or more batteries 310. The battery plant rectifier 300 includes a power input 320 for receiving input AC power; at least one switch (including a plurality of switches Q1, Q2, Q3, Q4) coupled to the power input 320 for switching the input AC power; a rectifier (including a plurality of rectifying diodes RD1, RD2) that rectifies the switched AC power to produce a DC power; and a filter (including an inductor L1 and capacitor C1) that filters the DC power to produce an output DC power to charge the batteries 310. The battery plant rectifier 300 also includes a transformer T1 to, among other things, provide electrical isolation between the input and output thereof. The battery plant rectifier 300 further includes the multiple loop controller or rectifier control circuit 200 that alternately controls one of the output voltage V out and a load current I load of the battery plant rectifier 300.
With continuing reference to FIG. 2, the rectifier control circuit 200 includes the output voltage control circuit 210 having the voltage sense amplifier (the first amplifier A1) for sensing the output voltage V out and a voltage error amplifier (the second amplifier A2) that develops a voltage control signal as a function of the output voltage V out . The rectifier control circuit 200 also includes the output current control circuit 220 having a current sense amplifier (the third amplifier A3) for sensing the load current I load and a current error amplifier (the fourth amplifier A4) that develops a current control signal as a function of the load current I load . The rectifier control circuit 200 further includes the diode OR circuit (including the diodes D1, D2) 230 that selects which one of the voltage control signal and the current control signal is to control the battery plant rectifier 300. The rectifier control circuit 200 further includes a voltage control signal overshoot limiting circuit (including the first feedback loop amplifier A5) 240 for establishing a feedback loop around the voltage error amplifier A2 as a function of a voltage present in the diode OR circuit 230 while the current control signal controls the battery plant rectifier 300. The rectifier control circuit 300 still further includes a current control signal overshoot limiting circuit (including the second feedback loop amplifier A6) 250 for establishing a feedback loop around the current error amplifier A4 as a function of a voltage present in the diode OR circuit 230 while the voltage control signal controls the battery plant rectifier 300. In the present embodiment, the feedback loops around the voltage and current error amplifiers A2, A4 limit the voltage and current control signals to a diode voltage (e.g., 0.6 volts) above the control voltage V err . The feedback loops around the voltage and current error amplifiers A2, A4 prevent a saturation thereof and thereby reduce a slew rate time delay when the diode OR circuit 230 switches between the voltage control signal and the current control signal.
Those skilled in the art should understand that while the present invention is embodied as hardware that other variations including software and firmware implementations are well within the broad scope of the present invention. Moreover, the present embodiment is introduced for illustrative purposes only and other applications subject to control by multiple control loops or schemes may benefit from and are well within the broad scope of the present invention. Furthermore, for a better understanding of control systems and architectures see Modern Control Engineering by Katsuhiko Ogata, Prentice Hall 1990 and for a better understanding of power electronics including power conversion technologies see Principles of Power Electronics, by J. G. Kassakian, M. F. Schlecht and G. C. Verghese, Addison-Wesley 1991. The aforementioned references are herein incorporated by reference.
Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form.
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A control circuit for, and method of, alternately controlling one of at least two controllable characteristics of a controlled circuit. The circuit includes: (1) a first control subcircuit having a first error amplifier for developing a first control signal as a function of a first controllable characteristic of the controlled circuit, (2) a second control subcircuit for developing a second control signal as a function of a second controllable characteristic of the controlled circuit, (3) an OR circuit for selecting which of the first control signal and the second control signal is to control the controlled circuit and (4) an overshoot limiting circuit for establishing a feedback loop around the first error amplifier as a function of a voltage present in the OR circuit while the second control signal controls the controlled circuit, the feedback loop preventing a saturation of the first error amplifier and thereby reducing a slew rate time delay when the first control signal is selected to control the controlled circuit.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of U.S. application Ser. No. 13/453,055, filed on Apr. 23, 2012, which is a continuation of U.S. Pat. No. 8,179,420, issued May 15, 2015, which is a continuation of U.S. Pat. No. 7,518,630, issued Apr. 14, 2009, which is a continuation of U.S. Pat. No. 6,956,600, issued Oct. 18, 2005, which are hereby incorporated herein by reference in their entirety for all purposes.
TECHNICAL FIELD
The present invention relates to combining multiple digital video picture frames into a single spatial multiplex video picture frame to produce a single displayed picture that is a composite of several individual pictures. More particularly, the present invention relates to generating the spatial multiplex video picture frame by altering header information of the individual video picture frames being combined.
BACKGROUND
A motion picture such as broadcast television is made of individual pictures that are rapidly displayed to give the illusion of continuous motion. Each individual picture in the sequence is a picture frame. A digitally encoded picture frame is made of many discrete picture elements, or pixels, that are arranged in a two-dimensional array. Each pixel represents the color (chrominance) and brightness (luminance) at its particular point in the picture. The pixels may be grouped for purposes of subsequent digital processing (such as digital compression). For example, the picture frame may be segmented into a rectangular array of contiguous macroblocks, as defined by the ITU-T H series coding structure. Each macroblock typically represents a 16×16 square of pixels.
Macroblocks may in turn be grouped into picture frame components such as slices or groups of blocks, as defined under the ITU-T H.263 video coding structure. Under H.263, a group of blocks is rectangular and always has the horizontal width of the picture, but the number of rows of group of blocks per frame depends on the number of lines in the picture. For example, one row of a group of blocks is used for pictures having 4 to 400 lines, two rows are used for pictures having 404 to 800 lines, and four rows are used for pictures having 804 to 1152 lines. A slice, on the other hand, is flexible grouping of macroblocks that is not necessarily rectangular. Headers within the encoded video picture bit stream identify and provide important information about the various subcomponents that make up the encoded video picture. The picture frame itself has a header, which contains information about how the picture frame was processed. Each group of blocks or slice within a video picture frame has a header that defines the picture frame component as being a slice or group of blocks as well as providing information regarding the placement of the component within the picture frame. Each header is interpreted by a decoder when decoding the data making up the picture frame in preparation for displaying it.
In certain applications, displaying multiple picture frames within a single display is desirable. For example, in video-conferencing situations it is useful for each participant to have a video display showing each of the other participants at remote locations. Visual cues are generally an important part of a discussion among a group of participants, and it is beneficial for each participant's display to present the visual cues of all participants simultaneously. Any method of simultaneously displaying all the conference participants is called a continuous presence display. This can be accomplished by using multiple decoders and multiple video displays at each site, or by combining the individual video pictures into a single video picture in a mosaic arrangement of the several individual pictures (called a spatial multiplex).
Multiplexing picture frames into a single composite picture frame requires some form of processing of each picture frame's encoded data. Conventionally, a spatial multiplex video picture frame could be created by completely decoding each picture frame to be multiplexed to a baseband level, multiplexing at the baseband level, and then re-encoding for transmission to the various locations for display. However, decoding and re-encoding a complete picture frame is computationally intensive and generally consumes a significant amount of time.
The H.263 standard provides a continuous presence multipoint and video multiplex mode that allows up to four individual picture frames to be included in a single bitstream, but each picture frame must be individually decoded by individual decoders or by one very fast decoder. No means of simultaneously displaying the pictures is specific in the standard. Additionally, time-consuming processing must be applied to the picture frames after they have been individually decoded to multiplex them together into a composite image for display. Therefore, there is a need in the art for a method and system that can spatially multiplex multiple picture frames into a single picture frame without requiring each individual picture frame to be fully decoded when being multiplexed and without requiring additional processing after decoding to multiplex the picture frames.
SUMMARY
The present invention spatially multiplexes several picture frames into a single spatial multiple video picture frame by manipulating header information for the picture frame components, such as the groups of blocks or slices, containing the picture frame data. A picture header associated with each picture frame is removed and a new picture header is generated that applies to the spatial multiplex video picture frame that is a composite of all of the individual picture frames. The new header provides an indication of a slice format for the spatial multiplex video picture frame. The component headers of each picture frame are altered to set a slice format based picture position for the picture frame within the picture that results from the spatial multiplex video picture frame. The slice format is prevalent within the H.263 standard. Thus, only the component headers need to be decoded and re-encoded to establish the spatial multiplex video picture frame.
The spatial multiplex video picture frame results from concatenating the new picture header together with the picture frames having the altered component header information. The spatial multiplex video picture frame may then be decoded as if it were a single picture frame to display the composite of the several individual picture frames. Displaying the spatial multiplex video picture frame allows the individual picture frames to be viewed simultaneously on one display screen.
The system that multiplexes the individual picture frames may be a scalable facility such that as the need for picture frame multiplexing increases, the system may be expanded to fill the need. The system includes a plurality of computing devices, such as single board computers, linked to a data packet switch through a serial interface. Each computing device within the system has the ability to combine individual picture frames into a single spatial multiplex video picture frame by altering the headers of the picture frame components to set a slice format based picture position for the picture frames. As the need for additional processing arises, additional computing devices in communication with the data packet switch may be added to provide additional capacity.
The present invention may be employed in a networked environment where a processing device, such as a network server, communicates with several client devices, such as videoconferencing devices. The processing device receives the multiple picture frames from various communication channels in the network. For example, the processing device may receive a stream of video picture frames from each participant in a videoconference through the network. The processing device then multiplexes the individual picture frames into a spatial multiplex video picture frame by altering the component header information to produce a slice based picture position for each frame. The spatial multiplex video picture frame is transmitted back through the communication channels of the network where it can be displayed by the display screen of the client devices.
The present invention may also be employed in a networked environment where each video site, such as a videoconferencing device, generates video picture frames. The picture frames are transmitted to other video sites in the network, and picture frames produced by other video sites are received. The video site multiplexes the picture frames to produces the multiplexed composite picture e by altering the component header information to set a slice format based picture position. The video site may then decode the spatial multiplex video picture frame and display it.
The various aspects of the present invention may be more clearly understood and appreciated from a review of the following detailed description of the disclosed embodiments and by reference to the drawings and claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a composite picture frame and slice structure, an individual picture frame that may be multiplexed into the composite picture frame, and alternative picture frame structures.
FIG. 2 is an exemplary picture layer syntax of a picture frame under the H.263 standard.
FIG. 3 is an exemplary group of blocks layer syntax under the H.263 standard.
FIG. 4 is an exemplary slice layer syntax under the H.263 standard.
FIG. 5 is an operational flow for multiplexing picture frames utilized by one embodiment of the present invention.
FIGS. 6A and 6B are an operational flow of the group of blocks to slice format conversion utilized by the embodiment.
FIG. 7 . is a block diagram of an embodiment employing single-point processing in a network environment.
FIG. 8 is a block diagram of an embodiment employing on-site processing in a networked environment.
FIG. 9 is a block diagram of an embodiment of a scalable multiplexing facility.
DETAILED DESCRIPTION
FIG. 1 Illustrates a display of a spatial multiplex video picture frame 100 made up of individual picture frames 102 . As shown, the spatial .multiplex video picture frame 100 includes sixteen picture frames 102 of individual people participating in a videoconference where the picture frames 102 form a mosaic pattern. Because each participant is always in view, the spatial multiplex video picture frame 100 is referred to as a continuous presence display. All will be discussed below, each individual picture frame 102 of the spatial multiplex video picture frame 100 is initially a normal picture frame 104 that may be displayed in full size on a display screen. The picture frame 104 may be represented as data that is encoded and segmented in various ways.
For the example shown, the picture frame 104 may have been transmitted in a quarter-size common image format (QCIF) indicating a pixel resolution of 16×144. In such a case, the spatial multiplex video picture frame 100 is decoded as a 4CIF picture indicating a resolution of 704×576 because it contains sixteen QCIFs where four QCIFs form a CIF size image. It is to be understood that other picture size formats for the individual picture frames 104 and for the spatial multiplex video picture frame 100 are possible as well. For example, the multiplexed image may contain 64 individual QCIF picture frames and therefore have a 16CIF size.
The group of blocks format 110 is one alternative for segmenting and encoding the picture frame 104 . The picture frame 104 of the group of blocks format 110 includes one or more rows of picture components known as groups of blocks 124 . In the example, shown, the QCIF frame 104 has three rows of groups of blocks. A picture header 122 is also included. The picture header provides information to a decoder when the picture frame 104 is to be displayed in full size and tells the decoder that the picture frame 104 has a group of blocks format 110 .
Each row 124 is made up of an array 112 of macroblocks 128 that define the luminance and chrominance of the picture frame 104 . Each row 124 also includes a header 126 that tells the decoder the position within the picture frame 104 where the row of group of blocks 124 belongs. In the example shown, the group of blocks 124 has two rows of macroblocks 128 because it is intended for the picture frame 104 to be displayed with 404 to 800 total lines. In reality, a group of blocks 124 will have many more macroblocks 128 per row than those shown in FIG. 1 .
As discussed above, the group of blocks format defined by the H.263 standard require that the row 124 always extends to the full width of the picture. Therefore, a 20 direct remapping of a group of blocks format 110 to a spatial multiplex video picture frame 100 is not possible because the spatial multiplex video picture frame 100 requires individual frames to have a width that may be less than the full width of the picture. In the videoconferencing context, several participants may need to be displayed across the width of the picture as shown in FIG. 1 , and a group of blocks format 110 does not permit such remapping.
An alternative format for segmenting and encoding the picture frame 104 is the slice format 106 , such as defined by the H.263 standard. The slice format 106 is more flexible and does not require each slice to maintain the full width of the picture. The slice format 106 includes one or more picture components known as slices n6 that may or 30 may not extend across the full width of the picture, and a picture header 114 that specifies to the decoder that the picture frame 104 has a slice format. Bach slice 116 is made up of a grouping 108 of macroblocks 120 . Each slice 116 also has a slice header 118 that indicates to the decoder the relative position of the slice in the picture 104 .
The slice format 106 of the picture frame 104 allows the picture frame 104 to be multiplexed into the composite picture frame 100 {with minimal decoding. The spatial 5 multiplex video picture frame 100 may be created in a slice format 130 of many slices 134 corresponding to the slices 116 of the individual picture frames 102 forming the composite. As shown, the slices 134 have a width that is less than the picture width so that multiple slices 134 are provided for each row of slices of the picture. A new picture header 132 is also generated to indicate to the decoder that the picture frame 100 is of the slice format 130 and is of a 4CIF size, 16CTF size, and so on. The header, such as 118 , of each slice 134 is modified to properly position the slice within the spatial multiplex video picture frame 100 .
FIG. 2 shows the picture layer syntax 200 that is made up of the picture header included at the beginning of each picture frame as well as the group of block layer or 15 slice layer. The picture layer syntax 200 includes a picture start code (PSC) 202 that signifies the beginning of a new picture frame. A temporal reference (TR) 204 follows in the bitstream and provides a value indicating the timing of display of the picture frame relative to a previous frame and the picture clock frequency. A PTYPE block 206 follows and provides information about the picture such as whether the source format of the picture frame is a quarter-size common image format (QCIF), a CIF format, or other.
The picture layer syntax 200 may also include a PLUS HEADER block 208 that contains information about the picture frame, including whether the frame consists of groups of blocks or slices. A PQUANT block 210 provides quantizer information to configure the quantization parameters used by the decoder. An optional continuous presence multipoint (CPM) block 212 signals the use of continuous presence multipoint and video multiplex mode discussed above that permits multiple individual frames to be included in the bitstream. As discussed the CPM mode causes the individual frames to maintain their identities as individual frames and requires that they be individually decoded and then processed to form a single image. A picture sub-bitstream indicator (PSBI) 214 may be included if CPM mode is indicated. CPM mode may be implemented in junction with the logical operations of FIGS. 5, 6A and 6B to provide sub-bitstreams that are themselves multiplexed bitstreams, or CPM may be turned off if only the logical operations of FIGS. 5, 6A and 6B are desired for providing continuous presence video.
A temporal reference for B-picture parts (TRB) 216 may be included if a PB-frame is indicated by the PTYPE block 204 or PLUS HEADER block 208 . A DBQUANT block 218 may also be included if a PB-frame is indicated to indicate the relation of the BQUANT quantization parameter used for B-picture parts in relation to the QUANT quantization parameter used or P-picture parts. A PEI block 220 includes a bit that signals the presence of the supplemental enhancement information (PSUPP) block 222 . PSUPP block 222 defines extended capabilities for picture decoding. The group of blocks (GOB) layer 24 or slice layer 226 then follows in the bitstream. The GOB layer 224 contains each group of block of the picture frame and is discussed in more detail in FIG. 3 . Slice layer 226 contains each slice of the picture frame and is discussed in more detail in FIG. 4 .
The ESTUF block 228 is included to provide mandatory byte alignment in the bitstrearn. The end of sequence (BOB) block 234 may be included to signal the end of the sequence of group of blocks or slices. Alternatively, the end of sub-bitstream sequence (EOSBS) block 230 may be included to indicate an end of a sub-bitstream when in CPM mode. An ending sub-bitstream indicator (ESBI) block 232 is included to provide the sub-bitstream number of the last sub-bitstream. The PSTUF block 236 is included to provide byte alignment for the PSC of the next picture frame.
FIG. 3 shows the group of blocks layer syntax 300 that is made up of the component header and the macroblocks of the array fanning a group of blocks and that would be found in each group of blocks of the group of blocks layer 224 of FIG. 2 . A GSTUF block 302 is included to provide byte alignment for a group of blocks start code (GBSC) 304 . The GBSC 304 indicates to the decoder the start of a group of blocks. A group number (GN) block 306 indicates the group of block number that defines the position of the group of blocks in the picture frame. A GOB sub-bitstream indicator (GSBI) 308 may be included when in CPM mode to indicate the sub-bitstream number.
A GOB frame ID (GFID) 310 is included to indicate the particular frame that the group of blocks corresponds to GQUANT block 312 provides quantizer information to control the quantization parameters of the decoder. A temporal reference indicator (TRI) block 314 is included to indicate the presence of a temporal reference when operating in a reference picture mode. A temporal reference (TR) block 316 is included to provide a value indicating the timing of display of the group of blocks relative to a previous group of blocks and the picture clock frequency. A temporal reference for prediction indication (TRPI) block 318 is included to indicate the presence of a temporal reference for prediction field (TRP) 320 . The TRP field 320 indicates the temporal reference to be used for prediction of the encoding.
A back channel message indication (BCI) field 322 is included to indicate whether a message is to be delivered from the decoder back to the encoder regarding conditions of the received coded stream. A back channel message (BCM) layer 324 contains a message that is returned from a decoder to an encoder in order to tell whether forward-channel data was correctly decoded or not. A macroblock (MB) layer 326 contains a macroblock header and the macroblock data for the group of blocks.
FIG. 4 shows the slice layer syntax 400 that is made up of the component header and the macroblocks of the array forming a slice and that would be found in each slice of the slice layer 226 of FIG. 2 . An SSTUF block 402 is included to provide byte alignment for a slice start code (SSC) block 404 indicating the beginning of a slice. A first slice emulation prevention bit (SEPB 1 ) 406 is included to prevent start code emulation after the SSC block 404 . A slice sub-bitstream indicator (SSBI) block 408 is included when in CPM mode to indicate the sub-bitstream number of the slice. A macroblock address (MBA) field 410 is included to indicate the first macroblock of the slice as counted from the beginning of the picture in scanning order to set the position of each slice in the picture frame.
A second slice emulation prevention bit (SEPB 2 ) block 412 is also included to prevent start code emulation after the MBA field 410 . An SQUANT block 414 is included to provide quantizer information that controls the quantization parameters of the decoder. A slice width indication (SWI) block 416 is provided to indicate the width of the current rectangular slice whose first macroblock is specified by the MBA field 410 . A third slice emulation prevention bit (SEPB 3 ) 418 is included to prevent start code emulation after the SWI block 416 . A slice frame ID (GFID) 420 is included to indicate the particular picture frame that the slice corresponds to. The TRI field 422 , TR field 424 , TRPI field 4261 TRP field . 428 , BCI field 430 , BCM layer 432 , and MB layer 434 are identical to the fields of FIG. 3 that go by the same name.
The operational flow of the process 500 for multiplexing individual picture frames containing the GOB syntax 300 or the slice syntax 400 into a single picture frame is shown in FIG. 5 . In this embodiment of the operational flow, it is assumed that the single picture frames are originating from encoder devices and are being processed by one or more decoder devices after transfer, such as through a network medium as shown in the systems of FIGS. 7 and 8 . The process 500 begins at call operation 502 where the two devices passing the picture data establish a common mode of operation suitable for generating continuous presence video. The common mode of operation includes a consistent usage of header information so that, for example, back channel messaging is employed between the encoder and decoder or other enhanced capabilities are realized. After communication is established, start operation 504 causes one device of the connection to broadcast a start indicator that allows synchronization of transmission of the individual picture frames from the various sources, such as the remote locations of the videoconference.
Once the picture frames to be included in the multiplex frame have been received, header operation 506 reads the picture layer header, such as shown in FIG. 2 , for each individual picture frame and discards them. This requires that only the picture header be decoded. A single new picture layer header that applies to the spatial multiplex video picture frame is created and encoded at header operation 506 . The single new picture layer header provides in the PTYPE field 206 an indication that the spatial multiplex video picture frame is of a size capable of including the number of individual frames being multiplexed. The PLUS HEADER field 208 of the new picture header is configured to indicate a rectangular slice format.
After substituting the new picture header, the component header of one of the individual frames is interpreted at read operation 508 in preparation for subsequent processing discussed below including conversion lo a slice format and repositioning within the multiplexed image. Query operation 510 detects whether the picture header read in header operation 506 for the current picture frame indicates a group of blocks format. If a group of blocks format is detected, then conversion operation 512 converts the group of blocks headers into slice headers. Conversion operation 512 is discussed in greater detail below with reference to FIGS. 6A and 6B . If a group of blocks format is not detected, then the conversion operation 512 is skipped since a slice format is already present in the picture frame.
After finding or converting to a slice format, macroblock operation 514 alters the MBA 410 within each slice of each picture frame to position the slice within a particular region of the spatial multiplex video picture frame. For example, one individual picture frame must go in the top left-hand corner of the multiplexed picture so the top-leftmost slice of that picture frame is given an MBA 410 corresponding to the top left-hand corner position. The component header is also re-encoded at this operation after the MBA 410 has been altered. The slice is then inserted into the proper location in the continuous presence picture stream by concatenating the bits of the slice with the bits already present in the picture stream ‘including the new picture header at stream operation 516 . The picture stream may be delivered as it is being generated at transmit operation 518 wherein the current slice is written to an output buffer and then transmitted to a network interface.
After writing the slice to the output buffer, query operation 520 detects whether the last slice was the end of the continuous presence or spatial multiplex video picture frame. If it was not the last slice of the multiplexed frame, then flow returns to read operation 508 where the header of the next group of blocks or slice to be included in the spatial multiplex video picture frame is read. If query operation 520 determines that the last slice was the end of the spatial multiplex video picture frame, then flow returns to header operation 506 wherein the picture headers for the next set of individual picture frames are read and discarded.
FIGS. 6A and 6B show the operational flow of the conversion operation 512 . Conversion operation 512 begins at alignment operation 602 where the GSTIJF field of the GOB syntax 300 is converted to an SSTUF field of the slice syntax 400 by adjusting the length of the stuff code to provide byte alignment of the next code element. At start code operation 604 , the GBSC 304 is maintained because it is already identical to the SSC 404 needed in the slice syntax 400 . At prevention operation 606 , the SEPB 1 406 is inserted into the bitstream to later prevent start code emulation when being decoded.
Translation operation 608 converts the GSBI 308 to the SSBI 408 . During this operation, GSBI ‘001 becomes SSBI ‘1001’, GSBI ‘011 becomes SSBI 11010’, GSBI ‘10’ becomes SSBI ‘1011’, and GSBI ‘11’ becomes SSBI ‘1101’. At MBA operation 610 , the GN 306 is replaced by an MBA 410 chosen to place the slice in its designated location within the composite picture frame resulting from multiplexing the individual picture frame bitstreams. Prevention operation 612 then places a SEPB 2 into the bitstream to prevent start code emulation. At quantizer operation 614 , GQUANT is maintained in the bitstream after SEPB 2 because GQUANT is already identical to SQUANT 414 .
Slice operation 616 then sets the width of the slice, or SWI 416 , to the width of the GOB in terms of the number of macroblocks. This is possible because the slice structure selection (SSS) field (not shown) of the PLUS HEADER field 208 of the picture syntax 200 of FIG. 2 has been set to the rectangular slice mode in header operation 506 of FIG. 5 . Prevention operation 618 then inserts a SEPB 3 into the bitstream to prevent start code emulation when the slice is decoded. At GFID operation 620 , the GFID 310 is maintained in the bitstream after SEPB 3 because it is already identical to GFID 420 . In substitute operation 622 , all remaining portions of the GOB syntax 300 are maintained in the bitstream because they are also identical to the remaining portions of the slice syntax 400 .
FIG. 7 shows one network environment for hosting a continuous presence videoconference. A server 702 communicates through bi-directional communication channels 716 with client devices 704 , 706 , 708 , and 710 . Each client device, such as a personal computer or special-purpose videoconferencing module is linked to a camera 712 or other video source and a video display 714 . The client devices transmit sequences of encoded picture frames produced by the camera 712 or other video source to the server 702 through the communication channels 716 . The server 702 then employs the processes of FIGS. 5, 6A and 6B to combine all of the encoded picture frames into an encoded spatial multiplex video picture frame. The server 702 then transmits the spatial multiplex video picture frame back through the communications channels 716 to the client devices where it is decoded and displayed on each display screen 714 . Thus, the client devices may include encoder and decoder processing but do not need to include the multiplexing processing discussed above.
Four client devices are shown only for exemplary purposes, and it is to be understood that any number of client devices may be used subject to the limitation on the total number of individual frames to be included on the display 714 . It is also to be understood that each individual frame to be included in the multiplexed frame through the processes of FIGS. 5, 6A and 6B do not have to be of the same size, such that one frame may occupy more screen area than others. For example, the frame showing the person currently speaking in a videoconference may be enlarged relative to frames showing other participants. One skilled in the art will recognize that negotiation between participating devices can be established such that mode switching can occur to permit one or more participants to provide one image size (e,g., QCIF) while other participants provide a different image size (e.g., C). subject to the ability to combine the image sizes into a composite that will fit on the intended display. Furthermore, it is to be understood that the server 702 may customize each videostream being returned to each client device 704 , 706 , 708 , and 710 , such as by removing the frame provided by the recipient client device from the spatial multiplex being returned or creating the spatial multiplex from some other subset.
The communication channel between the client devices 704 , 706 , 708 , and 710 and the server 702 can be of various forms known in the art such as conventional dial-up connections, asymmetric digital subscriber lines (ADSL), cable modem lines, Ethernet, and/or any combination. An Internet Service Provider (ISP) (not shown) may be provided between the server 702 and each client device or the server 702 may itself act as an ISP. The transmissions through a given channel 716 are asymmetric due to one picture frame being transmitted to the server 702 from each client device while the server 702 transmits a configuration of picture frames forming the multiplexed bitstream back to each client device. Therefore, ADSL is well suited to picture frame transfer in this network configuration since ADSL typically provides a much greater bandwidth from the network to the client device.
FIG. 8 shows an alternative network configuration where each client device 802 , 804 , 806 , and 808 has its own processing device performing the operations of FIGS. 5, 6A and 6B . Each client device is linked to a camera 810 or other video source and a display 812 . A bi-directional communication path 814 interconnects each client device to the others. The bi-directional communication paths 814 can also be of various forms known in the art such as conventional dial-up connections, asymmetric digital subscriber lines (ADSL), cable modem lines, Ethernet, and/or any combination. One or .more ISPs (not shown) may facilitate transfer between a pair of client devices.
Each client device generates an encoded picture frame sequence that is transmitted to the other client devices. Thus, each client device receives an encoded picture frame from the other client devices. The client device may then perform the multiplexing operations discussed above to create the spatial multiplex video picture frame that is displayed.
Multiplexing the individual picture frames together at each client device where the spatial multiplex video picture frame will be displayed allows each client device to have control over the spatial multiplex video picture frame it will display. For example, the client device can choose to exclude certain picture frames or alter the displayed size of particular picture frames. In a videoconference, the client device may choose to eliminate the picture frame that it generates and sends to others from the spatial multiplex video picture frame that it generates and displays. Because each client device performs the multiplexing operations, the communication paths 814 carry only the individual picture frame sequences generated by each sending client device rather than spatial multiplex video picture frame sequences.
FIG. 9 shows an example of a scalable multi-point conferencing facility 900 . The facility includes a packet switch 902 ; such as a multi-gigabit Ethernet switch, linked to several processing modules, such as single board computers (SBCs) 904 , 906 , and 908 . An SBC generally refers to a computer having a single circuit board including memory, magnetic storage, and a processor for executing a logical process such as those of FIGS. 5, 6A and 6B . The processing modules may include general-purpose programmable processors or dedicated logic circuits depending upon the performance necessary. Because the operations of FIGS. 5, 6A, and 6B to be performed by the processing modules require only decoding of header information, programmable processors are adequate for continuous presence processing in real time for most implementations.
The processing modules are linked to the packet switch 902 through high-speed serial interfaces 910 , such as Fast/Gigabit Ethernet. The packet switch 902 receives encoded picture frame sequences from client devices, such as discussed with reference to FIG. 7 , but possibly from several videoconferencing sessions. The packet switch 902 may then send all picture frame sequences corresponding to a particular videoconference to one of the processing modules 904 ) 906 , or 908 . The processing module multiplexes the picture frames to generate a spatial multiplex video picture frame and sends the spatial multiplex video picture frame sequence back to the packet switch 902 . The packet switch 902 then delivers the spatial multiplex video picture frame sequence back to client devices of the particular videoconference.
Thus, the scalable multi-point conferencing facility 900 can provide multiplexing services for multiple videoconference groups simultaneously. As the number of videoconference groups at any given time increases or decreases, the processing modules employed by the packet switch 902 can be added or removed from active service and made available for other duties when not needed by packet switch 902 .
Although the present invention has been described in connection with various exemplary embodiments) those of ordinary skill in the art will understand that many modifications can be made thereto within the scope of the claims that follow. Accordingly, it is not intended that the scope of the invention in any way be limited by the above, description, but instead be determined entirely by reference to the claims that follow.
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Multiple video picture frames are combined into a spatial multiplex video picture frame that may be fully decoded and displayed. The video display of the spatial multiplex video picture frame is a composite combination of all of the video picture frames that have been combined, and may have an appearance such as a mosaic. Multiplexing the video picture frames involves removing picture headers, creating a picture header for the spatial multiplex video picture frame, and altering the headers of individual components of each video picture frame. The new header for the spatial multiplex video picture frame indicates a slice format frame, and headers of the individual components are altered to provide a slice format based picture position for each video picture frame. The headers of the individual components are altered to become slice based, such as in accordance with the ITU-T H.263 video standard, prior to establishing the slice based picture position if the frames are not already of the slice format.
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BACKGROUND OF THE INVENTION
The invention relates generally to a head support for mounting on the backrest portion of a seat such as a vehicle seat.
With increasing concern about safety factors in motor vehicles, recent years have seen the increased adoption of head supports or headrest assemblies which are mounted on the backrest portion of a vehicle seat, to support the head in the event of abrupt forward acceleration of the motor vehicle, for example as a result of a tail-end impact, with the consequent risk of a whiplash injury to the neck of the occupant of the seat.
Whether a head support is used in a motor vehicle or in a different context, it is often desirable to provide for adjustment of the head support, for example to provide for pivotal movement thereof, thereby to adjust the angle of inclination of the head support, or to provide for displacement of the head support in a substantially vertical direction in order to adjust the height of the head support.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a head support for a seat backrest portion, which is adapted to provide for adjustment in respect of height and/or in respect of angle of inclination.
Another object of the invention is to provide a head support for a seat, which permits progressive stepless adjustment in respect of height and/or inclination.
A further object of the invention is to provide a head support arrangement for mounting to the backrest portion of a seat, which is adjustable in respect of height and/or inclination while being of a simple construction thereby to minimise production costs.
Still a further object of the present invention is to provide a head support arrangement for a seat, which permits adjustment in respect of height and/or inclination by simple means which are of light weight, thereby to minimise loadings acting on the head support arrangement due to the weight thereof.
In accordance with the present invention, in a first aspect, these and other objects are achieved by a head support for the backrest portion of a seat, comprising at least one elongate mounting member such as a rod or bar which interconnects the backrest portion of the seat and the head support carried thereon and which extends into the hollow space or cavity in the head support. To permit the head support to be pivotable about a transverse axis with respect to the elongate connecting member, for the purposes of adjustment of the angle of inclination of the head support, the elongate mounting member carries an annular flexible element which extends therearound. Disposed in the cavity in the head support are first and second wall portions which extend on respective sides of said annular flexible element on the elongate mounting member, in substantially parallel relationship to the desired plane of pivotal movement of the head support. The wall portions are spaced by a distance such that the annular flexible element is in substantial rubbing contact with the mutually facing surfaces of the wall portions. The head support can thus be pivoted relative to the elongate mounting member, against the resistance provided by the frictional engagement between the wall portions and the annular flexible element, such resistance then holding the head support in the adjusted position as required.
In a further aspect of the invention, a head support for the backrest portion of a seat comprises at least one elongate mounting member such as a rod or bar which interconnects the backrest portion of the seat and the head support and which extends into a cavity in the head support. The head support is displaceable lengthwise of the mounting member for the purposes of adjustment of the height of the head support relative to the backrest portion of the seat. Disposed on the elongate mounting member is at least one annular flexible element which is a fit on the mounting member without clearance relative thereto, being therefore a snug or tight fit. The at least one annular flexible element is fixed between first and second abutment means disposed in the cavity in the head support, whereby the mounting member is displaceable in the direction of its length, relative to the annular flexible element which is a snug fit thereon, against the frictional resistance afforded by the annular flexible element on the mounting member.
It will be seen therefore that in the constructions in accordance with the invention, the head support can be readily fixed in the respective adjusted position thereof, after adjustment either in respect of its height or in respect of its angle of inclination, by virtue of the frictional engagement between the respective annular flexible element on the mounting member and the spaced-apart wall portions, in the first aspect of the invention, or by virtue of the frictional engagement between the annular flexible element on the mounting member and the mounting member itself, in the second aspect of the invention. The frictional engagement in each case may be overcome sufficiently readily to permit the head support to be adjusted in the appropriate fashion.
A preferred feature of the invention provides that, in regard to the structure for providing adjustment of the head support in respect of the angle of inclination, provided in the cavity in the head support are first and second guide means which extend substantially transversely with respect to the direction of elongation of the elongate mounting member and at least substantially in the fore-and-aft direction relative to the seat on which the head support is mounted, the guide means thus extending generally horizontally in the position of use of the head support, in order thereby to guide the flexible annular element on the elongate mounting member upon pivotal movement of the head support, the annular flexible element being carried with clearance or play between the guide means, in the direction of elongation of the elongate mounting member. The clearance or play between the guide means disposed respectively above and below the annular flexible element on the elongate mounting member is necessary as, when the head support pivots relative to the mounting member, the guide means move in an arcuate path relative to the annular flexible element.
In another preferred feature of the construction of the first aspect of the invention, play or clearance is provided between the mounting member and the flexible element carried thereon, which is in frictional engagement with the inside surfaces of the first and second wall portions on respective sides thereof, so that that element is not in frictional engagement with the mounting member in the lengthwise direction thereof. In that case that flexible element only provides for adjustment of the head support in respect of its angle of inclination.
If the head support is to be adapted to be adjusted both in respect of angle of inclination and also in respect of height, then in the construction in accordance with the second aspect of the invention, the above-mentioned abutment means between which the annular flexible element which is a snug fit on the elongate mounting member is fixed are preferably in the form of guide means which in the position of use of the head support extend substantially horizontally, while provided between said guide means and the annular flexible element co-operating therewith are low-friction hard lining discs or plates, in order not to generate additional undefined friction upon pivotal movement of the head support, by virtue of the annular flexible element which is a snug fit around the elongate mounting member. The lining discs or plates may be for example of metal.
In a preferred embodiment of the teachings of the invention, to provide both adjustment in respect of angle of inclination and adjustment in a fore-and-aft direction, the mounting member carries two spaced-apart annular flexible elements which are each disposed between and in frictional contact with two wall portions which extend through the cavity in the head support, in substantially vertical positions and in parallel relationship to the desired plate of pivotal movement of the head support relative to the seat backrest portion on which it is mounted. In that way, not only may the head support be pivoted relative to the mounting member, by virtue of one of the annular flexible elements being displaced relative to the associated wall portions on respective sides thereof, but furthermore the head support may be shifted in the fore-and-aft direction relative to the seat on which the head support is mounted, by virtue of both the annular flexible elements being displaced relative to their respective pairs of wall portions on each side thereof.
Further objects, features and advantages of the present invention will be more clearly apparent from the following description of a preferred embodiment thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a head support, and
FIG. 2 is a front view in partial section of the head support shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, shown therein is a head support arrangement in accordance with the present invention, comprising a body portion 10 which is for example of a hard plastic material adequate for the intended use of the head support. The body portion 10 thus essentially imparts the required shape to the head support. The body portion 10 has a hollow space or cavity therein, as indicated by reference numeral 12 in both FIGS. 1 and 2, while extending into the cavity 12 is an elongate mounting member 14 which is connected in a suitable fashion to a backrest portion of a seat, for example by the lower end portion thereof (not visible in the drawings) being fitted into mountings provided on the support structure of the backrest portion. Although only one elongate mounting member 14 is shown in FIGS. 1 and 2, it will be appreciated that the head support may comprise a plurality thereof.
Reference numeral 16 in FIGS. 1 and 2 denotes a cushion or upholstery material which is disposed around the body portion 10 of the head support, in the usual fashion.
Referring now to both FIGS. 1 and 2, it will be seen therefrom that disposed in the cavity 12 of the head support is a plurality of bar or web portions 18, 20,22,24, 26 and 28 which in the position of use of the head support extend at least generally horizontally, as can best be seen from FIG. 1. The portions 18, 20, 22, 24, 26 and 28 also extend in at least substantially parallel relationship to each other, also as best seen in FIG. 1. Those portions from substantially horizontal guide and abutment means for a plurality of annular flexible elements as indicated at 30, 31, 32, 34 and 36 which are disposed on and thus extend around the mounting member 14 which, as mentioned, may be in the form of a rod or bar. As can be clearly seen from FIGS. 1 and 2, the flexible elements 30 and 31 are of such an internal dimension that they have clearance relative to the adjoining surface of the elongate mounting member 14, whereas the flexible elements 32, 34 and 36 extend around the mounting member 14 without clearance or play relative thereto. In other words, the elements 30 and 31 are freely slidable on the mounting member 14 in the axial direction thereof whereas the elements 32, 34 and 36 are in frictional engagement with the mounting member 14.
It will be seen that the flexible elements 32, 34 and 36 are held between the respective adjoining portions 20 and 22; 22 and 24; 24 and 26, with hard low-friction lining plates or discs 40 being disposed between each of the portions 20, 22, 24 and 26 and the respectively associated face of the flexible element 32, 34 and 36. The lining discs or plates, as indicated at 40, may comprise for example metal or other suitable material. The elements 32, 34 and 36 are thus disposed in such a way that they do not have clearance or play between the portions 20, 22, 24 and 26, in the lengthwise direction of the member 14. By virtue of the low-friction lining discs or plates 40, the flexible elements 32, 34 and 36 oppose virtually no frictional resistance to movement of the head support in a horizontal direction, that is to say from left to right or from right to left in FIG. 1, or about a transverse axis with respect to the mounting member 14, whereas, by virtue of the fact that they are a snug or fairly tight fit on the mounting member 14, they put up a considerable degree of frictional resistance to movement of the head support along the mounting member 14. The head support member comprising the body portion 10 and the cushion portion 16 can thus be displaced lengthwise of the mounting member 14, by virtue of the frictional resistance between the mounting member 14 and the elements 32, 34 and 36 being overcome by suitable force whereas when that force is removed, the head support member will remain in its adjusted position on the mounting member 14.
The situation is different in regard to the flexible elements 30 and 31 which are disposed with clearance around the mounting rod or bar 14. Those flexible elements 30 and 31 exert virtually no resistance to movement of the head support member lengthwise with respect to the mounting member 14, whereas they are operative to provide a substantial resistance to horizontal movement of the head support, that is to say in the fore-and-aft direction relative to the seat on which the head support is mounted, or a pivotal movement of the head support member about a transverse axis with respect to the mounting member 14. Such resistance produced by the elements 30 and 31 is afforded by virtue of the fact that they are disposed between and are in frictional engagement with first and second spaced-apart wall portions 42 which extend at least substantially parallel to the desired plane of pivotal movement or fore-and-aft movement of the head support member. As can be seen from FIG. 2, the wall portions 42 extend at least generally vertically in the position of use of the head support and extend between mutually oppositely disposed side walls of the body portion 10 of the head support, as can be seen from FIG. 1. It will be seen therefore that the lower part of the cavity 12 shown in FIG. 1 for example is bridged across by the web portions 18, 20, 22, 24 and 26, with a bottom web portion 28, each of those portions being disposed substantially horizontally, while the wall portions 42 provide frictional-engagement surfaces which also extend across the cavity 12 but which are substantially vertical and thus at right angles to the frictional-engagement surfaces afforded by the portions 20, 22, 24, 26 and 28.
It will be further seen more particularly from FIG. 1 that the flexible element 30 is disposed with play or clearance between the portions 18 and 20, in the lengthwise direction of the mounting member 14, thus permitting the body portion of the head support to move with a pivotal motion relative to the mounting member 14, as indicated by the dash-dotted outline in FIG. 1, in spite of the fact that the portions 18 and 20 are of a straight configuration. It will be further appreciated that such pivotal movement of the head support member is possible irrespective of the adjusted position thereof in respect of height on the mounting member 14.
It will be seen further from FIG. 2 that the portions 18, 20, 22, 24, 26 and 28 serve not just as horizontal guide and abutment means for the flexible elements 30, 31, 32, 34 and 36, but they also serve to guide the body portion 10 with respect to the mounting member 14 insofar as the mounting member 14 extends through suitable slots provided in the portions 18, 20, 22, 24, 26 and 28; the side surfaces defining such slots thus provide guide surfaces for the mounting member 14.
The flexible elements 30, 31, 32, 34 and 36 are preferably of a rubber, although they may also be of any other suitable material.
Although the illustrated construction provides for adjustment of the head support in respect of its angle of inclination, by pivotal movement about a transverse axis, adjustment in respect of height by displacement lengthwise of the mounting member 14, and adjustment in the fore-and-aft direction relative to the seat on the backrest portion of which the head support is mounted, by virtue of the head support member being displaced towards the right or towards the left in FIG. 1 relative to the mounting member 14, without however being inclined, it would be possible to reduce the number of modes of adjustment, if desired. Accordingly, if the head support is only to be pivotable about a transverse axis to provide for adjustment in respect of angle of inclination, without also providing for fore-and-aft adjustment, one of the flexible elements 30 and 31, preferably the element 31, can be eliminated. In that case, the portion 28 also does not need to be in the form of a guide means by virtue of having a slot therein.
It will be appreciated that the above-described construction has been set forth solely by way of example of the principles of the present invention, and that various modifications and alterations may be made therein without thereby departing from the spirit and scope of the invention.
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In a head support assembly comprising a head support member carried on a mounting bar member in such a way as to be adjustable in respect of height and/or inclination thereon, the mounting bar member carries at least one annular flexible element co-operating with portions of the head support member and in frictional engagement relationship with the mounting bar member and/or the portions of the head support member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a rechargeable battery pack having a plurality of secondary cells, and in particular to a protection control technique against overcharging and over-discharging
2. Description of the Related Art
Recently, a rechargeable battery or a secondary battery has been widely used as a power supply for portable or hand-held wireless communication equipment in consideration of running costs.
In general, a battery pack having a secondary battery such as lithium-ion battery therein is provided with a protection circuit for protecting the secondary battery from overcharging, over-discharging and overcurrent.
An example of such a protection circuit has been disclosed in Japanese Patent Laid-open No. 8-116627. This conventional protection circuit is provided with a first controller and a second controller. The first controller performs the on/off control of a switching circuit according to the output voltage of the secondary battery to adjust the charging current of the secondary battery. The second controller controls a cutoff circuit or a circuit breaker according to the charging voltage. More specifically, when the second controller judges that a fault condition occurs in the first controller under overcharging conditions, the second controller activates the circuit breaker so that the charging current is cut off. The circuit breaker is designed to automatically break and manually make a circuit. In this conventional protection circuit, a fuse circuit is used.
According to the above conventional protection circuit, however, the first and second controllers monitor the output voltage of the secondary battery to determine whether overcharging or over-discharging occurs. Therefore, if at least one of the first and second controllers is in fault conditions, resulting in incorrect detection of the battery output voltage, then there is a possibility that the secondary battery is subjected to overcharging or over-discharging.
Further, when detecting a charging voltage higher than a threshold, the first controller controls the switching circuit to turn it off. But, in case of the switching circuit being out of order, there is a possibility that the charging current is not cut off, resulting in the occurrence of overcharging or over-discharging.
SUMMARY OF THE INVENTION
An object of the present invention is to provide control method and device, which can effectively protect a secondary battery from overcharging and over-discharging.
Another object of the present invention is to provide a battery pack including a protection circuit with a self-diagnosis function to effectively protect a secondary battery from overcharging and over-discharging.
According to a first aspect of the present invention, in a battery pack including a battery composed of a plurality of secondary cells placed in a predetermined connection, a control device controls a protection circuit of the battery from over-charging/discharging. A first detector detects cell voltages of the secondary cells, respectively, and a second detector detects a battery voltage of the battery. A controller activates a circuit breaker to break an input/output circuit of the battery when the battery voltage does not match a total cell voltage obtained by adding the cell voltages.
Since the battery voltage detected by the second detector is checked by comparing it with the total cell voltage obtained from the cell voltages detected by the first detector, the self-diagnosis of the protection circuit can be performed. In other words, it can be determined whether the protection circuit is normally operating.
According to a second aspect of the present invention, the controller further activates the circuit breaker when the battery voltage does not match a power supply voltage of its own supplied from the battery.
Since the battery voltage detected by the second detector is checked by comparing it with the power supply voltage supplied from the battery to the controller, the self-diagnosis of the protection circuit can be performed in another way.
According to a third aspect of the present invention, the control device further includes a current detector for detecting current flowing through the input/output circuit, and a switch for making and cutting off the input/output circuit depending on a switching control signal received from the controller. The controller controls the switch such that the input/output circuit is cut off when a detected current is greater than a predetermined current threshold, thereafter determines whether the current detector detects the current, and when the detected current is not zero, activates the circuit breaker
The switch cuts off the input/output circuit when the current detected by the current detector is greater than the predetermined current threshold. Thereafter, the controller further determines whether the protection circuit is normally operating by checking the current detector whether the current is zero. When the detected current is not zero, it means that something unusual occurs and therefore the circuit breaker is activated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a circuit of a control device in a battery pack with a protection circuit according to an embodiment of the present invention;
FIG. 2 is a flowchart showing an operation of the control device as shown in FIG. 1; and
FIG. 3 is a circuit diagram showing an example of a circuit breaker used in the protection circuit.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a battery pack includes a secondary battery consisting of a plurality of rechargeable cells (for example, lithium-ion cells) placed in parallel, in series, or in a combination thereof. Here, for simplicity, three rechargeable cells C 1 -C 3 are placed in series to form the secondary battery 101.
The battery pack is provided with a cell voltage detector that is designed to detect the output voltage of each of the calls C 1 -C 3 . In this embodiment, the cell voltage detector is composed of a multiplexer 102 and a voltage detector 103. Using the multiplexer 102 allows only one voltage detector 103 to detect the respective output voltages of the cells C 1 -C 3 , resulting in simplified circuit configuration of the battery pack. The multiplexer 102 has four input terminals and two output terminals and operates such that two adjacent ones of the four input terminals are sequentially connected to the two output terminals in predetermined timing. The respective four input terminals are connected to the four taps of the series-connected cells C 1 -C 3 and the two output terminals are connected to the input terminals of the voltage detector 103. Therefore, the voltage detector 103 sequentially detects the respective output voltages of the cells C 1 -C 3 and outputs the detected voltages V1, V2, and V3 corresponding to the cells C 1 -C 3 to a processor 105.
Further, a voltage detector 104 is connected across the secondary battery 101 to detect a battery voltage of the secondary battery 101, which should be equal to a total voltage of the cells C 1 -C 3 connected in series. The voltage detector 104 outputs the detected battery voltage VA to the processor 105.
The positive terminal of the secondary battery 101 is connected to a positive terminal 106 of the battery pack and a power supply terminal of the processor 105 Therefore, the power supply voltage Vcc is directly supplied to the processor 105.
On the other hand, the negative terminal of the secondary battery 101 is connected to a circuit breaker 107 which will break a circuit in the case of a switch 108 turning on. The switch 108 connects the positive terminal 106 to the circuit breaker 107 which is normally kept open but closed when receiving a circuit-breaking control signal S BR from the processor 105. As will be described later, once the circuit breaker 107 has broken the circuit, it is necessary to manually make the circuit.
The negative terminal of the secondary battery 101 is connected to the negative terminal 111 of the battery pack through the circuit breaker 107, a switching circuit 109, and a current detector 110. The switching circuit 109 includes an N-channel metal-oxide-semiconductor(MOS) field effect transistor (FET) which switches on and off depending on a switching control signal S SW received from the processor 105 to prevent the secondary battery 101 from overcharging and over-discharging. Therefore, the switching circuit 109 allows the circuit to switch between open and closed states under control of the processor 105. The current detector 110 detects a magnitude of current flowing in the circuit to output a detected current value I DET to the processor 105. The current detector 110 may be composed of a shunt resistor and an operational amplifier. Therefore, the processor 105 can control the switching circuit 109 such that the charging or discharging current switches on and off depending on the detected current value I DET .
The processor 105 may be an electronic circuit including operational amplifiers. Alternatively, the same function may be implemented with software. In this embodiment, the processor 105 is a program-controlled processor on which a control program is running to perform the control operation as described hereinafter.
Referring to FIG. 2, after the control program has been activated on the processor 105, predetermined initialization is performed, that is, the switching control signal S SW is set to ON and the circuit-breaking control signal S BR to OFF (step S201). Thereafter, the processor 105 inputs the detected current value I DET from the current detector 110, the battery voltage VA from the voltage detector 104, the cell voltages V1-V3 from the voltage detector 103, and the power supply voltage Vcc with which the processor 105 Itself is now supplied (step S202). The cell voltages V1-V3 are received by controlling the timing of the multiplexer 102.
First, it is determined whether the power supply voltage Vcc is substantially equal to the battery voltage VA (step S203). When the voltage detector 104 and the processor 105 are normally operating, the power supply voltage Vcc should be equal to the battery voltage VA. Therefore, if Vcc is not equal to VA, more specifically, if the difference between Vcc and VA is greater than a predetermined threshold (NO in step S203), it is determined that something unusual occurs in at least one of the voltage detector 104 and the processor 105. When it is determined that something unusual occurs, the circuit-breaking control signal S BR is set to ON (step S209) and the circuit breaker 107 is activated to break the circuit, protecting the secondary battery 101 from overcharging, over-discharging, or something unusual.
When the power supply voltage Vcc is substantially equal to the battery voltage VA, that is, the difference between Vcc and VA is not greater than the predetermined threshold (YES in step S203), the detected cell voltages V1-V3 inputted from the voltage detector 103 are added to produce a total cell voltage VT. Then, it is determined whether the total cell voltage VT is substantially equal to the battery voltage VA (stop S205). When all of the multiplexer 102, the voltage detectors 103 and 104, and the processor 105 are in normal conditions, the total cell voltage VT should be equal to the battery voltage VA. Therefore, if VA is not equal to VT, more specifically, if the difference between VA and VT is greater than a predetermined threshold (NO in step S205), it is determined that something unusual occurs in at least one of the multiplexer 102, the voltage detectors 103 and 104, and the processor 105. When it is determined that something unusual occurs, the circuit-breaking control signal S BR is set to ON (step S209).
When the total cell voltage VT is substantially equal to the battery voltage VA (YES in step S205), it is further determined whether the detected current I DET is equal to or lower than a predetermined current value I TH (step S206). When the detected current I DET exceeds I TH (NO in step S206), the switching control signal S SW is set to OFF, which causes the switching circuit 109 to turn off (step S207). If the switching circuit 109 normally operates, then the switching circuit 109 makes the circuit open, so that the charging or discharging current is cut off. To confirm it, it is determined whether the detected current value I DET is equal to zero (step S208).
If the detected current value I DET is not equal to zero after the switching control signal S SW has been set to OFF (NO in step S208), it is determined that something unusual occurs. When it is determined that something unusual occurs in at least one of the switching circuit 109 and the current detector 110, the circuit-breaking control signal S BR is set to ON so that the circuit is broken (step S209).
When the detected current I DET is equal to or lower than a predetermined current value I TH (YES in step S206) or when the detected current value I DET is equal to zero after the switching control signal S SW has been set to OFF (YES in step S208), it is determined that all circuits are normally operating.
In the above-described manner, in the case where it is determined that something unusual occurs in the protection circuit, the processor 105 sets the circuit-breaking control signal S BR is set to ON so that the circuit is broken to protect the secondary battery 101. Since the circuit breaker 107 cannot make the circuit closed again without manually replacing a specific part with a new one, perfect protection can be achieved.
Referring to FIG. 3, the circuit breaker 107 is composed of a pair of heaters 301 and 302 connected in parallel and a pair of fuses 303 and 304 connected in series. The respective fuses 303 and 304 are placed near the heaters 301 and 302 so that the respective heaters 301 and 302 cause the fuses 303 and 304 to be burnt. One end of the parallel heaters 301 and 302 is connected to a terminal H1 and the other end thereof is connected to a connection point of the fuses 303 and 304. The other ends of the fuses 303 and 304 are connected to terminals H2 and H3, respectively.
The terminal H1 is connected to the switch 108 and the terminal H2 is connected to the switching circuit 109, and the terminal H3 is connected to the negative terminal of the secondary battery 101, as shown in FIG. 1. Therefore, in the case of charging, when the switch 108 is turned on, the charging voltage on the positive terminal 106 is applied to the terminal H1 through the switch 108 and current flows through the parallel heaters 301 and 302 and the fuse 303. The current causes the heaters 301 and 302 to heat up and burn the fuses 303 and 304. Since both fuses 303 and 304 are concurrently blown, a short circuit is prevented from occurring between the secondary battery 101 and the heaters 301 and 302.
On the other hand, in the case of discharging, when the switch 108 is turned on, the discharging voltage of the secondary battery 101 is applied to the terminal H1 through the switch 108 and current flows through the parallel heaters 301 and 302 and the fuse 304. The current causes the heaters 301 and 302 to heat up and burn the fuses 303 and 304. Since both fuses 303 and 304 are concurrently blown, a short circuit is prevented from occurring between the positive and negative terminals 106 and 111 through the circuit breaker 107 when an external circuit has been connected to the battery pack.
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In a battery pack including a battery composed of a plurality of secondary calls, a control device for a protection circuit of the battery from over-charging/discharging is disclosed. A cell voltage detector detects cell voltages of the second cells, respectively, and a battery voltage detector detects a battery voltage of the battery. A controller activates a circuit breaker to break an input/output circuit of the battery when the battery voltage does not match a total cell voltage obtained by adding the cell voltages.
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The present application is the national stage filing of and claims priority to International Application No. PCT/EP97/03185 filed Jun. 18, 1997 and Italian Application Ser. No. RM96A000430.
FIELD OF THE INVENTION
The present invention relates to 2-cyclopenten-1-one as an inducer of HSP70. In particular the invention relates to 2-cyclopenten-1-one and its pharmaceutically acceptable derivatives as inducers of HSP70 with antiviral activity.
BACKGROUND
As known, prostaglandins (PGs) are a class of naturally occurring cyclic 20-carbon fatty acids that are syntetized by various kinds of eukaryotic cells in response to external stimuli and play an important role in the physiological response to cell proliferation and differentiation. Since their discovery, they were shown to function as microenvironmental hormones and intracellular signal mediators and to control a large number of physiological and pathological processes, including cell proliferation and differentiation, immune response, inflammation, cytoprotection and the febrile response.
In particular, the type A and J PGs, which posses a cyclopentenonic structure, are strong inhibitors of virus replication (“Stress Proteins: Induction and Function” Schlesinger MJ, Garaci E., Santoro M. G. ed.s, Springer-Verlag, Heidelberg-Berlin, 27-44, 1990).
Stress proteins, also called Heat Shock Proteins (HSPs) (Proc. Natl. Acad. Sci. USA 86, 8407-8411, 1989) are a family of polypeptides synthetized by eukaryotic and prokariotyc cells in response to a heat shock or other kinds of environmental stress. The HSPs are encoded by a cellular subgroup of genes, identified as stress genes.
The cytoprotective role of the stress proteins has been described in numerous pathologies, among which ischemia (M.S. Marber et al., J. Clin. Invest. 93, March 1994, 1087-1094).
The authors have shown that some cyclopentenonic prostaglandins (PGA e PGJ) induce the synthesis of heat shock protein HSP70 in human cells through the activation of the heat shock transcription factor HSF (C. Amici et al., Proc. Natl. Sci. USA vol. 89, 6227-6231, 7 1992) It is also known that, in the pathogenesis of the viral infection, the stress proteins HSP interfere at various levels with the virus replication, and in particular a cytoprotective role of the HSP70 protein has been characterized in some experimental models of acute infection (M. G. Santoro, Experientia, Vol. 50, 1039-1047, 1994). The possibility to selectively activate some “heat shock” (hs) genes and to manipulate the cellular stress response to the host advantage is suggested by recent studies which demonstrate that prostaglandins are able to induce HSP70 synthesis in a non-stress situation and to protect the host cell during virus infection (M. G. Santoro, Experientia, Vol. 50, 1039-1047, 1994).
The authors have recently shown that the induction of HSP70 synthesis is one of the molecular mechanisms used by cyclopentenonic prostaglandins to cause a selective and reversible block of the protein synthesis in infection models with single strand negatively polarized RNA viruses (C. Amici et al., J. Virol. 68, 6890-6899, 1994).
In Biol. Pharm. Bull. 18(12)1784-1786 (1995) it is described the cytoprotective activity of the isolated functional groups of several sesquiterpene lactones. Among others 2-cyclopenten-1-one is tested to verify its capability to prevent the formation of gastric lesions induced by various necrotizing agents such as EtOH.
In Antiviral Research 26 (1995) 83-96 it is described the antiviral activity of prostaglandins and a mechanism of action is hypothesized correlating inhibition of VSV RNA polymerase in vitro by prostaglandins with different structures to inhibition of VSV replication in infected cells.
SUMMARY OF THE INVENTION
It has now been found that 2-cyclopenten-1-one, the structure constituting the center nucleus of PGA and PGJ, turns out to have an activity which is analogous to PGA and PGJ, that is, it is able to induce the synthesis of HSP70 protein, even though it does not contain the corresponding acid function and aliphatic lateral chains. Therefore it seems that the lateral chains, which are present in the PGA and PGJ, with their substituents and double bonds, in particular the acid function, which implies the fatty acid nature of prostaglandins, can be eliminated without substantially modifying the herein above described specific activity.
It is therefore an object of the present invention the 2-cyclopenten-1-one as inducer of HSP70.
Another object of the invention is the 2-cyclopenten-1-one as inducer of HSP70 with antiviral activity. Another object of the invention are the 2-cyclopenten-1-one pharmaceutically acceptable derivatives as inducers of HSP70 with antiviral activity.
Further objects of the invention are pharmaceutic compositions comprising 2-cyclopenten-1-one and/or its pharmaceutically acceptable derivatives to make medicaments with antiviral activity. In particular antiviral activity against single strand negatively polarized RNA viruses and DNA viruses. Further objects of the invention will be evident from the following detailed description of the invention.
BRIEF DESCRIPTION OF FIGURES
FIG. 1 AI shows the kinetics of HSF (Heat Shock Factor) activation by 2-cyclopenten-1-one. Whole cell extracts were subjected to EMSA.
FIG. 1 AII shows the kinetics of HSF (Heat Shock Factor) activation by 2-cyclopenten-1-one. The HSF-HSE complexes were quantitated with a Molecular Dynamics PhosphorImager (MDP).
FIG. 1 BI shows the transcription rates, measured by nuclear run-on assay. Following hybridization, filters were visualized by autoradiography.
FIG. 1 BII shows the transcription rates, measured by nuclear run-on assay. Following hybridization, the radioactivity was quantitated by MDP analysis.
FIG. 1 CI shows the effect of 2-cyclopenten-1-one on protein synthesis. Cells were processed for autoradiography.
FIG. 1 CII shows the effect of 2-cyclopenten-1-one on protein synthesis. HSP70 synthesis was determined by densitometric analysis of the autoradiograms.
FIG. 2A shows the effect of 2-cyclopenten-1-one on VSV replication. The VSV titers are shown.
FIG. 2 BI shows the effect of 2-cyclopenten-1-one on VSV protein synthesis. Uninfected cells are shown.
FIG. 2 BII shows the effect of 2-cyclopenten-1-one on VSV protein synthesis. VSV infected cells are shown. HSP70 is indicated by the arrow.
DETAILED DESCRIPTION OF THE INVENTION
The 2-cyclopenten-1-one is a known product, which can be synthetized according to the process described in Beilstein (Daene, Eder, A. 539 [1939] 207, 211).
According to the present invention 2-cyclopente-1-one, preferably in concentration ranging between 100 and 500 μM, can activate the HSF transcription factor and selectively induce the transcription and translation of the HSP70 gene. In particular, induction tests have been performed on human erythroleukemia cells (K562 cells), as shown in FIG. 1 .
The HSP70 synthesis was detected also in other types of human cells (HEp-2, HeLa) and in monkey epithelial cells (MA104 cells) (FIG. 2) treated with 2-cyclopenten-1-one. Moreover, the induction of HSP70 synthesis is found to be associated with high antiviral activity. Infact, in MA104 cells infected with the Vesicular Stomatitis Virus (VSV) (1-10P.F.U./cell) the treatment with 2-cyclopenten-1-one, started 1 hour after infection, causes a dose-dependent reduction in the production of infectious viral particles (FIG. 2 A). As in the case of other HSP70 inducers, the block in the replication of the virus is caused by the selective inhibition of the synthesis of viral proteins, associated with the synthesis of HSP70 protein (FIG. 2 B).
These results confirm the antiviral activity of 2-cyclopenten-1-one as inducer of HSP70 and show the possibility of using 2-cyclopenten-1-one to induce the synthesis of HSP70 and inhibit viral replication. Based on these results it is possible to use 2-cyclopenten-1-one, as well as its pharmaceutically acceptable derivatives, as active substances to produce medicaments, in particular medicaments having antiviral activity against negative strand RNA viruses and DNA viruses, sensitive to the antiviral activity of cyclopentenonic prostaglandins.
It is an advantage of the invention to have a product with antiviral action at low costs for its synthesis and a novel mechanism of antiviral action, different from antiviral drugs in use. The following examples are reported to illustrate the invention. They should be considered in any case non limiting the scope of the invention itself.
The reagents used in the examples, including 2-cyclopenten-1-one, were products of Sigma Aldrich. 32 P e 35 S were produced by AMERSHAM. Fetal calf serum and cellular culture media were produced by GIBCO.
EXAMPLE I
The effect of the treatment with 2-cyclopenten-1-one on the HSF activation, on the heat shock gene transcription and on the synthesis of the proteins have been evaluated in K562 cells with the methods described hereinbelow and shown in FIG. 1 .
KINETICS OF ACTIVATION
The cells were prepared according to the method described in C. Amici et al. Cancer Research 55, 4452-4457, 1995.
Whole-cell extracts, prepared at different times after treatment with 500 μM of 2-cyclopenten-1-one in ethanol or after 3 hours of heat shock (45° C. for 20 min) were subjected to EMSA (Electrophoretic Mobility Shift Assay) (FIG. 1 AI), as described in C. Amici et al. Cancer Research 55, 4452-4457, 1995. The positions of HSF, CHBA (HFS-DNA constitutive activity) and NS (proteins-DNA non-specific interaction) are indicated. The levels of HSF DNA-binding activity in cells treated with 2-cyclopente-1-one were quantitated with a Molecular Dynamics PhosphorImager (MDP) (FIG. 1 AII). The HSF values were normalized to the level of HSF DNA-binding activity at 9 h after treatment, which was given a value of 100%.
As evident, 2-cyclopenten-1-one is able to activate HSF. The activation is prolonged for the following 24 hours, with a maximum at 9 hours from the beginning of the treatment.
TRANSCRIPTION RATE OF HSP70 GENE.
The transcription rates were measured by Nuclear Run-On assay (C. Amici et al., Cancer Research 55, 4452-4457, 1995). The 32 P-labelled RNA was hybridized to nitrocellulose filters containing plasmids for the following human genes: hsp70 (pH,2,3; B. Wu et al., Mol. Cell. Biol. 5, 330 (1985)); grp78/BiP (glucose-regulated 78 protein) (pHG 23,1; C. Amici et al., Proc. Natl. Acad. Sci. USA 89, 6227, 1992); hsc70 (heat shock cognate 70) (pHA 7,6; C. Amici et al., Proc. Natl. Acad. Sci. USA 89, 6227, 1992); HO (heme oxygenase) (HO clone 2/10; A. Rossi e M. G. Santoro, Biochem. J., 308, 455, 1995); GAPDH (rat glyceraldehyde phosphate dehydrogenase) (GAPDH, 1400 bp, Pstl; A. Rossi e M. G. Santoro, Biochem. J., 308, 455, 1995). The vector plasmid (Bluescript) was used as a non-specific hybridization control. Following hybridization, the filters were visualized by autoradiography (FIG. 1 BI) and the radioactivity was quantitated by MDP analysis (FIG. 1 BII). The values are expressed as arbitrary units obtained by comparing transcription rates to control levels. As evident, 2-cyclopenten-1-one is able to selectively activate the hsp70 gene transcription. The transcription is prolonged at high levels for at least 9 hours from the beginning of the treatment.
EFFECT OF 2-CYCLOPENTEN-1-ONE ON HSP70 PROTEIN SYNTHESIS Equal amounts of protein from K562 cells labeled with [ 35 S]-methionine (10 μCi/10 6 cells, 1 h pulse) at different times after treatment with 500 μM 2cyclopenten-1-one were analyzed on 10% SDS/PAGE gels and processed for autoradiography (FIG. 1 CI) Hsp70 synthesis (?) was determined by densitometric analysis of the autoradiograms (FIG. 1 CII). Total protein synthesis (?) was determined as [ 35 S]-methionine incorporation into TCA-insoluble material (C. Amici et al., Exp. Cell. Res. 207, 230-234, 1993).
As evident, 2-cyclopenten-1-one is able to selectively stimulate HSP70 protein synthesis at concentrations that do not inhibit the cellular protein synthesis.
EXAMPLE II
The effect of 2-cyclopente-1-one on the replication of Vesicular Stomatitis Virus (VSV) and on the HSP70 protein synthesis was evaluated as described in the following and illustrated in FIG. 2 . Confluent nonolayers of monkey kidney MA104 cells, grown in RPMI-1640 medium supplemented with 5% FCS (fetal calf serum) and antibiotics, were infected with VSV (Indiana serotype, Orsay; 1 P.F.U./cell). After 1 h at 37° C., the viral inoculum was removed and cells were kept at 37° C. in RPMI-1640 medium containing 2% FCS and different concentrations of 2-cyclopenten-1-one in ethanol or control diluent. VSV titers were determined 24 h post infection (p.i.) by cytopathic effect 50% (CPE 50%) assay, as described in F. Pica et al., Antiviral Res., vol. 20, 193, 1993 and illustrated in FIG. 2 A.
Uninfected (U) or VSV-infected (VSV) MA104 cells were treated with 250 μM (lanes 2 and 5) and 500 μM (lanes 3 and 6) 2-cyclopenten-1-one, or with control diluent (lanes 1 and 4), soon after VSV infection and labeled with [ 35 S]-methionine (8 μCi/2×10 5 cells, 1 h pulse starting 5 h p.i.). Equal amounts of protein were analyzed on 10% SDS/PAGE gel and processed for autoradiography. The position of hsp70, identified by western blot analysis using anti-human hsp70 antibodies, is indicated by the arrow. VSV proteis L, G, N, NS and M are indicated. 2-cyclopenten-1-one, at concentrations ranging between 100 and 500 μM, inhibits the production of VSV infectious virions from 10 to more than 1000 times with respect to the control, under the indicated conditions. The inhibition is mediated by a selective block of the viral protein synthesis, combined with the induction of HSP70.
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The invention relates to 2-cyclopenten-1-one as an inducer of the heat shock protein HSP70 by activating the heat shock transcription factor HSF, and selectively inducing the transcription and translation of HSP70 in human cells. In particular, since a cytoprotective role of HSP70 during viral infection was previously shown, the invention refers to 2-cyclopenten-1-one and its pharmaceutically acceptable derivatives as inducers of HSP70 with antiviral activity. Treatment with 2-cyclopenten-1-one and its pharmaceutically acceptable derivatives causes a dose-dependent reduction of infectious virus yield during infection with vesicular stomatitis virus. The block of virus replication is due to inhibition of viral protein synthesis, associated with HSP70 synthesis.
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This is a continuation application of Ser. No. 153,463, filed Feb. 1, 1988, abandoned, which in turn is a continuation application of Ser. No. 057,714, filed June 1, 1987, abandoned, which in turn is a continuation application of Ser. No. 729,682, filed May 2, 1985, abandoned, which in turn is a continuation application of Ser. No. 351,605, filed Feb. 23, 1982, now U.S. Pat. No. 4,531,164, issued July 23, 1985.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a video system, particularly to a video system which uses a small size cassette for reducing the size and the weight of a video tape recorder and is chiefly intended for use during photography.
2. Description of Prior Arts
A conventional type of video system is shown in FIG. 1. In this drawing, what is shown as element 1 is a video camera, and element 2 is a VTR, while element 3 is a cable. An image photographed by the video camera 1 is converted into an NTSC signal by the camera which signal then is sent through the cable 3 to the VTR 2. The VTR 2 converts the NTSC signal, at the time of reproduction, into a signal which can be reproduced by a television set by a built in RF conversion system.
This type of VTR used in a portable video system has the function of recording images on a magnetic tape within a magnetic tape cassette and reproducing the image from said tape. NTSC signals from a video camera and NTSC signals from a television broadcasting station are used as an image recording signal. Also; output signals reproduced in this type of video system are VHF signals obtained by a frequency modulation of the NTSC signals to the VHF band, so that they can be reproduced at a home use TV set having no video input terminal using one of the channels of said TV set. Since a VTR having such reproduction function contains a servo-system for reproduction, a power source, a device to convert reproducing signals to NTSC signals, and an RF conversion system to make a frequency modulation for the NTSC signals, problems are such as inconvenience in portability and the maneuverability with respect to size and a weight, etc. of a VTR itself.
Also; in a conventional video tape recorder, a system has been known such that; after a power source switch is thrown before a recording is started, a recording button or a reproduction button is pressed to take out a tape from a cassette and the tape is wound around a cylindrical tape guide having a rotating head being built in the same (hereinafter called loading), then said loading is stopped by an output of a loading completion detecting switch. Also; when a stop button is pressed upon completion of a recording, the above-mentioned recording or reproduction button is reset. At this time, the separating of the tape from the cylindrical tape guide and housing the same in the cassette (hereinafter called unloading) is carried out. This function is carried out only when an unloading completion detecting switch has not detected an unloading completion and the stop button is pressed.
However, when such complicated arrangement is employed, not only does the mechanism within a video tape recorder become complicated but there will also be many elements not necessary for operating the system, which is detrimental to reducing the size and weight of the system.
SUMMARY OF THE INVENTION
The present invention, therefore, is made in view of the above-mentioned shortcomings of the conventional arrangement for providing a video system.
In particular, it is an object of the present invention to provide a video system comprising a VTR having a recording function on a recording medium and a video camera having a photographing function, and it is also intened to reduce the size and a weight of a total system and to improve its handling characteristic.
It is; further; another object of the present invention to provide a video system in which a reproduction unit for making a reproduction from a VTR is added to the VTR and the video camera.
Still other objects than what is mentioned above of the present invention will be made clear by the following detailed explanation of the present invention together with the drawings attached hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevation to show a conventional video system.
FIGS. 2(a) and (b) are drawings to show an example of the present invention.
FIG. 3 is a circuit diagram showing the circuit arrangement in each of units shown in FIG. 2.
FIG. 4 is a partially broken sketch of the video system shown in FIG. 3 to explain a change over of switches S1 to S8 in FIG. 3.
FIGS. 5(a) and (b) are drawings to show an unloading state and a loading state of a tape.
FIGS. 6(a) and 6(b) show control circuit diagrams of a loading motor.
FIG. 7 is a truth table to show the operating state of the motor shown in FIGS. 6(a) and 6(b).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 2(a) and (b) show an example of the present invention, a video system chiefly comprising a video camera 4, a VTR 5, a reproduction unit 6. The VTR 5 is so made to have mainly a recording function and a reproduction mechanism; a power source circuit (AC power source) and a system control mechanism, etc. are housed within a reproduction unit 6.
FIG. 2(a) is an oblique view showing the VTR 5 and the camera 4 in a combined state, wherein 4-M is a microphone, 7 shows an electronic view finder, while TG represents a trigger switch to instruct the starting of a photographing.
FIG. 2(b) shows the VTR 5 and the reproduction unit 6 as being combined at the time of reproduction, wherein the VTR 5 and the reproduction unit 6 may be combined either by a cable connection or by a mechanical connection with a connector such as a hot shoe, etc.
FIG. 3 shows a block diagram for a circuit in each of the units of the present invention. Video signals are produced by an optic 8, an image pickup element 9 and a camera signal processing circuit 11 within the video camera 4 and are output to a terminal b. Sound signals obtained by the microphone 4-M of FIG. 2(a) are output to a terminal a through a pre-amplifier 10. The sound signals and the video signals thus obtained go through a sound recording amplifier 34 and a video signal recording circuit 12 respectively and are recorded on a magnetic tape T by a sound head 20 and a rotating magnetic head or heads (not being shown in the drawing) provided on a cylindrical tape guide 18 (hereinafter called as a drum). At this time, a recording servo circuit 13 controls the rotation of a drum motor 16 in phase synchronism with synchronizing signals of recording video signals to control a capstan motor 17 for causing the same to run with a constant speed. The above-mentioned rotating magnetic head consecutively records video signals on slant track on the tape T being wound obliquely around the drum 18. The sound head records sound signals at an edge of the tape T in a traverse direction thereof. At the same time, control signals (hereinafter called as CTL) corresponding to a frame frequency of the video signals are recorded at the other edge of the tape T, thus forming a control track.
Detection heads 22 and 23 are provided to detect a number of rotations and a rotating phase of the rotating head and a capstan roller 19, respectively. Outputs of the detection heads 22 and 23 are fed back to the recording servo circuit 13 through switches S5 and S7. What are shown as 14, 15 are driving circuits respectively for the drum motor 16 and the capstan motor 17, wherein servo error signals, etc. are supplied from the recording servo circuit 13 at a time of recording. What is shown as 27 is a system control circuit, that is a circuit block to control a reel motor 24, a loading motor 37, a pinch roller solenoid 25, a shut off solenoid 26, etc. in correspondence with an operation of an operating part 28 of the VTR, for recording, fast forwarding, quick return, and to set a mode for loading and unloading which are conventionally known in a VTR and an audio tape recorder.
Since the camera 4 and the VTR 5 are combined at a time of recording, recording-reproducing mode change over switches S1, S2, S3 . . . S8 are to be changed over to a side shown by solid lines in FIG. 3. That is, in FIG. 4, a change over switch 35 is so made that the mode change over switches S1 to S8 are housed within the switch 35 and are to be changed over as mentioned above when being pressed by a projection 4-P provided at the camera. A recording-reproducing mode change over which requires change overs of a number of circuits can be done easily and surely by said arrangement and at the same time, a recording mode can be set by connecting the camera to the VTR, thus there will be no failures in the change over.
Also these change over switches S1 to S8 are changed over from their put in positions to the other side in FIG. 3 as the camera 4 is separated from the VTR 5 and the VTR 5 is combined with the reproduction unit 6. At the same time, the VTR 5 and the reproduction unit 6 are combined, their circuits are connected through connection terminals c to j.
What is shown element 29 at the reproduction unit 6 is a sound reproduction circuit, and element 30 is a video signal reproduction circuit, while element 31 is an RF converter, and element 32 is a reproduction servo circuit, while element 33 is a system control part.
Next, explanations will be made regarding the function and operation of the VTR 5 at the time of photographing referring to FIG. 6(a).
FIG. 6(a) is a circuit connection diagram to show an arrangement of a loading motor control circuit within the system control part 27 of FIG. 3. What is shown as element 38 is a switch to be closed when a tape loading is completed, and 39 is a switch to be closed when a tape unloading is completed, while 42 is associated with the switch 39 and is opened when the switch 39 is closed. Also, 36 is a power source switch provided at the VTR 5 as shown in FIG. 2 and is operated from outside, having three positions, OFF, a stand-by 1 and a stand-by 2. This power source switch 36 comprises associated switches 36' and 36" being so made as consecutively changed over to contacts a, b and c. When the power source 36 is at the OFF position, the switches 36', 36" are connected to the contact a, and when a cassette is loaded into the VTR 5 and the power source switch 36 is set at the stand-by 1, the associating switches 36', 36" are respectively connected to the contact b, while they are connected to the contact c as the power source switch 36 is set at the stand-by 2. What is shown as 41 is a switch which is opened only when the switch 36 is contacting the contact a that is at its OFF position, and is closed at any other time.
The above-mentioned three switches 36, 38 and 39, being connected in parallel will be grounded through resistors R1, R2 and R3 at their one end when they are connected to + side of a power source at the other ends, so that high level signals (hereinafter called as "H") can be obtained with the switches ON and low level signals (hereinafter called as "L") can be obtained with the switches OFF at their respecting connecting points with the resistors R1, R2 and R3.
What are shown as IV1, IV2 and IV3 are inverters to invert signals obtained corresponding to ON, OFF of switches 38, 36 and 39 respectively, and NA1 is a NAND gate to receive an output of the inverter IV1 and a signal obtained at a connecting point between the power source switch 36 and the resistor R2. And NA2 is a NAND gate to receive outputs of the inverters IV2 and IV3, and what are shown as IV4 and IV5 are inverters to invert outputs of the NAND gates NA1 and NA2 respectively. Outputs of said inverters IV4 and IV5 will be added to respective bases of npn switching transistors TR1 and TR2 through resistors R4 and R5.
Here, the collector side of the transistor TR1 is connected to the base of pnp switching transistor TR3 through a resistor 6 and its emitter side is connected to the base of an npn switching transistor TR4 placed at a diagonal position against the transistor TR3 and at the same time is connected to its own base through a resistor R7.
On the other hand, the collector side of the transistor TR2 is connected to the base of pnp switching transistor TR5 through a resistor R8, also its emitter side is connected to a base of an npn switching transistor TR6 placed at a diagonal position against the transistor TR5, and at the same time is connected to its own base through a resistor R9. Also, emitter sides and bases of the transistors TR3 and TR5 are connected to a power source path A (the bases being through resistors R10 and R11 respectively), and emitter sides and bases of the transistors TR4 and TR6 are grounded (the bases being through resistors R12 and R13, respectively). The above-mentioned loading motor 37 is insertedly connected between a collector connection point of the transistors TR5 and TR4 and a collector connecting point of the transistors TR3 and TR6.
In such an arrangement, when the power source switch 36 is made ON by a stand-by operation under a tape unloading completion state, an output of the NAND gate NA1 becomes "L", while an output of the NAND gate NA2 is left in "H", that is, an output of the inverter IV5 is left in "L". Therefore an output of the inverter IV4 becomes "H", and the transistor TR1 has power supplied thereto by this, then the transistors TR3 and TR4 also have power supplied thereto. Therefore, power flows to the loading motor 37 in the direction of an arrow X, and the motor 37 makes a normal rotation, thus a taking out of the tape will be done. That is, pull out pins 43, 44 and 46 and a pinch roller 45 positioned within the tape cassette as shown in FIG. 5(a) are shifted in association with a loading ring 47 being driven by the loading motor 37. A state at which said shifting has been completed is shown in FIG. 5(b). The loading completion switch will be closed at the state shown in FIG. 5(b).
And since the tape loading completion detecting switch 38 becomes ON as, mentioned above, at the loading completion position, an output of the NAND gate NA1 becomes "H" by this. Therefore, an output of the inverter IV4 becomes "L" and the transistor TR1 is placed in a non-conductive state, then the transistors TR3 and TR4 are both placed in a non-conductive state. Thus the motor 37 is stopped. As mentioned above, a loading action is carried out only by placing the power source switch at the VTR side to ON, not depending on an instruction from the camera side. Thus a photographer can concentrate his attention to photographing.
On the other hand, as the power source switch 36 is made OFF under the tape loading state when photographing is completed, the switch 41 is opened in association therewith. Since the tape unloading completion detecting switch 39 is placed in OFF state at this time, an output of the NAND gate NA2 becomes "L" while an output of the NAND gate NA1 is left in "H", that is, an output of the inverter IV4 is left in "L". Therefore, an output of the inverter IV5 becomes "H" and power is supplied to the transistor TR2 thereby, thus power is supplied to the transistors TR5 and TR6 and current flows to the loading motor 37 in the direction of an arrow Y causing the motor 37 to make a reverse rotation. And, when the tape unloading completion detecting switch 39 becomes ON at the tape unloading completion position, an output of the NAND gate NA2 becomes "H" by this. Therefore, an output of the inverter IV5 becomes "L", thus the transistor TR2 is placed in a non-conductive state. Therefore, the transistors TR5 and TR6 are placed in a non-conductive state and the motor 37 is stopped. Thus, loading will be done by a normal rotation of the motor 37 and an unloading into the cassette will be done by a reverse rotation of the same.
As has been mentioned above, as the power source switch is returned to OFF position, the switch 36 is opened (i.e. being ON at the contact a) and the switch 41 is opened in association therewith. Further, the loading motor makes reverse rotation until the unloading switch 39 is closed and the switch 39 is closed upon completion of loading, then the switch 42 is opened in association with the switch 39, placing the power source in a completely OFF state.
The state of the switches 36, 38, 39 and an ON-OFF relationship of the transistors TR1 to TR6 are shown in FIG. 7.
At this time, under a stand-by 1 state, power is not supplied to a power source path B which supplies power to other circuits such as a processing system and a servo system, etc. And, when the camera trigger switch TG, which directs the starting of recording, is operated, power is supplied to said circuit systems from the power source path A through the power source path B. After the trigger switch TG is made ON, a power supply to a driving circuit 49 of the pinch roller pressing solenoid 25 which presses the pinch roller against the capstan 19 is delayed by a time interval τ1 by a delay circuit 48. By this arrangement, an electrical and mechanical delay of the drum motor 16 and the capstan 17 are provided. Further, a start of a recording after the trigger switch TG is made ON, that is, after a release, is somewhat delayed, but power consumption can be reduced. That is, it is effective in the mode of the stand-by 1 when a non-photographing interval is comparatively long.
In the mode of the stand-by 2, since the switch 36" is connected to the contact c, the drum motor 16 and the capstan motor 17 are always rotating in said mode. And, since a delay time of the delay circuit 48 is set at τ2 which is shorter than the interval τ1, the pinch roller pressing solenoid 25 works immediately after the trigger switch TG is made ON, and recording is started. Thus the stand-by 2 mode is effective for photographing a scene in which timing of photographing is an important factor.
Details of the delay circuit 48 are shown in FIG. 6(b). In FIG. 6(b), element 48a is an analog switch which is connected to a contact a when the switch 36 is at the OFF position and is connected to a contact b when the switch 36 is at the stand-by mode 1, then is connected to a contact c at the time of the stand-by 2 mode. What is shown as element 48b is a delay circuit with the delay time τ1 and 48c is a delay circuit with the delay time τ2. As mentioned above, delay times are selected depending on the stand-by 1 mode and the stand-by 2 mode so that a selection of a stand-by mode suitable for a photographing object can be made.
Next, explanations will be made concerning operation at the time of reproduction.
At the time of reproduction, the camera is separated from the VTR and the reproduction unit 6 is combined. When said latter combination is made, the system control block 27 is controlled by an operating part 33 of the reproduction unit 6 electrically or mechanically. Therefore all operating functions will be placed at the reproduction unit side. Thus, a user can concentrate his attention to the reproduction unit without any hesitation.
Further, as the camera 4 is separated from the VTR, the recording-reproducing mode setting switches S1 to S7 are changed over to the other side of what is shown in FIG. 3 for recording. Therefore, video signals and sound signals recorded in the tape go through the switches S4, S3, respectively and through the video signal reproduction circuit 30 and the sound reproduction circuit 29 and are converted to RF signals in VHF band by the RF converter 31, and are reproduced in a TV set. Also the reproduction servo circuit 32 is provided at the reproduction unit side and obtains TACH pulses, reproduction CTL signals and capstan FG output, etc. obtained from the switches S5, S6, S7, thus making a reproduction tracking servo operation.
As has been explained above in detail, an arrangement wherein loading is done automatically by removing the power source switch from its OFF position is employed in the present invention, thus its handling characteristic is improved and structure thereof is simplified.
Also, when the above-mentioned power source switch is placed in other positions than OFF position, a mode to make power supply to a rotating system and a mode not to make the same are available and delay circuits having different delay times are respectively provided for each mode, thus a trigger can be made with due consideration being made for a start up time of the rotating system.
Also, an arrangement is provided wherein a detection means to detect an unloading completion is provided and, as the power source is made OFF, an unloading completion signal can be obtained from said detection means so that an unloading is automatically made, and, thus, its handling and operation can be done very easily.
Further, an arrangement is provided wherein power supply to circuits related to loading is maintained even if the power source is made OFF until said unloading is completed, and the power supply is automatically stopped by completion of unloading, therefore the handling characteristic is further improved and power saving can be made without any particular efforts.
Also, in a video system of the present invention, a VTR which is combined to a video camera for making a photographing is constructed of parts containing a recording mode only, therefore a camera and a VTR is integrally made and thus a reduction in size and weight can be achieved.
Further, since a VTR is made to have as small size as possible for having the minimum function needed solely for a recording, when the VTR is combined with a video camera, a burden on the user at the time of photographing can be reduced to the minimum, thus a handling characteristic is further improved and it will be easy to carry the same around.
Further, when the camera is removed from the VTR, the VTR is automatically changed over to a reproduction mode and it is combined with a reproduction unit so that a function in a reproduction mode can be obtained without delay, thus it is a very convenient device as a simple video system.
Also, a VTR in the present invention can naturally be combined with other video sources (for example, a tuner for television signal, etc.) for making a video recording without using a video camera. That is if the same projection as that provided at the video camera is provided at a unit to connect other video sources to the VTR of the present invention, said projection can be attached to an input of the VTR for automatically changing over the VTR to a recording mode.
While explanations of the present invention have been made above, taking a video camera and a VTR as an example, the invention can be applied to a disk type recording apparatus to make recording on a disk shape material, etc.
Also, various other applications and modifications are possible for the present invention within the scope of the claims attached hereto.
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A video system comprising a video camera and a recording device to record video signals obtained by the video camera. The recording device includes a video tape recorder (VTR) which may be combined with the video camera when recording and otherwise may be combined with a reproduction unit. Mode switches in the VTR are changed over depending on the combination desired. When the VTR is used with the camera, the combination records sound, video signal and controls signals on a tape wound around a drum. A system control circuit controls various motors and solenoids control operation of the VTR. Power supply to the system is controlled by a power source switch in the VTR, which element provides "OFF", "STANDBY I" and "STANDBY II" modes. Delay elements operate in the two standby modes. When the power source switch is in either standby mode, loading is done automatically. One standby mode provides power to a rotating system and the other mode provides no power. The delay elements provide different delay times for each mode so that triggering of the camera can be made with due consideration for the start up time of the rotating system. The built-in delays are effective in conserving power.
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TECHNICAL FIELD
The present invention is in the field of biological separations and processes.
BACKGROUND
In a variety of liquids containing cellular material, such as those used in fermentation processes, it is often desirable to be able to efficiently separate cellular products, such as cell bodies, lysed cells, and their breakdown products. It is often desirable to be able to remove or separate cellular products even in instances involving viscous liquids.
Accordingly, it is a general object of the present invention to be able to have available, a process for efficiently and completely removing or separating cellular products from liquid media, even in instances involving viscous liquids.
The process of the present invention can be applied inter alia to fermentation processes. Current industrial fermentations in conventional stirred tank fermentors for production of xanthan gum and other polysaccharides are energy-intensive and costly, mainly because the high broth viscosity causes agitation and aeration to be difficult and limits the final product concentration and productivity.
The production of xanthan gum is described here as an example of some of the problems encountered in biological processes that are addressed by the present invention, although the invention is not limited to that application.
Xanthan gum is a microbial polysaccharide widely used as a suspending, stabilizing, or thickening agent in the food industry. It is also used as a lubricant, emulsifier, or mobility-control agent in the oil-drilling industry. Presently, commercial xanthan gum is produced from glucose or dextrose by batch fermentation with the bacterium Xanthomonas campestris; the produced xanthan gum is then recovered and partially purified using alcohol precipitation The final product usually also contains some cells and cell debris; however, it is desirable to produce xanthan gum product that is free of any particulates or cells, particularly for applications in oil recovery. The production of cell-free xanthan broth also allows for efficient concentration of xanthan fermentation broth by ultrafiltration without significant membrane fouling caused by cells and their debris (e.g., DNA and RNA) that would otherwise be present in the xanthan broth.
The present industrial process for xanthan gum production is energy-intensive and costly, mainly because the highly viscous xanthan broth causes agitation and aeration to be difficult in conventional stirred tank fermentors. Consequently, conventional xanthan gum fermentation has low xanthan concentration (usually below 3% wt/v) and low productivity (usually below 0.5 g/L×h). There have been many attempts to increase xanthan productivity and to lower energy costs by using new agitation designs, and new types of bioreactors. Fermentation with water-in-oil emulsion and cell immobilization using porous Celite beads, which reduces broth viscosity and improves aeration and oxygen transfer, have also been studied. Although a high xanthan concentration of ˜5% was achieved in these processes, separating and recovering xanthan gum from the oil emulsion or Celite particles, though feasible, was difficult.
There have been only a few studies of xanthan fermentation using immobilized cells. Robinson and Wang (1988) used porous Celite beads to immobilize cells in xanthan fermentation. It is not clear, however, if the xanthan broth so produced was free of cells. Furthermore, a large portion of the xanthan product was trapped in the beads and could not be easily separated from the cells. Lebrun et al. (1994) studied polysaccharide production by cells immobilized in composite agar layer/microporous membrane structures, but concluded that the immobilized-cell system was not appropriate for xanthan gum production. It is clear that cell entrapment is not an appropriate cell immobilization method for xanthan gum fermentation because of the high viscosity of xanthan solution. The viscosity of the xanthan solution is high even at a low concentration. In batch xanthan fermentation, the broth viscosity has been found to reach more than 3000 cp at 2% (wt/v) xanthan concentration. The high viscosity of xanthan broth presents a major challenge in separating cells and cell debris from broth at industrial scale using conventional separation techniques, such as microfiltration, flocculation, and centrifugation. Thus, one of the objects of the present invention is to find an economical way to produce cell-free xanthan broth by either cell immobilization during fermentation or cell removal after fermentation.
One of the objects of the present invention is to provide a fermentation method which allows for the efficient and substantially complete removal of cells and cell debris from fermentation broths, even in instances involving viscous fermentation broths.
It is also an object of the present invention to allow for the removal of cellular products from liquids used as media for cellular reactions, such as fermentation broths, even those that are unusually viscous.
It is also an object of the present invention to produce an apparatus for carrying out the separation/removal process and cellular reactions of the present invention.
In view of the present disclosure, other advantages and the solutions to related problems may become apparent to one of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present invention includes a process for separating cells from a liquid media, a method of fermentation using such a separation, and an apparatus for conducting such a separation or for facilitating a cellular reaction.
In broadest terms, the separation process of the present invention is a process for separating cells from a liquid containing cells. The process comprises the steps of: (a) bringing the liquid containing the cells into contact with one or more microbial polysaccharide and a fibrous material so as to adsorb the cells onto the fibrous material; and (b) separating the liquid from the fibrous material so as to remove the cells from the liquid. This may be done either by having the microbial polysaccharide(s) be in the liquid or by having the fibrous material be pre-treated with the microbial polysaccharide(s). Either way, a polysaccharide-mediated adsorption of the cells onto the fibrous material is brought about.
The process of the present invention may be used to remove cells from any liquid, but such liquids typically will be aqueous solutions, such as growth media, biological fluids, diagnostic samples, aqueous test samples, etc.
As referred to with respect to the present invention, the term "cells" shall be understood to include, without limitation, cells--alive, dead or attenuated--and cell portions such as lysed cell walls, cell bodies, organelles, chromosome material and mixtures thereof.
The microbial polysaccharide(s) may be of any type. Naturally, there are a wide variety of microbial polysaccharides, such as the more well characterized and named polysaccharides selected from the group consisting of xanthan gum, dexter, pullulan, the polysaccharide types they represent and mixtures thereof.
The liquid may be brought into contact with the microbial polysaccharide and a fibrous material through any appropriate means, such as through the use of tanks and vats, liquid flows, etc.
The fibrous material used in accordance with the present invention may be any natural or synthetic fiber, and may for instance be selected from the group consisting of looped cotton terry cloth, cotton fabric sheet cloth, 50% cotton--50% polyester fabric sheet cloth, and polyester fabric sheet cloth. It has been found that cotton, particularly looped cotton terry cloth and cotton fabric sheet cloth, works best, with looped cotton terry cloth being most preferred.
The fibrous material may be in any non-woven, woven or geometrical arrangement (e.g., sheets, rolls, strands, threads, etc.), generally referred to as the "fibrous matrix," and naturally may be produced and arranged so as to afford efficient contact with the liquid.
The liquid may be brought into contact with the microbial polysaccharide(s) and the fibrous material through any arrangement. Such arrangements may include the use of a liquid container into which a matrix of the fibrous material is placed. As an alternative, the liquid may be brought into contact with the fibrous material by causing the liquid to flow through, within or over a fibrous matrix of the fibrous material. Either the liquid may be moved relative to the fibrous matrix, or vice versa, such as through a liquid flowing over or through the matrix or by having the fibrous matrix mounted on frames and swung or agitated within a container or within a flow of a liquid, etc. The liquid container may also be moved with respect to the liquid, such as through agitation or oscillation. In a preferred embodiment, especially for viscous liquids, the liquid may be brought into contact with the fibrous material by pumping or otherwise forcing the liquid through a fibrous matrix of the fibrous material. This may be done by passing the liquid through a rotating fibrous matrix of the fibrous material through application of centrifugal force, such as by placing the liquid in the interior of the fibrous matrix and spinning it so as to move the liquid from its interior to its outer surface, through application of centrifugal force.
The ultimate separation of the cells from the remaining liquid also may be done through any appropriate means, such as through draining the liquid from the fibrous matrix, the physical removal of the fibrous matrix from the liquid, etc., as each application may require.
The separation process of the present invention, as summarized above, may be used as part of a method for producing a product liquid containing one or more reaction product(s) of a cellular reaction, which liquid is substantially free of cells. In general terms, the method includes the steps: (a) preparing a reaction mixture of: (i) water; (ii) one or more substrate substance(s) for the cellular reaction; (iii) cells of an organism capable of converting the substrate substance(s) to one or more reaction product(s); and (iv) one or more microbial polysaccharide(s); and (b) allowing the reaction mixture to undergo the cellular reaction so as to form the at least one reaction product from the at least one substrate substance; followed by (c) bringing the reaction mixture into contact with a fibrous material so as to adsorb the cells onto the fibrous material, and (d) separating said fibrous material from the reaction mixture so as to remove the said cells from the reaction mixture.
As referred to with respect to the production methods of the present invention, it will be understood that "cellular reaction" is intended in its broadest sense and may be any chemical reaction and/or physical change brought about by or catalyzed by cells of an organism. Such cells may be those of one-celled organisms or the cells of multi-celled organisms, whether microbial plant or animal. Such cellular reaction may be those carried out for industrial production purposes, or for pure or applied research. Typically, cellular reactions in which the present invention may be applied will include those that rely upon enzymatic reactions, both anabolic and catabolic.
The cellular reactions may involve one or more substrate substances which are broadly intended to mean any one or more substances that are the subject of the cellular reaction. In turn, the cellular reaction may produce one or more reaction products. Such product(s) may be obtained through the use of reaction conditions appropriate to the cellular reaction of interest.
Once the reaction product(s) is/are formed, the reaction mixture is brought into contact with a fibrous material so as to adsorb the cells onto the fibrous material. The fibrous material may then be separated from the reaction mixture so as to remove the cells from the reaction mixture.
In a variation of the basic cellular reaction process, it may be the case that the substrate substance(s) and/or reaction product(s) comprise(s) one or more microbial polysaccharide(s) and thus supplies the microbial polysaccharide(s) required in the method of the present invention in the form of a substrate or reaction product. In such cases, the microbial polysaccharides(s) need not be added.
In another variation, the microbial polysaccharides may be applied to the fibrous material, rather than being put into the liquid or arising from the cellular reaction.
The present invention also includes a method for producing xanthan gum solution substantially free of cells using the separation process of the present invention as summarized above. The method generally comprises the steps: (a) preparing a fermentation broth mixture of: (i) water; (ii) a saccharide selected from the group consisting of glucose, dextrose and mixtures thereof; and (iii) Xanthomonas campestris bacterial cells; (b) allowing the fermentation broth mixture to undergo fermentation so as to form xanthan gum polysaccharide in the fermentation broth mixture; followed by (c) bringing the fermentation broth mixture into contact with a fibrous material so as to adsorb the bacterial cells onto the fibrous material, and (d) separating the fibrous material from the fermentation broth mixture so as to remove the cells from the fermentation broth mixture (herein "separating" is intended broadly, whether removing the fibrous material from the broth or allowing the broth to flow from the fibrous material).
The invention also includes an apparatus that may be used for carrying out the separation process of the present invention, and which also may be used in accordance with the production methods using the separation process. The apparatus in broad terms is one for separating cells from a liquid containing the cells and comprises: (a) a matrix of a fibrous material treated with one or more microbial polysaccharide(s) having an interior and an outer surface; (b) liquid application dispenser for dispensing the liquid into the interior of the matrix of the fibrous material; and (c) an apparatus to separate the liquid from the matrix of fibrous material. For example, a spinner may be adapted to spin the matrix of a fibrous material such that the liquid, once in the interior of the matrix of the fibrous material, moves out of the outer surface of the matrix of the fibrous material. The fibrous material may become treated with one or more microbial polysaccharide(s) through microbial polysaccharide(s) being resident in the liquid either naturally occurring or arising as a result of a cellular reaction. In an alternative embodiment to those described, where the fibrous material is not pretreated with microbial polysaccharide(s), the apparatus may contain a liquid to be supplied to the liquid application dispenser, the liquid containing at least one microbial polysaccharide and cells of an organism capable of converting the substrate substance(s) to the reaction product(s), such that when the liquid is brought into contact with the matrix of said fibrous material, said cells become adsorbed onto said fibrous material.
The apparatus may additionally include a recirculator adapted to recirculate liquid moving out of the outer surface of the mass of the fibrous material into the interior of the mass of the fibrous material, in order to increase the exposure of the polysaccharide-treated fibrous material to the cells over time. Such a device may be in the form of a recirculating pump or other appropriate flow control device.
The invention also includes an apparatus for facilitating a method for producing a cellular reaction product in a liquid, the apparatus comprising: (a) a matrix of a fibrous material having an interior and an outer surface, the fibrous material treated with at least one microbial polysaccharide and having adsorbed thereupon cells of an organism capable of converting the at least one substrate substance to the at least one reaction product; and (b) a liquid circulator device for circulating the liquid through the matrix of the fibrous material.
The invention also includes an apparatus for facilitating a method for producing a cellular reaction product in a liquid, the apparatus comprising: (a) a matrix of a fibrous material having an interior and an outer surface, the fibrous material treated with at least one microbial polysaccharide and having adsorbed thereupon cells of an organism capable of converting the at least one substrate substance to the at least one reaction product; (b) a reaction vessel for holding the liquid; (c) a liquid transport device adapted to move the matrix of the fibrous material relative to the liquid, such as through agitation or oscillation, for example.
The present invention also includes an apparatus for facilitating a method for producing a cellular reaction product in a liquid. The apparatus comprises a matrix of a fibrous material having an interior and an outer surface, the fibrous material treated with at least one microbial polysaccharide and having adsorbed onto it cells of an organism capable of converting one or more substrate substance to one or more reaction product The apparatus also includes a liquid application dispenser for dispensing the liquid into the interior of the matrix of the fibrous material; and a spinner adapted to spin the matrix of a fibrous material such that the liquid, once in the interior of the matrix of the fibrous material, moves through the matrix of a fibrous material toward the outer surface of the matrix of the fibrous material so as to bring the liquid in contact with the cells of the organism.
In an alternative embodiment to those described above, the fibrous material is not pretreated with microbial polysaccharide(s), and in such case the apparatus may contain a liquid to be supplied to the liquid application dispenser, the liquid containing at least one microbial polysaccharide and cells of an organism capable of converting the substrate substance(s) to the reaction product(s), such that when the liquid is brought into contact with the matrix of the fibrous material, the cells become adsorbed onto the fibrous material.
The apparatus of the present invention in all its embodiments may include fluid containment and/or conduction apparatus to allow the operator to cause (1) the liquid to flow through a fibrous matrix of the fibrous material, (2) pump the liquid through a matrix of the fibrous material, (3) agitate the liquid in a vessel containing a matrix of the fibrous material; (4) pass a matrix of the fibrous material through the liquid, (5) agitate a matrix of the fibrous material within the liquid and/or (6) force the liquid through a rotating matrix of the fibrous material through application of centrifugal force. Such apparatus may be supplied using liquid containment and/or conduction devices known in the art and which could be applied to bring about the desired result in accordance with the parameters of the specific separation or reaction to which the apparatus is to be applied. Examples may include arrangements of reaction vats, pumps and liquid conduits to contain the liquid and bring it into contact with the fibrous matrix.
The apparatus may additionally include a recirculator adapted to recirculate liquid within the fibrous matrix, such as by moving out of the outer surface of the mass of the fibrous material into the interior of the mass of the fibrous material so as to increase the exposure of substrate to the adsorbed cells over time.
In applications involving viscous liquids, it is preferred that the fibrous matrix be exposed to air and spun at such a rate that such that the viscosity is overcome by the mechanical shearing.
The high viscosity of a xanthan solution at low concentration presents a major challenge in agitating xanthan broth during fermentation. Xanthan solution, however, shows a high degree of pseudoplasticity, i.e., the viscosity decreases rapidly as the shear rate increases. This shear-thinning property allows efficient pumping of xanthan polymer at high pumping (shear) rates. The present invention thus includes a centrifugal, fibrous-bed bioreactor that may be used for instance for viscous xanthan gum fermentation, and in other processes that present similar problems of viscosity and the need for contact with cells. Difficulties in agitation and aeration in the conventional stirred-tank bioreactors, such as those used in traditional fermentation, are overcome by continuous medium recirculation through a rotating fibrous matrix, which contained immobilized cells. In this bioreactor, liquid media and air (or other oxygen-containing gas) were passed through the porous fibrous matrix to ensure intimate contact with the immobilized cells, thus achieving high oxygen transfer and reaction rates. The centrifugal force generated from rotating the fibrous matrix separated the xanthan polymer from the immobilized cells, thus producing a cell-free xanthan broth. It is important to produce xanthan gum solution free of any particulates or cells for applications in oil recovery. The production of cell-free xanthan broth also allows one to efficiently concentrate the xanthan fermentation broth by ultrafiltration without significant membrane fouling caused by cells and resulting debris (e.g., DNA and RNA) that would otherwise be present in the xanthan broth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the packed fibrous-bed for study of cell adsorption kinetics in accordance with one embodiment of the present invention.
FIG. 2 is a graph of cell density vs. time showing changes of cell concentration during batch xanthan gum fermentation in flasks containing various types of woven fibrous materials: (a) cotton towel, (b) cotton fabric sheet, (c) 50% cotton/50% polyester fabric sheet, and (d) polyester fabric sheet.
FIG. 3 is a graph of concentration/cell density vs. time showing the kinetics of a typical batch fermentation with cotton towel in the fermentor for cell adsorption (immobilization).
FIG. 4 shows two graphs of cell concentration vs. time showing the kinetics of cell adsorption to fibrous bed; graph (a) in the presence of xanthan gum, and graph (b) in the absence of xanthan gum.
FIG. 5 is a semi-logarithmic plot of C/C 0 vs. time, showing the kinetics of cell adsorption to a variety of fibers.
FIG. 6 shows two scanning electron micrographs showing adsorption of Xanthomonas campestris cells and xanthan gum on a cotton fiber surface.
FIG. 7 shows a schematic diagram of the centrifugal, packed-bed reactor (CPBR) showing (a) construction of fibrous matrix, and (b) fluid flow pattern in the reactor, that may be used for a process such as xanthan gum fermentation, in accordance with one embodiment of the present invention.
FIG. 8 shows two graphs pertaining to typical kinetics during reactor start-up: (a) a plot of concentration vs. cell density and (b) a plot of DOT vs. time.
FIG. 9 shows two graphs pertaining to repeated batch xanthan fermentations with CPBR at 150 rpm rotational speed for the fibrous bed: (a) a plot of concentration vs. time and (b) a bar graph of xanthan yield (Yp/s) and volumetric xanthan productivity (dP/dt) for four batches.
FIG. 10 shows a graph of concentration/cell density vs. time showing fermentation time course data for repeated batch xanthan fermentations with a CPBR at 350 rpm rotational speed for the fibrous bed under liquid continuous condition (CPBR-LC), in accordance with one embodiment of the present invention.
FIG. 11 shows two graphs pertaining to repeated batch xanthan fermentations with CPBR-LC at 350 rpm rotational speed: (a) a plot of xanthan gum yield and volumetric productivity, and (b) a plot of measured broth viscosity at 1.8% xanthan concentration, in accordance with one embodiment of the present invention.
FIG. 12 shows a graph of concentration/cell density vs. time as fermentation time course data for repeated batch xanthan fermentations with CPBR at 350 rpm rotational speed for the fibrous bed under gas continuous condition (CPBR-GC), in accordance with one embodiment of the present invention.
FIG. 13 shows two graphs pertaining to batch xanthan fermentations with CPBR-GC at 350 rpm rotational speed for the fibrous bed: (a) a bar graph of xanthan yield (Yp/s) and volumetric xanthan productivity (dP/dt) for eight batches, and (b) a plot of measured broth viscosity at 1.8% xanthan concentration, in accordance with one embodiment of the present invention.
FIG. 14 shows a scanning electron micrograph of adsorption of Xanthomonas campestris on a fiber surface.
FIG. 15 shows two graphs pertaining to a comparison of reactor performance and effect of C/N ratio: (a) a plot of volumetric productivity (dP/dt) for stirred tank reactor (STR),CPBR-LC and CPBR-GC, and (b) a plot of specific productivity (dP/dt/Xs) for STR, CPBR-LC, and CPBR-GC with two different glucose concentrations (2.5% and 5%) and the same 0.3% yeast extract concentration in the media.
FIG. 16 shows a graph of specific xanthan productivity (dP/dt/Xs) as a linear function of specific oxygen uptake rate (OUR) during batch xanthan gum fermentations.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the foregoing summary, the following presents a detailed description of the preferred embodiment of the present inventions as they might be applied to the fermentation of xanthan gum.
Example 1
The Production of Cell-Free Xanthan Fermentation Broth by Cell Adsorption on Fibers
The following Example shows the use of a method of removing cells from a liquid cellular reaction media (i.e., a fermentation broth) in accordance with one embodiment of the present invention.
Materials and Methods
Culture and Medium
Xanthomonas campestris NRRL B-1459, originally obtained from the Northern Regional Research Laboratory (NRRL) of the U.S. Department of Agriculture (Peoria, Ill.), was used. Stock cultures of X. campestris NRRL B-1459 were maintained on agar slants, which contained 10 g/L glucose, 3 g/L yeast extract, 5 g/L peptone, and 15 g/L agar, and were stored at 4° C. The culture was transferred once every two weeks to maintain good viability and stability for xanthan production. The medium used in fermentation consisted of 25 g/L glucose, 3 g/L yeast extract, 2 g/L K 2 HPO 4 , and 0.1 g/L MgSO 4 ×7H 2 O. Tap water was used in preparing the medium to provide trace elements. The medium pH was adjusted to 7 by adding 4N HCl.
Cell Adsorption to Fibers during Fermentation
Four different woven fibrous materials were used for cell adsorption during batch fermentation, including cotton towel (terry cloth, ˜5 mm thick), cotton fabric sheet (without looping, ˜1 mm thick), 50% cotton--50% polyester fabric sheet (˜1 mm thick), and polyester fabric sheet (˜1 mm thick). Each fibrous sample was tested for its cell adsorption capability by placing a small piece (3 cm×3 cm) of the fibrous material in a 500-mL fermentation flask containing 100 mL media. The flask was sterilized, inoculated with X. campestris, and then incubated in an incubator-shaker at 30° C. and 300 rpm shaking speed. The suspended cell density in each flask was monitored by measuring the optical density of the broth at regular time intervals for 50 hours. The attachment of X. campestris cells on each fibrous matrix was examined at the end of the experiment by using scanning electron microscopy (SEM).
Batch fermentation was then carried out in a 5-L fermentor containing a packed bed of cotton towel mounted on the reactor impeller shaft. The bioreactor was autoclaved, filled with 5 liter of sterile media, and then inoculated with 100 mL flask culture. Unless otherwise noted, the cells in the bioreactor were first grown at pH 6 and 23° C., the optimal conditions for cell growth. The bioreactor was aerated at a volumetric flow rate of 5.0 std. liter/min and agitated at 150 rpm. After ˜24 hours, the reactor conditions were changed to pH 7, 30° C., and 350 rpm to promote xanthan production. Samples were taken for analyses of glucose concentration, cell density, and xanthan concentration.
Cell Adsorption to Fibers after Fermentation
The kinetics of cell adsorption to fibers was further studied using cell suspension harvested from flask cultures. FIG. 1 shows the schematic diagram of the experimental apparatus used in studying cell adsorption. The cell suspension was circulated through a fibrous bed packed in a glass column (dimensions: 2.7 cm diameter.×9 cm height) with a total liquid volume of ˜42 mL. The fibrous materials were pre-wetted with distilled water, and the complete system was autoclaved for 30 minutes before use. A peristaltic pump (such as sold under the name Masterflex by Cole Parmer of Chicago, Ill.) was used to pump the cell suspension (˜300 mL) from the flask through the fibrous bed at a flow rate of 5.9 mL/min to approximate well-mixed condition in the flask. Samples were taken from the flask at regular time intervals to monitor the cell concentration change with time. These data were then used to study the adsorption kinetics and to determine the adsorption rate constant All experiments were done at the room temperature (˜25° C.).
Experiments were conducted with cells with and without their exopolysaccharide, xanthan gum, to determine the effect of xanthan gum on cell adsorption. Cells were first grown in flasks for two to three days. The whole broth containing cells and xanthan gum was then used in the adsorption experiment. Experiments were also conducted with cell suspension in a salt solution without xanthan gum. To prepare xanthan-free cell suspension, the fermentation broth was first diluted with water and centrifuged at 16,000 g for 30 min. to separate the cells from the broth containing xanthan gum. The cells were then collected and re-suspended in a salt solution, and the cell suspension was then used in the adsorption experiments. Two different fibrous materials, cotton and polyester, were studied to evaluate the effect of fiber surface properties on cell adsorption.
Determination of Cell Density
Samples of fermentation broth were collected into centrifuge tubes. Depending on the broth viscosity, the broth samples were diluted with tap water by a factor of two to six, and the diluted solutions were centrifuged at 12,000 rpm (16,000 g) for 30 minutes at 5° C. to precipitate the cells. Cells were then re-suspended in water and the optical density at 650 nm (OD 650 ) was measured using a spectrophotometer. The OD readings were then compared to a standard correlation between OD and cell density (g/L). The cell density was proportional to OD when the optical density was below 0.5, with one unit of OD equaling to 0.4 g/L cell. The total cell dry weight in the cell suspension was also determined after drying at 105° C. for ˜7 hours in a vacuum oven. The dry weight measurement was duplicated to reduce the experimental errors to within 0.2%.
Scanning Electron Microscopy
Several small pieces of the fibrous material were taken as samples from the drained fibrous matrix. These samples were immersed in 2.5% glutaraldehyde solution overnight and then rinsed completely with double distilled water. The samples were then gradually dehydrated with 20%-100% ethanol in increments of 10% by holding the samples at each concentration for 30 min. These samples were then cryogenically dried at critical point with liquid CO 2 . All steps, except for the critical drying, were carried out at 4° C. The completely dried samples were coated with gold/palladium before taking SEM photographs using the JOEL model 820 SEM.
Adsorption Kinetics
Adsorption of cells to substrates (fibers) can be considered to be a reversible surface reaction, as follows: ##EQU1## where C is the cell concentration, S is the concentration of substrate or active site on the substrate surface, C-S is the cell-substrate complex, and k a l and k d are adsorption and desorption rate constants, respectively. When there is no diffusion limitation, the rate of formation of the cell-substrate complex or the cell adsorption rate can be expressed as follows: ##EQU2## where t is the reaction time. Initially, adsorption of cells on the substrate predominates as C-S is zero or negligibly small. When the adsorption rate is much greater than the desorption rate, the desorption term in equation (2) can be neglected. Also, when S>>C, S can be considered as a constant and S≈S 0 . Equation (2) is thus reduced to equation (3). ##EQU3## Equation (3) can be integrated to the following form: ##EQU4## where C 0 is the initial cell concentration and S 0 is the initial substrate concentration.
If cell adsorption does follow the first-order reaction kinetics, a semi-logarithmic plot of C/C 0 versus time should yield a line with a slope equal to -k a S 0 . The adsorption rate constant, k a , thus can be determined from the slope and S 0 . Cell adsorption to fiber surface is not specific to "active sites" on the substrate surface. Since the surface area available to cell adsorption is proportional to the amount of the fibers present in the fibrous bed, the packing density (g/L) of the fiber in the fibrous bed was used as S 0 in this embodiment of the present invention.
Results
Cell Adsorption to Fiber during Fermentation
FIG. 2 shows the cell concentration changes during four batch xanthan fermentations with various fibrous materials in the flasks for cell adsorption. While xanthan production was not affected by the types of fibrous materials studied (data not shown), the 100% cotton towel with looping showed the fastest cell adsorption rate and had adsorbed almost all suspended cells by 50 hours fermentation time. The other materials also adsorbed cells, but at slower rates. In general, the hydrophilic cotton fiber was preferable to the hydrophobic polyester fiber, and more cells were attached to the 100% cotton towel than the other materials studied. The rough surface of cotton fibers and the looping of the towel seemed to be important factors for cell adsorption under the condition studied.
Batch xanthan fermentation was carried out with cotton towel present in the fermentor for cell adsorption. As shown in FIG. 3, exponential cell growth, but only small amounts of xanthan biosynthesis, occurred during the initial 24 hour period, a pattern which is also typical of xanthan gum batch fermentation with free cells. At ˜24 hours, when the culture reached the stationary phase, the cell density in the fermentation broth rapidly decreased while xanthan production continued to increase, indicating that the cells were immobilized (adsorbed) onto the matrix. All suspended cells disappeared and were immobilized onto the fibrous matrix by 50 hours, as indicated by the broth optical density of being zero. It appeared that the onset of cell adsorption coincided with the onset of xanthan production in the fermentation, suggesting that the production of xanthan gum helped or triggered cells to attach onto the fiber surfaces. Further discussions of the effect of xanthan gum on cell adsorption is given below.
Cell Adsorption to Fiber after Fermentation
The removal of cells from the fermentation broth by pumping the cell suspension through the fibrous bed was studied. FIG. 4 shows the kinetics of cell adsorption to the fibrous bed. In the presence of xanthan gum, the cell concentration in the broth was reduced from 1 g/L to 0.024 g/L with cotton and to 0.074 g/L with polyester, resulting in an almost cell-free xanthan broth. Complete cell removal was possible if longer time or more fibers were used for cell adsorption. Table 1 shows the amounts of cells adsorbed and cell loadings on each of the two fibrous materials studied. It is clear that large amounts of cells can be efficiently removed from the fermentation broth by adsorption of cells to fiber surfaces. A fibrous bed thus can be used to remove X. campestris cells from the xanthan fermentation broth.
TABLE 1______________________________________Cell adsorption to cotton and polyester Total Packing Cell Amt. of Density, Ad- Cell fiber S.sub.o sorbed Loading k.sub.a S.sub.o k.sub.aConditions used (g) (g/mL) (mg) (mg/g) (h.sup.-1) (mL/g × h)______________________________________with xanthangumCotton fiber 2.45 0.058 290.8 118.7 0.423 7.25Polyester 2.40 0.057 272.9 113.7 0.328 5.74fiberw/o xanthangumCotton fiber 2.94 0.070 17.7 6.0 0.061 0.87Polyester 2.55 0.061 13.3 5.2 0.037 0.61fiber______________________________________
Cell adsorption to fibers was slow and ineffective when xanthan gum had been removed from the cell suspension. As can be seen in FIG. 4b, under xanthan-free conditions only ˜24% and ˜30% of the cells initially present in the cell suspension were adsorbed to polyester and cotton fibers, respectively. This clearly indicated that cell adsorption was facilitated by the anionic exopolysaccharide, xanthan gum.
Adsorption Kinetics
As shown in FIG. 5, cell adsorption to fibers, both cotton and polyester, followed the first-order (monolayer) adsorption kinetics, which has also been reported for the adsorption of Pseudomonas florescens on glass surfaces. The adsorption rate constants for various experimental conditions were calculated from the slopes of these linear plots and are listed in Table 1.
Discussion
Although not limited to the theory of the invention's operation, the factors responsible for cell adsorption on surfaces can be categorized as specific and non-specific. The fibrous material substrates used in the present invention are non-biological and are essentially inert to the cells. The process of non-specific cell adsorption are known to be affected by: (i) character of microorganism (species, culture age, concentration), (ii) character of adsorbent (surface properties such as hydrophobicity and roughness, ionic form, charge, size), and (iii) environmental factors (culture medium, pH, inorganic salt concentration, presence of organic compounds, liquid flow velocity, contact time, temperature).
Hydrophobic interactions are important to cell adhesion to surfaces. Cell adhesion increases linearly with increasing surface hydrophobicity (or decreasing substrate surface tension) when the surface tension of the suspending liquid is larger than the surface tension of the adhering cells; conversely, adhesion increases with increasing surface hydrophilicity (or increasing substrate surface tension) when bacterial surface tension is larger than that of the suspending liquid. In most cases studied previously, it is the first case that prevails; i.e., cells adsorption to hydrophobic surface is generally better than to hydrophilic surfaces.
In this example of the present invention, only two types of fibers with different surface properties were used. The cotton (cellulose) fiber is more hydrophilic and has rough surfaces, whereas polyester fiber is more hydrophobic and has a smooth surface. As can be seen in FIG. 5 and Table 1, cell adsorption to cotton fibers was faster than to polyester fiber. The adsorption rate constants were 30-40% higher for cotton than for polyester. Thus, the adsorption mechanism cannot be solely explained by the surface hydrophobicity.
The structure of the woven fibrous sheet materials can be considered as filters where chromatographic effects can have a deterministic role in the adsorption mechanism of cells to the fibers. The surface roughness of the cotton fibers thus may be the major factor responsible for enhancing cell adsorption. Rough surfaces may provide more surface area per unit weight of the fiber material than smooth surface can. Also, under the flow conditions studied, the rough surfaces of cotton fibers may induce more turbulence and thus increased the contact frequency of cells with the fiber. It might also prevent adsorbed cells from being sheared off the surface due to fluid motion.
The influence of electrostatic interactions is also important to cell adsorption. It is not known if the two fiber materials used in this embodiment carried any surface charges. Bacterial attachment is generally increased by electrolytes at low ionic strengths. Xanthan gum is an anionic heteropolysaccharide; it can influence the electric charge of cells and the adhesiveness of the cells. As was observed in one xanthan fermentation study, the zeta potential of cells remained constant during the initial growth phase and then increased its negative value during the production phase. They also found that the zeta potential of cells decreased from -34 mV at zero xanthan concentration to -74 mV at 0.1 g/L xanthan gum. The large change in zeta potential or increase in cell surface charges caused by the xanthan gum present in the fermentation broth should increase cell adsorption. It is clear in the present invention that the xanthan gum present in the fermentation broth contributed to the ability of cells to adsorb to fibers. As can be seen in Table 1, the adsorption rate constant, k a , was much greater when xanthan gum was present in the broth. The total amounts of cells adsorbed to fibers were also much greater in the presence of xanthan gum. Without xanthan gum, the ability of cells to adsorb to fibers was poor. In fact, without xanthan gum, ˜80% of the adsorbed cells could be easily desorbed from the fiber by pumping water through the fibrous bed (data not shown). With xanthan gum, vigorous washing of the fibrous materials with water was required to remove the adsorbed cells from the fiber.
FIG. 6 shows the scanning electronic micrographs of X. campestris cells adsorbed on the cotton fiber surface. As is seen in these photographs, cells were well dispersed on the fiber surface as a monolayer; they adsorbed on the surface mainly as individual cells without forming large cell clumps or aggregates. As can be seen in these SEM photographs, the fiber surface was rough and was also heavily covered with thin filamentous material, which had similar structures and dimensions to those reported for xanthan molecules. These SEM photographs prove that xanthan gum indeed has helped cell adsorption to the fiber surface.
The removal of cells from the xanthan fermentation broth by cell adsorption to various woven fibrous materials was accomplished. It was found that both cotton and polyester fibers could be used to adsorb Xanthomonas campestris cells present in the fermentation broth either during batch fermentation or after the fermentation. Almost all cells were removed from the fermentation broth by adsorption to fibers. Cotton terry cloth had rough surfaces and was the preferred material for cell adsorption, as cell adsorption to cotton was faster than to polyester fibers. The adsorption kinetics can be modeled by a first-order rate equation. The adsorption rate constants were 30-40% higher for cotton than for polyester. Cell adsorption was not efficient in the absence of xanthan gum, suggesting that the exopolysaccharide, xanthan gum, was important for efficient cell adsorption to fibers.
Example 2
Xanthan Gum Fermentation by Xanthomonas campestris Immobilized in a Novel Centrifugal Fibrous-Bed Bioreactor
The following Example shows the use of a method making and using a fibrous bed reactor for fermentation using immobilized cells in accordance with one embodiment of the present invention.
In this embodiment of the present invention, a centrifugal fibrous-bed bioreactor was constructed and used for viscous xanthan gum fermentation. The feasibility and performance of a rotating fibrous-bed bioreactor for long-term production of cell-free xanthan gum broth is shown in repeated batch mode. The effects of rotational speed of the fibrous bed on oxygen transfer rate and xanthan production rate in the bioreactor were also demonstrated. A comparison between the performance of the reactor and that of a conventional stirred tank fermentor was made, and the effect of glucose (i.e., the carbon source) to yeast extract (i.e., the nitrogen source) ratio in the fermentation medium on xanthan production rate and yield are also reported.
Materials and Methods
Culture and Media
Xanthomonas campestris NRRL B-1459 was obtained from the Northern Regional Research Laboratory (NRRL) of the U.S. Department of Agriculture (Peoria, Ill.). Stock cultures of X. campestris NRRL B-1459 were maintained on agar slants, which contained 10 g/L glucose, 3 g/L yeast extract, 5 g/L peptone, and 15 g/L agar, and were stored at 4° C. The culture was transferred once every two weeks to maintain good viability and stability for xanthan production. Actively growing cells from a newly prepared slant culture (about 24-36 hour incubation time at 30° C.) were inoculated into 500-mL Erlenmeyer flasks containing 100 mL liquid medium. After incubation for 24 hours at 30° C. in an incubator-shaker, the 100-mL liquid culture was used to inoculate the fermentor containing 5 L of the medium.
Unless otherwise noted, the medium used in fermentation study consisted of 25 g/L glucose, 3 g/L yeast extract (USB, Cleveland, Ohio), 2 g/L K 2 HPO 4 , 0.1 g/L MgSO 4 ×7H 2 O, and 500 ppm (v/v) antifoam A (Sigma Chemicals). Tap water was used in preparing the medium to provide trace elements. The medium was prepared in two parts; the first part contained all the basic medium components except for glucose, and the second part was a concentrated glucose solution. The initial medium pH was adjusted to 7 by adding 4N HCl. These two solutions were autoclaved at 121° C. and 15 psig for 25 min., allowed to cool to room temperature, and then mixed together aseptically.
Construction of Centrifugal, Packed-Bed Bioreactor (CPBR)
The centrifugal, packed-bed bioreactor was constructed using a 5-L fermentor (BioFlo II, New Brunswick Scientific Co., Edison, N.J.) with the immobilized-cell matrix contained in a support container attached to the central spinning shaft of the fermentor impeller (see FIG. 7). The support container was a cylindrical cup (9 cm in diameter and 15 cm in height) with a central hollow core (2.7 cm in diameter), made of stainless steel plate with 3/16" round perforations (Small Parts, Miami, Fla.). A selected fibrous sheet matrix (100% cotton towel; 5 mm×15 cm×80 cm) was overlaid with a crimped stainless steel wire cloth of the same dimension (Goodloe, Glitch Technology Corp., Dallas, Tex.), spirally wound around the vertical axis, and packed in the support container. The packed volume was ˜850 mL. Four tilted exterior baffles mounted on the wall of the container caused a downloop flow pattern when the cup was rotated counterclockwise. A disk-blade turbine impeller installed at ˜1.5 cm below the cup provided turbulent mixing for the bottom part of the fluid in the fermentor. The centrifugal force generated from rotating the cup removed xanthan gum from the immobilized-cell matrix and moved it to the outer bulk broth. Broth was pumped from the bottom of the reactor vessel back into the center top of the rotating cup by a high-speed peristaltic pump (Masterflex with No. 24 pump head, Cole-Parmer, Chicago, Ill.) at a flow rate of ˜270 mL/min. This recirculation stream was sprayed onto the rotating fibrous matrix through a nozzle.
Sterile air was introduced into the medium through a ring sparger at the bottom of the fermentor vessel. Unless otherwise noted, the aeration rate was controlled at 1.5 vvm. The temperature was controlled at 30±0.1° C. The reactor pH value was maintained at 7.0±0.1 by adding 2.0 N potassium hydroxide. The dissolved oxygen tension in the broth was monitored by using a dissolved oxygen probe and analyzer (New Brunswick Scientific, DO-40), which was connected to a chart recorder (LINSEIS L4000 Digital Flatbed Recorder) to record dissolved oxygen tension profiles.
Bioreactor Startup and Cell Immobilization
The bioreactor was autoclaved twice at 121° C., 15 psig for 30 minutes and then filled with 5 liter sterile media containing 25 g/L glucose and 3 g/L yeast extract, and then inoculated with 100 mL flask culture. Unless otherwise noted, the cells in the bioreactor were first grown at pH 6 and 23° C., the optimal conditions for cell growth. The bioreactor was aerated at a volumetric flow rate of 5.0 std. liter/min. During this period, the reactor impeller and the fibrous matrix were spun at 150 rpm to provide good mixing. Then, when the reactor reached its highest cell density at ˜24 hours, the fermentation conditions were changed to pH 7, 30° C., and 350 rpm to promote xanthan production and cell immobilization. The fermentation broth was then harvested at ˜50 hours when all glucose in the medium had been consumed and by that time all cells had also been immobilized onto the fibrous matrix.
Repeated Batch Fermentation
After the first batch fermentation, the bioreactor was operated as a repeated batch system. The viscous broth was replaced with new sterile medium at the end of each batch fermentation, as determined from the alkali addition rate approaching zero. New medium for next batch fermentation was prepared in advance and pumped into the bioreactor at a flow rate of ˜200 mL/min. immediately after all xanthan broth had been pumped out of the bioreactor, which took about 25 minutes. The batch fermentation was repeated several times with 25 g/L glucose medium and then with 50 g/L glucose medium to study the effect of C/N ratio on xanthan production.
The CPBR performance was studied under either liquid-continuous mode, where the fibrous bed was completely immersed in 5 L media, or gas-continuous mode, where 90% of the fibrous bed was exposed to air with only 2.5 L media in the fermentor vessel. The first study was conducted in liquid-continuous mode (5 L media) and 150 rpm rotational speed. The second study was also in the liquid-continuous mode, but at 350 rpm rotational speed, the highest rotational speed that could be used with the present equipment without causing severe vibration of the rotating shaft. The third study was conducted in gas-continuous mode (2.5 L media) and at 350 rpm.
Samples of the fermentation broth were taken at proper time intervals. The cell density in the sample was determined immediately by measuring the optical density of the cell suspension. The sample was then frozen and stored for future analysis of glucose and xanthan concentrations. The quality of xanthan produced from each batch was also determined by measuring the apparent viscosity of the xanthan broth at a selected xanthan concentration of 18 g/L using a Brookfield viscometer.
Determination of Immobilized Cell Density
The immobilized cell density in the bioreactor was estimated at the end of each bioreactor study. First, all liquid in the bioreactor was drained, and the liquid volume and OD were measured to estimate the total suspended cells (cells in the free solution) present in the reactor. In this study, however, no cells were found in the liquid medium. The drained fibrous matrix was removed from the reactor and washed several times with water until almost all cells had been removed. The total volume of the washing water and its OD, as well as its dry weight, were measured and used to estimate the total amount of cells immobilized in the fibrous matrix
Determination of Cell Viability
The relative viability of immobilized cells as compared to free cells was determined by a plate count method. Small pieces of fibrous samples were cut off from the fibrous matrix and placed in test tubes containing sterile water. The immobilized cells in the fibrous matrix were then washed off from the matrix by vortexing for ˜3 minutes. One mL of the cell suspension sample was then subjected to serial dilutions with saline before transferred onto agar plates. The total viable cell number was determined from the colony count (between 30-300) times the dilution factor used in preparing the sample. Meanwhile, the OD of the cell suspension was also measured to estimate the total cell number in the sample using a standard correlation between OD and total cell number obtained using actively growing free cells in shake flasks (24 hours old), which should have 100% viability (i.e., viable cell number=total cell number). A linear relationship between the plate count number (which was assumed to be equal to the total cell number) and OD reading was obtained from the free cell sample and was used as the standard correlation. The viability of immobilized cells was then determined from the ratio of the total viable cell number determined from the plate count to the total cell number determined from the measured OD value.
Scanning Electron Microscopy
Several small pieces of the fibrous material were taken as samples from the drained fibrous matrix. These samples were immersed in 2.5% glutaraldehyde solution overnight and then rinsed completely with double distilled water, approximately 10 times for 15 minutes each The samples were then gradually dehydrated with 20%-70% ethanol in increments of 10% by holding the samples at each concentration for 30 min. The partially dehydrated samples were left in 70% ethanol overnight, then dehydrated further with 80% ethanol once and twice with 95% and 100% ethanol for 30 minutes each time. These samples were then cryogenically dried at critical point with liquid CO 2 . All steps, except for the critical drying, were carried out at 4° C. The completely dried samples were coated with gold/palladium before taking SEM photographs using the JOEL model 820 SEM.
Analytical Methods
Cell Density
Samples of fermentation broth were collected into centrifuge tubes. Depending on the broth viscosity, the broth samples were diluted with tap water by a factor of two to six, and the diluted solutions were centrifuged at 12,000 rpm (16,000×g) for 30 minutes at 5° C. to precipitate the suspended cells. Cells were then re-suspended in water and the optical density at 650 nm (OD 650 ) was measured using a spectrophotometer. The OD readings were then compared to a standard correlation between OD and cell density (g/L). The cell density was proportional to OD when the optical density was below 0.5, with one unit of OD equaling to 0.4 g/L cell. The total cell dry weight in the cell suspension was also determined after drying at 105° C. for ˜7 hours in a vacuum oven. The dry weight measurement was duplicated to reduce the experimental errors to within 0.2%.
Glucose Concentration
The glucose concentration was determined by using a glucose analyzer (YSI Model 2700 SELECT, detection range: 0-25 g/L). Properly diluted cell-free samples were presented to the needle port for automatic sample injection (adjustable from 5 to 65 microliters). The analysis is based on a biosensor membrane with immobilized glucose oxidase.
Xanthan Gum Concentration
Xanthan concentration in the fermentation broth was estimated from the broth viscosity with proper dilution. The viscosity of the cell-free fermentation broth was measured with a Brookfield viscometer (RVTD II) using spindle No. 1 at 100 rpm. The viscosity was then compared to a standard correlation between the viscosity and the xanthan concentration (g/L), which was linear when xanthan concentration was below 0.6 g/L. Samples were diluted with water to the proper concentration range before viscosity was measured, using known procedures. The final xanthan concentration of each batch fermentation was also determined by measuring the total dry weight of xanthan gum in the fermentation broth after purification by alcohol precipitation. The xanthan dry weight measurement was also used to verify the xanthan concentration determined from viscosity.
Results and Discussion
CPBR Reactor Startup
Typical kinetics of cell growth and xanthan production in the centrifugal, packed-bed bioreactor during reactor startup is shown in FIG. 8. Exponential cell growth, but small amounts of xanthan biosynthesis, occurred during the initial 24 hour period, which is also typical of xanthan gum batch fermentation with free cells. However, at ˜24 hours when the culture reached the stationary phase, the cell density in the fermentation broth rapidly decreased while xanthan production continued to increase, indicating that the cells were immobilized (adsorbed) onto the matrix. All suspended cells disappeared and were immobilized onto the fibrous matrix by 50 hours, as indicated by the broth optical density of being zero. No free cells were detected in the subsequent repeated batch fermentations, indicating that all cells, both existing and newly grown, remained immobilized on the fibrous matrix. With all cells immobilized in the fibrous matrix, a cell-free xanthan broth was produced. The reactor pH was changed from 6.0 to 7.0 and temperature from 23° C. to 30° C. at 24 hours when the cell growth reached a maximum value to promote xanthan production and cell immobilization.
Liquid-Continuous Fermentation (CPBR-LC)
FIG. 9 shows the kinetics for four repeated batch fermentations at the low rotational speed of 150 rpm. In the first two batches, the xanthan production rate remained almost unchanged, whereas the following two batches showed declined production rates. FIG. 9b shows that both xanthan yield (Y p/s ) and volumetric xanthan productivity (dP/dt) were lower for the last two batches. The reduced xanthan production in the later two batches was caused by oxygen limitation in the system and possibly a low cell viability at the low rotational speed used in the fermentation. Agitation and aeration were relatively poor at 150 rpm when the xanthan concentration was higher than 1%.
To improve oxygen transfer and CPBR performance, the rotational speed was increased to 350 rpm after cells were immobilized onto the matrix. As shown in FIG. 10, the fermentation time required for each batch at this rotational speed was much shorter than that at 150 rpm. The fermentation time to reach ˜2.5% xanthan concentration was reduced to ˜40 hours, as compared to 50 hours or longer for the conventional batch fermentation process. The productivity of the immobilized cells on the matrix was evaluated for long term operation by extending the repeated batch cycles. The reactor showed stable and consistent results for all six consecutive batches studied. As shown in FIG. 11, the xanthan yield remained at ˜85% and the quality of xanthan polymers produced, as determined by the solution viscosity of 1.8% xanthan concentration, remained unchanged for all six batches. The experiment was stopped because the reactor was contaminated by mold at the end of the last batch. The reactor productivity reached ˜0.7 g/L×h, which was significantly higher than that of the conventional batch xanthan fermentation (˜0.5 g/L×h). The immobilized cells in the CPBR thus can be repeatedly used for xanthan production for a long period.
It is clear that cell immobilization using fibrous matrix as the carrier can produce cell-free xanthan broth at high production rate. After the cells were successfully immobilized, they became available for reuse in subsequent batches, thus eliminating the long period (˜24 hours) for cell growth required in the conventional batch fermentation. Production of xanthan gum by repeated batch fermentations with free cells has also been demonstrated with good stability for three consecutive cycles. However, in these studies 20% of the fermentation broth was retained as inocula for new batch cycle and 50 hours were required to reach 2% xanthan concentration in each cycle. With cell immobilization, there is no need to retain any fermentation broth for the new batch cycle, thus greatly enhancing process productivity.
Gas-Continuous Fermentation (CPBR-GC)
Since all cells were immobilized in the fibrous matrix, xanthan gum production could only take place when the glucose medium was in contact with the fibrous matrix. The fermentation time thus should be further reduced by increasing the liquid-cell contact. Since it was difficult to increase the recirculation pump speed in the experiment, the total liquid volume in the reactor vessel was reduced to half. This not only would increase the contact frequency between cells and the liquid medium, it also increased the effective cell concentration per liter liquid medium in the reactor and mass transfer between liquid and air.
FIG. 12 shows the fermentation results from gas-continuous operation with 2.5 liters media in the fermentor vessel. As expected, the fermentation time for each batch cycle was dramatically reduced to 24-26 hours or about half of the time required for the conventional process. The xanthan yield, volumetric xanthan productivity, and xanthan quality from eight consecutive batches are shown in FIG. 13. The volumetric productivity was ˜1 g/L×h based on the total liquid volume in the fermentor vessel, and ˜3 g/L×h based on the packing volume (the volume occupied by the rotating fibrous matrix). The productivity can be further increased by increasing the medium recirculation rate, which increases gas-liquid and cell-liquid contacts in the fibrous matrix. The oxygen transfer rate can also be enhanced by increasing liquid recirculation rate and the rotational speed of the fibrous bed. This should result in an even higher xanthan production rate.
Immobilized Cell Density
Fibrous samples from various parts of the fibrous matrix were examined for cell density distribution at the end of each reactor study. It was found that cells were evenly distributed onto the fibrous matrix. FIG. 14 shows the attachment of Xanthomonas campestris on the fiber surface. The immobilized cells were well spread on the fiber surface. They adsorbed on the surface mainly as individual cells without forming large cell clumps or aggregates.
At the end of each reactor study, the amount of immobilized cells in the bioreactor was determined and was found to be 34 g for the liquid continuous reactor and 38.4 g for the gas-continuous reactor. This gave equivalent liquid cell densities of 6.8 g/L and 15.36 g/L, respectively, which were at least three to seven times that obtained in the conventional free-cell batch xanthan fermentation (<˜2 g/L). It is clear that the high immobilized cell density contributed to high productivity for CPBR. However, the increase in CPBR productivity was less proportional to the increase in the total cell density. The cell viability of the immobilized cells in the CPBR at the end of the study was only ˜60% of that for free, suspended cells. This explained partially why the volumetric xanthan productivity of CPBR was not proportional to the total cell density in the bioreactor.
Comparison between STR and CPBR
For comparison purposes, batch xanthan fermentations with free cells in conventional stirred tank bioreactor (STR) were also studied at 30° C. and pH 7.0. Compared to the CPBR results, the fermentation time with STR was long: ˜70 hours for fermentation with 2.5% glucose medium and ˜120 hours with 5.0% glucose medium. FIG. 15 shows the comparison of volumetric xanthan productivities (dP/dt) and specific xanthan productivities (dP/dt/X s ) from STR, CPBR-LC, and CPBR-GC. The specific productivity was estimated from the volumetric productivity divided by the final cell density in the bioreactor (X s ). As can be seen in FIG. 16, CPBR gave higher volumetric productivity than conventional STR, mainly because of its higher cell density in the reactor. However, CPBR had a lower specific productivity (FIG. 15b) because of the relatively low cell viability, only ˜60% at the end of the study. Some cells might have died due to starvation during medium change-over between batch runs. However, the low specific productivity also indicated that the oxygen transfer rate in the CPBR might not be high enough and thus must be further increased in order to fully utilize the high density of immobilized cells in the fibrous matrix.
Effect of Oxygen Uptake Rate
The dissolved oxygen tension (DOT) in the fermentation broth generally decreased as the fermentation progressed, dropping gradually from 100% to ca 50% during growth phase. As the broth became more viscous at 2%˜3% xanthan, DOT dropped quickly down to below 10%. The DOT must be maintained above 20% to prevent any adverse effect on xanthan production caused by oxygen limitation. Oxygen transfer rate has been found to have profound effects on both specific xanthan production rate and the molecular weight of the xanthan product from fermentation. The oxygen transfer rate (OTR) during the batch fermentation can be estimated from the measured DOT and the overall mass transfer coefficient, k L a, and the solubility of oxygen in xanthan broth. As was observed in practice of the present invention (data not shown), as the xanthan concentration increased, OTR, specific oxygen uptake rate (OUR), and specific xanthan productivity all decreased. There was a strong correlation between specific OUR and specific xanthan productivity. As shown in FIG. 16, the specific xanthan productivity was proportional to the specific oxygen uptake rate during xanthan gum fermentation, regardless of the bioreactor system used in the fermentation. Compared to STR, CPBR had relatively low specific OUR. Thus, the low specific xanthan productivity from CPBR can be attributed to the low specific oxygen uptake rate or OTR. The performance of CPBR thus can be further improved by increasing OTR in CPBR. This can be accomplished by increasing the liquid recirculation rate and the rotational speed of the fibrous matrix. The mass transfer rate between gas and liquid can be greatly enhanced by increasing their contact, which can be accomplished without incurring flooding under high gravitational force.
Effect of C/N Ratio
In batch fermentation, it took ˜24 hours for cells to reach a maximum cell density with the low glucose (e.g. 2.5%) medium. Large amounts of xanthan began to be produced when cell growth stopped. On the contrary, for the high glucose medium (5.0%), cell growth was much slower and was in parallel with xanthan formation for most of the fermentation time (data not shown). Both the cell yield and specific growth rate of X. campestris in the stirred tank reactor (STR) were found to decrease with increasing C/N (glucose to yeast extract) ratio in the medium. On the other hand, the xanthan yield and specific xanthan production rate increased with increasing C/N ratio in the medium. Similarly, it was also found with CPBR that the volumetric xanthan productivity was significantly higher with the medium with a higher C/N ratio (FIG. 15). As can also be seen from FIG. 13, both the xanthan yield and volumetric xanthan productivity were about the same for fermentations with 5.0% glucose/0.3% yeast extract and 2.5% glucose/0.15% yeast extract. Thus, the enhanced xanthan production rate at the higher C/N ratio also was achieved at a relatively low yeast extract concentration. This clearly showed that C/N ratio, instead of yeast extract or glucose concentration, was the major factor in affecting the xanthan gum production rate by the immobilized cells.
Conclusion
The centrifugal packed-bed bioreactor of the present invention was able to produce xanthan gum at a productivity of twice that for the present industrial process. The intimate air, liquid, and cell contact achieved via passing liquid medium and air through the porous fibrous matrix enhanced the oxygen transfer rate and allowed high cell density and xanthan productivity. The immobilized cells were able to be repeatedly used for xanthan fermentation to achieve stable, semi-continuous production of cell-free xanthan broth, as demonstrated in repeated batch mode for more than 8 batch cycles in this study. In principle, as long as the cells are able to be maintained at a high viability level, the production of xanthan gum could continue. Even with reduced viability, the high cell numbers present in the fibrous matrix can more than compensate for the problem. Cell density as high as 30 to 100 g/L has been attained with the fibrous bed bioreactor. The immobilized cell density in the CPBR can thus be increased several fold to further increase the reactor productivity if the oxygen transfer rate in the fibrous bed can also be increased.
Moreover, fermentation conditions can be easily shifted from growth-oriented for reactor startup to production-oriented for the following production period. The productivity of xanthan polymers can thus be further optimized in the immobilized cell bioreactor. Xanthan gum is produced as a secondary metabolite and its production is usually non-growth associated The optimal conditions for cell growth and xanthan biosynthesis are known to be quite different. In general, optimal cell growth requires a relatively low temperature, 22 to 24° C., a pH of 6 or lower, and a low C/N ratio in the medium; whereas a higher temperature, 31 to 33° C., neutral pH, and a higher C/N ratio are needed for optimal xanthan production. Therefore, separation of cell growth and xanthan production into two stages should improve xanthan fermentation with enhanced cell growth as well as xanthan production. Such a two-step fermentation process can be easily carried out with the present immobilized cell bioreactor.
Accordingly, the present invention may include a process for separating cells from a cellular reaction media, which is mediated through the presence of a microbial polysaccharide (which may be added or be produced through the cellular reaction). The present invention also includes a cellular reaction method in a liquid media that may use the inventive separation process to remove cells.
The present invention also includes a method for conducting a cellular reaction in a liquid media which uses microbial polysaccharide-mediated or -enhanced attachment of cells to a fibrous material matrix. The invention also includes an apparatus for carrying out such a method.
In view of the foregoing disclosure, it may become apparent to one of ordinary skill in the art to make modifications to the present invention, such as through substitution of equivalent materials and process steps, without departing from the spirit of the invention as reflected in the appended claims.
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The present invention includes a process for separating cells from a liquid media. In broadest terms, the separation process of the present invention is a process for separating cells from a liquid containing cells. The process comprises the steps of: (a) bringing the liquid containing the cells into contact with one or more microbial polysaccharide and a fibrous material so as to adsorb the cells onto the fibrous material; and (b) separating the liquid from the fibrous material so as to remove the cells from the liquid. The process of the present invention may be used to remove cells from any liquid, but such liquids typically will be aqueous solutions, such as growth media, biological fluids, diagnostic samples, aqueous test samples, etc.
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RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/785,325 filed on Mar. 23, 2006, which is incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a composition useful as an additive in the manufacture of gypsum wallboard that permits the manufacture of wallboards with little or no starch binder. The present invention also relates to paper treated with the additive as well as to a process for manufacturing gypsum wallboard that significantly reduces the quantity of drying energy required as compared to prior art processes. More specifically, the present invention relates to a process for making the paper component of gypsum wallboard with an improved bonding affinity for wet plaster.
BACKGROUND OF THE INVENTION
[0003] The gypsum wallboard industry produces wallboard through a process designed to ensure an effective adhesive bond between two external layers of heavy caliper paper that enclose an interior gypsum plaster core. The industry traditionally has added large quantities of starch binder to the plaster core in order to promote adhesion to the paper shell. The industry also adds a large excess of water to the plaster so that, during drying of the plaster between the two paper layers, the excess water can migrate from the wet plaster into the paper carrying starch binder along with it to establish bonding of the plaster to the paper surface. However, such a process is highly energy-intensive due to the amount of drying energy required to migrate and evaporate the excess water from the gypsum plaster core.
[0004] There is general industry need for reducing the amount of water used in the production of wallboard since drying costs have increased substantially for the gypsum wallboard producers. It is also apparent that a reduced plaster to water ratio can be attainable with the present invention that can in turn result in a higher strength wallboard. This strength enhancement, attained by including the paper surface treatment in the gypsum wallboard manufacturing process, in turn optionally could allow the production of stronger, low density, wall board products.
[0005] It has unexpectedly found that an alternative to the use of starch and high water ratio in the wet plaster core can be practiced and yet still achieve strong bond between the paper layers and the plaster core.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a process for making gypsum wallboard by applying a surface treatment to a paper component of the wallboard prior to contacting the paper component with wet plaster to enhance the plaster bond to the paper component. The plaster component can then employ a relatively low amount of water and yet still form a strong bond to this substrate.
[0007] The present invention also relates to a composition useful as an additive in the manufacture of gypsum wallboard that permits the manufacture of wallboards with little or no starch binder. The present invention also relates to paper treated with the additive.
[0008] Additionally the present invention relates to a wallboard having an interior gypsum plaster core, and at least one treated paper adhered to a surface of the interior gypsum plaster core wherein the paper sheet has a surface treated with a surface treating adhesive. The surface of the interior gypsum plaster core is adhered to the surface of the paper sheet treated with the surface treating adhesive.
[0009] The treated paper for use in wallboard contains a paper sheet wherein a surface of the paper sheet is treated with a surface treating adhesive comprised of water and a latex binder. The surface treating adhesive may also contain an amount of a mineral filler. The surface treating adhesive may also contain an amount of a rheology modifier, such as a cellulose ether or a biopolymer or mixtures thereof.
[0010] Prior to this invention, the use of high levels of starch and water in gypsum wallboard has been required in order to assure proper bond of the gypsum to the paper component. Generally, the water/plaster ratio has been greater than 70/100 in prior art practice. In the present invention, the water/plaster ratio may be less than 70/100.
[0011] This invention has advantages in allowing a reduction in the water/plaster ratio and hence can provide a reduced the energy requirement to make wallboard, and an improved the strength of wall board through use of lower water/plaster ratio. The invention thus represents a process to permit the production of wallboard with improved properties.
DETAILED DESCRIPTION OF THE INVENTION
[0012] It was unexpectedly found that a paper shell component of gypsum wallboard can be surface treated with selected materials so as to enhance the bonding tendency of the wallboard's plaster inner core to the paper. This enhanced bonding tendency or affinity in turn allows a plaster core to be formulated with lower water and starch content, which reduces the amount of energy needed to dry the wallboard. Among the advantages of reducing or eliminating the starch content of the plaster core of a wallboard is that the resultant wallboard is potentially less susceptible to microbial attack when exposed to high humidity or other favorable environmental conditions which promote microbial growth.
[0013] The present invention relates to a surface treatment adhesive employed as a surface treatment of the paper components of wallboard. This surface treatment adhesive comprises water and a latex binder. The surface treatment adhesive may additionally preferentially comprise a mineral filler. The surface treatment adhesive may also optionally contain such additional ingredients as rheology modifiers, stabilizers and preservatives.
[0014] The latex binder component of the surface treatment adhesive is preferred to be in the range of about 1-55 wt % of the surface treatment adhesive. The latex binder component of the surface treatment adhesive may be selected from commonly available latex polymers and may be selected from the group consisting of ethylene polyvinyl acetate, poly(vinyl acetate) (PVOAc)latex, styrene butadiene (SBR), acrylic, vinyl acrylic. Preferably, the latex binder component is ethylene polyvinyl acetate or poly(vinyl acetate) (PVOAc)latex.
[0015] The use of the mineral filler in the surface treatment adhesive is optional. If used, the ratio of the mineral filler in the surface treatment adhesive is generally in the range of about 1-50 wt % of the surface treatment adhesive. Many types of minerals and a wide selection of particle size distributions of the mineral filler are possible, although generally finer particle sizes are be preferred for use in the surface treatment adhesive. The mineral filler can include, and may be selected from, the group consisting of calcium sulfate hemi hydrate, calcium sulfate dihydrate, ground gypsum, Portland cement, calcium carbonate, clays, and powdered silica. Other inorganic species may also be of utility as the mineral filler.
[0016] Other water-soluble species selected from the group consisting of rheology modifiers, salts, accelerators and dispersants may be used as additives in surface treatment adhesive to affect other properties of the treated paper and the resultant wallboard. The preferred rheology modifier comprises cellulose ethers. The cellulose ethers of use in the present invention may be selected from the group consisting of carboxymethylcellulose(CMC), hydrxoypropylmethylcellulose(HPMC), methylcellulose(MC), hydroxypropylcellulose(HPC), hydrophobically modified hydroxypropylcellulose(HMHPC), hydroxyethylcellulose(HEC), ethyl hydoxyethylcellulose(EHEC), hydrophobically modified hydroxyethylcellulose(HMHEC), cationic hydrophobically modified hydroxyethylcellulose(cationic HMHEC), and anionic hydrophobically modified hydroxyethylcellulose (anionic HMHEC). The preferred cellulose ether comprises hydroxyethylcellulose.
[0017] The rheology modifier may also comprise biopolymers. The preferred biopolymer comprises xanthan gum.
[0018] One aspect of the invention is that surface treatment adhesive, when it contains the mineral filler as well as the rheology modifier, results in fluid mixtures having high levels of mineral filler. A high level of mineral filler is a level of mineral filler about 20% by weight or more, preferably about 30% by weight of the surface treatment adhesive. The preferred rheology modifier is HEC. Another preferred rheology modifier is xanthan gum. Still more preferred is a rheology modifier comprising a mixture of HEC and xanthan gum.
[0019] To produce the surface treatment adhesive with a high level of mineral filler, a quantity of water is first mixed with a small amount of a rheology modifier and stirred to dissolve. Once the rheology modifier is dissolved in the water, the high level of mineral filler is gradually added to the aqueous solution containing the rheology modifier in stages with high speed mixing. The viscosity of the aqueous mixture containing the mineral filler is sheer thinned after each stage in order to control the viscosity of the mixture. Finally, an amount of the latex binder is added to the mixture. A fluid stable mixture is obtained.
[0020] An alternative method to produce the surface treatment adhesive is to mix the quantity of water with the latex binder followed by gradual addition of the mineral filler and finally add in the rheology modifier(s).
[0021] In practice, the surface treatment adhesive composition described above is diluted with water to a working concentration of from about 2-20% solids by weight then this mixture is applied to a surface of the paper by any of the mechanical processes typically used in the art of paper conversion, including, but not limited to, using a doctor blade, using a roll, using a puddle applicator, or using of a spray applicator. The surface treatment adhesive composition is applied to both interior surfaces of paper employed in wallboard manufacture and preferentially dried in place, although this is not required, producing a paper with a surface-treated side. The amount of surface treatment adhesive used to treat the paper is of a level of greater than about 0.1 gm/m 2 , preferably in the range of greater than about 0.1 gm/m 2 to 4 gm/m 2 , preferably about 0.1 to 2 gm/m 2 , more preferably about 0.5 to 1 gm/m 2 , still more preferably in the range of about 0.2 to 0.5 gm/m 2 . By applying the surface treatment adhesive composition as a coating in this range, the surface treatment adhesive composition promotes an adhesion affinity of the surface-treated paper layers to the plaster inner core of the wallboard in the case where the plaster either contains no starch at all or a reduced quantity of starch compared to standard practice.
[0022] It is preferred that the surface treatment adhesive have minimal effects on the porosity of the paper when producing a paper with a surface-treated side. This preservation of the paper porosity is of utility in the production of wallboard since after wet plaster is applied to the treated surface of the paper with a surface-treated side, water found at this surface may readily evaporate through the paper layers. The porosity property of paper can be measured by means of a standard test method termed “Gurley porosity” involving Hagerty Porosimeter apparatus at a “low” setting. A typical Gurley porosity measurement of the surface-treated paper of the present invention will be on the order of less than 20 seconds difference vs. control non-treated wallboard paper. If a one step continuous process is desired, the mixture may be applied to the surface of the paper and the wet plaster is then applied to the paper with a surface-treated side.
[0023] The paper with a surface-treated side is converted into a wallboard by a mechanical process whereby both sides of a layer of wet plaster are brought into contact with treated surface of the paper with a surface-treated side to create a wallboard composition useful in construction applications. The wet plaster in the present invention case contains either no starch or a reduced quantity of starch compared to the prior art. The wet plaster also generally will optimally contain a reduced level of water compared to standard wallboard plaster preparations. Therefore by replacing all or a proportion of the starch component of the final wallboard composition with the paper with a surface-treated side of the present invention a novel wallboard composition is created.
[0024] In the process of producing wallboard, a two-step process is envisioned where the paper with a surface-treated side of the present invention which has been previously produced and dried is subsequently combined with a layer of wet plaster to produce a wallboard. Alternatively, a one step process is also envisioned where the surface treatment adhesive composition is applied to the paper surface and, prior to completely drying the paper surface, wet plaster is applied to the paper with a surface-treated side to produce a wallboard.
[0025] The wallboard that is produced through the process of the present invention has several improvements over similar prior art process such as enhanced strength due to the lesser quantity of water employed to prepare the wallboard as well as economic benefits. Thus, this process can be envisioned in a further step to potentially allow the production of significantly lower density wallboard products with acceptable strength dimensions, than is currently possible with existing art technology.
[0026] The invention is further demonstrated by the following examples. The examples are presented to illustrate the invention, parts and percentages being by weight, unless otherwise indicated.
EXAMPLES
Comparative Example 1
[0027] A quantity of 30 parts by weight of calcium sulfate hemi-hydrate of water was mixed with 70 parts by weight of water with high shear mixing. Within a period of mixture of five (5) minutes a solid gel was formed, making this composition unsuitable for use as a surface treatment adhesive. This mixture is shown in Table 1 as Composition 1.
Comparative Example 2
[0028] A quantity of 5 parts by weight of calcium sulfate hemi-hydrate was mixed with 80 parts by weight of water with high shear mixing. The mixture was observed to thicken briefly to a very viscous state then redisperse with high shear mixing after about ten (10) minutes. Then an additional quantity of 5 parts by weight of calcium sulfate hemi-hydrate was added with additional high shear mixing. This process was repeated until approximately 20 parts by weight of calcium sulfate hemi-hydrate was added to the water. Thus a means to make a concentrated dispersion of gypsum particles by adding calcium hydrate hemi-hydrate, slowly to water with dispersive mixing was demonstrated. This mixture was very viscous and of limited practical utility and is shown in Table 1 as Composition 2.
Example 1
[0029] A quantity of 20 parts by weight of Airflex® 526 BP ethylene vinyl acetate latex (available from Air Products and Chemicals, Inc.) was mixed with 80 parts by weight of water. A fluid stable dispersion was obtained. This mixture is shown in Table 1 as Composition 3.
Example 2
[0030] A quantity of 49.8 parts by weight of water was mixed with 0.2 parts by weight of Natrosol® 250H4BXR hydroxyethylcellulose (available from Hercules Incorporated) and stirred to dissolve. Once the hydroxyethylcellulose (HEC) was dissolved in the water, 30 parts by weight of calcium sulfate hemihydrate (gypsum) was added gradually and in stages with high speed mixing. Viscosity was relatively high when each successive portion of the gypsum was initially added to the HEC aqueous solution but this mixture was shear thinning with time and so was considered to be a controllable process. Finally, 20 parts by weight of Airflex® 526 BP ethylene vinyl acetate latex (available from Air Products and Chemicals, Inc.) was added to the mixture. A fluid stable mixture was obtained. This process demonstrated that a highly concentrated dispersion of gypsum particles can be obtained by adding calcium sulfate hemi hydrate to water containing an HEC component. This composition is shown in Table 1 as Composition 4.
Example 3
[0031] A quantity of 20 parts of Airflex® 526 BP ethylene vinyl acetate latex (available from Air Products and Chemicals, Inc.) was added to 49.7 parts of water then 30 parts by weight of calcium sulfate hemi hydrate was added gradually and in stages with high speed mixing. Only a slight viscosity rise was observed with each successive calcium hemi hydrate addition making this method a very easily controlled process. After all of the calcium sulfate hemihydrate was added, 0.1 parts by weight of Natrosol® 250H4BXR HEC (available from Hercules Incorporated) and 0.2 parts of Keltrol® RD xanthan gum (available from CP Kelco Inc.) are added and dissolved in the mixture as stabilizers for the gypsum slurry as the last components of the batch. In this case, the viscosity of the product was measured to be 1000 cps Brookflield viscosity and there is no settling of the fluid slurry observed after 24 hours. This composition is shown in Table 1 as Composition 5.
TABLE 1 Surface Treatment Adhesive Compositions Composition 1 Composition 2 Composition 3 Composition 4 Composition 5 INGREDIENTS Parts by weight Parts by weight Parts by weight Parts by weight Parts by weight Water 70 80 80 49.8 49.7 Airflex ® 526BP 20 20 20 polyethylene polyvinyl acetate latex Calcium sulfate 30 20 30 30 hemihydrate Natrosol ® 0.2 0.1 250H4BXR HEC Keltrol ® RD xanthan 0.2 gum Observations Solid gel forms Viscous mixture Fluid mixture Mixture settles Stable fluid settles rapidly to gradually suspension 1000 cps dense cake viscosity
Example 4
[0032] Standard wallboard paper is surface-treated with a variety of water-based based mixtures then the wet paper surface is dried under direct IR lamp. The list of surface treatments employed is described in Table 1 compositions 2-5. Two control conditions were also tested including a) no surface treatment of the paper surface and b) treatment of the paper surface with water only. The surface-treated treated paper samples treated with the compositions from Table 1 were then contacted with wet plaster containing no starch using the following procedure.
1) Dilute compositions from Table 1 to active level indicated below with water; 2) Apply diluted compositions to paper surface with a Gardco drawdown apparatus (available from Paul N. Gardner Company, Inc.), dry by heat lamp to produce a paper with a surface-treated side; 3) A standard dry plaster, without starch added, was added in a quantity of 60 parts by weight to 30 parts by weight of water then hand-mixed by rod stirrer for 30 seconds; 4) The wet mix of step 3 was immediately troweled into a plastic mold ¼″ (0.6 cm) in depth and leveled by hand tool to form a smooth exposed surface; 5) The wet outer surface of the plaster in the mold was immediately applied to the paper with a surface-treated side sample; 6) The paper and mold were placed in a 60° C. oven and dried to constant weight over 16 hours;
[0039] 7) The paper/plaster mold samples were removed from the oven and were manually separated from each other. The relative area of the paper layer adhered to the plaster mold was quantitatively estimated. In this manner, an estimate of the percentage of surface coverage of paper fibers visibly adhering to plaster mold surface was recorded.
TABLE 2 Bond areas of surface-treated paper samples with plaster Paper Surface treatment None Composition 2 Composition 3 Composition 4 Composition 5 ingredients: (Control) Water only Comp. Ex. 2 Example 1 Example 2 Example 3 Active Solids level — 5% 2% 12.5% 6% After dilution Approximate coating weight 0.5 gm/m2 0.2 gm/m2 1.0 gm/m2 0.6 gm/m2 applied to paper surface Paper % adherence by area No bond No bond <10% bond area ˜50% bond area ˜90% bond area ˜90% bond area to plaster mold after drying: Treated paper Gurley 57 secs 57 secs ND 57 secs 58 secs ND porosity
[0040] It was found in the control case in which there was no surface treatment of the paper that no appreciable bond between the paper and the plaster was achieved. In the second control case where water alone was employed to coat the surface of the paper, no bond with the plaster was observed.
[0041] In Example 4 in which latex alone was employed to treat the paper surface, it was found that a moderately strong bond was observed to form to the paper surface. Thus, the use of latex alone as the paper surface treatment is a variation of the process of the present invention that, while not optimal, is still operational.
[0042] In Example 4, it was found that where a paper with a surface-treated side where a dispersion of latex and gypsum particles was employed as the surface treatment adhesive a strong complete bond was attained between the paper and the gypsum plaster.
[0043] While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Paper useful in the manufacture of gypsum wallboard is surfaced treated with an additive to improve the bonding affinity of the paper for wet plaster thereby permitting the manufacture of gypsum wallboard with little or no added starch and reduced amounts of water. A surface treating adhesive, a method of converting the paper and wallboards containing the paper are also described.
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FIELD OF THE INVENTION
The present invention relates to concrete forms. More specifically, the present invention is concerned with concrete wall formwork modules that can be assemble like bricks to form a mold into which concrete is poured. Once assembled and filled with concrete, the modules are left in place thereby providing a concrete wall with panels on both of its sides.
BACKGROUND OF THE INVENTION
A formwork for casting a concrete wall is traditionally assembled on the premises using two wood or metal panels maintained in spaced parallel relationship by tie-wires and other appropriate connection means at their ends. This formwork is expensive since its mounting and dismounting are time consuming.
U.S. Pat. No. 4,888,931 issued to Serge Meilleur on Dec. 26, 1989 and entitled “Insulating Formwork for Casting a Concrete Wall” discloses an insulating formwork for casting a concrete wall, which is made of foam panels connectable to each other in parallel relationship by means of tie-rods. Once assembled, the panels define a concrete formwork into which concrete can be poured.
Even though the assembly of this formwork is simplified by the configuration of the panels, the formwork must still be completely assembled on the premises, thereby requiring time and manual dexterity.
U.S. Pat. No. 6,070,380 also issued to Meilleur on Jun. 6, 2000 and entitled “Concrete Wall Formwork Module” discloses a prefabricated concrete formwork module that may be assembled with others similar modules in the manner of a brick wall to form a mould into which concrete is poured. Even though Meilleur's module solves the above-mentioned problem of the assembly, it presents the new drawback that it is cumbersome, takes a lot of space and is therefore costly to transport.
OBJECTS OF THE INVENTION
An object of the present invention is therefore to provide a concrete wall formwork module free of the above-mentioned drawbacks.
SUMMARY OF THE INVENTION
More specifically, in accordance with a first aspect of the present invention, there is provided a concrete wall formwork reinforcing mesh structure comprising:
a first side wall grid;
a second side wall grid; and
at least two connecting rods having about a same length hingedly interconnecting the first and second side wall grids to allow movement thereof between a retracted parallel relationship to a spaced apart parallel relationship.
According to a second aspect of the present invention, there is provided a concrete wall formwork module comprising:
a first side wall panel structure including a first grid and a first panel mounted to the first grid;
a second side wall panel structure including a second grid and a second panel mounted to the second grid; and
at least two connecting rods having about a same length hingedly interconnecting the first and second side wall panel structures to allow movement thereof between a retracted parallel relationship to a spaced apart parallel relationship.
When the first and second side wall panel structures are in the retracted parallel relationship, the concrete wall formwork module is more compact and therefore easier and less costly to transport.
According to a third aspect of the present invention, there is provided a concrete wall formwork corner element for interconnecting two pairs of formwork side walls, each pair positioned in a spaced apart parallel relationship, the corner element comprising:
a reinforcing mesh defining two grid walls defining an angle therebetween; each grid wall having a side edge and a fastening plate secured to the side edge; and
two panel elements, each secured to a respective grid walls;
whereby, in operation, the corner element is positioned between the two pairs of formwork side walls so that each of the two panel elements contacts a side edge of a side wall from a respective pair of the two pairs of formwork side walls while the fastening plate overlays the side wall from a respective pair of the two pairs of formwork side walls.
According to a fourth aspect of the present invention, there is provided a method for creating a corner assembly for a formwork comprising:
providing a corner element according to the third aspect of the present invention;
providing first and second modules according to the second aspect of the present invention;
positioning each the first and second modules in the spaced apart relationship;
abutting both the first and second modules to the corner element so that the first side wall panels of both the first and second modules are positioned adjacent one another, the second wall panel of the first module contacts a first one of the fastening plates of the corner element and the second wall panel of the second module contacts a second one of the fastening plates of the corner element;
fastening the second wall panel of the first module to the first one of the fastening plates of the corner element and the second wall panel of the second module to the second one of the fastening plates of the corner element;
securing the first wall panel of the first module to the first wall panel of the second module using an iron angle; and
securing the iron angle to the corner element.
The concrete wall formwork module according to the present invention allows resisting to sideways thrusting which occurs during the pour of the concrete therein and to the use of a vibrator to stiffen the concrete. It allows assembling formworks which are functionally similar to conventional formworks since the facing side wall panel structures of the module are connected in a parallel relationship by thin spacer connecting rods which allow concrete to freely travel within the formwork.
Other objects, advantages and features of the present invention will become more apparent upon reading the following non restrictive description of illustrated embodiments thereof, given by way of example only with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the appended drawings:
FIG. 1 is a perspective view of a concrete wall formwork module according to a first illustrative embodiment of the present invention;
FIG. 2 is a side elevation taken along line 2 - 2 from FIG. 1 ;
FIG. 3 is a top plan view of the module from FIG. 1 , illustrating the first and second side wall panel structures of the module in a retracted parallel relationship;
FIG. 4 is a top plan view of the module from FIG. 1 , illustrated the first and second side wall panel structures of the module in a spaced apart parallel relationship;
FIG. 5 is a perspective view of an assembly of a plurality of module from FIG. 1 in a formwork, the formwork being only partially illustrated, including a concrete wall formwork corner element according to a first illustrative embodiment of the present invention;
FIG. 6 is a partial top plan view of the assembly from FIG. 5 , illustrating the assembly of the corner element with two adjacent modules from FIG. 1 ;
FIG. 6A is a partial top plan view of a concrete wall formwork corner element according to a second illustrative embodiment of the present invention;
FIG. 7 is a top plan view similar to FIG. 6 , illustrating the resulting formwork with concrete poured therein; and
FIG. 8 is a perspective view of the assembly from FIG. 6 ;
FIG. 9 is a perspective view of a concrete wall formwork module according to a second illustrative embodiment of the present invention;
FIG. 10 is a side elevation of the module From FIG. 9 ;
FIGS. 11A-11B are top plan partial views of the module from FIG. 9 , illustrating the first and second side wall panel structures of the module respectively in a retracted parallel relationship and in a spaced apart parallel relationship;
FIG. 12 is a top plan view illustrating a method for creating a 90 degrees corner between two intersecting modules similar to the module from FIG. 9 ;
FIG. 13 is a top plan view illustrating a method for creating a 135 degrees corner between two intersecting modules similar to the module from FIG. 9 ;
FIG. 14 is a perspective view of a concrete wall formwork module according to a third illustrative embodiment of the present invention;
FIG. 15 is a side elevation of the module From FIG. 14 ;
FIGS. 16A-16B are top plan partial views of the module from FIG. 14 , illustrating the first and second side wall panel structures of the module respectively in a retracted parallel relationship and in a spaced apart parallel relationship;
FIG. 17 is a side elevation of a concrete wall formwork module according to a fourth illustrative embodiment of the present invention;
FIG. 18 is a side elevation of a concrete wall formwork module according to a fifth illustrative embodiment of the present invention;
FIG. 19 is a top plan view illustrating a method for creating a 90 degrees corner between two intersecting modules similar to the module from FIG. 18 ;
FIG. 20 is a top plan view illustrating a method for creating a 135 degrees corner between two intersecting modules similar to the module from FIG. 18 ; and
FIG. 21 is a perspective view illustrating the assembly of a formwork wall using modules from FIG. 1 .
DETAILED DESCRIPTION
A concrete wall formwork module 10 according to a first illustrative embodiment of the present invention will now be described with reference to FIGS. 1 and 2 of the appended drawings.
The concrete wall formwork module 10 comprises first and second side wall panel structures 12 and 14 and a plurality of connecting spacer rods 16 for hingedly interconnecting the first and second side wall panel structures 12 and 14 .
Each side wall panel structures 12 and 14 includes a rectangular metallic side wall wire grid 18 embedded in a respective insulated foam panel 20 , 22 . The two side wall grids 18 together with the plurality of spacer rods 16 define a deployable concrete wall formwork reinforcing mesh structure.
Each wire grid 18 includes a series of parallel vertical metallic rods 24 generally extending along the height of its respective panel 12 or 14 . The rods 24 are configured so as to define stand-out portions yielding lugs 26 as will be described furtherin in more detail. The vertical rods 24 allow providing structural integrity to the module 10 when concrete is poured therein.
Each grid 18 further includes parallel horizontal metallic rods 28 extending along the width of the respective panel 12 or 14 . The horizontal rods 28 are secured to the vertical rods 24 through welding. More specifically, the horizontal rods 28 are positioned on the interior side of the vertical rods 24 so as to protect the welding joints from the sideways thrust which occurs during the pour of the concrete between the two side wall panel structures 12 and 14 as will be explained hereinbelow in more detail.
The top and bottom edge portions 30 and 32 of each panel 12 or 14 are configured for complementary engagement. More specifically, the top and bottom edge portions 30 and 32 are provided with grooves 34 and 36 positioned on opposite sides in a complementary way. Other engagement means, including tongues and grooves can alternatively be provided on the top and bottom edge portions 30 and 32 .
When the top and bottom edge portions 30 and 32 of the panels 12 - 14 are flat, fastening means can be used to assemble modules 10 on top of each other.
The panels 12 and 14 are made of low density plastic foam having a high insulating ability such as polyurethane and expanded or extruded polystyrene. Other materials can also be used. Moreover, as will be explained and illustrated hereinbelow, the two panels 12 and 14 need not to be made from the same material.
Each panel 12 or 14 is rectangular in shape and extends along a given height (h) and a given length (l).
The thickness of each panel 12 and 14 may vary depending on the applications, its material, its insulating ability, the strength of the material, the surface of the panel, etc.
Each panel 12 or 14 is molded with the grid 18 so positioned therein that the stand-out portions 26 extend therefrom for receiving the connecting rods 16 as will now be explained. More specifically, the stand-out portions 26 extend from their respective panel 20 and 22 from a distance sufficient to allow the rods 16 to freely pivot thereabout. The extending length is however kept to a minimum so as to provide stiffness to the module 10 .
The connecting spacer rods 16 are in the form of elongated metal plates having bended longitudinal ends defining hook portions 35 for receiving the stand-out portions 26 of the grid 18 . The metal plates 16 are so bended as to yield the hooks 35 on opposite sides thereof, resulting in a more secured attachment between the two panels 12 - 14 .
As illustrated in FIGS. 3 and 4 , the two side wall panel structures 12 and 14 are movable between a retracted parallel relationship (illustrated in FIG. 3 ) to a spaced apart parallel relationship (illustrated in FIG. 4 ) (see arrow 38 ).
While in the retracted parallel relationship, the module 10 is easily transportable and can be stored or transported without taking too much space.
The module 10 can be easily extended and assembled with other similar modules to provide a concrete wall formwork. The connecting rods 16 allow to readily position the two side walls defined by the side wall panel structures 12 and 14 at the predetermined distance. Therefore, no measuring is required on the premises to set the appropriate distance between the two walls 12 and 14 . Of course, the module 10 can be modified and more specifically the connecting rods 16 can be sized for a specific formwork application.
Even though only two connecting rods 16 are sufficient to maintain the parallel relationship between the two side wall panel structures 12 and 14 , a person skilled in art would appreciate that the use of a plurality of connecting spacer rods 16 disposed regularly throughout the surface of the module 10 further allows maintaining the integrity of the concrete wall formwork module 10 during the sideways thrust which occurs during pouring of the concrete between the two side wall panel structures 12 and 14 .
Returning briefly to FIGS. 1 and 2 , an elongated fastening plate 40 extends along the width of each side wall panel structures 12 and 14 parallel to the horizontal rods 28 . The plate 40 includes a flange for securing the plate 40 on the top portion of the grid 18 in a snap fitted way. The fastening plate 40 can also be secured to the grid 18 using fasteners or other fastening means.
Even though the module 10 has been illustrated with a grid 18 having stand-out portions 26 on the vertical rods 24 , a person skilled in the art will appreciate that the horizontal rods can alternatively be shaped to include stand-out portions.
The assembly of a plurality of modules 10 in a formwork and their use to receive concrete will now be explained in more detail with reference to FIGS. 5 to 8 .
As illustrated in FIG. 5 , two adjacent modules 10 on a same row are abutted. Then they are secured to one another by attaching adjacent pairs of stand-out portions 26 , one from each module 10 , using tie wires.
Two adjacent modules 10 and 10 ′ on two different rows are connected through their top and bottom end edge portions 30 and 32 . More specifically, as described hereinabove, the complementary grooves 34 and 36 are joined. Two adjacent modules 10 and 10 ′ are also secured to one another by attaching adjacent pairs of stand-out portions 26 , one from each module 10 and 10 ′, using tie wires (not shown).
Of course, all the modules 10 and 10 ′ are then fully extended and their first and second side wall panel structures 12 and 14 are in their spaced apart relationship. It is to be noted that the modules 10 ′ are identical to the modules 10 . A different numeral reference is used to enlighten the fact that they are located on the second row and thus are distinct modules.
The assembly of the concrete wall formwork module 10 and 10 ′ in two parallel formwork walls is done similarly to the assembly of a brick wall: the modules 10 ′ on the second row are so positioned that the lateral joints 39 between two adjacent modules are not aligned with similar lateral joints 41 between two adjacent modules from the first row. The same principle of course applies for any two consecutive rows. Of course, a person skilled in the art would appreciate that at least one concrete wall formwork module 10 or 10 ′ from at least one out of two consecutive rows is of a different width than the others. This narrower module is either manufactured narrower or cut to the required width.
A concrete wall formwork corner element 42 according to a first illustrative embodiment of the present invention is provided at the intersection of two perpendicular rows to close the formwork and obviously restrain concrete 43 therein. The corner element 42 will now be described in more detail with references to FIGS. 5 to 8 .
The corner element 42 includes an L-shaped grid 44 embedded in an L-shaped insulated foam panel 46 . Similarly to the grid 18 ′, the L-shaped grid 44 includes a series of vertical rods 48 and a series of horizontal rods 50 secured to the vertical rods 48 . An L-shaped support corner 52 is secured to the external side of the corner of the grid 44 . The horizontal rods 48 are so shaped as to define stand-out portions 54 at the intersection of the two walls defined by the L-shaped foam panel 46 . The stand-out portions are so configured and sized so as to extend from the foam panel 46 .
Each of the two lateral side arm portions of the L-shaped grid 44 ends with a protruding portion 56 which extends out of the foam panel 46 parallel thereto. Each of the two lateral edges of the grid 48 , which are defined by the extremities of the protruding portions 56 , receives an elongated fastening plate 58 , similar in structure to the elongated fastening plate 40 . The fastening plates 58 allow securing adjacent modules 10 or 10 ′ thereto by providing a surface to receive fasteners 57 . Washers 59 are further used to limit the penetration of the fastener 57 in the module 10 or 10 ′ as it is well known. The fastening plates 58 are welded to the protruding portions 56 of the grid 48 . Other securing method can of course be used.
The top and bottom edge portions 60 and 62 of the corner element 42 are also configured for complementary engagement. More specifically, the top and bottom edge portions 60 and 62 are provided with grooves 34 and 36 positioned on opposite sides in a complementary way and for complementary engagement with the top and bottom edge portions 30 and 32 of the module 10 and 10 ′.
The corner element 42 is further secured to each pair of adjacent intersecting modules 10 or 10 ′ by the use of a series of parallel transversal corner rods 61 . Each corner rod 61 has one of its longitudinal ends is mounted to a stand-out portion 54 of the L-shaped grid 44 . The other longitudinal end of each corner rod 61 is secured to an angle iron 65 mounted to both adjacent modules 10 or 10 ′ at the intersection thereof using fasteners 67 in the form of screws. Other fasteners can also be used.
The rods 61 are provided with widening ball portions 63 at predetermined position along its length. The corner portion of the angle iron 65 includes engagement slots 69 for receiving a ball portion 63 of the rod 61 . Each engagement slot 69 includes an enlarged portion for allowing passage for the ball portions 63 and an elongated portion for receiving the narrower portion of the rod 61 as it is believed to be well known in the art.
The plurality of ball portions 63 on a single rod 61 make them adaptable for corner elements and corresponding modules having different geometries.
Of course, the number or gap between each corner rods 61 may vary.
The angle iron 65 can be removed when the formwork is complete.
As illustrated in FIG. 6A , a concrete wall formwork corner element 42 A according to a second illustrative embodiment of the present invention is provided at the intersection of two rows defining a 135 degrees angle between them. Since the corner element 42 A is very similar to the corner element 42 , only the differences between these two corner elements will be described herein in more detail.
The corner element 42 A, including its inner mesh and its foam panel is so shaped as to define a 135 angle. The iron angle 65 is replaced by a similar 135-degrees corner plate 65 A.
A concrete wall formwork module 64 according to a second illustrative embodiment of the present invention will now be described with reference to FIGS. 9-10 . Since the module 64 is very similar to the module 10 , and for concision purposes, only the differences between the two modules 10 and 64 will be described herein in more detail.
The concrete wall formwork module 64 comprises first and second side wall panel structures 12 and 14 and a plurality of connecting spacer rods 66 for hingedly interconnecting the first and second side wall panel structures 12 and 14 .
The connecting spacer rods 66 are in the form of elongated rectangular wire frames having their longitudinal ends folded up towards each other so as to define two hinges 68 with respective stand-out portions 26 of the grid 18 .
The connecting spacer rods 66 allow providing stability to the module 64 along the horizontal axis. Also, as illustrated in FIGS. 11A-11B , the two side wall panel structures 12 and 14 are made movable by hinges 68 between a retracted parallel relationship (illustrated in FIG. 11A ) and a spaced apart parallel relationship (illustrated in FIG. 11B ).
FIGS. 12 and 13 illustrate two alternative methods to the corner element 42 to create closed junctions between two intersecting concrete wall formwork modules according to the present invention. Even though, the present method of assembly will be described with reference to the modules structurally identical to the module 64 , it can also be used to assemble other concrete wall formwork modules from the present invention as will be described furtherin.
In FIG. 12 , two modules 70 are joined perpendicularly forming a 90 degrees corner. The modules 70 are identical to the modules 64 with the exception that one of the two side wall panel structures 72 and 74 is shorter than the other. This allows perpendicularly abutting the two modules 70 and still yielding a continuous canal 76 for receiving concrete (not shown).
Connections between the two modules 70 and integrity of the corner assembly is provided 1) by attaching the facing pair of stand-outs 77 (each pair including a stand-out from each module 70 ) located near the actual intersection of the two modules 70 using tie wire 75 , and 2) by securing an angle iron 79 at the intersection of the two modules 74 opposite the stand-outs 77 outside the channel 76 .
FIG. 13 illustrates the assembly of two modules 78 into a 135 degrees corner. This assembly is achieved by providing modules 78 structurally similar to the modules 64 and 74 but having the following differences: 1) one of the two side panel structures 80 and 82 is shorter than the other, and 2) the two longitudinal ends 84 and 86 of both side panel structures 80 and 82 defines a 67.5 degrees with the plane defined by the panels 80 and 82 . Thereby, abutting the two longitudinal ends 84 and 86 of a first module 78 with the respective longitudinal ends 84 and 86 of another module 78 results in a 135 degrees corner. Of course, a corner defining another angle can be achieved by providing side panel structures having longitudinal ends defining half that angle.
As described with reference to FIG. 12 , connections between the two modules 78 and integrity of the resulting corner assembly is provided 1) by attaching the facing pairs of stand-outs 87 (each pair including a stand-out from each module 78 ) located near the actual intersection of the two modules 78 using a clip 85 , and 2) by securing an elongated 135-degrees angled corner plate 89 at the intersection of the two modules 78 opposite the stand-outs outside the channel formed thereby.
FIGS. 14-16 illustrate a concrete wall formwork module 88 according to a third illustrative embodiment of the present invention. Since the module 88 is similar to the module 64 , and for concision purposes, only the differences between the two modules 64 and 88 will be described herein in more detail.
The concrete wall formwork module 88 comprises first and second side wall panel structures 90 and 92 and a plurality of connecting spacer rods 66 for hingedly interconnecting the first and second side wall panel structures 90 and 92 .
Each side wall panel structures 90 and 92 includes a metallic wire grid 18 and a respective panel 94 and 96 so mounted thereon that the grid 18 is positioned on the exterior side surface of the panel 94 or 96 .
The panel 94 is a rigid panel of wood, made for example of presswood, laminated wood, or cement fiberboard, just to name a few.
The panel 96 is a low density plastic foam panel similar to the panels 20 and 22 .
Both panels 94 and 96 include respective slots 98 and 100 for receiving the stand-out portions 26 of the grids 18 . The panels 94 and 96 are secured to their respective grid 18 by positioning the spacer rods 66 .
FIG. 16A illustrates the first and second side wall panel structures 90 and 92 fully extended in a spaced apart relationship. FIG. 16B illustrate the first and second side wall panel structures 90 and 92 in a retracted relationship.
Of course, the present invention allows many types and combination of board panels to be mounted to the grid 18 .
A person skilled in the art will appreciate that the grids 18 of the side wall panel structures 90 and 92 of the module 88 can be further used as fixation boards whereby construction elements, such as brick's strip, crepidoma, stucco, bushing (all not shown), can be attached thereon since it is not embedded in the panels 94 and 96 .
Of course, the concrete wall formwork corner element 42 can be adapted to complement the module 88 . Such corner element (not shown) would include two panels mounted on an L-shaped grid.
FIGS. 17 and 18 show two concrete wall formwork modules 102 and 104 respectively according to fourth and fifth embodiments of the present invention.
Since both modules 102 and 104 are very similar to the module 88 , only the differences between these respective modules and the module 88 will be described herein.
The concrete wall formwork module 102 comprises two side wall panel structures 90 and a plurality of connecting spacer rods 66 for hingedly interconnecting the two side wall panel structures 90 .
Each side wall panel structures 90 and 92 includes a metallic wire grid 18 and a panel 94 so mounted thereon that the grid 18 is positioned on the exterior side surface of the panel 94 .
The concrete wall formwork module 104 comprises two side wall panel structures 92 and a plurality of connecting spacer rods 66 for hingedly interconnecting the two side wall panel structures 92 .
Each side wall panel structures 92 includes a metallic wire grid 18 and a panel 96 so mounted thereon that the grid 18 is positioned on the exterior side surface of the panel 96 .
In FIG. 19 , two modules 106 are joined perpendicularly so as to form a 90 degrees corner assembly. The modules 106 are identical to the modules 104 with the exception that the side wall panel structure 108 is shorter than the side wall panel structure 110 or 110 ′. This allows perpendicularly abutting the two modules 106 and still yielding a continuous canal 112 for receiving concrete (not shown). Moreover, the horizontal rods 113 of the side wall panel structure 110 of the module 106 are made longer on one side so as to extend beyond the panel 114 for a distance sufficient to act both as support and as a longitudinal end stop for the side wall panel structure 110 ′ of the module 106 .
Connections between the two modules 106 and integrity of the resulting corner assembly are provided by 1) attaching the facing pair of stand-outs 115 located near the actual intersection of the two modules 106 using a clip 111 , and 2) by securing an angle iron 117 at the intersection of the two modules 106 opposite the stand-outs 115 outside the channel 112 .
FIG. 20 illustrates the assembly of two modules 116 into a 135 degrees corner. This assembly is achieved by providing modules 116 structurally similar to the modules 104 but having the following differences: 1) the side panel structure 118 is shorter than the side panel structure 120 , and 2) the two longitudinal ends 122 and 124 of both side panel structures 118 and 120 defines a 67.5 degrees with the plane defines by the panels 118 and 120 . Thereby, abutting the two longitudinal ends 122 and 124 of a first module 116 with the respective longitudinal ends 122 and 124 of another module 116 results in a 135 degrees corner. Of course, a corner having another angle can be provided by providing side panel structures having longitudinal ends defining half that angle.
As described with reference to FIG. 19 , connections between the two modules 116 is provided 1) by attaching facing pairs of stand-outs 126 located near the actual intersection of the two modules 116 using a clip 125 , and 2) by securing an elongated 135-degrees angled corner plate 89 at the intersection of the two modules 116 opposite the stand-outs outside the channel formed thereby.
The assembly of formwork 128 will now be further described with reference to FIG. 21 .
The formwork 128 comprises a plurality of concrete wall formwork modules 10 assembled as described with reference to FIG. 5 . The use of scaffolding 130 , including erecting beams 132 , allows to vertically leveling the formwork 128 in additions to serve as working platform for workers (not shown).
Aligning beams (not shown) can also be used for vertically aligning leveling the formwork.
The erecting beams 132 are secured to the modules 10 via their respective fastening plate 40 (not shown in FIG. 21 ). In cases where the formwork is assembled from concrete wall formwork module from the present invention wherein the grid is not embedded into the panel, the erecting beams 132 can be secured directly to the grid.
The scaffolding 130 further includes telescopic poles 134 for aligning the wall 128 . The poles 134 are further provided with fine adjustment means operable by rotation of the poles 134 .
As mentioned hereinabove, the formwork 128 is erected similarly to a brick wall. For example, the modules 10 on the second row are so positioned that the lateral joints 39 between two adjacent modules are not aligned with similar lateral joints 41 between two adjacent modules 10 from the first row. The same principle of course applies for any two consecutive rows.
Even though the formwork 128 is illustrated comprised of modules 10 , other concrete wall formwork modules according to the present invention can also be used.
According to the present invention, tie wires, clips tie-rods or any fasteners can be used for attaching pairs of stand-outs while securing two adjacent modules.
The panels of the side wall panel structures are not limited to the materials described hereinabove. They can also be made without limitations of counterveneer, plasterboard, particle board, and any insolating plastic material. Also, as it has been described herein, any combination is also possible.
It is to be noted that a concrete wall formwork module according to the present invention can be provided with grids having different geometries than the one described herein. For example, the profile of the lugs may differ. They can have, for example, a rounded profile. Also, they can be made of independent pieces secured to the grids.
The general configuration of the grid may also differ from the orthogonal configuration illustrated. Also, the grid is not limited to the wire type.
The grid can be made of any metal, or of any composite material.
Even though the side wall panel structures of the concrete wall formwork modules form the present invention have been described as being rectangular, they can have other configuration.
Also, the two side wall panel structures of a single module can have different geometries.
Even though the lateral side edges of the panels have been illustrated as being flat, they can be provided with tongues-and-grooves or with any other complementary cooperating means.
Although the present invention has been described hereinabove by way of illustrated embodiments thereof, it can be modified without departing from the spirit and nature of the subject invention, as defined in the appended claims.
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A concrete wall formwork module comprising a first side wall panel structure including a first grid and a first panel secured to the first grid, a second side wall panel structure including a second grid and a second panel secured to the second grid, and connecting rods having about a same length hingedly interconnecting the first and second side wall panel structures to allow movement thereof between a retracted parallel relationship to a spaced apart parallel relationship. A plurality of such concrete wall formwork modules allow assembling a formwork which is functionally similar to conventional formwork since the facing side wall panel structures are connected in a parallel relationship by the thin spacer connecting rods which allow concrete to freely travel within the formwork. When the first and second side wall panel structures are in the retracted parallel relationship, the concrete wall formwork module is more compact and therefore easier and less costly to transport.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. Pat. application Ser. No. 07/677,142, filed on Mar. 29, 1991, entitled METHOD AND APPARATUS FOR GENERATING CALIBRATION INFORMATION FOR AN ELECTRONIC ENGINE CONTROL MODULE, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to electronic engine control systems, and more particularly to systems and methods of calibration of electronic engine control systems.
Field-programmable electronic engine control systems have enabled product enhancements to be made at a greatly reduced cost. One generic control module can be reprogrammed for many different applications, e.g., different engine ratings, without any changes to the physical configuration of the module. This concept is discussed in a paper by Lannan et al. entitled "Cummins Electronic Controls for Heavy Duty Diesel Engines," IEEE 88 CH2533-8, presented at tile International Congress on Transportation Electronics, Convergence 88, Dearborn, Michigan, Oct. 17-18, 1988, and in a paper by Stamper entitled "A Second Generation Approach to Service of Electronic Systems," SAE Paper No. 891681, presented at the Future of Transportation Technology Conference and Exposition, Vancouver, British Columbia, Canada, Aug. 7-10, 1989.
Various memory organization techniques have been suggested, making use of RAM, EPROM, EEPROM, or NVRAM, as illustrated by the following patents:
______________________________________Patent No. Inventor Issue Date______________________________________4,677,558 Bohmler et al. Jun. 30, 19874,751,633 Henn et al. Jun. 14, 19884,908,792 Przybyla et al. Mar. 13, 1990______________________________________
While field programmability is recognized as a highly desirable feature, there remains a need for more efficient and secure techniques for distributing new software, as well as a need for improved techniques for generating software to support new engine ratings and the like.
SUMMARY OF THE INVENTION
The present invention overcomes these and other disadvantages of the prior art with a method and apparatus for generating calibration information in which a subfile type is defined for each of a plurality of categories of data, and a separate subfile is created in memory for each of a plurality of individual sets of data in each of the data categories. Each subfile is automatically assembled, with data entries automatically verified based on rules stored in memory in a rules file. A compatibility file is created in memory to identify subfiles of one type which are compatible with a subfile of another type. Each subfile and the compatibility file are distributed individually via an electronic communication link to multiple service computers programmed to determine compatibility among selected subfiles based on information stored in the compatibility file and to assemble compatible subfiles into a calibration file for a particular engine control module.
It is a general object of this invention to provide an improved method and apparatus for generating calibration information for an electronic engine control module.
A further object of the invention is to provide an improved technique for generation of software to support changes in engine ratings and the like.
Yet another object of tile invention is to provide an improved system of distributing control module software to the field.
These and other objects and advantages of the present invention will be more apparent upon reading the following detailed description of the preferred embodiment in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the development and distribution of calibration files according to the preferred embodiment of the present invention.
FIG. 2 is a block diagram illustrating the calibration file and subfile relationship for the preferred embodiment of the present invention.
FIG. 3 illustrates the memory organization in an engine control module for the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
With reference to FIG. 1, a software development tool 10, which may be a personal computer (PC), is used to develop subfiles which are used to form a file of application-specific calibration information for an electronic control module (ECM) 20. Each ECM 20 contains a ROM, which stores the primary executable code for control of the ECM, and an EEPROM, which is divided into a ROM-independent area and a ROM-dependent area, and which is programmed remotely with the calibration information via a serial data link.
The subfiles mentioned above are developed in conjunction with the development of new or changed engine or fuel system ratings and, according to one aspect of the present invention, are directly generated by engine developers or fuel system developers without the involvement of software engineers. For example, in the case of a new engine torque requirement, an engine developer develops new torque curve data and, through the development tool, reprograms an ECM with the new data and then performs engine tests with the reprogrammed ECM to validate the changes.
The development tool uses a configuration file to determine how to change data in the control module. The configuration file contains information about each item in the control module that can be monitored or calibrated and provides the information that defines the compatibility situation for items in the calibration. More specifically, the file contains a record which defines, first of all, how to label the data: A unique 8-character name is assigned to each piece of data. The record also defines how to scale and display data. That is, it specifies the number of bytes per data item, the units to be associated with the data, the decimal location when the data is printed, the scaling information directly or indirectly, and the level of authorization needed to change the data.
The configuration file also identifies whether the data desired is available. Each data item record has information about the version of control module and/or calibration in which it is available. This record provides support for backward compatibility. The file provides the user with text information for each data item to describe its meaning.
Two- or three-dimensional tables are identified by several records in the configuration file. These records can be associated with a particular Y or Z data table and then displayed for the user. Several key table characteristics are defined by these records:
1) X and/or Y axis breakpoint tables;
2) Y and/or Z data tables (surface data);
3) X, Y and Z scaling information which can normalize different data ranges to one range for display. For example, 0-255 can correspond to 0-3000 RPM. The normalized range can be scaled with information from the configuration file to cover the desired range for the particular type of data.
The configuration file also defines how to group records into subfile types and how to group records pertaining to one function. Subfile grouping puts data pertaining to a specific engine rating or other engine control data into one subfile type while other data such as that which is specific to an electronic dash or other vehicle interface data would be grouped into different subfile type. Each record contains information which allows it to be grouped with one specific function. For example, one group might be for all of the records in the configuration file associated with cruise control. One group can contain information that can be monitored and calibrated.
The authorization level for each item in the file is also defined. This gives each item a unique user-authorization level require before a user can change the data item.
The ability to support many revisions of one product through the use of one configuration file is an important concept. One of the major goals of this strategy is that all revisions of the product be backward compatible with all previous records in a configuration file.
A CRC assures the integrity of the configuration file before it is used by the software development tools. If the check passes, the file is available for use; otherwise, no operation by the tool can be performed.
Subfiles are created using a unique file format with line checksums and a complete file cyclic redundancy check. They are also provided with time and date information taken from the configuration file. This information is later used to determine what versions of control module are supported by this subfile. Also embedded in the subfiles are an indicator of subfile type and a subfile authorization level.
Subfiles are released only if the data contained in them pass checks made regarding formal guidelines and if the data pass rule checks that verify the data values and interrelationships between data items within one subfile. Some data items are set to default values before release.
Subfiles are uploaded to a mainframe computer 12 in an engine manufacturing plant or design facility after verification that they can be assembled with other subfiles to make a complete calibration. Once a subfile has been through this process, it is marked accordingly and the subfile authorization level is set. Subfiles are labeled with a seven-digit part number and then encoded (compacted for upload) prior to upload to the mainframe. Subfiles uploaded to the mainframe are accompanied with appropriate release documentation, a manual paperflow process.
Several operations are performed on the subfiles uploaded to the mainframe and, once available for release, the subfiles are distributed via phone lines 13 or otherwise to various locations such as engineering, service, manufacturing and end-customer sites. First, compatibility information must be defined and a determination made of what subfiles can be put together to form a calibration for a given engine family (10 liter, 14 liter) and engine rating (350 horsepower at 2100 rpm). The compatibility information must be pulled together, put into a file and distributed to PCs 14 at end-customer and service locations. These compatibility files are downloaded to customer PCs on a regular basis reflecting the latest configurations available. The files are distributed to the appropriate authorization level locations. Some files may only be used for field test, experimental or developmental reasons. Only the latest revision of a subfile is normally available. To retrieve an older revision, special action must be taken.
File security and protection against accidental and/or intentional changes are provided in several ways. The following methods of protection are for those files residing in storage on a service PC 14. First, files encoded before distribution to the PC are put in a download directory and decoded. Once a received file has been verified by decoding and checking its CRC and authorization level, the file is stored in a predetermined product directory in PC 14. FIG. 2 shows six types of subfiles which correspond to the following categories of data:
______________________________________Subfile type Category of data______________________________________N engine control dataN - 1 engine family dataN - 2 vehicle interface data3 software sequencing data2 electronic configuration data1 memory configuration data______________________________________
The configuration file used to create files for upload is not available for service locations at predefined authorization level. Therefore, the PC software that performs the editing function is not supplied to this predefined authorization level user. These two situations make it extremely difficult for people at service locations to tamper with the data in these files.
The file formats used have been uniquely designed for this application. They contain unique record types defined for this application, and twos complement line checksums for each line of the file. Date stamps help determine compatibility with control module ROM re]eases. This information is also used to verify that a given set of files is capable of being assembled together to form a calibration. All subfiles must fall inside the range of dates associated with a given control module ROM release in order to be assembled together. File type identifiers are used to associate rules files for verification of the data in a particular subfile and to assure that one each of the required file types is used in an assembled calibration. Subfiles are encapsulated with a custom CRC checksum. A unique algorithm is used to complete the CRC attached to each file. These CRCs are checked prior to allowing the file to be used.
The calibration assembler software in the service computer 14 performs many checks to verify an assembled calibration file. The calibration file is left available for use only if all the checks pass successfully. The calibration assembler attaches calibration loading instructions for an associated service/recalibration tool 16 to use. The process is illustrated in FIG. 2: PC 14 assembles subfiles (block 22) to form a calibration (block 24), adding load instructions (block 26) to produce a complete file (block 28). Calibration files created by the calibration assembler are not stored for future use. Each assembly process clears the previous result to assure that if a particular calibration is desired it will be assembled with the latest revision level of subfiles. Only the latest revision level of subfiles are available on the PC. The file format for the calibration file is based on a unique format that is expected by the service/recalibration tool. The file is also encapsulated by a CRC checksum. The calibration file format used for files being sent to the service/recalibration tool contains the following characteristics:
1) CRC over the entire file;
2) ASCII decimal data which relays the control module loading instructions; and
3) binary data representing the calibration data to be put into the control module memory.
The calibration file is transferred over an RS232 connection 15 from service PC 14 to service/recalibration tool 16. At the end of the transfer, the service/recalibration tool verifies the process by validating the CRC on the calibration file received. The tool checks the calibration file format (CRC, load instructions and calibration data), as well as the control module ID. If the CRC is validated, the process was successful.
The service/recalibration tool is connected to control module 20 via data link 17 when the control module is to be calibrated or recalibrated. Tool 17 programs the control module using SAE J1708 data link interface standard and a unique protocol. The protocol employs a 10-character security handshake that changes for each secure message. The recalibration tool and the ECM are provided with matching security algorithms designed to prevent the deciphering of the security scheme simply by monitoring data link messages. According to the algorithms, the passwording is modulated by a continuously changing value which, therefore, produces a password that appears different for each secure control module operation. In order for the control module to perform the requested operation, the security algorithm checks must pass. Also, per-message checksums must be valid. In addition, specific control module loading instructions must be followed to calibrate the control module successfully. EEPROM validation checks are also performed.
One of the important operating assumptions the service/recalibration tool follows is that it will only correct control module EEPROM checksum errors if it knows why they exist. If the reason is not known, the correction will not be attempted. The procedure includes the following steps:
1) check control checksum;
2) install footprint;
3) processes header records (part 1);
4) load calibration data;
5) process header records (part 2);
6) verify every byte of calibration data in the control module with that in the recalibration tool; and
7) clear the footprint.
The above Header Records provide the capability for the calibration assembly tools to give instructions to be used during calibration load of control module. The first level of record defines whether the operation should be performed on all, first time calibration loads or on non first time initial loads. The next level of record indicates how the particular header record should be used. These uses include:
Save and Restore--This means the calibration loading tool should read a given set of information from the control module before loading the calibration and then restore this information after the process is complete. Example uses of this record type are for control module serial number, engine serial number, vehicle identification information, etc.
Update after calibration load--This record is used to program in some information after the calibration has been loaded into the control module. Example uses of this record are to store the calibration part numbers into an electronic data plate, reset specific nonvolatile memory information such as engine run time, etc.
Compare for equal, not equal, greater than, or less than--The compare capability allows for certain checks to be performed before the calibration is loaded into the control module. These checks can use the logic expressions just mentioned to So checks before loading calibrations possibly to limit the calibration to be able to be used with one specific control module and engine serial number.
The calibration header records have a third level record which identifies how many times a specific calibration is allowed to be loaded. This capability allows the calibration assembly device to specify how many times a specific calibration can be loaded before the file should be destroyed.
The procedure attempts to minimize the chance of a control module failure caused by an invalid EEPROM which is the result of a failed recalibration procedure. This is done by inserting an identifier (footprint) into EEPROM at the start of the EEPROM change process. Then if the process is interrupted, the service/recalibration tool recognizes that it is the device performing the changes and will recalibrate the control module to correct the situation. The footprint is stored in a nonchecksummed area of nonvolatile memory.
The control module in the uncalibrated state delivered from the supplier must have a factory test pattern which is used to verify that the module passed the pertinent factory tests. If for some reason a factory test fails, the control module will not be loaded with the factory test pattern. Therefore, when the calibration loading device begins its process to calibrate tile control module, it will verify that either the test pattern or a calibration loading device footprint is there before it will attempt to perform its process of recalibration. This process puts a valid calibration and checksum into the control module.
The control module will perform checks on its EEPROM memory to see if it may be used. The control module will not correct its own EEPROM checksum if it is in error. This ensures that the control module has a valid EEPROM at all times. If for some reason EEPROM changes and the checksum becomes invalid, the control module will not allow the engine to run from a poweron condition.
Referring now to FIG. 3, the memory in the ECM includes a ROM 30 and an EEPROM 32, with the EEPROM divided as shown into a ROM-independent area and a ROM-dependent area. The ROM contains a number of stored routines which can be addressed by a microprocessor (not shown) based on pointers stored in corresponding routine lists in the EEPROM. The EEPROM includes an index table containing pointers to corresponding locations elsewhere in the EEPROM, either in a ROM-independent area A (sequence table 1 and fuel map 1) or in a ROM-dependent area B (routine list, patch, and diagnostic and other nonvolatile data). Functions or data in the EEPROM are addressed from ROM-based routines by reference to an index table location assigned to store the address of the desired function or data. Similarly, addresses of memory locations in the routine list are contained in memory locations in a sequence table, whereby routines residing in ROM can be executed in a desired order, such as routine 3, 1 and then 4 in the example of FIG. 3.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A method and apparatus for generating calibration information in which a subfile type is defined for each of a plurality of categories of data including (1) engine control data, (2) engine family data, (3) vehicle interface data, (4) software sequencing data, (5) electronic configuration data, and (6) memory configuration data. A separate subfile is created in memory for each of a plurality of individual sets of data in each of the data categories. Each subfile is automatically provided with line checksums, a cyclic redundancy code, date information, a subfile type identifier, and a subfile authorization level, and data entries are automatically verified base on rules stored in memory in a rules file, each of the subfile types having an associated rules file, and each of the rules files defining criteria for individual data items and for interrelationships between data items in its associated subfile type. A compatibility file is created in memory to identify subfiles of one type which are compatible with a subfile of another type. Each subfile and the compatibility file are distributed individually via an electronic communication link to multiple service computers programmed to determine compatibility among selected subfiles based on information stored in the compatibility file and to assemble compatible subfiles into a calibration file for a particular engine control module.
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RELATED APPLICATION
This application is a continuation of U.S. Application Ser. No. 875,334, filed June 17, 1986, now U.S. Pat. No. 4,837,049, whose disclosure is, by reference, incorporated herein.
BACKGROUND
The invention relates to electrodes employed for electrically sensing or stimulating biological tissues. In particular, the invention relates to two dimensional electrode arrays and to methods for making and using such electrode arrays. The electrode array is particularly useful for making multiple electrical contacts at the cellular level, for electronically discriminating amongst individual cells or small groups of cells within a tissue or organ, and for directing electrical signals to or from such individual cells or small groups of cells within such tissue or organ, especially neural tissues and organs.
A nerve is a cordlike structure which is composed of numerous nerve fibers conveying impulses between a part of the central nervous system and some other region of the body. A nerve is made up of individual nerve fibers with their sheaths and supporting cells, small blood vessels, and a surrounding connective tissue sheath. Each nerve fiber is surrounded by a cellular sheath (neurilemma) from which it may or may not be separated by a laminated lipo-protein layer (myelin sheath). A group of such nerve fibers surrounded by a sheet of connective tissue (perineurium) is called a fasciculus. The fasciculi are then bound together by a thick layer of connective tissue (epineurium) to form the nerve.
Neurologists have long sought an electrode device which could establish stable electrical contact with a large number of individual nerve fibers within a nerve. Such a device would find wide medical application for sensing neurological impulses, facilitating the analysis and interpretation of such impulses, and delivering electrical stimuli to target nerve fibers as a reaction to such analysis or as a result of external input. The ideal electrode device would be adapted to the anatomy of the nerve so that it could penetrate the nerve in a nondestructive fashion in order to form focused electrical contacts with a very large number of individual nerve fibers.
Nerve cuff electrodes are employed in the neurological sciences for sensing nervous impulses and for electrically stimulating nerves The nerve cuff electrode encircles the entire nerve and senses gross nervous impulses arising from the nerve fibers within the nerve. The nerve cuff electrode may also be employed to electrically stimulate the nerve. Individual nerve fibers within a nerve may be functionally distinct from the other nerve fibers. The utility of the nerve cuff electrode is limited by its inability to specifically direct signals to or from selected nerve fibers within the nerve.
In order to make electrical contact with individual nerve fibers within a nerve, narrow gauge needle electrodes may be employed. When a narrow gauge needle is inserted into the nerve, there is a chance that it may make electrical contact with an individual nerve fiber or a small number of such fibers. If electrical contact is desired with each of several nerve fibers, then several needle electrodes must be employed. However, the technique of using multiple needle electrodes becomes progressively more and more difficult as the number of electrodes increases. Hence, there is a limit to the number of needle electrodes which can be usefully employed on a single nerve. Also, the electrical contact between a needle electrode and its corresponding nerve fiber can be disrupted by muscle motion and other forms of motion, since the end of the needle opposite the electrode extends outside the nerve and can be levered by relative motion of neighboring tissues. Therefore, long term implantation of needle electrodes with stable electrical contact with nerve fibers is not possible with prior art needle electrodes.
An electrode array having several electrodes integrated into one device is disclosed by Robert L. White. (Proceedings of the first International Conference on Electrical Stimulation of the Acoustic Nerve as a Treatment for Profound Sensorineural Deafness in Man, published by Velo-Bind, Inc. (1974), edited by Michael M. Merzenich, et al., chapter entitled "Integrated Circuits and Multiple Electrode Arrays," pp. 199-207, by Robert L. White) White's electrode array employs a prong shaped base fabricated from a silicon wafer. The silicon base supports an array of electrodes which are deposited thereon toward the end of the prong. Each of the electrodes is small, flat, and circular, about 50 micrometers in diameter. Each electrode is connected to a corresponding conductor which carries signals to and from the electrode. The conductor is electrically insulated from the tissue by a layer of silicon dioxide. In use, the prong is inserted tip first into neural tissue. Neural tissue is displaced by the prong as it is inserted. Substantial damage to neural tissue can result from the insertion process due to the relatively large bulk of the prong. Since neural tissue slides tangentially past the electrodes during the insertion process, the flatness of the electrodes helps to minimize the resultant disruption and destruction of neural tissue. However, once the device is inserted, the flatness of the electrodes limits the contact between the electrode and the neural tissue. Flat electrodes can make electrical contact only with neural tissue which is directly adjacent to the surface of the prong.
Multiple electrode devices with micro electrode tips protruding beyond and in a plane parallel to a silicon carrier (i.e. planar electrodes) are disclosed by Wise et al. (IEEE Transactions on Biomedical Engineering, Vol. BME-17(3), pp 238-247, July 1970, "An Integrated Circuit Approach to Extracellular Microelectrodes," and Vol. BME-22(3), May 1975, "A Low-Capacitance Multielectrode Probe for Use in Extracellular Neurophysiology") and by Ko (IEEE Transactions on Biomedical Engineering, Vol. BME-33, pp 153-162 (Feb. 1986), "Solid State Physical Transducers for Biomedical Research"). Wise et al. teach that the lateral spacing and length of the protruding tips may be controlled to produce various planar electrode arrays. Like the White device, the silicon carrier of the Wise et al. and Ko devices have the shape of a prong and may cause significant tissue damage to the nerve during the insertion process. Also, if the Wise et al. and Ko prong-shaped devices are implanted, their large bulk compromises the stability of the electrical contact between the electrode tips and individual target cells. Additionally, the thinness of the prong can make it susceptible to shear damage with side loading. Further, since the silicon carrier and the electrode tips are essentially coplanar with the tips cantilevered freely beyond the end of the carrier, the carrier imparts little if any transverse stability to the fragile tips during insertion of the Wise et al. and Ko prong-shaped devices or after their implantation. Moreover, the number of useful electrodes which may be incorporated into the Wise et al. and Ko devices is inherently limited. Moreover, since the electrode tips are aligned in a row along the edge of the silicon carrier, it is not possible to array the electrodes into a configuration with more than one dimension.
Thus, what is missing from the prior art and what is needed by practicing neurologists is an implantable electrode device which can electrically contact a large number of individual cells within an organ or tissue for sensing and controlling various bodily functions. The individual contacts should each be focused within a small region so that they involve single cells only. However, the range of the contacts should extend over a relatively large two or three dimensional region within the organ or tissue. The electrodes of the device should make positive contact with target cells and should be electrically stable over long periods of time, even with recurrent movement in adjacent tissues. On the other hand, the device should be able to penetrate the target organ without being intrusive so that tissue damage to the target organ is minimal. The device should have a small volume and a robust construction for practical medical applications.
SUMMARY
The electrode array of the present invention is a device for establishing stable electrical contact with biological tissues. In the preferred embodiment, the electrode array has a configuration for making multiple extracellular contacts and for conducting electrical signals to or from each cell with which there is contact. However, the electrode array can also be employed for measuring the voltage potential of the surface of organs and tissues, e.g. for EKG or EEG.
The electrode array includes a base of semiconducting or nonconducting material having a support surface, a two dimensional array of conducting protuberances which extend substantially perpendicular to and from the support surface of the base and serve as electrodes, and conductors incorporated onto or in the base and connected to the protuberances for carrying electrical signals to and/or from such protuberances. The invention also includes various embodiments of the electrode array and methods for using and fabricating such electrode arrays.
In a preferred embodiment of the electrode array, the protuberances are coated with an insulating layer of dielectric material, except for their tips. This feature narrows and focuses the contact area of each protuberance to a relatively small region and facilitates the ability of the protuberance to contact single cells or small groups of cells. The average number of extracellular contacts per protuberance may be adjusted to one by adapting shape and height of the protuberances and the exposed surface area of the tips.
In an alternative embodiment, the electrode array is capacitive. In this embodiment, the entire length of the protuberances, including the tip, is covered with an insulating dielectric. Hence, each protuberance makes capacitive contact with cellular tissue.
In yet another embodiment which is particularly well adapted for establishing multiple electrical contacts with a large number of nerve fibers, a combination of two electrode arrays are employed to form a sandwich on either side of a nerve or target organ. The two electrode arrays are situated on opposing sides of the nerve with the protuberances facing toward the center. The two electrode arrays are then brought closer together until they both contact the nerve and the protuberances penetrate into the nerve for making electrical contact with individual nerve fibers. At this point the electrode arrays are joined together as for example by intermeshing protuberances from the arrays. The combination electrode array is then supported by the nerve to which it is clamped. Since electrical contact is made on both sides of the nerve, the sandwich electrode array will make approximately twice the number of electrical contacts as compared to a single electrode array. Also, electrical contact between the electrode array and the nerve is enhanced by the fact that the electrode array is supported by the nerve to which it is attached. Each of the electrode arrays within the sandwich may be either the conductive type or the capacitive type.
The invention also includes various biomedical applications for the different embodiments of the electrode array. The electrode array may be either implanted or attached to skin. An electrode array may be employed for measuring the voltage potential of individual cells or of the surface area of an organ. However, in the preferred application, the electrode array is surgically implanted for establishing long term electrical contact with multiple cellular elements of an internal organ or tissue. The implanted electrode array may either electrically stimulate individual cells within the target organ or may sense nervous impulses within individual cells. Under some circumstances, the electrode array may both sense and stimulate electrical activity. Also, the electrical activity may be amplified and/or analyzed. And finally, the stimuli may be electronically correlated with the activity of the target cells. Because the two dimensional array greatly increases the number of protuberance which may be incorporated into a single device, the complexity and redundancy of the protuberances is greatly enhanced. Consequently, it is possible to establish multiple electrical contacts with relatively complex biological systems.
The invention also includes various special procedures employed for the fabrication and subsequent use of the electrode array. Since several electrode arrays may be fabricated on a single wafer, it is useful to employ indexing cones which mark out the various electrode arrays. The indexing cones can have a shape which is similar to the protuberances, but are greater in height. After the electrode arrays have been deposited onto the wafer and the various subsequent steps have been completed, the indexing cones may be used as an index for guiding the sawing of the wafer into separate base pieces. The indexing cones may also be employed with the sandwich electrode array for aligning the two electrode arrays with one another and for controlling and limiting the proximity of opposing electrode arrays so as to avoid damaging the sandwiched nerve by exerting excessive pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one embodiment of the electrode array illustrating a semiconductor base, an array sharp protuberances arising from the base, and corresponding terminals. The array of sharp protuberances illustrate the concept of "bed of nails."
FIG. 2 is a schematic diagram of the electrode array of FIG. 1 illustrating the path of the individual conductors which electrically connect each protuberance to a corresponding terminal or bonding pad.
FIG. 3 is an enlarged view of a fragment of the electrode array of FIG. 1, illustrating the pyramidal shape of the protuberances and indicating typical dimensions for the height of the protuberances and the distance between adjacent protuberances.
FIG. 4 is a perspective view of a section of an alternative embodiment of the electrode array having conical protuberances illustrating a deposition mask attached to a metallic film atop the base for growing the conical protuberances.
FIG. 5 is a further schematic diagram of the electrode array of FIG. 1 illustrating the layout of the protuberances, terminals, and conductor.
FIG. 6 is a sectional view of the electrode array of FIG. 4 illustrating the relationship between the conical protuberances and the deposition mask.
FIG. 7 is sectional view of an alternative embodiment of the electrode array illustrating a protuberance having a dielectric coat covering the protuberance, exclusive of the tip.
FIG. 8 is a perspective view of two electrode arrays forming a sandwich on either side of a flattened nerve.
FIG. 9 is a sectional view of the two electrode arrays of FIG. 8 illustrating interdigitated protuberances penetrating a nerve from opposite sides and electrically contacting individual nerve cells.
FIG. 10 is a sectional view of Schwann cells enveloping unmyelinated nerve fibers illustrating the conductive tip of a protuberance from an electrode array lying in close proximity to a nerve fiber.
FIG. 11 is a sectional view of two myelinated nerve fibers having nodes of Ranvier illustrating the conductive tips of protuberances of differing heights from an electrode array lying in close proximity to said nodes.
FIG. 12 is a side plane view of an alternative embodiment of the electrode array having a monolithic base structure, protuberances, and several electronic devices.
FIG. 13 is schematic diagram of the electrode array of FIG. 12 illustrating the interconnections for outputting the signal of the protuberances. Included are a transmitter and receiver for transmitting signals between the protuberances and an external unit.
FIG. 14 is a sectional view of the fragment of two electrode arrays shown in FIG. 15 indicating the relative position of the opposing indexing cones.
FIG. 15 is a plane view of indexing cones from two opposing electrode arrays illustrating the aligning and vertical positioning of the two electrode arrays by means of the indexing cones.
DETAILED DESCRIPTION OF THE INVENTION
The invention is an electrode array which is to be applied to body tissue to provide an effective electrical connection therewith, whether for sensing or stimulating purposes. The electrode array provides a multiple possibility of successful electrical contact, and is intended to cause minimal damage to the body tissue or upset to the body system. The electrode array includes an array of conductive protuberances which serve as electrodes. The protuberances arise from a base and are connected by electrical conductors to terminals on the base. The terminals and conductors may be employed to connect individual protuberances or groups of protuberances of the electrode array to other electrical circuits.
If the electrode array is to be used for sensing low voltage body signals, an amplifier would likely be the first electrical circuit connected to the protuberances and/or terminals. Then, of course, the signals (information) may go on to be handled by analog or digital electronic methods and may involve transmission, multiplexing, filtering, data processing or other known electronic techniques. The particular use would determine the particular other electrical circuits to be used.
If the electrode array is to be used for electrically stimulating a tissue, the terminals would be connected to circuits which provide the output for the stimulation signals. The conductors would then carry these stimulation signals from the terminals to the corresponding protuberances.
FIG. 1 is a perspective view illustrating the concept of a "bed of nails," showing the protuberances and terminals. It is drawn to illustrate the concept of a base (1) having a support surface with protuberances (2) arising substantially normal therefrom with conductors (3) leading from the protuberances (2) to terminals (4). The terminals illustrated in FIG. 1 are bonding pads.
FIG. 2 is a more detailed view of FIG. 1 and illustrates the concept of connecting an array of protuberances (2) to an array of terminals (4) by means of conductors (e.g. 5 and 6).
FIG. 3 is a view of an array of protuberances in the shape of pyramids, illustrating the dimensions which may be involved. The protuberances, or needles, may, of course, be taller and narrower. Spacing may vary, as may the size of the protuberances. Of course, such protuberances may be conical or other elongated shapes.
FIG. 4 illustrates protuberances being grown through a mask onto a metallic film (9). The protuberances shown in FIG. 4 have the shape of cones or needles. Below the mask lies a sandwich which includes a silicon base (7), an insulation layer of silicon dioxide (8), and the metallic layer (9) upon which the protuberances are being grown. Above the metal layer (9) is a spacing layer (10). The spacing layer (10) may have a composition of silicon dioxide, photoresist, or other material. The spacing layer (10) is not required for all applications. Atop the spacing layer (10) is a the top mask or fine mesh screen (11). After the protuberances are completely grown, the mask is carefully removed, leaving the protuberances atop the metallic layer (9}. The conductors are subsequently formed from the metallic layer (9).
FIG. 5 shows a schematic layout for an electrode array. An array of protuberances arise from a base (1) and are connected by electrical conductors (3) to bonding pads (4).
FIG. 6 is a cross-section of a deposition mask (11), showing the cones having been deposited through the holes of the mask. The cones (e.g. 12 and 13) are shown atop metallic layer (9). The underlying insulating layer (8) and base or substrate (7) are also shown.
FIG. 7 is an illustration of a needle protuberance (14) covered with an insulating layer of dielectric (15), e.g. silicon dioxide. The tips of the needle protuberances are left exposed and uncovered by dielectric (15). Below the protuberance (14) is metallic layer (9) upon which the conductors are formed. The underlying insulation layer of dielectric (8), e.g. silicon dioxide, is also shown The underlying base is not shown.
FIG. 8 is an illustration of a combination of two electrode arrays (16 and 17) disposed on a single nerve (18) to form a sandwich electrode array or combination electrode array. The nerve is shown simply flattened although it may be further prepared to receive a sandwich electrode array by removal of a portion of its sheath and/or surrounding structures. The bonding pads or terminal portion of the electrode array may overhang from the nerve so as to clear the nerve in order to permit the bonding pads or terminals to be connected to external circuits. In one embodiment of the electrode array, the bonding pads or terminals are located on the edge of the base so as to facilitate the connection between the electrode array and external circuits.
Electrode arrays may be employed for measuring the voltage potential of the skin surface, e.g. for electrocardiograph and electroencephalograph measurements. In such applications, the electrode array may either penetrate the skin or may be applied more lightly. By penetrating the skin, a better connection is obtained without the use of conductive ointments. In addition, a capacitive coupling may be obtained by having the protuberances entirely covered with a passivating layer (dielectric) and applied to penetrate the skin. Thus, if the protuberances are electrically joined, the surface areas of the protuberances become one capacitive plate of substantial area and the dielectric lies between such plate and the other plate of the capacitor, viz. the surface of the skin or body tissue which is being measured.
FIG. 9 is a cross-section of a nerve and shows interdigitated needle shaped protuberances as might occur from the arrangement shown in FIG. 8. The interdigitated needles (e.g. 19 and 20) are shown penetrating a nerve from opposite sides and contacting or coming into near proximity to the myelinated or unmyelinated fibers (21 and 22). The needles are shown penetrating the perineurial sheath (43) and the extraperineurial tissue (44). Some of such tissue may be removed in preparation for the application of the electrode arrays. It is noted that the needles are shown as exposed only at their tips or ends. Such structure is particularly useful in sensing, in order to limit the sensed electrical activity to a single fiber or a few fibers. A larger portion of the needle may be exposed in stimulating situations. In order to enhance the likelihood of successfully sensing or stimulating a particular nerve fiber within a particular type of nerve, the dimensions, needle length, exposed tip length, amount of interdigitation, and needle spacing of the electrode array may be adapted to the anatomy of such nerve.
FIG. 10 shows Schwann cell structures (23 and 46) disposed around "C" class nerve fibers, such as (25). A needle shaped protuberance (24) is shown in close proximity to nerve fiber (25).
FIG. 11 shows two nerve fibers (26 and 27), their nodes of Ranvier (28 and 29), and needles (30, 31, and 32) penetrating into the nerve Needles (30 and 32) are in proximity to said nodes and would more likely pick up electrical signals than would needle (31).
FIG. 12 illustrates a monolithic base structure (33) in which several active electronic devices (34, 35, 36, 37, and 38) are created and on which are created the protuberances (2), for penetrating the body tissue.
FIG. 13 shows the interconnected electronic devices for switching the output of a sensory device. The transmitter and receiver (38) are shown, for transmitting the sensed information and receiving information for controlling the multiplexor (36) and the selective logic (34) of the sensing needles, or protuberances. Logic control (37) provides control over the multiplexor (36) and selective logic (34). In this manner external control may be exercised in order to select particular needles which are in suitable contact, or proximity, to desired nerve fibers. Amplifiers (35) provide increased signal strength. Integrated circuit technology may be used to provide the desired interconnections. Further, it may be appreciated that the transmitter and receiver (38) may be other than radio frequency. Then may transmit and receive utilizing infrared, magnetic induction, reflected impedance, acoustic waves, volumetric conduction or any other suitable well-known means for transmitting and receiving information. Such transmitter and receiver may be powered from inside or outside of the body. The entire implanted electrode array may be powered from outside the body by power transferred into the body through the receiver. In this manner, one or more electrode arrays could be coordinated to operate together or in response to one another. An electrode array implanted in the brain could, without any wires (tetherless), communicate and control an electrode array attached to a muscle, a nerve or other body part. An electrode array or several electrode arrays attached to the motor cortex of the brain could transmit, in tetherless fashion, many channels of information to receiving body parts, such as muscles, to which electrode arrays are attached.
FIG. 14 illustrates indexing cones or aligning means Three indexing cones (39, 40, and 41) arise from a first base piece which a single crosshatched indexing cone (42) descending from a second opposing base piece. The indexing cones from the first and second base pieces intermesh. The crosshatched cone (42) may register and align a mask, cover or other item which overlies the second base piece.
FIG. 15 shows a side view of the indexing cones of FIG. 14 and illustrates how such indexing cones intermesh so as to index or align two devices. Two or more of such groups of indexing cones would be used in accomplishing the registration. It is not believed alignment was been achieved previously using such microstructures. In the preferred use of the invention, the electrode array is connected to a nerve A nerve is generally of linear shape, but does not ordinarily lie in a straight line. Considering the needles of the array to be longitudinally disposed along the direction of the nerve, one or more needles along such longitudinal direction may make contact with the same or different nerve fibers. The needles most likely to be useful are those which touch or are in close proximity to the desired fibers. Laterally spaced needles may also be found to have made contact with the same nerve fiber. Other laterally spaced needles may connect to nearby nerve fibers which may have the same or different signals. Reinforcement of the sensing of signals can thus be obtained. Similarly, reinforcement of stimulation signals can thus be provided. From the explanation provided above, it can be seen that sensing or stimulation of the same or different nerve fibers is possible.
The smallest class of nerve fibers are unmyelinated "C" fibers. Adjacent fibers of this class appear, from our own observation, to be spaced from approximately 1/2 micrometer to 5 micrometers apart, center to center. Larger nerve fibers, e g "A" and "B" fibers, which are usually myelinated (surrounded by a sheath) appear to be spaced approximately 10 micrometers to 50 micrometers from adjacent fibers. In addition, a thickness of connective tissue encloses all of the component fibers in a nerve. In order to penetrate the nerve or in order to enter the fiber bundle sufficientlY, but not too much, the needles would be approximately 1/2 micrometer high to on the order of 100 micrometers high. In selecting the correct needle height, consideration has to be given to the sheaths, Schwann cells, and other tissue to be penetrated in order to contact the nerve fiber. Similarly, for other tissues, the depth of penetration desired would determine the height of the needles. If the needles are fabricated with optimal materials and geometry within the above described dimensions, emphasizing a small tip radius, narrow taper, spacing and length appropriate to the tissue involved, the likelihood of making electrical contact with a minimum of tissue damage is high.
Depending on the capability of creating long needles, it is desired to have them as long and narrow as possible. Aspect ratios (height to base) of 10 to 1 are readily achievable. A needle which is 100 micrometers high might have a base of from 5 micrometers to 10 micrometers in diameter or greater.
It should be appreciated that the small size of the needles minimizes the likelihood that nerves, organs, tissue, or other body parts would be damaged by application of the electrode array and penetration by the needles.
The spacing of the needles, transversely across a nerve, would be from approximately 1/2 micron to on the order of 100 micrometers. "On the order of" means, in this context, and as used herein, within the range of 1/10 of the dimension to 10 times the dimension. Spacing of the needles along the length of a nerve might well be greater than the lateral spacing of the needles across the nerve. That is, the spacing distance between needles along the length of a nerve can vary a great deal. Needles or groups of needles might well be longitudinally spaced 1000 micrometers, 2000 micrometers, etc., from one another, depending on the desired density of electrical contact with the nerve.
The needles (electrodes) must, therefore, be spaced having in mind the specific application. The needles should be small and sharp enough to avoid damaging the nerve. Also the electrically conductive portion of each needle should be small enough to contact only a single fiber and thereby obtain signals from only one fiber. Consequently, a preferred embodiment of the invention is to insulate the needles, except at or near their tips so that only a small electrically conductive portion of each needle is exposed. In this way, each needle is less likely to electrically contact more than one fiber.
In addition, the needles must be high or long enough to assure sufficient penetration of the desired nerve so as to make electrical connection with the nerve fiber inside the nerve. In order to reach the nerve fiber, the sheath and other connective tissues must be penetrated. However, "electrical connection" or "contact" with a nerve fiber or other body tissue may mean actual physical contact with the nerve fiber or tissue or it may mean being in sufficiently close location to sense the electrical signals therefrom or to stimulate the fiber or tissue as discussed previously in connection with FIG. 11. Further, as discussed previously, if the needles are entirely covered with a dielectric and utilize capacitive coupling, the needles do not actually make conductive contact with the body tissue.
If the longitudinal direction of the electrode array is slightly canted with respect to a nerve, electrical contact by some of the needles with some of the nerve fibers is greatly enhanced
The spacing and needle length may vary on a given base. In order to reach down into a fissure in the brain, for example, it may be desirable to have longer needles on one portion of the electrode array and shorter needles on another portion. Also, spacing density on one portion of the electrode array may be greater or lesser than on another portion. There may be an abrupt change of needle length or density, or both, in one or more directions. Or there may be a graded or gradual changes in one or more directions.
It is to be understood that the array may be sized to fit the particular application and may be planar, multiplanar, curved, twisted, or other desired shape as required in the particular circumstances involved. Ordinarily, the needles of the electrode array would be disposed on a rigid base. However, it is to be appreciated that the base may be flexible, or that the electrode array may be comprised of needles on a plurality of bases In general, the needles in an array should be held in relatively fixed spacing with respect to each other. It is intended to cover by "relatively fixed" terminology, instances in which the base is flexible, curved, stretchable, etc. Among the suitable bases are silicon, sapphire, or germanium. Numerous ceramics are also suitable for such biomedical use. Biomedical grade plastics may also be used such as the polyamides, polymethacrylate, acrylics, polycarbonates, etc., to the extent that such plastics may be implantable or rendered implantable.
The needles may be arranged in random fashion or ordered in columns and/or rows or other ordered arrangements. The optimum embodiment from the standpoint of orderly electrical connection is an ordered arrangement. One embodiment which may be desired is that in which each electrode (except, of course, those near the edges of the array) is surrounded by six other electrodes, all equidistantly spaced. The needles are electrically connected to a terminal which may, likewise, be randomly located or located in columns and/or rows. The terminal may include bonding pads which provide an electrical connection between the needles and other electrical circuits. Connection points need not be in the same arrangement as the needles. Thus, the needles may be located in columns, but not rows, and the terminals may be located in columns and rows.
It should be understood that the electrode array, as described herein, provides a greater likelihood than the prior art of successfully contacting a desired nerve fiber or desired location in a part of the brain or other part of the body. Through testing and selection of appropriate terminals, needles which have successfully made a desired contact with a particular nerve fiber or target cell can be connected to output equipment for sensing purposes or input equipment for stimulating purposes.
It may be further understood that the electrical parameters which govern the successful application of the electrode array, employed either as a recording electrode or as a stimulating electrode, are the same as the parameters employed for prior art electrodes. For stimulating, the parameters include stimulus rate, wave form, analog or pulsatile type, and amplitude sufficient to depolarize nearby neurons without exceeding the minimum amplitude sufficient to cause electrolysis at the electrode surface. For sensing, the parameters involve the reduction of noise and amplification of signal. These various electrical parameters are discussed in the prior art literature and may be employed for use and operation the electrode arrays disclosed and described herein.
The needles may be constructed as "cones" and a method of construction may use techniques similar to those taught in U.S. Pat. Nos. 3,755,704, 3,789,471, and 3,812,559, each naming Charles A. Spindt et al. as inventors U.S. Pat. No. 3,453,478, naming Kenneth R Soulders and Louis N. Heynick as inventors, also discloses background technology for constructing cones. Of course, it is not essential that the needles be "cones" as described therein, but may be of pyramidal shape or shaped as any sharp protuberance. Further information on the fabrication technology involved, may be found in an article by C. A. Spindt and others, entitled "Physical Properties of Thin-Film Field Emission Cathodes with Molybdenum Cones," Journal of Applied Physics, vol. 47 (12), Dec. 1976. In those patents and the article, the intended use of the structure and method is to provide field emission cathodes and field ionizers. Such needles, as disclosed by Spindt, contemplate electron-emitting structures as may be utilized in a vacuum tube. Also, he contemplates an electric field of megavolts per centimeter and current density of millions of amperes per square centimeter. For electron emission, contemplated voltages are of the order of kilovolts and for field ionization, approximately ten fold higher See Col. 2, 1.3 et seq., Pat. No. 3,812,559.
The device of the invention, on the other hand, as either a sensor or a stimulator, is concerned with very low electrical currents and voltages. The needles of the electrode array of this invention would, ordinarily, not be connected in common, but each needle would provide its individual output, although it is to be understood that groups of needles could be connected together, to provide a common or reinforced output of either stimulation or sensing. Further, in a particular situation, all needles of an array could be connected together to provide a single stimulating output or a single sensing output.
In one contemplated method of manufacture, a common base (substrate) is used in order to mount the needles and to achieve desired deposition. The base may have to be modified to provide the desired isolation of the individual needles or needle groupings. Such original base, as modified, may provide the necessary electrical conductors to convenient terminals of bonding pads for connecting to other electrical circuits.
The various steps of manufacture of the electrical conductors and terminals (bonding pads) may be accomplished by known techniques of chemical or electrical plating, etching, diffusing, sputtering, evaporation or other suitable techniques. This may be accomplished by using photolithographic or photographic techniques, masks, photoresists, etchants, and associated materials, known to those skilled in the microcircuit art.
A suitable mask may be generated by a drawing, followed by a photograph of the drawing, the making of a negative or positive, covering a mask material with a photoresist, exposing the photoresist through the negative or positive, developing it and etching to generate the mask. Fine mesh screens may be readily purchased or a mask may be created as described above, or by other known techniques.
In one embodiment, the steps of manufacture are as follows:
1. A non-conductive substrate, e.g. silicon having a silicon dioxide layer formed thereon, is used. A foil or film of conductive material is affixed thereon, possibly by sputtering, evaporation or other known integrated circuit manufacturing technologies;
2. Using a photoresist and a suitable mask, a pattern of electrical conductors and terminals (bonding pads) is laid out on the conductive material and all the rest of the material is etched or removed. It would be possible to commence with a non-conducting substrate, and using known chemical deposition techniques, lay down a sensitizer in the form of the desired conductive pattern, which would allow subsequent chemical deposition of a conductive metal as the electrical conductors and terminals;
3. After cleansing the article, a glass passivation layer is laid down on the electrical conductors and terminals;
4. Again, a photoresist, a suitable mask, defining the needle sites, and an etchant are used in order to locate the needle sites and to etch through the glass passivating layer, exposing each of the sites for growing a needle on an electrical conductor of the layer below;
5. The same mask or a similar mask having holes therethrough, at the desired needle sites is disposed over the exposed needle sites in registration with such sites, and deposition of the needles is accomplished through such mask by metallic evaporation using, for example, electron beam or resistive element heating, in a high vacuum chamber. The metal deposits on the mask as well as within the hole on the needle site. The size of the hole becomes progressively smaller as metal is deposited atop the mask. The reduction of the size of the hole is precisely correlated with a reduction in the rate of metal deposition within the hole. The reduction of the size of the hole also reduces the target field within the hole upon which the metal is deposited. As a result, the protuberance formed within each hole assumes a tapered shape, e.g. conical, pyramidal, or needle shaped. The evaporating metal used to form the cones (needles) may be platinum, activated iridium, platinum iridium alloy, possibly, rhenium, or other suitable implantable electrode material. It is desired that the cones be made of a conductor which can deliver stimulus current, if stimulating, or sense very small voltages, if sensing, with little or no corrosion. If the mask is a fine mesh screen through which the needles are deposited, the precise size of the holes required for creating the needles may be obtained by placing the mask (covering the device) in a vacuum deposition system and rotating the device about an axis vertical to its surface and depositing, at a grazing incidence, more metal on the screen or mask layer. This can be used to decrease the starting size of the holes to any diameter. Upon arriving at the desired diameter, the needles may be created by orthogonally plating through such narrowed holes as taught in U.S. Pat. No. 3,812,550, referred to above;
6. The mask through which deposition is accomplished is carefully removed, leaving the needles exposed and providing the "bed of nails;"
7. A photoresist, a mask having the pattern of the test points and terminals and an etchant are used to remove the passivating layer over the test points and terminals in order that connection can be made to the array; and
8.a. If it is desired to make a capacitive electrode array, the protuberances must be coated with a passivating or insulating layer. Aluminum oxide (Al(2)O(3)) is a preferred composition for the passivating layer and is widely described and employed in the prior art for this purpose; or
8.b. If it is desired to make a conductive electrode array, the focus and specificity of the protuberances can be enhanced by covering the protuberances with a passivating or insulating layer, except for an area of 1-5 square micrometers at the tips. Hence, electrical contact is made only at the tip of the protuberances and the probability of contacting only one cell is enhanced. The protuberances are initially covered over their entire height with a passivating layer, e.g. aluminum oxide (Al(2)O(3)). The passivating layer is then removed from a small area of the tips by exposure to a controlled plasma etch; or
8.c. Alternatively, passivation may be achieved by fabricating the protuberances with self passivating compositions or with a combination of self passivating and non-passivating composition. For example, the first 9/10ths of the height of the protuberances may be fabricated with tantalum, a self passivating composition. The incomplete cone will have a flat top and will form a passivating layer upon exposure to the atmosphere. However, before the passivation layer is allowed for form, the cone is then completed by the deposition of a non-passivating metal, e.g. gold, iridium, platinum, etc. The last 1/10th of the cone will remain conductive.
The above process utilizes various of the manufacturing steps disclosed in the above mentioned article from the Journal of Applied Physics and in the above mentioned patents.
The manufacturing operation may commence with a thin film sandwich of metal on a dielectric (e.g. silicon dioxide on a base of silicon). The conductive and terminal pattern is formed out of the metal layer, by etching away excess metal. Then the needles are deposited through an appropriately patterned mask to coincide with the conductive patterns, as desired. After the needles have been formed, the entire device could be covered with a glass passivating coat, except with needle tips and terminals if they are desired to be left exposed. They could, of course, be exposed later.
In another method, a thin film sandwich is used, having a bottom layer of dielectric, a next layer of metal, then a dielectric and then metal on top of that. The top layer of metal becomes the mask for creating the needles. The thickness of the bottom dielectric layer is determined by what rigidity and strength is necessary in order to hold on to and carry the electrode array. The second dielectric thickness is determined by the spacing desired between the top metal layer (which will form a mask for the needle growing) and the middle metal layer upon which the needles will be grown. A very thin second dielectric layer may be created between the metal layer by the use of evaporated silicon dioxide. The under layer of metal will form the needle sites, the electrical conductors, test points, if any and terminals, (bonding pads, in one embodiment). The top layer of metal is used as a mask for depositing the needle cones on the under layer of metal. This is accomplished by first making holes in the top layer of metal, at intended needle sites, without penetrating the dielectric between the metal layers. This is done by a selective metal etchant (together with a photoresist and a mask) which does not attack the dielectric. Then, an etchant is used to remove the dielectric between the metal layers, at the needle sites. The needles are then "grown" by vacuum evaporation, sputtering or other known techniques. After having formed the needles on the metal layer on the bottom dielectric layer, all of the second dielectric layer and top metal layer would be removed. The excess metal, not needed for electrical conductors, test points and terminals, of the exposed under layer metal could then be removed. In the alternative the entire underlayer metal could be removed and new metal, making electrical conductors between the needles and terminals could be deposited. The entire electrode array could then be covered with a passivating material, such as silicon dioxide, silicon nitride, aluminum oxide (Al(2)O(3)) or other biocompatible dielectric, and then selectively etched at the terminals, if desired and at the needle points.
If the substrate is silicon or germanium or the like, the electrical conductors and, if desired, switches, multiplexors, amplifiers and other electronic circuits may be provided by doping selected portions of the substrate or by other commonly used techniques. Electrical conductors may be created on the surface of the semiconductor material, in it, or through it, to the opposite side from the protuberances.
In obtaining registration or indexing of masks, covers, or other items, which must be aligned with the array, one or more groups of three cones or needles could be grown in two or more places on the array and a registering cone or needle grown on the other item to be aligned. A needle on the overlying device fits into the space within the group on the other device, as previously described in connection with FIGS. 14 and 15. Of course, the overlaying device may have the groups of needles and the base have the single registering needles. Further, both devices may have a group which fits into a group on the other device.
The materials used in the structure must be biocompatible and suitable for use in or in connection with the living body. It is understood, of course, that certain materials which are not considered biocompatible could be rendered suitable by being treated or covered with a biocompatible material. Thus, glass passivation (covering with glass), oxidation of certain materials, the coating or depositing of biocompatible materials (such as, but not limited to, silicone rubber, certain metals and ceramics or one of the many plastics which are used in the body) may be used to provide a final product which is biocompatible and may be implanted. The electrode or needle material may be platinum, activated iridium, a platinum iridium alloy, a conductive polymer, carbon or other suitable electrically conductive material known by those skilled in the art as suitable for use in connection with the body. In general, metals or other conductive substances which are inert and are least subject to corrosion are used. In the case of stimulating devices, conductive materials which can handle the necessary current densities are required.
In view of the above discussion, it may be understood that the electrode array would be useful in stimulating a gland or a nerve to or in the gland to cause the gland to be active or more active. The electrode array may be used to cause hormonal secretions.
Other uses of a stimulating electrode array or a plurality of electrode arrays would include stimulation of a group of muscles or successive stimulation of groups or portions of a group in order to achieve a desired muscular coordination. Such electrode array may be applied directly to or in the muscle or it may be applied to or in selected nerves (or the central or peripheral nervous system) to provide signals to the muscle. Also, a number of such electrode array may be applied at different locations and their stimulation or sensing coordinated to achieve desired results.
One stimulation application of the electrode array or a plurality of such electrode arrays is in excitation of the brain to provide a sensory response, e.g. vision. The electrode array and its numerous needles may be disposed in the visuosensory and visuopsychic areas of the brain, which involve several kinds of cells. The electrode array may be disposed along the optic nerve or the paths where the optic nerve enters the cortex. The array may be attached to the cortex with the needles penetrating the brain rather than the optic nerve.
The concept of the invention in one of its more important aspects provides for electrical access to the individual elements of a tissue in order to determine which element or elements and its associated needle or needles are useful for the intended purpose. One or more needle outputs may be found to be useful in the particular application involved.
It should also be appreciated that, as taught hereinabove, the device may be untethered, through one or more means for transmitting information, receiving information or receiving power.
Although the invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of this invention being limited only by the terms of the appended claims.
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The electrode array is a device for making multiple electrical contacts with cellular tissue or organs. The electrode array includes a base (1), a two dimensional array of conducting protuberances (2) arising from the base and serving as electrodes, and conductors (3) embedded onto the base and connected to such protuberances for transmitting electrical signals to and/or from the protuberances. The protuberances may also include an insulating layer (15) which covers either the entire protuberance or which leaves the tips exposed for making focused electrical contact. Electrode arrays may be used used singly or in combination with a second electrode array so as to form a sandwich around a target tissue. The sandwich electrode array (16, 17) may employ indexing cones for aligning the opposing electrode arrays and for limiting their vertical proximity. The conductors of the electrode array may be electronically connected or coupled to processing circuitry which amplifies and analyzes the signal received from the tissue and/or which generates signals which are sent to the target tissue and possibly coordinates the generated signals with signals which originate with the tissue.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to the manufacture of dry ice and, more particularly, to a method and apparatus for producing slabs or blocks of dry ice.
[0003] 2. Background Information
[0004] Solid state carbon dioxide (CO 2 ), known as dry ice, is used in many different applications. Dry ice is ideal for preserving food because it sublimates directly from its solid phase to its gaseous phase, leaving no odor, color, taste, or residue and causes no deleterious effects to the food. In cooling and preserving food, dry ice pellets may be placed directly onto the food to rapidly cool it below some specified temperature to prevent spoilage.
[0005] Dry ice has traditionally been produced and distributed in blocks with each block weighing about 55 pounds. The blocks are cumbersome, expensive and require extra effort to crush or break apart to make the dry ice easy to use by reducing the block to reasonable size pieces. In recent years, dry ice has been produced in pellet form, which pellets are much easier to use.
[0006] A dry ice pelletizer that is made by Tomco Equipment Co. is shown in U.S. Pat. No. 4,780,119, to Brooke, where liquid CO 2 is injected into a chamber known as an extrusion chamber and flashed at atmospheric pressure. In this flashing process, part of the liquid CO 2 changes phase to a solid known as “snow,” with the remaining part of the liquid CO 2 changing phase to gas. The gaseous CO 2 can exit the extrusion chamber through gas vents and the remaining snow may be compressed at the end of the extrusion chamber. The proportionate amount of the gaseous CO 2 versus the snow depends upon the pressure and temperature of the liquid CO 2 that is fed into the extrusion chamber and the surrounding pressure and temperature of the extrusion chamber. The lower the pressure and temperature, the greater the amount of snow produced in the flashing process.
[0007] When liquid CO 2 is flashed under ideal conditions at atmospheric pressure, approximately 48% of the liquid CO 2 is changed to snow, while approximately 52% of the liquid CO 2 is changed to gas. Because the percentage of snow formation is directly proportional to the pressure inside the extrusion chamber, when flashing occurs, it is important that the pressure inside the extrusion chamber be kept as close to atmospheric pressure as possible.
[0008] Once the snow is formed in the extrusion chamber, a piston is used to compact the snow in one end of the extrusion chamber against a die. In the traditional pelletizer, the snow will collect in the openings of the die and before long block the openings. While some small amount of snow may escape, it is not that significant. Thereafter, when the pistons move back and forth to compress the snow, the snow is compressed at the end against the die to form what is called a puck. As additional dry ice (i.e., snow) is compressed against the puck, the puck will extrude through the openings in the die.
[0009] For some applications, the use of pelletized dry ice is not the ideal situation. For example, in some occasions, blocks or slabs of dry ice are much better than pellets of dry ice. However, the 55 pound blocks of dry ice are normally much larger than desired. Sometimes it is necessary to cut the blocks of dry ice into other shapes or sizes, such as shown in U.S. Pat. No. 5,189,939, to Allen. However, when the blocks of dry ice are cut, there is attendant waste in the cutting process.
[0010] As an example of an industry that uses smaller blocks or slabs of dry ice, the airline industry uses thousands of pounds of dry ice per day to keep food cool in their serving carts. At the bottom of the serving cart is a tray located a block or slab of dry ice that is approximately 1″×5″×5″. In other words, the 55 pound block would have to be cut into small slabs of dry ice that can be put in the tray in the bottom of the serving cart for the airline industry. This small slab of dry ice will then sublimate directly from the solid to gaseous state leaving no odor and no deleterious effects while keeping the food cool. The airline industry uses large amounts of dry ice per day for this particular purpose.
[0011] Slabs or blocks of dry ice could be used for many other purposes other than in the airline industry. Anytime there is a necessity to keep something cool for a period of time in which there is no residue to be dealt with during or after cooling, dry ice becomes an ideal candidate because it sublimates from solid to gaseous state, which gaseous state has no adverse effects.
[0012] If smaller blocks or slabs of dry ice can be formed directly from liquid CO 2 , the losses attendant with cutting of large blocks of dry ice would not occur. The present invention is designed to solve this problem by providing for the extrusion of smaller blocks or slabs of dry ice that can be used in many different applications. None of the devices known by applicant allow for direct extrusion of blocks of dry ice, which blocks could be used by an end user, such as the airline industry.
SUMMARY OF THE INVENTION
[0013] A conventional dry ice pelletizer is used, which consists of a cylinder in which liquid CO 2 is introduced through an injection port for flashing to form gaseous CO 2 and solid CO 2 therein. The gaseous CO 2 is vented and a piston is used to compress any solid CO 2 (snow) that forms in the chamber into a single mass of dry ice at one end of the cylinder, which mass of dry ice is known as a puck. For traditional pelletizers, the openings in the die quickly fill up with snow that blocks the openings. Then the snow is compressed against the die with each stroke of the piston. Ultimately, the piston pushes against the snow and puck with sufficient pressure to force the solidified CO 2 out the openings in the die as a continuous rod of dry ice. Periodically, the rod of dry ice is broken off into pellets.
[0014] In the present invention, the die has been changed. In the die, there is a large slot with 1″×5″ being a typical size slot. If nothing is done to block the slot, the CO 2 , either in the gaseous state or as snow, will simply escape through the slot. To prevent that from occurring, a gate is moved over the slotted opening. The gate, once in place, prevents CO 2 either in the gaseous state or solid state of snow from escaping from the compression chamber. Now as a piston moves back and forth with the introduction of liquid CO 2 , the snow begins to compress against the die. Once a puck is formed against the die, then the gate can be removed. Thereafter, as the piston continues to reciprocate inside the cylinder with the introduction of liquid CO 2 that flashes to a combination of gaseous CO 2 and snow, the snow is compressed against the puck, and the puck is extruded through the die. If the slot in the die is approximately 1″×5″, the extruded dry ice will have a cross-sectional area of approximately 1″×5″.
[0015] Immediately upon passing through the die, the 1″×5″ slab of dry ice has not set up into a good solid form. Therefore, an additional distance known as a forming chamber will be located adjacent to the die. The forming chamber may be a part of the die or a separate item attached thereto. Typically, the forming chamber would be approximately 2 inches thick.
[0016] As the extrusion process continues and the 1″×5″ slab of dry ice is extruded, at some time the slab of dry ice will reach a desired length. A sensing device, such as a photocell, would be used to indicate the desired length of the slab has been reached. Assuming the desired length is 6 inches, once the extruded 1″×5″ cross-section of dry ice reaches 6 inches, the photocell will send a signal back indicating the desired length has been reached. That signal can then be used to activate a sizing cylinder that will move a sizing block that breaks off the extruded dry ice into slabs of approximately 1″×5″×6″ size. The sizing block can be controlled by any type of actuation device that has sufficient strength and speed, but in the present process, a pneumatic cylinder is probably ideal. Therefore, a pneumatic sizing cylinder would move a sizing block that would break off the extruded dry ice into desired lengths.
[0017] Since liquid CO 2 is continuously being fed to the extrusion chamber for compression by the piston, snow continues to compress and the rectangular shaped cross-sectional area continues to be extruded. The next time the rectangular shaped extruded dry ice reaches the desired length, the process is repeated again. By repeatedly using this process, numerous blocks or slabs of dry ice of the desired dimensions are formed without the necessity for sawing or cutting.
[0018] The gate only needs to be used during startup of the extrusion process. At that time, some force needs to hold the gate against the die. That force of holding the gate against the die may be provided by any of a number of different means, including a track that would force the gate against the outside of the die. On the other hand, the sizing block does not need the force to push it against the die because all the sizing block is doing is breaking off the extruded rectangular section of dry ice.
[0019] It is an object of the present invention to provide a device for extruding blocks or slabs of dry ice.
[0020] It is another object of the present invention to provide a dry ice extruder that can automatically extrude blocks or slabs of dry ice.
[0021] It is yet another object of the present invention to modify a dry ice extruder to have a die that will extrude a rectangular shaped slab of dry ice, which slab may be broken upon reaching a predetermined length.
[0022] It is another object of the present invention to provide a die with a slot therein for extruding a rectangular cross-section of dry ice, which slot is blocked during startup of the extruder to allow for the building of a puck of dry ice therein.
[0023] It is still another object of the present invention to provide a dry ice extruder for extruding a slab of dry ice, which slab may be broken into predetermined lengths, the process being automated for blocking the slot in the die upon startup and thereafter to actuate a sizing device for breaking the extruded slab into predetermined lengths.
[0024] These and other objects of the present invention are met when practicing the method or device as described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a perspective view of a Tomco type dry ice extruder which has been modified to extrude blocks or slabs of dry ice in accordance with the present invention.
[0026] FIG. 2 is an exploded perspective view of the extrusion cylinder portion of the dry ice extruder, including the die, forming chamber, gate and sizing device.
[0027] FIG. 3 is an elevated end view of the die on the dry ice extruder.
[0028] FIG. 4 is an elevated partial cross-sectional view of FIG. 3 showing the extrusion cylinder on the dry ice extruder showing the die, forming chamber, gate and sizing device.
[0029] FIG. 5 is a simplified schematic diagram indicating hydraulic, pneumatic and liquid CO 2 supply systems for the dry ice extruder.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] FIG. 1 shows a commercially available, widely used, dry ice extruder 10 that has been modified from a pelletizer to extrude blocks or slabs of dry ice. The dry ice extruder 10 is commercially available for purchase without the modifications from companies, such as Tomco Equipment Company. Initially hereinbelow, the items commercially available through Tomco or some other supplier will be described before describing the modifications that constitute the present invention. Because dry ice extruders are widely available in the marketplace, dry ice extruder 10 will only be described generally hereinbelow.
[0031] Dry ice extruder 10 has a pair of side-by-side extrusion cylinders 12 that are operated by a pair of side-by-side hydraulic cylinders 14 . The hydraulic cylinders 14 are separated from the extrusion cylinders 12 by a spreader box 16 . Extrusion cylinders 12 , hydraulic cylinders 14 , and spreader box 16 are all mounted on frame 18 , as well as other components that will be described hereinbelow.
[0032] To operate dry ice extruder 10 , liquid CO 2 is delivered to extrusion cylinders 12 through liquid CO 2 feed hoses 20 from a source of liquid CO 2 (not shown). Feed hoses 20 feed liquid CO 2 into extrusion cylinders 12 through injection connectors 22 . Inside of extrusion cylinders 12 , the liquid CO 2 is flashed so a portion thereof forms gaseous CO 2 and the remainder forms solid CO 2 in what is commonly called “snow.” The gaseous CO 2 is vented or removed from the extrusion cylinders 12 (see FIG. 2 ) and the snow compacted or compressed by piston 24 (see FIG. 2 ) as will subsequently be explained.
[0033] To operate piston 24 inside of extrusion cylinders 12 , hydraulic cylinder 14 is connected via hydraulic hoses 26 through a pump (not shown) to a reservoir of hydraulic fluid 28 . A control box 30 controls the operation of the dry ice extruder 10 with motor controller 32 receiving commands from connection 34 to spreader box 16 and from control box 30 . Hydraulic hoses 26 are connected through fittings 36 to deliver hydraulic fluid to and from hydraulic cylinders 14 .
[0034] Extrusion cylinders 12 are connected on one end of spreader box 16 through extrusion flange 38 , while hydraulic cylinders 14 are connected on the opposite end of spreader box 16 by hydraulics flange 40 .
[0035] The parts described in the foregoing Description of the Preferred Embodiment are old and can be found in a Tomco extruder. The portions described hereinbelow are what is new and added by the present invention.
[0036] Referring to FIG. 2 now in combination with FIG. 1 , extrusion cylinders 12 are held together by four prestressed rods 42 that connect from extrusion flange 38 , around extrusion cylinders 12 , through die holder 44 , die 46 , and forming chamber 48 , and extend there beyond. On one end, the prestressed rods 42 can end at the extension flange 38 of spreader box 16 , or they may extend therethrough to hold together hydraulic cylinders 14 and end with hydraulic flange 50 (see FIG. 1 ).
[0037] While it may not be immediately clear upon viewing FIG. 1 , the dry ice extruder 10 is a dual system with two extrusion cylinders 12 and two hydraulic cylinders 14 being side by side. The operation of extrusion cylinders 12 alternates with piston 24 being retracted by piston rod 52 (see FIG. 2 ) in the first extrusion cylinder 12 and extended in the second extrusion cylinder 12 . This operation is controlled by hydraulic cylinders 14 , alternately extending and retracting piston rods 52 connected to pistons 24 in the side-by-side extrusion cylinders 12 . This alternating type of compression and retraction provides balance to dry ice extruder 10 , so it will operate much smoother. Because extrusion cylinders 12 are identical, only one extrusion cylinder 12 , along with die holder 44 , die 46 , forming chamber 48 , and the controls associated therewith, will be explained in detail.
[0038] Prestressed rods 42 extend through holes 54 of die holder 44 and notches 56 in die 46 . Nuts 58 thread onto the prestressed rods 42 to clamp the inner lip 60 of the die holder 44 around cylinder 62 of extrusion cylinders 12 . Forming chamber 48 can be made either integral with die 46 or may be bolted thereto by recessed bolt 68 . Die 46 is also held to die holder 44 by bolts 64 connecting into holes 66 . In the center of die 46 is an extruding slot 70 , through which dry ice may be extruded. The dry ice feeding through extruding slot 70 has not yet formed, so forming slot 72 in forming chamber 48 will give the dry ice sufficient time to form and harden prior to being exposed to atmosphere.
[0039] In typical operation, liquid CO 2 from a suitable source would be injected into cylinder 62 of extrusion cylinder 12 through feed hoses 20 and injection connectors 22 . Inside of cylinder 62 , the liquid CO 2 will be flashed to atmospheric pressure thereby forming gaseous CO 2 and solid CO 2 in the form of snow. The gaseous CO 2 will be vented to either atmosphere or a gaseous CO 2 collection system through vent holes 74 . Pressure port 76 on cylinder 62 is used to monitor the pressure inside of cylinder 62 through either a pressure gauge 78 (see FIG. 1 ) or by appropriate feedback to control box 30 . Depending upon the pressure inside of cylinder 62 , the amount of liquid CO 2 being injected or the repetition rate of piston 24 can be varied.
[0040] To prevent the gaseous CO 2 and the solid CO 2 (snow) from escaping through extruding slot 70 and forming slot 72 to atmosphere, something must block slots 70 or 72 . In the present invention, a mounting plate 80 is bolted onto prestressed rods 42 by nuts 82 . (See FIGS. 3 and 4 in combination with FIGS. 1 and 2 .) Mounting plate 80 is located along the prestressed rods 42 so that gate 84 and sizing block 86 are flush with an outer surface 88 of the forming chamber 48 . Mounted on the mounting plate 80 is a sizing cylinder 90 for operating the sizing block 86 . Also mounted on mounting plate 80 is a gate cylinder 92 for operating gate 84 .
[0041] On the ends of prestressed rods 42 is located an end plate 94 on which a photocell 96 is located. The photocell 96 may be adjusted inward or outward by adjusting slotted rod 98 and screw 100 .
[0042] In actual operation, when someone starts the dry ice extruder 10 , liquid CO 2 comes in through feeder hoses 20 from a source of liquid CO 2 (not shown) into cylinder 62 of extrusion cylinders 12 . The liquid CO 2 is flashed to gaseous CO 2 and to solid CO 2 (snow) inside of cylinder 62 . The gaseous CO 2 is removed through vent holes 74 . At this time, the forming slot 72 of the forming chamber 48 should be blocked by gate 84 . Gate 84 may either be a manual operation of physically bolting a plate over forming slot 72 or may be an automatic gate 84 that is moved into place by gate cylinder 92 . Gate 84 should be pressed tightly against the outer surface 88 of the forming chamber 48 by any convenient means, such as tracks (not shown), that press gate 84 tightly over forming slot 72 .
[0043] As liquid CO 2 is continually flashed inside cylinder 62 while piston 24 is operating therein via hydraulic cylinders 14 , the extrusion cylinder 12 will be cooled down. With the cooling of extrusion cylinder 12 , snow will begin to accumulate therein and be pushed against die 46 at the end of cylinder 62 . Further accumulation of snow (solidified CO 2 ) will further consolidate to form a puck at the die end of cylinder 62 . The puck once sufficiently solidified and formed, it is now time for extruding cylinder 12 to start extruding dry ice. Therefore, gate cylinder 92 retracts gate 84 to allow solid dry ice to be pushed through extruding slot 70 of die 46 and formed or hardened in forming slot 72 of forming chamber 48 . Thereafter, solidified dry ice in slab form is extruded out through extruding slot 70 and forming slot 72 . Extruding slot 70 has the normal amount of taper as is normally used for extruding dry ice. Typically there is an approximately 1° taper in both extruding slot 70 and forming slot 72 .
[0044] As the slab of dry ice continues to be extruded through extruding slot 70 and formed in forming slot 72 , at some point the slab of extruded dry ice will reach a desired length. In the present invention, photocell 96 , which is mounted on end plate 94 , may be adjusted to determine that length. Assume photocell 96 is set to give a signal to control box 30 via connection 102 when the slab of extruded dry ice reaches a predetermined length. The signal being fed back to control box 30 via connection 102 from photocell 96 will actuate the sizing cylinder 90 that moves sizing block 86 against the dry ice to break off the slab of dry ice that has been extruded. Assuming photocell 96 is set for 6 inches, the extruded slab of dry ice will be approximately 6 inches long.
[0045] While different types of actuating devices may be used to move gate 84 or sizing block 86 , in the preferred embodiment the sizing cylinder 90 and gate cylinder 92 are pneumatically operated. The pneumatic pressure may be provided by pneumatic pressure in the facility or can be from gaseous CO 2 that has been formed. Even a hydraulic cylinder can be used for gate cylinder 92 , but typically a hydraulic cylinder would be too slow for the sizing cylinder 90 . Sizing cylinder 90 must be fairly rapid in operation to break off the extruded slab of dry ice while the extrusion process continues. Electrical solenoids can be used in place of sizing cylinder 90 and gate cylinder 92 . Assuming pneumatic pressure is used in sizing cylinder 90 and gate cylinder 92 , the supply lines 104 (see FIG. 1 ) are connected to a suitable source of pneumatic pressure (not shown).
[0046] Referring now to FIG. 5 , a schematic illustration as to the operation of the dry ice extruder 10 is illustrated in a schematic diagram. Where appropriate, like numbers will be utilized the same as numbers previously used hereinabove.
[0047] Hydraulic fluid 28 is pumped by pump 106 through control valve 108 to extrusion cylinders 112 in an alternating manner. In other words, as piston 24 (not shown in FIG. 5 ) is compressing in one extrusion cylinder 112 , the piston 24 is retracting in the other extrusion cylinder 112 . Control valve 108 acts as a double-pole, double-throw electrical switch except control valve 108 is controlling the direction of fluid flow rather than current. From control valve 108 , fluid is returned through return line 110 to the reservoir for hydraulic fluid 28 .
[0048] On the other end of extrusion cylinder 112 , the liquid CO 2 is introduced through CO 2 lines 114 via control valve 116 from liquid CO 2 reservoir 118 . Inside of extrusion cylinder 112 , the liquid CO 2 is flashed to form gaseous CO 2 and solid CO 2 (snow). The gaseous CO 2 is vented through vents 120 , either to atmosphere or to a gaseous CO 2 collection system.
[0049] On the end of the extrusion cylinder 112 is mounted a die 122 , followed by forming chamber 124 . Initially, when starting the operation, gate actuator 126 moves a gate (not shown) to block the extruding slot (not shown) through die 122 and forming chamber 124 . In this illustrative embodiment, gate actuator 126 is a pneumatic cylinder operated by gate valve 128 , which receives pressurized air from pressurized air source 130 . After the extrusion cylinder 112 has operated for a sufficient length of time to form a puck at the die end thereof, gate valve 128 operates gate actuator 126 to move the gate (not shown) from blocking the extrusion slot (not shown in FIG. 5 , but previously explained in connection with FIGS. 1-4 ). Thereafter, dry ice is extruded in slab form through die 122 and forming chamber 124 . However, once the dry ice reaches a predetermined length, the extruded slab of dry ice will be sensed by photocell 132 , which will send a signal to sizing valve 134 . Sizing valve 134 , which receives pneumatic pressure from pressurized air source 130 , will deliver pressurized air to sizing cylinder 136 . Sizing cylinder 136 will actuate sizing block 138 , which will be pressed against the extruded slab of dry ice causing the slab to break off at the face of forming chamber 124 . The actuation of sizing cylinder 136 , causing the movement of sizing block 138 , is fairly rapid because the extrusion process continues without interruption. In other words, sizing block 138 is moved downward to break the extruded slab of dry ice and retracted in a fairly rapid manner. The extrusion process continues uninterrupted until again photocell 132 senses the end of the extruded slab of dry ice to again operate the control valve 134 to actuate the sizing cylinder 136 and move sizing block 138 .
[0050] In this manner, continual slabs of dry ice are extruded that will have a predetermined thickness, width and length. The length is controlled by adjustment of photocell 132 , with the width and thickness determined by the size of the slot in die 122 and forming chamber 124 .
[0051] While in the preferred embodiment it is envisioned the extruded slabs of dry ice would be approximately 1″×5″×5″, different dimensions can be extruded with the equipment currently available on the market today. It is envisioned that current equipment could extrude slabs of dry ice as thick as 2 inches and as wide as 5 inches without significant modification. The length can be any length desired, but a 5 inch length is what is typically used in the airline industry. Depending upon how the slab or block of dry ice is to be used, the length of the slab or block can be changed very quickly. If other dimensions are desired to be changed, simply by changing the die, the other dimensions can also be changed.
[0052] Initially, the gate that blocks the extruding slot, because it only needs to be used once at the beginning of the extrusion process, could be set up by any of a number of different means, including even the bolting of a blank plate on the end of the forming chamber and removing the blank plate once the puck has been formed.
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A method and device for forming slabs of dry ice is shown. A dry ice extruding machine has been modified with a die that has a slot for extruding a slab of dry ice therethrough. The slot is blocked until a puck is formed in an end of a forming chamber of the dry ice extruding machine. The block is then removed and dry ice extruded to a desired length and then broken to give a slab of dry ice. The last step is repeated over and over as the extruded portion reaches the desired length to give the number of slabs wanted.
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This is a division, of application Ser. No. 440,628, filed Feb. 7, 1974 which is a continuation of Ser. No. 248,005, filed Apr. 27, 1972 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to novel compositions of matter, to novel methods for producing those, and to novel chemical intermediates useful in those processes. Particularly, this invention relates to certain novel analogs of some of the known prostaglandins in which a cis carbon-carbon double bond links C-4 and C-5 in the carboxy-terminated chain.
The known prostaglandins include, for example, prostaglandin E 2 (PGE 2 ), prostaglandin F 2 alpha and beta (PGF 2 .sub.α and PGF 2 .sub.β), prostaglandin A 2 (PGA 2 ), prostaglandin B 2 (PGB 2 ), and the corresponding PGE compounds. Each of the above-mentioned known prostaglandins is a derivative of prostanoic acid which has the following structure and atom numbering: ##SPC1##
See, for example, Bergstrom et al., Pharmacol. Rev. 20, 1 (1968), and references cited therein. A systematic name for prostanoic acid is 7-[(2β-octyl)-cyclopent-1α-yl]heptanoic acid.
PGE 2 has the following structure: ##SPC2##
Pgf 2 .sub.α has the following structure: ##SPC3##
PGF 2 .sub.β has the following structure: ##SPC4##
PGA 2 has the following structure: ##SPC5##
PGB 2 has the following structure: ##SPC6##
Each of the known PG 3 prostaglandins, PGE 3 , PGF 3 .sub.α, PGF 3 .sub.β, PGA 3 , and PGB 3 , has a structure the same as that shown for the corresponding PG 2 compound except that, in each, C-17 and C-18 are linked with a cis carbon-carbon double bond. For example, PGE 3 has the following structure: ##SPC7##
In formulas II to VII, as well as in the formulas given hereinafter, broken line attachments to the cyclopentane ring indicate substituents in alpha configuration, i.e., below the plane of the cyclopentane ring. Heavy solid line attachments to the cyclopentane ring indicate substituents in beta configuration, i.e., above the plane of the cyclopentane. ring.
The side-chain hydroxy at C-15 in formulas II to VII is in S configuration. See Nature, 212, 38 (1966) for discussion of the stereochemistry of the prostaglandins.
Molecules of the known prostaglandins each have several centers of asymmetry, and can exist in racemic (optically inactive) form and in either of the two enantiomeric (optically active) forms, i.e., the dextrorotatory and levorotatory forms. As drawn, formulas II to VII each represent the particular optically active form of the prostaglandin which is obtained from certain mammalian tissues, for example, sheep vesicular glands, swine lung, or human seminal plasma, or by carbonyl and/or double bond reduction of that prostaglandin. See, for example, Bergstrom et al., cited above. The mirror image of each of formulas II to VII represents the other enantiomer of that prostaglandin. The racemic form of a prostaglandin contains equal numbers of both enantiomeric molecules, and one of formulas II to VII and the mirror image of that formula is needed to represent correctly the corresponding racemic prostaglandin. For convenience hereinafter, use of the terms PGE 1 , PGE 2 , PGE 3 , PGF 2 .sub.α, and PGF 3 .sub.α, will mean the optically active form of that prostaglandin with the same absolute configuration as PGE 1 obtained from mammalian tissues. When reference to the racemic form of one of those prostaglandins is intended, the word "racemic" or "dl" will preceed the prostaglandin name, thus, racemic PGE 2 or dl-PGF 2 .sub.α.
PGE 2 , PGE 3 , and the corresponding PGF.sub.α, PGF.sub.β, PGA, and PGB compounds, and their esters, acylates, and pharmacologically logically acceptable salts, are extremely potent in causing various biological responses. For that reason, these compounds are useful for pharmacological purposes. See, for example, Bergstrom et al., cited above. A few of those biological responses are systemic arterial blood pressure lowering in the case of the PGE, PGF.sub.β, and PGA compounds as measured, for example, in anesthetized (pentobarbital sodium) pentolinium-treated rats with indwelling aortic and right heart cannulas; pressor activity, similarly measured, for the PGF.sub.α compounds; stimulation of smooth muscle as shown, for example, by tests on strips of guinea pig ileum, rabbit duodenum, or gerbil colon; potentiation of other smooth muscle stimulants; antilipolytic activity as shown by antagonism of epinephrine-induced mobilization of free fatty acids or inhibition of the spontaneous release of glycerol from isolated rat fat pads; inhibition of gastric secretion in the case of the PGE and PGA compounds as shown in dogs with secretion stimulated by food or histamine infusion, activity on the central nervous system; controlling spasm and facilitating breathing in asthmatic conditions; decrease of blood platelet adhesiveness as shown by platelet-to-glass adhesiveness, and inhibition of blood platelet aggregation and thrombus formation induced by various physical stimuli, e.g., arterial injury, and various biochemical stimuli, e.g., ADP, ATP, serotonin, thrombin, and collagen; and in the case of the PGE and PGB compounds, stimulation of epidermal proliferation and keratinization as shown when applied in culture to embryonic chick and rat skin segments.
Because of these biological responses, these known prostaglandins are useful to study, prevent, control, or alleviate a wide variety of diseases and undesirable physiological conditions in birds and mammals, including humans, useful domestic animals, pets, and zoological specimens, and in laboratory animals, for example, mice, rats, rabbits, and monkeys.
For example, these compounds, and especially the PGE compounds, are useful in mammals, including man, as nasal decongestants. For this purpose, the compounds are used in a dose range of about 10 μg. to about 10 mg. per ml. of a pharmacologically suitable liquid vehicle or as an aerosol spray, both for topical application.
The PGE, PGF.sub.α, and PGA compounds are useful in the treatment of asthma. For example, these compounds are useful as bronchodilators or as inhibitors or mediators, such as SRS-A, and histamine which are released from cells activated by an antigen-antibody complex. Thus, these compounds control spasm and facilitate breathing in conditions such as bronchial asthma, bronchitis, bronchiectasis, pneumonia and emphysema. For these purposes, these compounds are administered in a variety of dosage forms, e.g., orally in the form of tablets, capsules, or liquids; rectally in the form of suppositories; parenterally, subcutaneously, or intramuscularly, with intravenous administration being preferred in emergency situations; by inhalation in the form of aerosols or solutions for nebulizers; or by insufflation in the form of powder. Doses in the range of about 0.01 to 5 mg. per kg. of body weight are used 1 to 4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. For the above use these prostaglandins can be combined advantageously with other anti-asthmatic agents, such as sympathomimetics (isoproterenol, phenylephrine, ephedrine, etc); xanthine derivatives (theophylline and aminophyllin); and corticosteriods (ACTH and predinisolone). Regarding use of these compounds see South African Patent No. 68/1055.
The PGE and PGA compounds are useful in mammals, including man and certain useful animals, e.g., dogs and pigs, to reduce and control excessive gastric secretion, thereby reducing or avoiding gastrointestinal ulcer formation, and accelerating the healing of such ulcers already present in the gastrointestinal tract. For this purpose, the compounds are injected or infused intravenously, subcutaneously, or intramuscularly in an infusion dose range about 0.1 ∥g. to about 500 μg. per kg. of body weight per minute, or in a total daily dose by injection or infusion in the range about 0.1 to about 20 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful whenever it is desired to inhibit platelet aggregation, to reduce the adhesive character of platelets, and to remove or prevent the formation of thrombi in mammals, including man, rabbits, and rats. For example, these compounds are useful in the treatment and prevention of myocardial infarcts, to treat and prevent post-operative thrombosis, to promote patency of vascular grafts following surgery, and to treat conditions such as atherosclerosis, arteriosclerosis, blood clotting defects due to lipemia, and other clinical conditions in which the underlying etiology is associated with lipid imbalance or hyperlipidemia. For these purposes, these compounds are administered systemically, e.g., intravenously, subcutaneously, intramuscularly, and in the form of sterile impants or prolonged action. For rapid response, especially in emergency situation, the intravenous route of administration is preferred. Doses in the range about 0.005 to about 20 mg. per kg. of body weight per day are used, the exact dose depending on the age, weight, and condition of the patient or animal and on the frequency and route of administration.
The PGE, PGF.sub.α, and PGF.sub.β compounds are especially useful as additives to blood, blood products, blood substitutes, and other fluids which are used in artificial extracorporeal circulation and perfusion of isolated body portions, e.g., limbs and organs, whether attached to the original body, detached and being preserved or prepared for transplant, or attached to the new body. During these circulations and perfusions, aggregated platelets tend to block the blood vessels and portions of the circulation apparatus. This blocking is avoided by the presence of these compounds. For this purpose, the compound is added gradually or in single or multiple portions to the circulating blood, to the blood of the donor animal, to the perfused body portion, attached or detached, to the recipient, or to two or all of those at a total steady state dose of about 0.001 to 10 mg. per liter of circulating fluid. It is especially useful to use these compounds in laboratory animals, e.g., cats, dogs, rabbits, monkeys, and rats, for these purposes in order to develop new methods and techniques for organ and limb transplants.
PGE compounds are extremely potent in causing stimulation of smooth muscle, and are also highly active in potentiating other known smooth muscle stimulators, for example, oxytocic agents, e.g., oxytocin, and the various ergot alkaloids including derivatives and analogs thereof. Therefore, PGE 2 , for example, is useful in place of or in combination with less than usual amounts of these known smooth muscle stimulators, for example, to relieve the symptoms of paralytic ileus, or to control or prevent atonic uterine bleeding after abortion or delivery, to aid in expulsion of the placenta, and during the puerperium. For the latter purpose, the PGE compound is administered by intravenous infusion immediately after abortion or delivery at a dose in the range about 0.01 to about 50 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, subcutaneous, or intramuscular injection or infusion during puerperium in the range 0.01 to 2 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal.
The PGE, PGA, and PGF.sub.β compounds are useful as hypotensive agents to reduce blood pressure in mammals, including man. For this purpose, the compounds are administered by intravenous infusion at the rate about 0.01 to about 50 μg. per kg. of body weight per minute, or in single or multiple doses of about 25 to 500 μg. per kg. of body weight total per day.
The PGA compounds and derivatives and salts thereof increase the flow of blood in the mammalian kidney, thereby increasing volume and electrolyte content of the urine. For that reason, PGA compounds are useful in managing cases of renal disfunction, especially in cases of severely impaired renal blood flow, for example, the hepatorenal syndrome and early kidney transplant rejection. In cases of excessive or inappropriate ADH (antidiuretic hormone; vasopressin) secretion, the diuretic effect of these compounds is even greater. In anephretic states, the vasopressin action of these compounds is especially useful. Illustratively, the PGA compounds are useful to alleviate and correct cases of edema resulting, for example, from massive surface burns, and in the management of shock. For these purposes, the PGA compounds are preferably first administered by intravenous injection at a dose in the range 10 to 1000 μg. per kg. of body weight or by intravenous infusion at a dose in the range 0.1 to 20 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, intramuscular, or subcutaneous injection or infusion in the range 0.05 to 2 mg. per kg. of body weight per day.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful in place of oxytocin to induce labor in pregnant female animals, including man, cows, sheep, and pigs, at or near term, or in pregnant animals with intrauterine death of the fetus from about 20 weeks to term. For this purpose, the compound is infused intravenously at a dose of 0.01 to 50 μg. per kg. of body weight per minute until or near the termination of the second stage of labor, i.e., expulsion of the fetus. These compounds are especially useful when the female is one or more weeks post-mature and natural labor has not started, or 12 to 60 hours after the ruptured have reptured and natural labor has not yet started. An alternative route of administration is oral.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful for controlling the reproductive cycle in ovulating female mammals, including humans and animals such as monkeys, rats, rabbits, dogs, cattle, and the like. By the term ovulating female mammals is meant animals which are mature enough to ovulate but not so old that regular ovulation has ceased. For that purpose, PGF 2 .sub.α, for example, is administered systemically at a dose level in the range 0.01 mg. to about 20 mg. per kg. of body weight of the female mammal, advantageously during a span of time starting approximately at the time of ovulation and ending approximately at the time of menses or just prior to menses. Intravaginal and intrauterine are alternative routes of administration. Additionally, expulsion of an embryo or a fetus is accomplished by similar administration of the compound during the first third of the normal mammalian gestation period.
As mentioned above, the PGE compounds are potent antagonists of epinephrine-induced mobilization of free fatty acids. For this reason, this compound is useful in experimental medicine for both in vitro and in vivo studies in mammals, including man, rabbits, and rats, intended to lead to the understanding, prevention, symptom alleviation, and cure of diseases involving abnormal lipid mobilization and high free fatty acid levels, e.g., diabetes mellitus, vascular diseases, and hyperthyroidism.
The PGE and PGB compounds promote and accelerate the growth of epidermal cells and keratin in animals, including humans, useful domestic animals, pets, zoological specimens, and laboratory animals. For that reason, these compounds are useful to promote and accelerate healing of skin which has been damaged, for example, by burns, wounds, and abrasions, and after surgery. These compounds are also useful to promote and accelerate adherence and growth of skin autografts, especially small, deep (Davis) grafts which are intended to cover skinless areas by subsequent outward growth rather than initially, and to retard rejection of homografts.
For these purposes, these compounds are preferably administered topically at or near the site where cell growth and keratin formation is desired, advantageously as an aerosol liquid or micronized powder spray, as an isotonic aqueous solution in the case of wet dressings, or as a lotion, cream, or ointment in combination with the usual pharmaceutically acceptable diluents. In some instances, for example, when there is substantial fluid loss as in the case of extensive burns or skin loss due to other causes, systemic administration is advantageous, for example, by intravenous injection or infusion, separate or in combination with the usual infusions of blood, plasma, or substitutes thereof. Alternative routes of administration are subcutaneous or intramuscular near the site, oral, sublingual, buccal, rectal, or vaginal. The exact dose depends on such factors as the route of administration, and the age, weight, and condition of the subject. To illustrate, a wet dressing for topical application to second and/or third degree burns of skin area 5 to 25 square centimeters would advantageously involve use of an isotonic aqueous solution containing 1 to 500 μg./ml. of the PGB compound or several times that concentration of the PGE compound. Especially for topical use, these prostaglandins are useful in combination with antibiotics, for example, gentamycin, neomycin, polymyxin B, bacitracin, spectinomycin, and oxytetracycline, with other antibacterials, for example, mafenide hydrochloride, sulfadiazine, furacolium chloride, and nitrofurazone, and with corticoid steroids, for example, hydrocortisone, prednisolone, methylprednisolone, and fluprednisolone, each of those being used in the combination at the usual concentration suitable for its use alone.
4,5-Didenydro-PGE 1 is mentioned in the prior art (see van Dorp, Annals N.Y. Acad. Sci. vol. 180, page 181, esp. pp 184-185, 1971).
SUMMARY OF THE INVENTION
It is a purpose of this invention to provide novel prostaglandin analogs in which a cis carbon-carbon double bond links C-4 and C-5 in the carboxy-terminated chain. It is a further purpose to provide esters, lower alkanoates, and pharmacologically acceptable salts of said analogs. It is a further purpose to provide a novel process for preparing said acids and esters. It is still a further purpose to provide novel intermediates useful in said process.
The presently described acids and esters of the 4,5-unsaturated prostaglandin analogs include compounds of the following formulas, and also the racemic compounds of each respective formula and the mirror image thereof: ##SPC8##
In Formulas VIII to XXIII, R 1 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, phenyl substituted with one to 3 chloro or alkyl or one to 4 carbon atoms, inclusive; R 2 is hydrogen, methyl, or ethyl; R 3 is methyl or ethyl; and the wavy line ˜ indicates attachment to the cyclopentane ring in alpha or beta configuration.
Formula IX represents 4,5-cis-didehydro-PGF 1 .sub.α when R 1 and R 2 are hydrogen and ˜ indicates the alpha configuration. Formula XII represents 4,5-cis-17,18-cis-tetradehydro-PGE 1 when R 1 and R 2 are hydrogen. Formula XVII represents 4,5-cis-didehydro-15β-PGF 1 .sub.β, methyl ester, when R 1 is methyl, R 2 is hydrogen, and ˜ indicates the beta configuration.
As in the case of formulas II to VII, formula VIII to XV are each intended to represent optically active prostanoic acid derivatives with the same absolute configuration as PGE 1 obtained from mammalian tissues. Furthermore, formulas VIII to XV represent compounds having the S configuration at C-15, i.e. wherein the hydroxyl is attached to the side chain in alpha configuration. Also included within this invention are the 15-epimer compounds corresponding to ##STR1## of formulas XVI to XXIII wherein the C-15 hydroxyl is in R (beta) configuration. Hereinafter, "15β" refers to the epimeric configuration. Thus, "4,5-cis-didehydro-15β-PGF 1 .sub.α " identifies a compound of formula XVII, similar to that of formula IX except that it has the beta (or R) configuration at C-15 instead of the natural alpha (or S) configuration of 4,5-cis-didehydro-PGF 1 .sub.α. Each of formulas VIII to XV plus its mirror image describe a racemic compound within the scope of this invention; likewise each of the 15-epimer formulas corresponding to formulas XVI to XXIII plus its mirror image describe a racemic compound within the scope of this invention. For convenience hereinafter, such a racemic compound is designated by the prefix "racemic" (or "dl") before its name; when that prefix is absent, the intent is to designate an optically active compound respresented by the appropriate formula VIII to XXIII.
With regard to formula VIII to XXIII, examples of alkyl of one to 12 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomeric forms thereof. Examples of cycloalkyl of 3 to 10 carbon atoms, inclusive, which includes alkyl-substituted cycloalkyl, are cyclopropyl, 2-methylcyclopropyl, 2,2-dimethylcyclopropyl, 2,3-diethylcyclopropyl, 2-butylcyclopropyl, cyclobutyl, 2-methylcyclobutyl, 2-propylcyclobutyl, 2,3,4-triethylcyclobutyl, cyclopentyl, 2,2-dimethylcyclopentyl, 2-pentylcyclopentyl, 3-tert-butylcyclopentyl, cyclohexyl, 4-tert-butylcyclohexyl, 3-isopropylcyclohexyl, 2,2-dimethylcyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, and cyclodecyl. Examples of aralkyl of 7 to 12 carbon atoms, inclusive, are benzyl, phenethyl, 1-phenylethyl, 2-phenylpropyl 4-phenylbutyl, 3-phenylbutyl, 2-(1-naphthylethyl), and 1-(2-naphthylmethyl). Examples of phenyl substituted by one to 3 chloro or alkyl of one to 4 carbon atoms, inclusive, are p-chloro-phenyl, m-chlorophenyl, o-chlorophenyl, 2,4-dichlorophenyl, 2,4,6-trichlorophenyl, p-tolyl, m-tolyl, o-tolyl, p-ethylphenyl, p-tert-butylphenyl, 2,5-dimethylphenyl, 4-chloro-2-methylphenyl, and 2,4-dichloro-3-methylphenyl.
Accordingly, there is provided an optically active compound formula ##SPC9##
or a racemic compound of that formula and the mirror image thereof, wherein is one of the three carbocyclic moieties; ##SPC10##
wherein ˜ indicates attachment of hydroxyl to the cyclopentane ring in alpha or beta configuration; wherein M is ##STR2## wherein R 2 is hydrogen, methyl, or ethyl; wherein R 1 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl or one to 4 carbon atoms, inclusive; and wherein T is 1-pentyl or cis 1-pent-2-enyl; including the lower alkanoates thereof, and the pharmacologically acceptable salts thereof when R 1 is hydrogen.
Formula XXIV, which is written in generic form for convenience represents PGF.sub.α-type compounds when is ##SPC11##
Pgf.sub.β-type compounds when is ##SPC12##
Pga-type compounds when is ##SPC13##
and PGB-type compounds when is ##SPC14##
There is also provided an optically active compound of the formula ##SPC15##
or a racemic compound of that formula and the mirror image thereof, wherein M' is ##STR3## wherein R 3 is methyl or ethyl; wherein R 1 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl of one to 4 carbon atoms, inclusive; including the lower alkanoates thereof, and the pharmacologically acceptable salts thereof where R 1 is hydrogen.
There is further provided an optically active compound of the formula ##SPC16##
or a racemic compound of that formula and the mirror image thereof, wherein M is ##STR4## wherein R 2 is hydrogen, methyl, or ethyl; and wherein R 1 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl of one to 4 carbon atoms, inclusive; including the lower alkanoates thereof, and the pharmacologically acceptable salts thereof when R 1 is hydrogen.
The novel formula VIII-to-XXIII compounds and the racemic compounds of this invention each cause the biological responses described above for the PGE, PGF.sub.α, PGF.sub.β, PGA, and PGB compounds, respectively, and each of these novel compounds is accordingly useful for the above-described corresponding purposes, and is used for those purposes in the same manner as described above.
The known PGE, PGF.sub.α, PGF.sub.β, PGA, and PGB compounds are all potent in causing multiple biological responses even at low doses. For example, PGE 1 and PGE 2 both cause vasodepression and smooth muscle stimulation at the same time they exert antilipolytic activity. Moreover, for many applications, these known prostaglandins have an inconveniently short duration of biological activity. In striking contrast, the novel prostaglandin analogs of formulas VIII to XXIII and their racemic compounds, are substantially more specific with regard to potency in causing prostaglandin-like biological responses, and have a substantially longer duration of biological activity. Therefore, each of these novel prostaglandin analogs is surprisingly and unexpectedly more useful than one of the corresponding above-mentioned known prostaglandins for at least one of the pharmacological purposes indicated above for the latter, because it has a different and narrower spectrum of biological potency than the known prostaglandin, and therefore is more specific in its activity and causes smaller and fewer undesired side effects than when the known prostaglandin is used for the same purpose. Moreover, because of its prolonged activity, fewer and smaller doses of the novel prostaglandin analog can frequently be used to attain the desired result.
Another advantage of the novel compounds of this invention, especially the preferred compounds defined hereinabove, compared with the known prostaglandins, is that these novel compounds are administered effectively orally, sublingually, intravaginally, buccally, or rectally, in addition to usual intravenous, intramuscular, or subcutaneous injection or infusion methods indicated above for the uses of the known prostaglandins. These qualities are advantageous because they facilitate maintaining uniform levels of these compounds in the body with fewer, shorter, or smaller doses, and make possible self-administration by the patient.
The 4,5-didehydro and 4,5,17,18-tetradehydro PGE 1 , PGF 1 .sub.α, PGF 1 .sub.β, PGA 1 , and PGB 1 type compounds encompassed by Formulas VIII to XXIII including their alkanoates, are used for the purposes described above in the free acid form, in ester form, or in pharmacologically acceptable salt form. When the ester form is used, the ester is any of those within the above definition of R 1 . However, it is preferred that the ester be alkyl of one to 12 carbon atoms, inclusive. Of those alkyl, methyl and ethyl are especially preferred for optimum absorption of the compound by the body or experimental animal system; and straight-chain octyl, nonyl, decyl, undecyl and dodecyl are especially preferred for prolonged activity in the body or experimental animal.
Pharmacologically acceptable salts of these Formula VIII-to-XXIII compounds useful for the purposes described above are those with pharmacologically acceptable metal cations, ammonium, amine cations, or quaternary ammonium cations.
Especially preferred metal cations are those derived from the alkali metals, e.g., lithium, sodium and potassium, and from the alkaline earth metals, e.g., magnesium and calcium, although cationic forms of other metals, e.g., aluminum, zinc, and iron are within the scope of this invention.
Pharmacologically acceptable amine cations are those derived from primary, secondary, or tertiary amines. Examples of suitable amines are methylamine, dimethylamine, trimethylamine, ethylamine, dibutylamine, triisopropylamine, N-methylhexylamine, decylamine, dodecylamine, allylamine, crotylamine, cyclopentylamine, dicyclohexylamine, benzylamine, dibenzylamine, α-phenylethylamine, β-phenylethylamine, ethylenediamine, diethylenetriamine, and like aliphatic, cycloaliphatic, and araliphatic amines containing up to and including about 18 carbon atoms, as well as heterocyclic amines, e.g., piperidine, morpholine, pyrrolidine, piperazine, and lower-alkyl derivatives thereof, e.g., 1-methylpiperidine, 4-ethylmorpholine, 1-isopropylpyrrolidine, 2-methylpyrrolidine, 1,4-dimethylpiperazine, 2-methylpiperidine, and the like, as well as amines containing water-solubilizing or hydrophilic groups, e.g., mono-, di-, and triethanolamine, ethyldiethanolamine, N-butylethanolamine, 2-amino-1-butanol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-2-methyl-1-propanol, tris(hydroxymethyl)aminomethane, N-phenylethanolamine, N-(p-tert-amylphenyl)diethanolamine, galactamine, N-methylglucamine, N-methylglucosamine, ephedrine, phenylephrine, epinephrine, procaine, and the like.
Examples of suitable pharmacologically acceptable quaternary ammonium cations are tetramethylammonium, tetraethylammonium, benzyltrimethylammonium, phenyltriethylammonium, and the like.
The compounds encompassed by Formulas VIII to XXIII are used for the purposes described above in free hydroxy form or also in the form wherein the hydroxy moieties are transformed to lower alkanoate moieties, e.g., --OH to --OCOCH 3 . Examples of lower alkanoate moieties are acetoxy, propionyloxy, butyryloxy, valeryloxy, hexanoyloxy, heptanoyloxy, octanoyloxy, and branched chain alkanoyloxy isomers of those moieties. Especially preferred among these alkanoates for the above described purposes are the acetoxy compounds. These free hydroxy and a alkanoyloxy compounds are used as free acids, as esters, and in salt form all as described above.
As discussed above, the compounds of Formulas VIII to XXIII are administered in various ways for various purposes; e.g., intravenously, intramuscularly, subcutaneously, orally, intravaginally, rectally, buccally, sublingually, topically, and in the form of sterile implants for prolonged action. For intravenous injection or infusion, sterile aqueous isotonic solutions are preferred. For that purpose, it is preferred because of increased water solubility that R 1 in the Formula VIII-to-XXIII compound be hydrogen or a pharmacologically acceptable cation. For subcutaneous or intramuscular injection, sterile solutions or suspensions of the acid, salt, or ester form in aqueous or non-aqueous media are used. Tablets, capsules, and liquid preparations such as syrups, elixirs, and simple solutions, with the usual pharmaceutical carriers are used for oral sublingual administration. For rectal or vaginal administration, suppositories prepared as known in the art are used. For tissue implants, a sterile tablet or silicone rubber capsule or other object containing or impregnated with the substance is used.
The 4,5-didehydro and 4,5,17,18-tetradehydro PGE 1 -, PGF 1 .sub.α -, PGF 1 .sub.β -, PGA 1 -, and PGB 1 -type compounds encompassed by formulas VIII to XXIII are produced by the reactions and procedures described and exemplified hereinafter.
Reference to Chart A, herein will make clear the transformation from the formula-XXVII lactol compounds to the formula-XXX PGF-type compounds by steps 1-3, inclusive. Formulas XXVII, XXVIII, XXIX, and XXX, hereinafter referred to, are depicted in Chart A, wherein R 4 is alkyl of one to 4 carbon atoms, inclusive, THP is tetrahydropyranyl, T is 1-pentyl or cis 1-pent-2-enyl, and ˜ indicates attachment of OH or OTHP in alpha or beta configuration. Examples of alkyl of one to 4 carbon atoms, inclusive, are methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, and ##SPC17##
tert-butyl.
Consider, first, step 1 of Chart A wherein the formula-XXVII compounds undergo condensation to form the formula-XXVIII enol ethers. For this purpose, an alkoxymethylenetriphenylphosphorane is useful. See, for example, Levine, J. Am. Chem. Soc. 80, 6150 (1958). The reagent is conveniently prepared from a corresponding quaternary phosphonium halide and a base, e.g., butyl lithium or phenyl lithium, at a low temperature, e.g. preferably below -10° C. The formula-XXVII lactol is mixed with the reagent and the condensation proceeds smoothly within the temperature range -30° C. to +30° C. At higher temperatures the reagent is unstable, whereas at low temperatures the rate of condensation is undesirably slow. Examples of the alkoxy-methylenetriphenylphosphoranes preferred for forming the formula-XXVIII enol ethers are methoxy-, ethoxy-, propoxy-, isopropoxy-, butoxy-, isobutoxy-, sec-butoxy-, and tertbutoxymethylenetriphenylphosphorane.
Various hydrocarbyloxymethylenetriphenylphosphoranes which may be substituted for the alkoxymethylenetriphenylphosphoranes and are therefore useful for preparing formula-XXVIII intermediates wherein R 4 is hydrocarbyl, include alkoxy (of 4 to 18 carbon atoms)-, aralkoxy-, cycloalkoxy-, and aryloxymethylenetriphenylphosphoranes. Examples of these hydrocarbyloxymethylenetriphenylphosphoranes are 2-methylbutoxy-, isopentyloxy-, heptyloxy-, octyloxy-, nonyloxy-, tridecyloxy-, octadecyloxy-, benzyloxy-, phenethyloxy-, p-methylphenethyloxy-, 1-methyl-3-phenylpropoxy-, cyclohexyloxy-, phenoxy-, and p-methylphenoxymethylenetriphenylphosphorane. See, for example, Organic Reactions, Vol. 14, pages 346-348, John Wiley and Sons, Inc., N.Y., (1965).
Consider, next, step 2 of Chart A, wherein the formula-XXVIII enol ether intermediates are hydrolyzed to the formula-XXIX lactols. This hydrolysis is done under acidic conditions, for example with perchloric acid or acetic acid. Tetrahydrofuran is a suitable diluent for this reaction mixture. Reactions temperatures of from 10° C. to 100° C. may be employed. The length of time required for hydrolysis is determined in part by the hydrolysis temperature. With acetic acid-water-tetrahydrofuran at about 60° C., several hours are sufficient.
Finally in step 3 of Chart A, the formula-XXIX lactols are transformed to the formula-XXX PGF-type products by condensation with a Wittig reagent derived from 3-carboxypropyltriphenylphosphonium halide and sodio methylsulfinylcarbanide. Dimethyl sulfoxide is conveniently used as a solvent, and the reaction may be done at about 25° C.
The various formula-XXVIII and -XXIX intermediates are useful directly as produced or they may be subjected to separation procedures, for example silica gel chromatography or recystallization.
The initial optically active and racemic reactants of formula XXVII in Chart A and their 15β-epimers are known in the art or are prepared by methods known in the art. See, for example, Corey et al., J. Am. Chem. Soc. 92,397 (1970) and 93, 1490 (1971). Use of the lactol wherein T is 1-pentyl yields a 4,5-cis-didehydro-PGF 1 .sub.α product; use of the lactol wherein T is cis 1-pent-2-enyl yields a 4,5-cis-17,18-cis-tetradehydro-PGF 1 .sub.α product. The stereochemistry at C-15 is preserved, i.e. a 15β formula-XXVII reactant yields a 15β formula-XXX product.
Reference to Chart B, herein, will make clear the transformation from the PGF-type compounds XXXI to the PGE-type compounds XXXIV by steps 1-3, inclusive. Formulas XXXI, XXXII, XXXIII, and XXXIV, hereinafter referred to, are depicted in Chart B, wherein A is alkyl of one to 4 carbon atoms, inclusive, phenyl, phenyl substituted with one or 2 fluoro, chloro, or alkyl of one to 4 carbon atoms, inclusive, or aralkyl of 7 to 12 carbon atoms, inclusive; wherein R 1 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl of one to 4 carbon atoms, inclusive; wherein R 3 is R 1 as defined above or silyl of the formula --Si--(A) 3 wherein A is as defined above; wherein T is 1-pentyl or cis 1-pent-2-enyl; and wherein ˜ indicates attachment of hydroxyl or silyl in alpha or beta configuration. The various A's of a --Si--(A) 3 moiety are alike or different. For example, an --Si--(A) 3 can be trimethylsilyl, dimethylpropylsilyl, dimethylphenylsilyl, or methylphenylbenzylsilyl. Examples of alkyl of one to 4 carbon atoms, inclusive, are methyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, and tert-butyl. Examples of aralkyl of 7 to 12 carbon atoms, inclusive, are benzyl, phenethyl, α-phenylethyl, 3-phenylpropyl, α-napthylmethyl, and 2-(β-naphthyl)ethyl. Examples of phenyl substituted with one or 2 fluoro, chloro, or alkyl or one of 4 carbon atoms, inclusive, are p-chlorophenyl, m-fluorophenyl, o-tolyl, 2,4-dichlorophenyl, p-tert-butyl, 4-chloro-2-methylphenyl, and 2,4-dichloro-3 -methylphenyl. ##SPC18##
Consider, then, step 1 of Chart B, wherein the formula-XXXI compounds are selectively silylated at the C-11 and C-15 positions, by choice of reagents and conditions. Silylating agents are known in the art. See, for example, Pierce, "Silylation of Organic Compounds," Pierce Chemical Co., Rockford, Ill. (1968). Silylating agents of the type (A) 3 SiN(E) 2 , i.e. substituted silylamines wherein A is as defined above and E has the same definition as A, being the same or different, are useful for the above purpose at temperatures below about -25° C. A preferred temperature range is about -35° to -50°. At higher temperatures some silylation of C-9 hydroxyl groups as well as the C-11 and C-15 hydroxyl groups occurs, whereas at lower temperatures the rate of silylation is undesirably slow. Examples of the silylamine type silylating agents suitable for forming the formula-XXXII intermediates include pentamethylsilylamine, pentaethylsilylamine, N-trimethylsilyldiethylamine, 1,1,1-triethyl-N,N-dimethylsilylamine, N,N-diisopropyl-1,1,1-trimethylsilylamine, 1,1,1-tributyl-N,N-dimethylsilylamine, N,N-dibutyl-1,1,1-trimethylsilylamine, 1-isobutyl-N,N,1,1-tetramethylsilylamine, N-benzyl-N-ethyl-1,1,1-trimethylsilylamine, N,N,1,1-tetramethyl-1-phenylsilylamine, N,N-diethyl-1,1 -dimethyl-1-phenylsilylamine, N,N-diethyl-1-methyl-1,1-diphenylsilylamine, N,N-dibutyl-1,1,1-triphenylsilylamine, and 1-methyl-N,N,1,1-tetraphenylsilylamine.
The reaction is carried out with exclusion of atmospheric moisture, for example under a nitrogen atmosphere. It is conveniently done in a solvent such as acetone or dichloromethane, although the silylating agent itself, when used in excess, may also serve as a liquid medium for the reaction. The reaction ordinarily is completed in a few hours, and should be terminated when the C-11 and C-15 hydroxyl groups are silylated, to avoid side reactions. The progress of the reaction is conveniently monitored by thin-layered chromatography (TLC), utilizing methods known in the art.
An excess of the reagent over that stoichiometrically required is used, preferably at least a four-fold excess. When R 1 in the formula-XXXI starting material is hydrogen, the --COOH moiety thereby defined may be partially or even completely transformed to --COO--Si--(A) 3 , additional silylating agent being used for this purpose. Whether or not this occurs is immaterial for the success of the process, since --COOH groups are not changed by the subsequent steps and --COO--Si--(A) 3 groups are easily hydrolyzed to --COOH groups.
Consider, next, step 2 of Chart B, wherein the formula-XXXII 11,15-disilyl ether intermediate is oxidized to compound XXXIII. Oxidation reagents useful for this transformation are known in the art. An especially useful reagent for this purpose is the Collins reagent, i.e. chromium trioxide in pyridine. See J. C. Collins et al., Tetrahedron Lett., 3363 (1968). Dichloromethane is a suitable diluent for this purpose. A slight excess of the oxidant beyond the amount necessary to oxidize the C-9 secondary hydroxy group of the formula-XXXII intermediate is used. Reaction temperatures of below 20° C. should be used. Preferred reaction temperatures are in the range -10° to +10° C. The oxidation proceeds rapidly and is usually complete in about 5 to 20 minutes.
Finally in step 3 of Chart B, all silyl groups of the formula-XXXIII intermediates are removed by hydrolysis, thereby forming the formula-XXXIV PGE-type products. These hydrolyses are carried out by prior art procedures known to be useful for transforming silyl ethers and silyl esters to alcohols and carboxylic acids, respectively. See, for example, Pierce, cited above, especially p. 447 thereof. A mixture of water and sufficient of a water-miscible organic diluent to give a homogeneous hydrolysis reaction mixture represents a suitable reaction medium. Addition of a catalytic amount of an organic or inorganic acid hastens the hydrolysis. The length of time required for the hydrolysis is determined in part by the hydrolysis temperature. With a mixture of water and methanol at 25° C., several hours is usually sufficient for hydrolysis. At 0° C., several days is usually necessary. The formula-XXXIV PGE-type product is isolated by conventional means.
Those PGF-type compounds of formulas IX, XIII, XVII, and XXI wherein R 2 is methyl or ethyl are transformed to the corresponding PGE-type compounds by the steps shown in Chart C. Therein, formula XLIV is generic to those PGF-type compounds named above. In Chart C, the symbols A, R 1 , R 5 , and ˜ have the same meaning as in Chart B. M' represents either ##STR5## wherein R 3 is methyl or ethyl. Following steps 1-3, which utilize essentially the same reagents and conditions as in steps 1-3 of Chart B, there are obtained the PGE-type compounds represented by formula XLVII. Under these conditions, the intermediates of formula XLV and XLVI are 11-silyl derivatives rather than the 11,15-disilyl derivatives of Chart B.
The novel 15-substituted PGF-type acids and esters of ##SPC19##
this invention represented by formulas IX, XIII, XVII, and XXI wherein R 2 is methyl or ethyl are prepared by the sequence of transformations shown in Chart D, steps 1-3, inclusive. Formulas XXXV, XXXVI, XXXVII, XXXVIII, and XXXIX, hereinafter referred to, are depicted in Chart D, wherein Q is ##STR6## R 3 is methyl or ethyl, and A, R 1 , R 5 , T, and ˜ are as defined for Chart B.
Consider, then, step 1 of Chart D, wherein the formula-XXXV PGF-type compounds are oxidized to the intermediate formula-XXXVI 15-oxo acids and esters. For this purpose, reagents such as 2,3-dichloro-5,6-dicyano-1,4-benzoquinone, activated manganese dioxide, or nickel peroxide are used, according to procedures known in the art. See Fieser et al., "Reagents for Organic Synthesis," John Wiley and Sons, Inc., New York, N.Y., (1967) pp. 215, 637, and 731.
Considering step 2 of Chart D, the formula-XXXVI 15-oxo compounds are transformed to silyl derivatives of formula XXXVII by procedures known in the art. See, for example, Pierce, "Silylation of Organic Compounds," Pierce Chemical Co., Rockford, Ill. (1968). Both hydroxy groups of the formula-XXXVI reactants are thereby transformed to --O--Si(A) 3 moieties wherein A is as defined above, and sufficient of the silylating agent is used for that purpose according to known procedures. When R 1 in the formula-XXXVI intermediate is hydrogen, the --COOH moiety thereby defined is simultaneously transformed to --COO--Si(A) 3 , additional silylating agent being used for this purpose. This latter transformation is aided by excess silylating agent and prolonged treatment. When R 1 in formula XXXVI is alkyl, then R 5 in formula XXXVII will also be alkyl. The necessary silylating agents for these transformations are known in the art or are prepared by methods known in the art. See, for example, Post, "Silicones and Other Organic Silicon Compounds," Reinhold Publishing Corp., New York, N.Y. (1949).
Considering step 3 of Chart D, the intermediate silyl compounds of formula XXXVII are transformed to the final 15-substituted compounds of Formulas XXXVIII and XXXIX by first reacting the silyl compound with a Grignard reagent of the formula R 3 MgHal wherein R 3 is as defined above, and Hal is chloro, bromo, or iodo. For this purpose, it is preferred that Hal be bromo. This reaction is carried out by the usual procedure for Grignard reactions, using diethyl ether as a reaction solvent and saturated aqueous ammonium chloride solution to hydrolyze the Grignard complex. The resulting disilyl, trisilyl, or tetrasilyl tertiary alcohol is then hydrolyzed with water to remove the silyl groups. For this purpose, it is advantageous to use a mixture of water and sufficient of a water-miscible solvent, e.g., ethanol to give a homogenous reaction mixture. The hydrolysis is usually complete in 2 to 6 hours at 25° C., and is preferably carried out in an atmosphere of an inert gas, e.g., nitrogen or argon.
The mixture of 15-α and 15-β isomers obtained by this Grignard reaction and hydrolysis is separated by procedures known in the art for separating mixtures of prostanoic acid derivatives, for example, by chromatography on neutral silica gel. In some instances, the lower alkyl esters, especially the methyl esters of a pair of 15-α and 15-β isomers are more readily separated by silica gel chromatography than are the corresponding acids. In those cases, it is advantageous to esterify the mixture of acids as described below, separate the two esters, and then, if desired, saponify the esters of procedures known in the art for saponification of prostaglandins F.
The 15-substituted PGE-type compounds represented by formulas VIII, XII, XVI, and XX are prepared from the above 15-substituted PGF-type compounds following the steps of Chart C, discussed above.
Chart E shows transformations from the formula XL PGE-type compounds to the corresponding PGF-, PGA-, and PGB-type compounds. In FIGS. XL, XLI, XLII, and XLIII of Chart E, M is ##STR7## wherein R 2 is hydrogen, methyl, or ethyl; and R 1 , T, and ˜ are as defined above for Chart B.
Thus, the various PGF.sub.β-type compounds encompassed by formulas IX, XIII, XVII, and XXI, wherein ˜ is beta, are prepared by carbonyl reduction the corresponding PGE type compounds, e.g. formulas VIII, XII, XVI, and XX. For example, carbonyl reduction of 4,5-cis-didehydro-PGE 1 gives a mixture of 4,5-cis-didehydro-PGF 1 .sub.α and 4,5-cis-didehydro-PGF 1 .sub.β.
These ring carbonyl reductions are carried out by methods known in the art for ring carbonyl reductions of known prostanoic acid derivatives. See, for example, Bergstrom et al., Arkiv Kemi 19, 563 (1963), Acta. Chem. Scand. 16, 969 (1962), and British Specification No. 1,097,533. Any reducing agent is used which does not react with carbon-carbon double bonds or ester groups. Preferred reagents are lithium(tri-tert-butyoxy)aluminum hydride, the metal borohydrides, especially sodium, potassium and zinc ##SPC20##
borohydrides, the metal trialkoxy borohydrides, e.g., sodium trimethoxyborohydride. The mixtures of alpha and beta hydroxy reduction products are separated into the individual alpha and beta isomers by methods known in the art for the separation of analogous pairs of known isomeric prostanoic acid derivatives. See, for example, Bergstrom et al., cited above, Granstrom et al., J. Biol. Chem. 240, 457 (1965), and Green et al., J. Lipid Research 5, 117 (1964). Especially preferred as separation methods are partition chromatographic procedures, both normal and reversed phase, preparative thin layer chromatography, and countercurrent distribution procedures.
The various PGA-type compounds encompassed by formulas X, XIV, XVIII, and XXII are prepared by acidic dehydration of the corresponding PGE-type compounds, e.g. formulas VIII, XII, XVI, and XX. For example, acidic dehydration of 4,5-cis-didehydro-PGE 1 gives 4,5-cis-didehydro-PGA 1 .
These acidic dehydrations are carried out by methods known in the art for acidic dehydrations of known prostanoic acid derivatives. See, for example, Pike et al., Proc. Nobel Symposium II, Stockholm (1966), Interscience Publishers, New York, pp. 162-163 (1967); and British Specification 1,097,533. Alkanoic acids of 2 to 6 carbon atoms, inclusive, especially acetic acid, are preferred acids for this acidic dehydration. Dilute aqueous solutions of mineral acids, e.g., hydrochloric acid, especially in the presence of a solubilizing diluent, e.g., tetrahydrofuran, are also useful as reagents for this acidic dehydration, although these reagents may cause partial hydrolysis of an ester reactant.
The various PGB-type compounds encompassed by formulas XI, XV, XIX, and XXIII are prepared by basic dehydration of the corresponding PGE-type compounds encompassed by formulas VIII, XII, XVI, and XX, or by contacting the corresponding PGA-type compounds encompassed by formulas X, XIV, XVIII, and XXII with base. For example, both 4,5-cis-didehydro-PGE 1 and 4,5-cis-didehydro-PGA 1 give 4,5-cis-didehydro-PGB 1 on treatment with base.
These basic dehydrations and double bond migrations are carried out by methods known in the art for similar reactions of known prostanoic acid derivatives. See, for example, Bergstrom et al., J. Biol. Chem. 238, 3555 (1963). The base is any whose aqueous solution has pH greater than 10. Preferred bases are the alkali metal hydroxides. A mixture of water and sufficient of a water-miscible alkanol to give a homogeneous reaction mixture is suitable as a reaction medium. The PGE-type or PGA-type compound is maintained in such a reaction medium until no further PGB-type compound is formed, as shown by the characteristic ultraviolet light absorption near 278 mμ for the PGB-type compound.
Optically active products are obtained from optically active intermediates according to the process steps of Chart A. Likewise, optically active products are obtained by the transformations of optically active compounds following the processes of Charts B, C, D, and E. When racemic intermediates are used, and racemic products are obtained, these racemic products may be used in their racemic form or, if preferred, they may be resolved as optically active isomers by procedures known in the art.
For example, when final compound VIII to XXIII is a free acid, the d1 form thereof is resolved into the d and l forms by reacting said free acid by known general procedures with an optically active base, e.g., brucine or strychnine, to give a mixture of two diastereoisomers which are separated by known general procedures, e.g., fractional crystallization, to give the separate diastereoisomeric salts. The optically active acid of formula VIII to XXIII is then obtained by treatment of the salt with an acid by known general procedures.
As discussed above, the stereochemistry at C-15 is not altered by the transformations of Chart A; the 15β epimeric products of formula XXX are obtained from 15β formula-XXVII reactants. Another method of preparing the 15β products is by isomerization of the PGF 1 - or PGE 1 -type compounds having 15-(S) configuration, by methods known in the art. See, for example, Pike et al., J. Org. Chem. 34, 3552 (1969).
As discussed above, the processes of Charts A, B, C, D, and E lead variously to acids (R 1 is hydrogen) or to esters (R 1 is alkyl, cycloalkyl, aralkyl, phenyl or substituted phenyl, as defined above). When an acid has been prepared and an alkyl ester is desired, esterification is advantageously accomplished by interaction of the acid with the appropriate diazohydrocarbon. For example, when diazomethane is used, the methyl esters are produced. Similar use of diazoethane, diazobutane, and 1-diazo-2-ethylhexane, and diazodecane, for example, gives the ethyl, butyl, and 2-ethylhexyl and decyl esters, respectively.
Esterification with diazohydrocarbons is carried out by mixing a solution of the diazohydrocarbon in a suitable inert solvent, preferably diethyl ether, with the acid reactant, advantageously in the same or a different inert diluent. After the esterification reaction is complete, the solvent is removed by evaporation, and the ester purified if desired by conventional methods, preferably by chromatography. It is preferred that contact of the acid reactants with the diazohydrocarbon be no longer than necessary to effect the desired esterification, preferably about one to about ten minutes, to avoid undesired molecular changes. Diazohydrocarbons are known in the art or can be prepared by methods known in the art. See, for example, Organic Reactions, John Wiley and Sons, Inc., New York, N.Y., Vol. 8, pp. 389-394 (1954).
An alternative method for esterification of the carboxyl moiety of the acid compounds comprises transformation of the free acid to the corresponding silver salt, followed by interaction of that salt with an alkyl iodide. Examples of suitable iodides are methyl iodide, ethyl iodide, butyl iodide, isobutyl iodide, tert-butyl iodide, and the like. The silver salts are prepared by conventional methods, for example, by dissolving the acid in cold dilute aqueous ammonia, evaporating the excess ammonia at reduced pressure, and then adding the stoichiometric amount of silver nitrate.
The final formula VIII-to-XXIII compounds prepared by the processes of this invention, in free acid form, are transformed to pharmacologically acceptable salts by neutralization with appropriate amounts of the corresponding inorganic or organic base, examples of which correspond to the cations and amines listed above. These transformations are carried out by a variety of procedures known in the art to be generally useful for the preparation of inorganic, i.e., metal or ammonium, salts, amine acid addition salts, and quaternary ammonium salts. The choice of procedure depends in part upon the solubility characteristics of the particular salt to be prepared. In the case of the inorganic salts, it is usually suitable to dissolve the formula VIII-to-XXIII acid in water containing the stoichiometric amount of a hydroxide, carbonate, or bicarbonate corresponding to the inorganic salt desired. For example, such use of sodium hydroxide, sodium carbonate, or sodium bicarbonate gives a solution of the sodium salt. Evaporation of the water or addition of a water-miscible solvent of moderate polarity, for example, a lower alkanol or a lower alkanone, gives the solid inorganic salt if that form is desired.
To produce an amine salt, the formula VIII-to-XXIII acid is dissolved in a suitable solvent of either moderate or low polarity. Examples of the former are ethanol, acetone, and ethyl acetate. Examples of the latter are diethyl ether and benzene. At least a stoichiometric amount of the amine corresponding to the desired cation is then added to that solution. If the resulting salt does not precipitate, it is usually obtained in solid form by addition of a miscible diluent of low polarity or by evaporation. If the amine is relatively volatile, any excess can easily be removed by evaaporation. It is preferred to use stoichiometric amounts of the less volatile amines.
Salts wherein the cation is quaternary ammonium are produced by mixing the formula VIII-to-XXIII acid with the stoichiometric amount of the corresponding quaternary ammonium hydroxide in water solution, followed by evaporation of the water.
The final formula VIII-to-XXIII acids or esters prepared by the processes of this invention are transformed to lower alkanoates by interaction of the formula VIII-to-XXIII hydroxy compound with a carboxyacylating agent, preferably the anhydride of a lower alkanoic acid, i.e., an alkanoic acid of two to 8 carbon atoms, inclusive. For example, use of acetic anhydride gives the corresponding acetate. Similar use of propionic anhydride, isobutyric anhydride, and hexanoic acid anhydride gives the corresponding carboxyacylates.
The carboxyacylation is advantageously carried out by mixing the hydroxy compound and the acid anhydride, preferably in the presence of a tertiary amine such as pyridine or triethylamine. A substantial excess of the anhydride is used, preferably about 10 to about 10,000 moles of anhydride per mole of the hydroxy compound reactant. The excess anhydride serves as a reaction diluent and solvent. An inert organic diluent, for example, dioxane, can also be added. It is preferred to use enough of the tertiary amine to neutralize the carboxylic acid produced by the reaction, as well as any free carboxyl groups present in the hydroxy compound reactant.
The carboxyacylation reaction is preferably carried out in the range about 0° to about 100° C. The necessary reaction time will depend on such factors as the reaction temperature, and the nature of the anhydride and tertiary amine reactants. With acetic anhydride, pyridine, and a 25° C. reaction temperature, a 12 to 24-hour reaction time is used.
The carboxyacylated product is isolated from the reaction mixture by conventional methods. For example, the excess anhydride is decomposed with water, and the resulting mixture acidified and then extracted with a solvent such as diethyl ether. The desired carboxyacylate is recovered from the diethyl ether extract by evaporation. The carboxyacylate is then purified by conventional methods, advantageously by chromatography.
By this procedure, thee formula VIII, XII, XVI, and XX PGE-type compounds are transformed to dialkanoates, the formula IX, XIII, XVII, and XXI PGF-type compounds are transformed to trialkanoates, and the formula X, XIV, XVIII, and XXII PGA-type and formula XI, XV, XIX, and XXIII PGB-type compounds are transformed to monoalkanoates.
When a PGE-type dialkanoate is transformed to a PGF-type compound by carbonyl reduction as shown in chart E, a PGF-type dialkanoate is formed and is used for the above-described purposes as such or is transformed to a trialkanoate by the above-described procedure. In the latter case, the third alkanoyloxy group can be the same as or different from the two alkanoyloxy groups present before the carbonyl reduction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following examples.
All temperatures are in degrees centigrade.
Infrared absorption spectra are recorded on a Perkin-Elmer model 421 infrared spectrophotometer. Except when specified otherwise, undiluted (neat) samples are used.
Mass spectra recorded on an Atlas CH-4 mass spectrometer with a TO-4 source (ionization voltage 70 ev).
"Brine", herein, refers to an aqueous saturated sodium chloride solution.
EXAMPLE 1
3α,5α-Dihydroxy-2β-(3α-hydroxy-trans-1-octenyl)-1.alpha.-cyclopentanepropionaldehyde δ Lactol (Formula XXIX: T is 1-pentyl and ˜ is alpha)
Refer to Chart A. A suspension of methoxymethyltriphenylphosphonium chloride (Levine, J. Am. Chem. Soc. 80, 6150 (1958), 32.4 g.) in 150 ml. of tetrahydrofuran (THF) is cooled to -15° C. and to it is added 69.4 ml. of butyllithium (1.6 M. in hexane) in 45 ml. of THF. After 30 min. there is added a solution of the formula-XXVII 3α,5α-hydroxy-2β-(3α-hydroxy-trans-1-octenyl)-1.alpha.-cyclopentaneacetaldehyde γ lactol bis (tetrahydropyranyl) ether (Corey et al., J. Am. Chem. Soc. 92, 397 (1970), 10.0 g.) in 90 ml. of THF. The mixture is stirred for 1.5 hrs., meanwhile warming to about 25° C., and is then concentrated under reduced pressure. The residue is partitioned between dichloromethane and water, and the organic phase is dried and concentrated. This residue is then subjected to chromatography over silica gel, eluting with cyclohexaneethyl acetate (2:1). Those fractions shown by thin-layer chromatography (TLC) to contain the formula-XXVIII intermediate are combined and concentrated to yield that enolether, 5.2 g.
The above enol-ether, in 20 ml. of THF, is hydrolyzed with 50 ml. of 66% acetic acid at about 57° C. for 2.5 hrs. The mixture is concentrated under reduced pressure. Toluene is added to the residue and the solution is again concentrated. Finally the residue is subjected to chromatography on silica gel, eluting with chloroform-methanol (6:1). The title compound is obtained by combining and concentrating suitable fractions, 2.54 g.; recrystalized from ethyl acetate, m.p. 121°-123° C., infrared absorption at 3500, 1315, 1220, 1140, 1120, 1045, 1020, and 970 cm.sup. -1 .
Following the procedures of Example 1, but replacing the formula-XXVII compound with the corresponding racemic 3α,5α-dihydroxy-2β-(3α-hydroxy-trans-1-octenyl)-1.alpha.-cyclopentaneacetaldehyde γ lactol bis(tetrahydropyranyl) ether (Corey et al., J. Am. Chem. Soc. 91, 5675 (1969)), there is obtained the corresponding racemic δ lactol, namely, dl-3α,5α-dihydroxy-2β-(3α-hydroxy-trans-1-octenyl)-1α-cyclopentanepropionaldehyde δ lactol.
Following the procedures of Example 1, but replacing the formula-XXVII compound with the corresponding 3β-hydroxy ether compound, there is obtained the corresponding formula-XXIX 3β-hydroxy compound, namely 3α,5α-dihydroxy-2β-(3β-hydroxy-trans-1-octenyl)-1.alpha.-cyclopentanepropionaldehyde δ lactol.
Likewise following the procedures of Example 1, but replacing the formula-XXVII compound with the corresponding racemic 3β-hydroxy ether compound, there is obtained the corresponding racemic 3β-hydroxy δ lactol, namely dl-3α,5α-dihydroxy-2β-(3β-hydroxy-trans-1-octenyl)-1α-cyclopentanepropionaldehyde δ lactol.
EXAMPLE 2
4,5-cis-Didehydro-PGF 1 .sub.α (Formula IX: R 1 and R 2 are hydrogen, and ˜ is alpha)
Refer to Chart A. 3-Carboxypropyltriphenylphosphonium bromide is prepared by heating triphenylphosphine (156.8 g.) and 4-bromobutyric acid (100 g.) in 125 ml. of benzene at reflux for 18 hrs. The crystalline product is filtered off, washed with benzene, and recrystallized from ethanolacetonitrile-ether, 150 g., m.p. 247°-249° C.
The above phosphonium bromide (10.6 g.) is added to sodio methylsulfinylcarbanide prepared from sodium hydride (2.08 g., 57%) and 30 ml. of dimethyl sulfoxide, and the resulting Wittig reagent is combined with the Formula-XXIX lactol (Example 1, 1.76 g.) in 20 ml. of dimethyl sulfoxide. The mixture is stirred overnight, diluted with about 200 ml. of benzene, and washed with potassium hydrogen sulfate solution. The two lower layers are washed with dichloromethane, and the organic phases are combined, washed with brine, dried, and concentrated under reduced pressure. The residue is subjected to chromatography over acid-washed silica gel, eluting with ethyl acetate-isomeric hexanes (3:1). Those fractions shown to contain the desired compound by TLC are combined and concentrated to yield the title compound, 0.14 g.; high resolution mass spectral peak (trimethylsilyl derivative) at 642.3929.
Following the procedures of Example 2, but replacing the formula-XXIX lactol with either the corresponding racemic lactol, the corresponding formula-XXIX 3β-hydroxy lactol, or the corresponding racemic 3β-hydroxy lactol obtained following Example 1, there is obtained the corresponding dl-4,5-cis-didehydro-PGF 1 .sub.α, the formula-XVII 4,5-cis-didehydro-15β-PGF 1 .sub.α product, or dl-4,5-cis-didehydro-15β-PGF 1 .sub.α.
EXAMPLE 3
4,5-cis-Didehydro-PGF 1 .sub.α, Methyl Ester (Formula IX: R 1 is methyl, R 2 is hydrogen, and ˜ is alpha)
A solution of diazomethane (about 50% excess) in diethyl ether (25 ml.) is added to a solution of 4,5-cis-didehydro-PGF 1 .sub.α (Example 2, 50 mg.) in 25 ml. of a mixture of methanol and diethyl ether (1:1). The mixture is left standing at 25° C. for 5 min. and then is concentrated under reduced pressure to the title compound.
Likewise following the procedures of Example 3, the methyl esters of dl-4,5-cis-didehydro-PGF 1 .sub.α, 4,5-cis-didehydro-15β-PGF 1 .sub.α, and dl-4,5-cis-didehydro-15β-PGF 1 .sub.α are prepared.
EXAMPLE 4
4,5-cis-Didehydro-PGE 1 , Methyl Ester (Formula XXXIV: R 1 is methyl, T is 1-pentyl, and ˜ is alpha)
Refer to Chart B. 1. A solution of 4,5-cis-didehydro-PGF 1 .sub.α, methyl ester (Example 3, 480 mg.) in 20 ml. of acetone is cooled to about -50° C. and to it is added 4 ml. of N-trimethylsilyldiethylamine. The mixture is kept under nitrogen at -50° C. for 2.5 hrs. Progress of the reaction is monitored by TLC. The reaction mixture is diluted with about 200 ml. of diethyl ether. The solution is washed with about 150 ml. of cold brine and cold saturated potassium bicarbonate solutions. The ether extract is concentrated to a residue containing 4,5-cis-didehydro-PGF 1 .sub.α, 11,15-bis(trimethylsilyl) ether, methyl ester (Formula XXXII).
2. For the oxidation step, a solution of the above 11,15-bis(trimethylsilyl) ether in dichloromethane (4 ml.) is added to a solution of CrO 3 -pyridine (prepared from 0.26 g. of CrO 3 and 0.4 ml. of pyridine in 16 ml. of dichloromethane). The mixture is stirred for 5 min. at about 0° C. and 5 min. at about 25° C., then diluted with 10 ml. of ethyl acetate and filtered through silica gel. The solution, together with rinsings, is concentrated under reduced pressure.
3. The product of step 2 is hydrolyzed in 6 ml. of methanol, 1 ml. of water, and about 0.1 ml. of acetic acid at about 35° C. for 15 min. The volatiles are removed under reduced pressure and the residue is partitioned between dichloromethane and water. The organic phase is separated, dried over sodium sulfate, and concentrated under reduced pressure. The residue is chromatographed on silica gel, eluting with ethyl acetate-Skellysolve B (isomeric hexanes) (4:1). Those fractions containing the title compound free of starting material and impurities are combined and concentrated to yield the title compound, 77 mg.; mass spectral peaks (for trimethylsilylated derivative) at 495, 492, 479, 439, 420 and 349; mass 510.3198.
Following the procedures of Example 4, but replacing 4,5-cis-didehydro-PGF 1 .sub.α, methyl ester with dl-4,5-cis-didehydro-PGF 1 .sub.α, methyl ester obtained following Example 3, there is obtained dl-4,5-cis-didehydro-PGE 1 , methyl ester.
Following the procedures of Example 4, but replacing 4,5-cis-didehydro-PGF 1 .sub.α, methyl ester, with 4,5-cis-didehydro-15β-PGF 1 .sub.α obtained following Example 2, there is obtained the formula-XVI 4,5-cis-didehydro-15β-PGE 1 product.
Likewise, using dl-4,5-cis-didehydro-15β-PGF 1 .sub.α, methyl ester, there is obtained dl-4,5-cis-didehydro-15β-PGE 1 , methyl ester.
EXAMPLE 5
4,5-cis-Didehydro-PGF 1 .sub.β, Methyl Ester (Formula IX: R 1 is methyl, R 2 is hydrogen, and ˜ is beta).
Refer to Chart E. A solution of sodium borohydride (300 mg.) in 6 ml. of ice-cold methanol is added to a solution of 4,5-cis-didehydro-PGE 1 , methyl ester (Example 4, 650 mg.) in 30 ml. of methanol at -5° C. The mixture is stirred for 0.5 hrs. at 0° C. and 5 ml. of acetone is added, after which the mixture is stirred for 5 min. and made slightly acid with acetic acid. The mixture is evaporated under reduced pressure until most of the methanol and acetone are removed, then the residue is extracted with dichloromethane. The extract is washed with water, dilute aqueous sodium bicarbonate, and brine, then dried over sodiumm sulfate and evaporated under reduced pressure to give a residue. This residue is chromatographed over silica gel wet-packed in ethyl acetate, eluting with 2%, 4%, 7.5%, and 10% ethanol in ethyl acetate, taking 25 ml. fractions. Those fractions containing the title compound free of starting material and impurities, as shown by TLC, are combined and concentrated to yield the formula-IX product.
Following the procedure of Example 5, the corresponding 15β compound and the respective racemic compounds are each reduced and separated as the corresponding 4,5-cis-didehydro-PGF 1 .sub.β -type compounds.
EXAMPLE 6
4,5-cis-17,18-cis-Tetradehydro-PGF 1 .sub.α (Formula XIII: R 1 and R 2 are hydrogen, and ˜ is alpha)
Following the procedures of Example 1 and 2, but replacing the formula-XXVII 3α,5α-dihydroxy-2β-(3α-hydroxytrans-1-octenyl)-1α-cyclopentaneacetaldehyde γ lactol bis(tetrahydropyranyl) ether of Example 1 with 3α, 5α-dihydroxy-2β-(3α-hydroxy-trans-1-cis-17-octadienyl)1.alpha.-cyclopentaneacetaldehyde γ lactol bis (tetrahydropyranyl) ether (Corey et al., J. Am. Chem. Soc. 93, 1490 (1971)), there is obtained first the corresponding formula-XXVIII intermediate enol-ether, then the formula-XXIX lactol, wherein T is cis 1-pent-2-enyl, and finally the title compound.
Following the procedures of example 6 but replacing the formula-XXVII ether of that example with the coresponding 3β-hydroxy ether, namely, 3α,5α-dihydroxy-2β-(3β-hydroxy-trans-1-cis-5-octadienyl)-1α-cyclopentaneacetaldehyde γ lactol bis(tetrahydropyranyl) ether, there is obtained the corresponding formula-XXI 4,5-cis-17,18-cis-tetradehydro-15β-PGF 1 .sub.α product.
Following the procedures of Example 6 but using the appropriate racemic intermediate, there is obtained dl-4,5-cis-17,18-cis-tetradehydro-PGF 1 .sub.α and dl-4,5-cis-17,18-cis-tetradehydro-15β-PGF 1 .sub.α.
EXAMPLE 7
4,5-cis-17,18-cis-Tetradehydro-PGE 1 (Formula XII: R 1 and R 2 are hydrogen)
Following the procedures of Example 4, but replacing the 4,5-cis-didehydro-PGF 1 .sub.α, methyl ester of that Example with formula-XIII 4,5-cis-17,18-cis-tetradehydro-PGF 1 .sub.α (Example 5), there is obtained the title compound.
Likewise following the procedures of Example 7, but using formula-XXI 4,5-cis-17,18-cis-tetradehydro-15β-PGF 1 .sub.α, there is obtained the corresponding formula-XX 4,5-cis-17,18-cis-tetradehydro-15β-PGE 1 compound.
Following the procedures of Example 7, but using the racemic tetradehydro PGF 1 .sub.α - and 15β-PGF 1 .sub.α -type compounds, there is obtained dl-4,5-cis-17,18-cis-tetradehydro-PGE 1 and dl-4,5-cis-17,18-cis-tetradehydro-15β-PGE 1 .
EXAMPLE 8
4,5-cis-Didehydro-PGA 1 (Formula X: R 1 and R 2 are hydrogen)
Refer to Chart E. A solution of 4,5-cis-didehydro-PGE 1 methyl ester (Example 4, 300 mg.), 4 ml. of tetrahydrofuran and 4 ml. of 0.5 N hydrochloric acid is left standing at 25° C. for five days. Brine and dichloromethane-ether (1:3) are added and the mixture is stirred. The organic layer is separated, dried and concentrated. The residue is dissolved in ether and the solution is extracted with saturated aqueous sodium bicarbonate. The aqueous phase is acidified with dilute hydrochloric acid and extracted with dichloromethane. This extract is dried and concentrated to yield the formula-X title compound.
Following the procedure of Example 8, the corresponding 4,5-cis-didehydro-15β-PGA 1 and racemic products are obtained.
EXAMPLE 9
4,5-cis-Didehydro-PGB 1 (Formula XI: R 1 and R 2 are hydrogen)
Refer to Chart E. A solution of 4,5-cis-didehydro-PGE 1 methyl ester (Example 4, 200 mg.) in 100 ml. of 50% aqueous ethanol containing about one gram of potassium hydroxide is kept at 25° C. for 10 hrs. under nitrogen. Then, the solution is cooled to 10° C. and neutralized by addition of 3 N. hydrochloric acid at 10° C. The resulting solution is extracted repeatedly with ethyl acetate, and the combined ethyl acetate extracts are washed with water and then with brine, dried, and concentrated to give the desired formula-XI title compound.
Following the procedure of Example 9, the corresponding 4,5-cis-didehydro-15β-PGB 1 and racemic products are obtained.
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This invention is a group of 4,5-didehydro and 4,5,17,18-tetradehydro PG 1 (prostaglandin-type) compounds, and processes for making them. These compounds are useful for a variety of pharmacological purposes, including anti-ulcer, inhibition of platelet aggregation, increase of nasal patency, labor inducement at term, and wound healing.
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RELATED U.S. APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 11/505,445, filed Aug. 17, 2006, which is a continuation of U.S. patent application Ser. No. 10/612,016, filed Jul. 3, 2003, now U.S. Pat. No. 7,109,157, which, in turn, is a continuation-in-part of U.S. patent application Ser. No. 10/373,787, filed Feb. 27, 2003, now U.S. Pat. No. 6,946,435, which claims benefit of U.S. Provisional Application No. 60/423,978, filed Nov. 6, 2002, all of which are incorporated herein by reference in their entireties.
TECHNICAL FIELD OF THE INVENTION
This invention relates to products, methods and kits useful for removing stains, such as menstrual fluid or underarm perspiration stains, from clothes and other soft fabric articles. This invention also relates to methods for reducing the damaging effect of hypochlorite-containing solution on cotton and other soft fabrics.
BACKGROUND OF THE INVENTION
Menstrual fluid, a composition of blood and endometrial cells, is difficult to remove from cotton panties once it has stained the fabric. Regular bleach is one of the leading household products used for the purpose of cleaning white cotton panties of menstrual fluid stain. Ultra Clorox® Regular Bleach is a designated trademark of the Clorox® Company. A typical, undiluted regular bleach solution contains about 6 wt % of sodium hypochlorite and less than 0.2 wt % of sodium hydroxide. The pH of the undiluted Clorox® Regular Bleach solution is around 11.4. Like other chlorine-releasing bleaches, Clorox® Regular Bleach, even diluted, will disintegrate the fabric. Moreover, even after lengthy soaking, a dark residue stain may still remain on the cotton fabric, even with scrubbing. Vigorous scrubbing accelerates deterioration of the bleach-weakened cotton fibers which, again, leads to damaged panties, and expense and frustration. Some household products, such as hydrogen peroxide, produce free oxygen to dislodge menstrual fluid discharge from cotton fabric but this process may be effective only when the discharge is fresh and minimal fluid penetration of the fabric has occurred.
Perspiration stain in the underarm areas of white cotton fabric shirts and blouses is also difficult to remove, even for professionals in the garment laundry and cleaner business. Often the stain is not completely removed.
There is a clamor among women around the world for a process that they can use to remove fresh, set-in or old menstrual fluid or perspiration stain from white cotton fabric, a process that can be used easily, rapidly, with little or no scrubbing, and with no damage to the cotton fabric.
SUMMARY OF THE INVENTION
One object of the present invention is to provide cleaning products and methods for reducing the damaging effect of hypochlorite-containing solutions on soft fabrics. The fabrics can be made of cotton, cotton/polyester, or other materials. The fabrics may be, for example, in white.
In accordance with one aspect of the present invention, the method comprises the steps of modifying a hypochlorite-containing solution by adding an alkali metal hydroxide to the solution, such that the weight concentration ratio of the hypochlorite salt over the alkali metal hydroxide in the modified solution is less than 12.5:1, where the modified solution can then be used in contacting a stain on a soft fabric article for at least one minute to remove the stain. In certain cases, the contact with the stain can last for at least 5, 10, 15, 30, 60 minutes or longer before the stain is cleaned, necessitating an appropriate weight concentration ratio in order to maintain a reduced damaging effect.
The stain can be any type of hard-to-remove stains, such as fresh, set-in or old menstrual fluid or underarm perspiration stains. Other examples of hard-to-remove stains include, but are not limited to, those caused by wine, grass, urine, feces, and certain types of ink.
In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide, and the hypochlorite salt is sodium hypochlorite. The weight concentration ratio of sodium hypochlorite over sodium hydroxide in the modified solution can be less than 10:1, 5:1, and about 3:1 to 1:1. A sodium hypochlorite/sodium hydroxide ratio also can be less than 1:1.
In one embodiment, the modified solution includes at least 0.2, 0.3, 0.5, 1, 2, 3 or higher weight percent of sodium hydroxide. For instance, the weight percentage of sodium hydroxide can range from about 0.5% to about 3%.
In another embodiment, the modified solution includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In yet another embodiment, the modified solution includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide.
In accordance with another aspect of the present invention, the method for reducing the damaging effect of a hypochlorite salt-containing solution comprises the steps of modifying the solution by adding an alkali metal hydroxide to the solution, such that the pH of the modified solution is at least 11.8, where the modified solution can then be used in contacting a stain on a soft fabric article for at least one minute to remove the stain. The fabric article may be, for example, in white.
The pH of the modified solution can be at least 12, 12.5 or 13. In one embodiment, the pH of the modified solution is about 13.
In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide, and the hypochlorite salt is sodium hypochlorite. The weight percentage of sodium hypochlorite in the modified solution can be at least 0.5%, 1%, 2%, 3%, 4%, 5%, 6% or more.
In one embodiment, the modified solution is a modified form of Ultra Clorox® Bleach Regular. Ultra Clorox® Bleach Regular typically contains about 6 weight percent of sodium hypochlorite and less than 0.2 weight percent of sodium hydroxide. To make the modified solution with reduced damaging effect, an additional amount of sodium hydroxide is added.
Another object of the present invention is to provide products, methods and kits useful for removing hard-to-remove stains from soft fabric articles. The soft fabric articles can be, for example, panties, shirts, blouses, pants, jeans, trousers or other soft fabric articles. The removal preferably is accomplished with little or no scrubbing of the fabrics.
In one embodiment, the metallic salt of hypochlorous acid is sodium hypochlorite, and the alkali metal hydroxide is sodium hydroxide. The cleaning composition can include, for example, at least 0.3 weight percent of sodium hydroxide. Preferably, the cleaning composition contains about 0.5 to about 3 weight percent of sodium hydroxide. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is preferably about 2:1.
The stain to be removed can be menstrual fluid or underarm perspiration stain. For the weight concentration ratio of sodium hypochlorite over sodium hydroxide of about 2:1, the contact between the cleaning composition and the stain can last at least five, fifteen, thirty minutes, or longer, with no damage to the soft fabric article.
In accordance with another aspect of the present invention, the method includes the steps of providing a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and has a pH of at least 11.8, where the cleaning composition can then be used in contacting a stain on a soft fabric article for at least one minute. The metallic salt of hypochlorous acid preferably is sodium hypochlorite.
In accordance with yet another aspect of the present invention, a kit is provided that is useful for removing stains from clothes or other soft fabrics. The kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and at least 0.2 weight percent of an alkali metal hydroxide. The kit also has an instruction indicating that the cleaning composition contained therein can be used for removing stains from soft fabric articles. In another embodiment, the kit includes a spray bottle capable of spraying the cleaning composition onto the soft fabric article.
In accordance with yet another aspect of the present invention, the kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and which has a pH of at least 11.8. The kit also has an instruction for removing stains from soft fabric articles employing the cleaning composition. The metallic salt of hypochlorous acid preferably is sodium hypochlorite. In one embodiment, the cleaning composition includes 0.5-3 weight percent of sodium hydroxide.
In one embodiment, the cleaning composition contains at least 0.3 weight percent of sodium hydroxide. In another embodiment, the cleaning composition contains about 0.5 to about 3 weight percent of sodium hydroxide. The pH of the cleaning composition can be, for example, at least 12, 12.5, or 13. The cleaning composition can contact with the stain on the soft fabric article for at least five, fifteen, thirty minutes, or longer, with no damage to the fabric article.
In accordance with yet another aspect of the present invention, a kit is provided that is useful for removing stains from clothes or other soft fabrics. The kit includes a cleaning composition which contains an effective amount of a metallic salt of hypochlorous acid and at least 0.2 weight percent of an alkali metal hydroxide. The kit also has an instruction indicating that the cleaning composition contained therein can be used for removing stains from soft fabric articles.
The metallic salt of hypochlorous acid preferably is sodium hypochlorite, and the alkali metal hydroxide preferably is sodium hydroxide. In one embodiment, the cleaning composition comprises about 0.5 to about 3 weight percent of sodium hydroxide. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 2:1. In another embodiment, a kit includes a spray bottle capable of spraying the cleaning composition onto the soft fabric article.
Other features, objects, and advantages of the present invention are apparent in the detailed description that follows. It should be understood, however, that the detailed description, while indicating preferred embodiments of the present invention; is given by way of illustration only, not limitation. Various changes and modifications within the scope of the invention will become apparent to those skilled in the art from the detailed description.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on a bleach cleaning composition which contains a metallic salt of hypochlorous acid and an alkali metal hydroxide for removing hard-to-remove stains from clothes and other soft fabric articles. In addition, appropriate amounts of alkali metal hydroxide added to a hypochlorite solution retard the damaging effect of the hypochlorite solution on soft fabric (such as cotton fabric). The metallic salt of hypochlorous acid preferably is sodium hypochlorite. The alkali metal hydroxide preferably is sodium hydroxide. Other hypochlorous salts and/or alkali metal hydroxides can also be used in the present invention.
The concentration of sodium hypochlorite in the bleach cleaning composition of the present invention preferably is at least 0.5% by weight, based on the total weight of the cleaning composition. For instance, the concentration of sodium hypochlorite can be at least 0.5, 1, 2, 3, 4, 5, 6, 7 or 8% by weight. In one embodiment, the concentration of sodium hypochlorite ranges from 0.5 to 10% by weight. In another embodiment, the concentration of sodium hypochlorite is about 0.5 to 5% by weight. In yet another embodiment, the concentration of sodium hypochlorite is about 1 to 2.5% by weight. In still another embodiment, the concentration of sodium hypochlorite is about 1.5 to 2% by weight.
The concentration of sodium hydroxide in the bleach cleaning composition preferably is at least 0.2% by weight, based on the total weight of the cleaning composition. For instance, the concentration of sodium hydroxide can be at least about 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, 3, 4 or 5% by weight. In one embodiment, the concentration of sodium hydroxide ranges from about 0.5 to about 3% by weight. In another embodiment, the concentration of sodium hydroxide ranges from about 1 to 2% by weight. Without limiting the present invention to any particular mechanism, Applicant has found that an appropriate amount of alkali metal hydroxide (such as sodium hydroxide) significantly increases the compatibility of sodium hypochlorite with soft fabric, such as cotton fabric, thereby preventing sodium hypochlorite from damaging the fabric.
The weight concentration ratio of sodium hypochlorite over sodium hydroxide may vary substantially without affecting the stain-removing power of the cleaning composition. However, the fabric damaging effect of hypochlorite varies with the weight concentration ratio for a given concentration of hypochlorite. Preferably, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is less than 12.5:1. In one embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide can range from about 5:1 to about 1:5. In another embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 3:1 to about 1:1. Ideally, the ratio is about 2:1 for minimum damaging effect.
In one embodiment, the bleach cleaning composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In another embodiment, the cleaning composition includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In both embodiments, the concentration ratio varies from 5:1 to 2:1. Hence, in both embodiments, the range of concentration ratios is the same and, likewise, the degree of fabric damage effect can be expected to follow suit, ranging to the same minimum. However, in the two embodiments, the pH values are different. It is noted that the concentration ratio is dependent on both the hypochlorite and the hydroxide, whereas the pH is dependent on only the hydroxide. The cleaning composition of the present invention can be a form of regular Clorox® Bleach modified with additional sodium hydroxide.
The pH of the cleaning composition preferably is at least about 11.8. For instance, the pH of the cleaning composition can be at least 12, 12.5 or 13. In one embodiment, the pH of the cleaning composition is about 13.
Other ingredients or additives can be added in the bleach cleaning composition. These ingredients or additives include, for example, chelating agents, phosphorous-containing salts, surfactants, or abrasive agents. These ingredients or additives, however, are not necessary for the stain-removing function of the cleaning composition. In one embodiment, the cleaning composition is free of chelating agents, phosphorous-containing salts, surfactants, and abrasive agents.
The bleach cleaning composition of the present invention can be stored in a container, such as a spray bottle, prior to use. Preferably, the container has an instruction indicating that the enclosed cleaning composition can be used for removing menstrual fluid, perspiration, and other such difficult stains from soft fabric articles and to do so with fabric protection.
Sodium hypochlorite and sodium hydroxide can be separately stored prior to use. For instance, they can be stored in two separate compartments of a container. The first compartment encloses a sodium hypochlorite solution. The second compartment encloses a concentrated sodium hydroxide solution. The two solutions are mixed together upon use. An exemplary device suitable for this purpose is illustrated in U.S. Pat. No. 6,398,077, which is incorporated herein by reference.
Soft fabric articles suitable for the present invention can be made of a variety of materials, such as cotton or cotton/polyester. The fabric articles preferably are in white or colorfast fabrics. Examples of soft fabric articles suitable for the present invention include, but are not limited to, panties, shirts, blouses, pants, jeans, trousers, and other wear and bed products.
The stains to be removed can be menstrual fluid stains or underarm perspiration stains. Other hard-to-remove stains, such as wine, grass, urine, feces, or ink stains, can also be removed using the present invention. The contact between the bleach cleaning solution and the stain may last for at least one minute before the stain is removed. In one embodiment, the contact between the cleaning solution and the stain lasts for at least 5, 10, 15, 30, 60 or more minutes before the stain is removed.
In accordance with one aspect of the present invention, the soft fabric article that is to be de-stained is first soaked in cold water until the stain areas are thoroughly saturated with water. The fabric article can be swirled around in the water to dislodge as much stain as possible. For articles heavily soiled with stains, the water may be changed to repeat the soaking and swirling step
The fabric article is then squeezed to remove excess water. White cotton articles heavily stained with menstrual fluid may be tinted slightly pink after this step. The stained areas are arranged for maximal exposure in preparation for the spray with the cleaning composition.
The cleaning composition can be sprayed on the stain areas, or the entire article if necessary. After spraying, the stain areas can be compressed and confined into a small container to saturate and soak the stain areas or the entire article in the cleaner.
The stained areas are soaked with the cleaning composition until the stain has been removed. This may require about one to five minutes for removing fresh menstrual fluid stain, and about thirty minutes or more for removing old underarm perspiration stain. The fabric article can be subsequently inspected for any remaining stain. If necessary, spot spray can be applied again to remove the remaining stain.
After all stain has been removed, the fabric article is thoroughly rinsed in cold water before being put through the detergent wash/rinse and dry cycle, particularly if the fabric article is combined with non-colorfast clothing in the wash. Also, this assures that all sodium hydroxide has been removed from the fabric article before it is worn next to the skin. According to the present invention, menstrual fluid stains or underarm perspiration stains may be removed from a soft fabric article with little or no scrubbing of the article.
After the stain is removed, the fabric article preferably is not soaked with the cleaning composition any longer than necessary.
It should be understood that the above-described embodiments and the following examples are given by way of illustration, not limitation. Various changes and modifications within the scope of the present invention will become apparent to those skilled in the art from the present description.
EXAMPLES
Example I
Comparison of Clorox® Bleach to a Cleaning Composition Comprising 2.4 wt % Sodium Hypochlorite and 1.25% Sodium Hydroxide
Two similar patches (approximately 2.5×2.5 cm 2 ) of 100% cotton fabric were cut from the crotch of a new panty. The first patch was immersed in a diluted Clorox® Bleach solution. The diluted Clorox® Bleach solution contained about 2.4 wt % sodium hypochlorite. After six hours of soaking, the first patch showed signs of shredding. After ten hours of soaking, the first patch shredded completely. In comparison, the second patch was immersed in a solution which contains about 2.4 wt % sodium hypochlorite and 1.25 wt % sodium hydroxide. After ten hours of soaking, no effect of shredding was observed.
Example II
The Damage Effects of Hypochlorite Solutions to Cotton Patches and the Reduction Thereof
Cotton patches which were resistant to hand-tearing were soaked in different bleach solutions until damages have begun to occur as evidenced by weakening of the fabric such that it can be torn by hands with moderate forces. For each bleach solution to be tested, multiple cotton patches were used. Each patch was inserted into a vial containing the bleaching solution. The patch was removed periodically from the vial to determine the extent of damage by manually administering a tearing action. T c (D) was the cumulative time of soaking before the patch became hand-tearable.
The bleach solutions were modified from Ultra Clorox® Bleach which contains about 6% NaOCl and less than 0.2% NaOH. Additional NaOH in dry form was added to Ultra Clorox® Bleach to increase the concentration of NaOH. As Table 1 shows, Ultra Clorox® Bleach damages cotton fabrics in an accumulated time of approximately one hour. Decreasing the ratio of NaOCl/NaOH progressively increases the accumulated times for which the bleach solution is cotton-safe. This Example indicates that NaOH, added to Ultra Clorox® Bleach, can abate the damage of cotton fabrics; thereby rendering the bleach solution cotton-safe.
TABLE 1
Comparison of the Damage Effects of
Bleaching Solutions
NaOCl/NaOH
NaOH
(weight
(weight
percentage
T c (D)
Cleaning Solution
percentage)
ratio)
(hours)
Ultra Clorox Beach
0-0.2
over 30:1
1
Solution #1
0.4-0.6
12:1
4
Solution #2
1.0-1.2
5.5:1
6
Solution #3
2.0-2.2
3:1
6
Solution #4
3.0-3.2
2:1
9.5
Solution #5
4.0-4.2
1.5:1
9.5
Solution #6
6.0-6.2
1:1
9.5
The foregoing description of the present invention provides illustration and description, but is not intended to be exhaustive or to limit the invention to the precise one disclosed. Modifications and variations are possible consistent with the above teachings or may be acquired from practice of the invention. Thus, it is noted that the scope of the invention is defined by the claims and their equivalents.
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This invention discovers that laundry-strength hypochlorite bleach compositions are described by three essential components; hypochlorite, hydroxide, and the concentration ratio (CR), the latter defined as the concentration of hypochlorite over the concentration of hydroxide (also, its reciprocal). The hypochlorite content determines fabric cleaning efficacy, the hydroxide content determines stability, and the CR indicates quality of fabric safety, such quality ranging from damaging to gentle. Therefore, hypochlorite bleach compositions can range from fabric damaging to degrees of fabric protection, depending upon the values of CR. Values of CR (as defined) greater than 30:1 characterize fabric-damaging common regular bleach. By decreasing the ratio value, fabric protection progressively improves to a relatively broad maximum at a ratio value about 2:1.
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RELATED APPLICATIONS
[0001] The present application claims benefit of priority of U.S. Prov. App. No. 61/959,379 and U.S. Prov. App. No. 61/959,380 (filed 22 Aug. 2013), both of which were filed within the twelve months preceding the filing date of the present application or is an application of which a currently co-pending application is entitled to the benefit of the filing date.
SUMMARY
[0002] Various novel decking systems and methods are presented, each effective for deck assembly facilitation. In one or more various aspects, for example, a decking method includes but is not limited to mounting a deck fascia board to a deck joist and another deck fascia board to a deck rim joist and subsequently mounting a fascia-expansion-accommodation corner covering having a first mounting layer and a second mounting layer and a stress distribution hinge so that the first and second mounting layers each have a mounting surface and a fascia expansion overlap lip and so that the fascia expansion overlap lips each overlap an end of a respective one of the deck fascia boards. In some variants the corner covering may be made of a plastic or composite by molding, extruding, or planing operations. The stress distribution hinge operably couples the first mounting layer to the second mounting layer so that a half-plane adjacent the mounting surface of the first mounting layer and a half-plane adjacent the mounting surface of the second mounting layer are both bounded by a single line along the stress distribution hinge, so that the fascia expansion overlap lip of the first mounting layer is configured to remain against a first of the deck fascia boards (notwithstanding longitudinal expansion or contraction thereof, e.g.), and so that the fascia expansion overlap lip of the second mounting layer is configured to remain against a second of the deck fascia boards. In addition to the foregoing, other method aspects are described in the claims, drawings, and text forming a part of the disclosure set forth herein.
[0003] An embodiment provides a decking system. In one implementation, the decking system includes but is not limited to a fascia-expansion-accommodation corner covering having a first mounting layer and a second mounting layer and a stress distribution hinge, the first and second mounting layers each having a mounting surface and a fascia expansion overlap lip, the stress distribution hinge operably coupling the first mounting layer to the second mounting layer so that a half-plane adjacent the mounting surface of the first mounting layer and a half-plane adjacent the mounting surface of the second mounting layer are both bounded by a single line along the stress distribution hinge and so that the fascia expansion overlap lip of the first mounting layer is configured to remain against a first deck fascia board notwithstanding a longitudinal expansion of the first deck fascia board and so that the fascia expansion overlap lip of the second mounting layer is configured to remain against a second deck fascia board notwithstanding a longitudinal expansion of the second deck fascia board.
[0004] Some variants comprise a railpost support that includes a baseplate and a plurality of flexible finger mounts and a sleeve section, optionally made from sheet metal that is laser cut or stamped and punched and bent. One or more tensile elements (screws, e.g.) are configured to hold the baseplate removably in rigid engagement (metal-to-metal contact, e.g.) with at least a threaded portion of a railpost support interface. This can occur, for example, in a context in which one or more top surfaces of the railpost support interface are roughly even with (nominally flush with or within a few centimeters higher than) a walking surface of the deck (when adjacent decking boards are applied, e.g.) and in which the sleeve section is supported by the baseplate and supports the flexible finger mounts in contact with a railpost inserted into the sleeve section.
[0005] In addition to the foregoing, various other method and/or system and/or program product aspects are set forth and described in the teachings such as text (e.g., claims and/or detailed description) and/or drawings of the present disclosure. The foregoing is a summary and thus may contain simplifications, generalizations, inclusions, and/or omissions of detail; consequently, those skilled in the art (professional or do-it-yourself deck builders, e.g.) will appreciate that the summary is illustrative only and is NOT intended to be in any way limiting. Other aspects, features, and advantages of the devices and/or processes and/or other subject matter described herein will become apparent by reference to the detailed description, the corresponding drawings, and/or in the teachings set forth herein.
BRIEF DESCRIPTION OF THE FIGURES
[0006] FIG. 1 depicts a deck mounted onto a primary structure (a house or commercial building, e.g.).
[0007] FIG. 2 depicts a decking system comprising joists and fascia boards in relation to a railpost support interface.
[0008] FIG. 3 depicts a railpost in relation to railpost support and boards of a deck.
[0009] FIG. 4 depicts a bottom view of the railpost support of FIG. 3 .
[0010] FIG. 5 depicts a railpost support engaging a railpost support interface.
[0011] FIG. 6 depicts a railpost inserted into a railpost support before engaging with a railpost support interface.
[0012] FIG. 7 depicts an oblique view of a railpost support in relation to a deck bracket of a railpost support interface.
[0013] FIG. 8 depicts a side view of the deck bracket of FIG. 7 .
[0014] FIG. 9 depicts a railpost support engaging a railpost support interface in relation to two joists of a decking system.
[0015] FIG. 10 depicts deck fascia boards and a fascia expansion accommodation structure in relation to two joists of a decking system.
[0016] FIG. 11 depicts several fascia expansion accommodation structures.
[0017] FIG. 12 depicts several additional fascia expansion accommodation structures.
[0018] FIG. 13 depicts several views of an additional fascia expansion accommodation structure.
[0019] FIG. 14 depicts a decking system that incorporates the fascia expansion accommodation structure of FIG. 13 .
[0020] FIG. 15 depicts another decking system that incorporates the fascia expansion accommodation structure of FIG. 13 .
[0021] FIG. 16 depicts several additional fascia expansion accommodation structures.
DETAILED DESCRIPTION
[0022] For a more complete understanding of embodiments, reference now is made to the following descriptions taken in connection with the accompanying drawings. The use of the same symbols in different drawings typically indicates similar or identical items, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.
[0023] In light of teachings herein, numerous existing techniques may be applied for implementing decking components with materials appropriate for achieving the significantly improved accommodation of thermal and assembly variations as described herein without undue experimentation. See, e.g., U.S. Pat. No. 8,739,489 (“Decking system”); U.S. Pat. No. 8,714,887 (“Fascia counter-bore bit and fascia screw”); U.S. Pat. No. 8,516,777 (“Method of fabricating building wall panels”); U.S. Pat. No. 8,499,505 (“Pultruded trim members”); U.S. Pat. No. 8,371,556 (“Multi-function deck tool”); U.S. Pat. No. 8,322,097 (“Methods of constructing buildings and building appurtenances”); U.S. Pat. No. 8,291,647 (“Self-contained structure configurable as a shipping container and as a dwelling”); U.S. Pat. No. 8,272,190 (“Method of fabricating building wall panels”); U.S. Pat. No. 8,256,614 (“Interconnected and on-site severable deck clips with cooperating installation tool for joining two adjacent decking planks to an underlying support structure”); U.S. Pat. No. 8,091,500 (“Over-the-water dock”); U.S. Pat. No. 7,926,226 (“Deployable prefabricated structure with an extension structure that is sealable to the prefabricated structure upon deployment from the prefabricated structure”); U.S. Pat. No. 7,908,812 (“Decking system and anchoring device”); U.S. Pat. Pub. No. 2013/0111840 (“Kit and assembly for compensating for coefficients of thermal expansion of decoratively mounted panels”); U.S. Pat. Pub. No. 2012/0328823 (“Trim components for lapboard siding that are co-extruded from wood-plastic composites and polyvinyl chloride”); and U.S. Pat. Pub. No. 2006/0076545 (“Railing assemblies and related methods and apparatuses”).
[0024] FIG. 1 depicts a context in which one or more technologies may be implemented. An unconventional deck 100 is mounted onto a primary structure 101 (a house or commercial building, e.g.) and adjoining a stairway (not shown). Deck 100 comprises several decking boards 182 laid across deck joists as shown and described below. Deck fascia boards 133 and border boards 181 cover portions of the deck joists and deck rim joists around the perimeter of the deck 100 as shown and described below. Various fascia expansion accommodation structures 104 allow for longitudinal variation (of the deck fascia boards 133 , e.g.) as shown and described below. Moreover a railing 108 comprises several removable railposts 105 that facilitate deck assembly while providing extra safety for occupants of deck 100 (from a dropoff 199 , e.g.), especially in a context in which a railpost 105 is not in direct contact with a joist. See FIGS. 3-9 . Those skilled in the art will recognize that the systems and methods described below advance the state of the art significantly (in comparison with existing deck structures and techniques, e.g.) in terms of both quality and cost-effectiveness.
[0025] FIG. 2 depicts a context in which one or more technologies may be implemented. Decking system 200 optionally implements particular aspects of deck 100 (in a variant in which deck fascia board 233 instantiates deck fascia board 133 , e.g.). Deck rim joist 234 optionally covers an end of deck joist 236 at a joist interface 208 as shown. Several fasteners 247 mount deck fascia board 233 directly on a joist surface 272 of deck rim joist 234 and other fasteners 246 permit deck fascia board 232 to be supported directly or indirectly by deck joist 236 . A railpost support interface 260 is mounted alongside or over deck rim joist 234 and optionally alongside and over deck joist 236 (by an overhang 249 of one or more centimeters, e.g.) by any of several support structures, such as those described in detail below. A rigid railpost support interface 260 (constructed of aluminum or a similarly stiff material, e.g.) is used for mounting a railpost support to one or more joists rather than relying upon a railpost that supports the weight of the deck (extending vertically to the ground or diagonally to a primary structure, e.g.) without a railpost 105 thereof coming into direct contact with the joist. Also as shown one or more deck fascia boards 232 , 233 are cut short (by one or more centimeters, e.g.), leaving an endmost portion of a joist surface 272 of one or more perimeter joists (a deck rim joist or deck joist along a deck perimeter, e.g.) partly exposed at the time of initial deck assembly.
[0026] FIG. 3 depicts another context in which one or more technologies may be implemented. As shown, railpost support 320 includes a sleeve section 315 supporting a plurality of flexible finger mounts 310 and mounted on a baseplate 311 . (See FIG. 4 for a top-down view 321 of this structure.) Also as shown, deck 300 has been assembled in an atypical and significantly advantageous sequence made possible by its novel structure. The several fasteners 345 that rigidly engage railpost support 320 to railpost support interface 360 (optionally with metal-to-metal contact therebetween, e.g.) have been installed after some or all border boards 381 or decking boards 382 of deck 300 adjacent railpost support 320 have been fastened onto their respective joists (deck rim joist 234 or deck joist 236 , e.g.). This can occur in a variant in which railpost 305 instantiates railpost 105 , for example, or in which railpost support interface 360 instantiates railpost support interface 260 . Moreover in one or more optional aspects, railpost support 320 may comprise a composite or wooden railpost 305 having a diameter 355 of 5 to 20 centimeters, the railpost extending (downward, e.g.) into a gap among a plurality of flexible finger mounts 310 (each 5 to 50 centimeters in length and engaging railpost 305 with a plurality of fasteners 316 , e.g.) of the railpost support 320 . Such assembly methods (incorporating such a railpost support 320 rigidly attached in this way, e.g.) permit a railing to be made safe even at a site in which an adjacent dropoff 399 is substantial (exceeding 3 meters, e.g.), as further described below.
[0027] FIG. 4 depicts a top view 321 of a primary component of the railpost support 320 depicted in FIG. 3 . As shown baseplate 311 is a rounded square layer (of aluminum or other suitable metal, e.g.) having one or more access holes 430 therein totaling more than 10% of its area and welded (by an annular arrangement of one or more weldments 426 , e.g.) to sleeve section 315 . Moreover a fastener hole 424 at each of several corners facilitates the mounting of baseplate 311 onto railpost support interface 360 (before or after sleeve section 315 receives railpost 305 , e.g.). In some variants this can occur after the installation of one or more border boards 381 or decking boards 382 adjacent railpost support interface 360 , facilitating assembly. In this way a plurality of such fasteners (screws or other tensile elements configured to extend downward through the baseplate 311 into a threaded portion of the railpost support interface 360 , e.g.) may be configured to hold the baseplate 311 removably in rigid engagement with (an instance of) a railpost support interface 360 built into deck 300 . This can occur, for example, in a context in which a top surface of the railpost support interface 360 is nominally flush with a top of the decking boards 382 ; in which the sleeve section 315 is configured to be supported by the baseplate 311 and to support the flexible finger mounts 310 in contact with a railpost 305 inserted (nominally vertically, e.g.) into the sleeve section 315 .
[0028] FIG. 5 depicts another context in which one or more technologies may be implemented, showing specifics of how a railpost support 520 (having a baseplate 511 and sleeve section 515 generally like those of the railpost support 320 of FIG. 3 , e.g.) may be rigidly and removably supported by a railpost support interface 560 (generally like the railpost support interfaces 260 , 360 depicted in FIGS. 2 & 3 , e.g.). In the variant of FIG. 5 , the railpost support interface 560 (depicted in a darker pattern) provides such rigid support by several bosses 513 (four or more, e.g.) integrally formed or otherwise mounted onto a substrate 566 (at its periphery as shown, e.g.). A tubular undercarriage 515 or similar rigid support is affixed to one or more joists (deck rim joist 234 or deck joist 236 , e.g.) over which a portion of substrate 566 overhangs. Such overhang 549 may have a length of 3 to 15 centimeters, for example.
[0029] FIG. 6 depicts another context in which one or more technologies may be implemented, showing specifics of how another system 600 incorporating railpost support 520 may be constructed and arranged. As shown there, railpost support 520 may optionally include a baseplate 611 and a pair of flexible finger mounts 610 and a sleeve section 615 therebetween, with railpost 605 being installed between finger mounts 610 and into sleeve section 615 before being mounted onto a railpost support interface 260 . In some contexts, this permits a factory assembly of railpost 605 into railpost support 520 , with an adhesive sealant in addition to or in lieu of fasteners affixing finger mount 610 into (opposite sides of) railpost 605 . In some contexts, for example, hot glue may be used for such assembly at all surfaces where railpost 605 is adjacent finger mount 610 or sleeve section 615 , reducing the vulnerability of the railpost 605 to water-induced deterioration.
[0030] FIG. 7 depicts another context in which one or more technologies may be implemented, a system 700 for implementing several optional features in the deck 300 of FIG. 3 . As shown in FIG. 3 , railpost support 320 includes a baseplate 311 and several flexible finger mounts 710 each tapered (to become steadily narrower along a majority of its length, e.g.) to become progressively more flexible (tolerant of lateral bending, e.g.) at several places along its length but still thick enough (having a diameter of about 1 millimeter or more for a majority of its length, e.g.) to resist longitudinal stretching or compression. As shown, fasteners 316 are implemented as screws (1-5 centimeters in length, e.g.) that self-tap into respective corners of railpost 305 . Railpost support interface 360 is implemented, in the variant of FIG. 7 , as a rigid deck bracket 714 (implemented in galvanized steel, aluminum, or a similar or more rigid material, e.g.) with an aesthetic covering (i.e. filler block 712 ). Deck bracket 714 (optionally painted, galvanized, or anodized) comprises several threaded bosses 713 mounted on a rigid substrate 766 (with a drain hole 730 as shown, e.g.) resembling the substrate 566 of FIG. 5 , but welded onto two mounting layers that are welded together (one being mountable to one deck joist and other being mountable to a deck rim joist with self-tap screws 740 , e.g.). Screws 745 that pass through baseplate 311 are configured with threading to match that of corresponding threaded bosses 713 of the deck bracket 714 as shown. In some variants, filler block 712 and substrate 766 have a combined thickness nominally equal to that of border board 381 and decking board 382 as shown in FIG. 3 .
[0031] FIG. 8 depicts a side view of deck bracket 714 , showing further specifics about how weldments 826 may be used to attach the one or more mounting layers 767 thereof to substrate 766 and to deck bracket brace 836 .
[0032] FIG. 9 depicts another context in which one or more technologies may be implemented. A railpost support interface 960 is firmly mounted onto undercarriage 915 , which optionally implements tubular undercarriage 515 , deck bracket 714 , or other such suitable structures for rigid mounting onto one or both joists as shown (i.e. each with a plurality of fasteners 940 ). Thereafter, atypically, railpost support 920 (implementing one of the railpost supports 320 , 520 described above, e.g.) has been installed onto railpost support interface 960 and annular base trim 919 has been installed (around the sleeve section and over the baseplate and fasteners, e.g.) before and border boards 181 or decking boards 182 are installed onto the joists. This configuration is useful for clarity of illustration or to confirm dimensional appropriateness but is generally not as efficient (for production installation, e.g.) as methods described herein in which other deck components (decking boards 182 , 382 and deck fascia boards 133 , e.g.) have been installed before railpost support 920 .
[0033] FIG. 10 depicts another context in which one or more technologies may be implemented. A system 1000 comprises a convex-corner fascia expansion accommodation structure 1004 covering a 90° corner of a deck 100 , 300 as described above. This can occur, for example, in a context in which deck fascia board 1033 instantiates deck fascia board 133 or in which border board 381 will soon be mounted over deck rim joist 1034 or deck joist 1036 . The fascia expansion accommodation structure 1004 has a first mounting layer 1042 and a second mounting layer 1043 and hinge operably coupling the mounting layers 1042 , 1043 so that a half-plane adjacent the mounting surface of the first mounting layer and a half-plane adjacent the mounting surface of the second mounting layer are both bounded by a single line (nominally parallel to vertical axis 1071 , e.g.) along the hinge, as further described below. Deck fascia board 1032 and mounting layer 1042 are each mounted onto deck joist 1036 with a longitudinal gap 1053 therebetween (i.e. along a longitudinal axis 1072 ). Mounting layer 1042 has a fascia expansion overlap lip extending (leftward as shown) over (a front of) this longitudinal gap 1053 so that (part of) the lip remains laterally adjacent deck fascia board 1032 irrespective of a longitudinal expansion of or contraction of deck fascia board 1032 . Likewise deck fascia board 1033 and mounting layer 1043 are each mounted onto deck rim joist 1034 with a longitudinal gap therebetween, along a longitudinal axis 1073 corresponding to deck fascia board 1033 . Mounting layer 1043 likewise has a fascia expansion overlap lip extending (rightward as shown) over this latter longitudinal gap so that (part of) the lip remains laterally adjacent deck fascia board 1033 irrespective of a longitudinal expansion of or contraction of deck fascia board 1033 .
[0034] FIG. 11 depicts another context in which one or more technologies may be implemented, including a top view of the convex-corner fascia expansion accommodation structure 1004 of FIG. 10 . Insofar that stress distribution hinge 1141 is several centimeters in length (along axis 1071 , e.g.) and curved and somewhat more pliable than the structures it couples (by virtue of being 0.5 to 5 millimeters in thickness, e.g.), this structure provides sufficient rigidity and strength and is effective for preventing hinge damage by distributing structural tension laterally (orthogonal to vertical axis 1071 , e.g.) across a width of about a millimeter or more in response even to a significant hinging stress (deviating from a nominal angle by 1-5 degrees, e.g.) when the hinge is made of a suitable material (a vinyl or similar composite, e.g.). Convex-corner fascia expansion accommodation structure 1004 likewise includes first and second mounting layers 1155 that each include a mounting surface 1156 and a fascia expansion overlap lip 1150 . The stress distribution hinge 1141 operably couples the first mounting layer to the second mounting layer so that a half-plane 1162 adjacent the mounting surface of the first mounting layer and a half-plane adjacent the mounting surface of the second mounting layer are both bounded by a single line 1161 along the stress distribution hinge and so that the fascia expansion overlap lip 1150 of the first mounting layer 1155 is configured to remain laterally adjacent a first deck fascia board irrespective of a longitudinal expansion of or contraction of the first deck fascia board and so that the fascia expansion overlap lip of the second mounting layer is configured to remain laterally adjacent a second deck fascia board irrespective of a longitudinal expansion of or contraction of the second deck fascia board.
[0035] Those skilled in the art will recognize that some list items may also function as other list items. Each such listed term should not be narrowed by any implication from other terms in the same list but should instead be understood in its broadest reasonable interpretation as understood by those skilled in the art.
[0036] “Adhesed,” “adjacent,” “affixed,” “along,” “arranged,” “at least,” “at most,” “constructed,” “covering,” “first,” “from,” “further,” “integrally,” “irrespective,” “longitudinal,” “metallic,” “mounting,” “nominal,” “of,” “overlapping,” “recessed,” “remaining laterally adjacent,” “sealed,” “single,” “spanning,” “supporting,” “vertical,” “welded,” “toward,” or other such descriptors herein are used in their normal yes-or-no sense, not as terms of degree, unless context dictates otherwise. “To” is not used to articulate a mere intended purpose in phrases like “configured to,” moreover, but is used normally, in descriptively identifying a particular device or pattern that is actually performing or implementing a task or arrangement or to a structure that can serve this function without significant modification. “Substantially” is used herein (in relation to approximately ideal or aligned entities, e.g.) to refer to having a difference or deviation of at most about 2° or 2% or 2 millimeters, unless context dictates otherwise. Positional relation terms like “along” or “adjacent” are used herein to refer to nominal (substantially ideal, e.g.) relations, having a difference or deviation of at most about 2° or 2% or 2 millimeters, unless context dictates otherwise.
[0037] In some variants of convex-corner fascia expansion accommodation structure 1004 , the half-plane 1162 adjacent the mounting surface 1156 of the first mounting layer 1155 and the half-plane 1162 adjacent the mounting surface 1156 of the second mounting layer 1155 form a nominal right angle configured to span both a joist (deck joist 236 , e.g.) that supports the first deck fascia board 232 and a joist (deck rim joist 234 , e.g.) that supports the second deck fascia board 233 . Insofar that this nominal angle is less than 180°, the fascia-expansion-accommodation corner covering may be described as a “convex-corner” fascia expansion accommodation structure. Moreover the fascia expansion overlap lips as shown may (optionally) each have a nominal lip length 1152 of at least about 2 millimeters or at most about 2 centimeters. Also as shown the gap depth 1154 created by longitudinally recessed surface 1151 behind the lip may likewise be at least about 2 millimeters (at least about equal to a thickness of the first deck fascia board, e.g.) or at most about 2 centimeters. Moreover the thicker portion of the mounting layers 1155 of FIG. 11 (thicker than the respective fascia expansion overlap lips, e.g.) may be about 3 millimeters or more thick, so that they can accommodate a fastener slot 1148 in each mounting surface thereof that can receive fasteners that are later covered by slot cover 1149 , as shown.
[0038] FIG. 11 also depicts a co-linear fascia expansion accommodation structure 1101 (not configured to accommodate a corner, e.g.). Also depicted are convex-corner fascia expansion accommodation structures 1102 , 1103 in which the respective (instance of) half-plane 1162 adjacent the mounting surface 1156 of the first mounting layer 1155 and the respective half-plane 1162 adjacent the mounting surface 1156 of the second mounting layer 1155 form an obtuse angle (nominally equal to 135° or 150°, e.g.) spanning two joists that come together at an angle as shown in several instances described herein, such fascia-expansion-accommodation corner coverings each being an example of a “convex-corner” fascia expansion accommodation structure.
[0039] FIG. 12 depicts another context in which one or more technologies may be implemented, a decking system 1200 depicted as (a top view of) three concave-corner fascia expansion accommodation structures 1201 , 1202 , 1203 (having respective nominal reflex angles 1268 of 210°, 225°, and 270° as shown). Each of these structures is a corner covering having first and second mounting layers 1155 and a stress distribution hinge 1241 therebetween, the layers each having a mounting surface 1256 and a fascia expansion overlap lip 1250 configured so that the stress distribution hinge 1241 operably couples the layers and so that a half-plane 1262 adjacent the mounting surface 1256 of the first mounting layer 1155 and a half-plane 1262 adjacent the mounting surface 1256 of the second mounting layer 1155 are both bounded by a single line 1261 (perpendicular to the page of FIG. 12 and thus depicted as a dot in FIG. 12 ) along the stress distribution hinge 1241 and so that the fascia expansion overlap lip 1250 of the first mounting layer is configured to remain laterally adjacent a first deck fascia board 1231 irrespective of a longitudinal expansion of or contraction of the first deck fascia board 1231 as shown (when deck fascia board 1232 is mounted on its corresponding joist, deck rim joist 1234 . Likewise the fascia expansion overlap lip of the second mounting layer 1155 is configured to remain laterally adjacent a second deck fascia board 1232 (mounted onto deck joist 1236 , e.g.) irrespective of a longitudinal expansion of or contraction of the second deck fascia board 1232 .
[0040] FIG. 13 depicts another context in which one or more technologies may be implemented, a top view 1391 and oblique view 1392 , and side view 1393 of a convex-corner fascia expansion accommodation structure 1301 that can be used in various covering configurations. FIG. 14 depicts one such configuration, a decking system 1400 comprising an assembly that includes the convex-corner fascia expansion accommodation structure 1301 assembled according to a method embodiment in which that assembly includes completing a corner assembly before the installation of a railpost support interface 260 (in replacing a rotted interface or component thereof, e.g.). The corner covering of FIG. 14 comprises a plurality of mounting layers 1442 , 1443 and a stress distribution hinge 1441 therebetween as shown. Mounting layer 1442 includes a fascia expansion overlap lip 1450 and a spacer 1421 (optionally made of the same material as deck fascia board 1432 , e.g.) that has a mounting surface 1156 in contact with deck rim joist 1434 , constructed and arranged so that the fascia expansion overlap lip 1450 of the first mounting layer 1442 remains laterally adjacent deck fascia board 1432 irrespective of a longitudinal expansion of or contraction of the first deck fascia board. Likewise mounting layer 1443 includes a fascia expansion overlap lip 1450 and a spacer 1422 that has a mounting surface in contact with deck joist 1436 , constructed and arranged so that the fascia expansion overlap lip 1450 of the second mounting layer 1443 remains laterally adjacent the second deck fascia board 1433 irrespective of a longitudinal expansion of or contraction of the second deck fascia board 1433 (by providing a longitudinal gap 1053 behind that lip of at least about 0.5 millimeters and at most about 5 millimeters, e.g.).
[0041] FIG. 15 depicts another decking system 1500 that includes the convex-corner fascia expansion accommodation structure 1301 of FIG. 13 . The fascia-expansion-accommodation corner covering of FIG. 15 comprises a plurality of mounting layers 1542 , 1543 and a stress distribution hinge 1541 therebetween as shown, the mounting layers 1542 , 1543 each including a fascia expansion overlap lip 1550 . Moreover a contiguous deck fascia board 1532 is configured to support layer 1542 (in lieu of spacer 1421 and in lieu of a greatly thickened portion like those depicted in FIGS. 11 & 12 , e.g.). This is feasible, in the system 1500 of FIG. 15 , by virtue of one or more fastener non-engagement apertures 1586 in deck fascia board 1532 long enough to permit horizontal slippage of an endmost portion of fascia board 1532 (more than one millimeter in length along axis 1572 , e.g.) without deck fascia board 1532 directly pushing or pulling on the gap-spanning fasteners 1596 that support layer 1542 (relative to deck joist 1536 , e.g.) longitudinally along axis 1572 . Likewise one or more fastener non-engagement apertures 1586 (visible in cutaway view 1587 , e.g.) long enough to permit horizontal slippage of an endmost portion of fascia board 1533 (more than one millimeter in length along axis 1573 , e.g.) without deck fascia board 1532 directly causing a longitudinal dislocation of the fasteners 1596 that support layer 1543 (relative to deck rim joist 1534 , e.g.). As shown deck fascia board 1532 is affixed tightly to deck joist 1536 by one or more fascia board fasteners 1546 . Likewise deck fascia board 1533 is affixed tightly to deck rim joist 1534 by one or more fascia board fasteners 1546 . Also deck fascia boards 1532 , 1533 each have one or more fastener non-engagement apertures 1586 through which one or more gap-spanning fasteners 1596 that support the fascia-expansion-accommodation corner covering pass (slidably engaging or not engaging the respective deck fascia boards 1532 , 1533 ).
[0042] FIG. 16 depicts another context in which one or more technologies may be implemented, a decking system 1600 that includes the convex-corner fascia expansion accommodation structure 1301 depicted in FIGS. 13-15 with regard to joists nominally mounted at right angles (like those of FIGS. 2 & 9 , e.g.). System 1600 provides an inventory that also includes a co-linear fascia expansion accommodation structure 1601 and a plurality of convex-corner fascia expansion accommodation structures 1602 (for use in contexts like those described above with joists at obtuse angles, e.g.). See FIG. 11 . The inventory of system 1600 likewise includes a plurality of concave-corner fascia expansion accommodation structures 1603 (for use in contexts like those described above with joists at reflex angles, e.g.). See FIG. 12 .
[0043] In some variants (of deck 100 or deck 300 , e.g.), the respective first mounting layers 1442 and second mounting layers 1443 thereof may be configured generally as described with regard to FIG. 14 insofar that each fascia-expansion-accommodation corner covering in the inventory of system 1600 (having a substantially uniform nominal thickness 1653 of at least about 0.5 millimeters and at most about 5 millimeters over at least 80% of the area thereof, e.g.) may be configured to include a corresponding fascia expansion accommodation structure (as shown in FIG. 16 ) and first and second spacers 1421 , 1422 . In use at least a single “first” fastener 1446 may hold the first spacer 1421 in contact with both a fascia expansion accommodation structure 1301 , 1602 , 1603 and the first joist (a deck rim joist 1234 , 1434 as described above, e.g.). Likewise a “second” fastener 1447 may hold the second spacer 1422 in contact with both the fascia expansion accommodation structure and the second joist (a deck joist 1236 , 1436 as described above, e.g.).
[0044] Alternatively or additionally, the respective first mounting layers 1542 and second mounting layers 1543 thereof may be configured generally as described with regard to FIG. 15 insofar that each fascia-expansion-accommodation corner covering in the inventory (having a substantially uniform nominal thickness 1653 of at least about 0.5 millimeters and at most about 5 millimeters over at least 80% of the area thereof, e.g.) may be affixed (in use) to the first and second joists each by a plurality of fascia board fasteners, the first and second deck fascia boards each having a fastener non-engagement aperture 1586 through which one or more gap-spanning fasteners 1596 that support the fascia-expansion-accommodation corner covering pass.
[0045] One skilled in the art will recognize that the herein described components (e.g., operations), devices, objects, and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific exemplars set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplar is intended to be representative of its class, and the non-inclusion of specific components (e.g., operations), devices, and objects should not be taken limiting.
[0046] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations are not expressly set forth herein for sake of clarity.
[0047] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated” such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any two components capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and/or physically interacting components, and/or wirelessly interactable, and/or wirelessly interacting components, and/or logically interacting, and/or logically interactable components.
[0048] In some instances, one or more components may be referred to herein as “configured to,” “configurable to,” “operable/operative to,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc. Those skilled in the art will recognize that “configured to” can generally encompass active-state components and/or inactive-state components and/or standby-state components, unless context requires otherwise.
[0049] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B” in respective included configurations.
[0050] With respect to the numbered clauses and claims expressed below, all terms therein identify or describe one or more entities described above with particularity. With regard to methods described herein, those skilled in the art will appreciate that recited operations may generally be performed in any order, unless context dictates otherwise. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise. Also in the numbered clauses below, specific combinations of aspects and embodiments are articulated in a shorthand form such that (1) according to respective embodiments, for each instance in which a “component” or other such identifiers appear to be introduced (with “a” or “an,” e.g.) more than once in a given chain of clauses, such designations may either identify the same entity or distinct entities; and (2) what might be called “dependent” clauses below may or may not incorporate, in respective embodiments, the features of “independent” clauses to which they refer or other features described above.
CLAUSES
[0051] 1. A decking system comprising:
[0052] a fascia-expansion-accommodation corner covering (any of fascia expansion accommodation structures 104 , 1004 , 1102 , 1103 , 1201 , 1202 , 1203 , 1301 , 1602 , 1603 , e.g.) having a first mounting layer and a second mounting layer and a stress distribution hinge, the first and second mounting layers each having a mounting surface and a fascia expansion overlap lip (any of lips 1150 , 1250 , 1450 , 1550 , e.g.), the stress distribution hinge (any of hinges 1141 , 1241 , 1441 , 1541 , e.g.) operably coupling the first mounting layer to the second mounting layer so that a half-plane (either of 1162 , 1262 , e.g.) adjacent the mounting surface of the first mounting layer and a half-plane adjacent the mounting surface of the second mounting layer are both bounded by a single line (substantially) along the stress distribution hinge and so that the fascia expansion overlap lip of the first mounting layer is configured to remain laterally (substantially) adjacent a first deck fascia board (any of deck fascia boards 133 , 232 , 233 , 1032 , 1033 , 1231 , 1232 , 1432 , 1433 , 1532 , 1533 , e.g.) irrespective of a longitudinal expansion of or contraction of the first deck fascia board (of deck fascia board 1032 along axis 1072 or of deck fascia board 1033 along axis 1073 , e.g.) and so that the fascia expansion overlap lip of the second mounting layer is configured to remain laterally adjacent a second deck fascia board irrespective of a longitudinal expansion of or contraction of the second deck fascia board.
[0053] 2. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0054] the fascia expansion overlap lip (lip 1250 , e.g.) of the first mounting layer being less than half as thick as a remainder of the first mounting layer (mounting layer 1155 , e.g.), the fascia expansion overlap lip of the second mounting layer being less than half as thick as a remainder of the second mounting layer.
[0055] 3. The decking system of SYSTEM CLAUSE 1 further comprising:
[0056] the fascia expansion overlap lip (lip 1450 , e.g.) of the first mounting layer being about as thick (within a factor of two, e.g.) as a remainder of the first mounting layer (either of layers 1442 , 1443 , e.g.), the fascia expansion overlap lip of the second mounting layer being about as thick as a remainder of the second mounting layer.
[0057] 4. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0058] a first joist (any of deck rim joists 234 , 1434 or deck joists 236 , 1436 , e.g.); a second joist;
[0059] the first deck fascia board, being affixed to the first joist by a plurality of fascia board fasteners; and
[0060] the second deck fascia board, being affixed to the second joist by a plurality of fascia board fasteners, the fascia-expansion-accommodation corner covering including a fascia expansion accommodation structure and first and second spacers, a first fastener 1446 holding the first spacer 1421 in contact with both the fascia expansion accommodation structure 1301 and the first joist, a second fastener 1447 holding the second spacer 1422 in contact with both the fascia expansion accommodation structure 1301 and the second joist, the fascia-expansion-accommodation corner covering including the fascia expansion overlap lip of the first mounting layer and including the fascia expansion overlap lip of the second mounting layer, the first spacer being a component of the first mounting layer and about as thick as the first deck fascia board 1432 , the second spacer being a component of the second mounting layer and about as thick as the second deck fascia board 1433 .
[0061] 5. The decking system of any of the above SYSTEM CLAUSES 1-3 further comprising:
[0062] a first joist;
[0063] a second joist;
[0064] the first deck fascia board, being affixed to the first joist by a plurality of fascia board fasteners; and
[0065] the second deck fascia board, being affixed to the second joist by a plurality of fascia board fasteners, the first and second deck fascia boards each having a fastener non-engagement aperture (item 1586 , e.g.) through which one or more gap-spanning fasteners (item 1596 , e.g.) that support the fascia-expansion-accommodation corner covering pass.
[0066] 6. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0067] the single line being substantially vertical (within at most about 2°, e.g).
[0068] 7. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0069] the stress distribution hinge having a length (in a direction parallel to the single line, e.g.) of at least about 2 centimeters.
[0070] 8. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0071] the stress distribution hinge having a length (in a direction parallel to the single line, e.g.) of at most about 20 centimeters.
[0072] 9. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0073] the stress distribution hinge being at least about 0.5 millimeters thick (at its thinnest position, e.g.).
[0074] 10. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0075] the stress distribution hinge being at most about 5 millimeters thick (at its thinnest position, e.g.).
[0076] 11. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0077] an entirety of the stress distribution hinge being at least 2 millimeters from the single line along the stress distribution hinge.
[0078] 12. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0079] an entirety of the stress distribution hinge being at most 2 centimeters from the single line along the stress distribution hinge.
[0080] 13. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0081] the half-plane adjacent (at least) the mounting surface of (at least) the first mounting layer and (at least) the half-plane adjacent (at least) the mounting surface of (at least) the second mounting layer forming a (nominal) right angle spanning (at least) both a joist that supports the first deck fascia board and a joist that supports the second deck fascia board, the fascia-expansion-accommodation corner covering being a convex-corner fascia expansion accommodation structure.
[0082] 14. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0083] the half-plane adjacent the mounting surface of the first mounting layer and the half-plane adjacent the mounting surface of the second mounting layer forming an obtuse angle (nominally equal to 135° or 150°, e.g.) spanning both a joist that supports the first deck fascia board and a joist that supports the second deck fascia board, the fascia-expansion-accommodation corner covering being a convex-corner fascia expansion accommodation structure (any of items 1004 , 1102 , 1103 , 1301 , 1602 , e.g.).
[0084] 15. The decking system of any of the above SYSTEM CLAUSES 1-13 further comprising:
[0085] the half-plane adjacent the mounting surface of the first mounting layer and the half-plane adjacent the mounting surface of the second mounting layer forming a reflex angle (reflex angle 1268 , e.g.) spanning both a joist that supports the first deck fascia board (deck fascia board 1231 , e.g.) and a joist that supports the second deck fascia board (deck fascia board 1232 , e.g.), the fascia-expansion-accommodation corner covering being a concave-corner fascia expansion accommodation structure (any of items 1201 , 1202 , 1203 , 1603 , e.g.).
[0086] 16. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0087] the first and second mounting layers (any of layers 1042 , 1043 , 1155 , 1442 , 1443 , 1542 , 1543 , e.g.) and the stress distribution hinge all having been formed of a single composition (vinyl or a mixture comprising a polymer, e.g.).
[0088] 17. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0089] the first mounting layer having a longitudinally recessed surface 1151 that forms a gap depth (between the fascia expansion overlap lip of the first mounting layer and the half-plane 1162 , 1262 adjacent the mounting surface 1156 , 1256 of the first mounting layer, e.g.) of at least about 2 millimeters, the gap depth being at least about equal to a thickness of the first deck fascia board.
[0090] 18. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0091] the first mounting layer having a longitudinally recessed surface that forms a gap depth (depth 1154 , e.g.) of at most about 2 centimeters, the gap depth being at least about equal to a thickness of the first deck fascia board.
[0092] 19. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0093] the first and second mounting layers (any of layers 1042 , 1043 , 1155 , 1442 , 1443 , 1542 , 1543 , e.g.) each having a nominal thickness of at least about 0.5 millimeters.
[0094] 20. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0095] the first and second mounting layers and the stress distribution hinge (any of hinges 1141 , 1241 , 1441 , 1541 , e.g.) all having been formed integrally by a single injection molding process (with one or more other processes but without a second injection molding process, e.g.)
[0096] 21. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0097] the first and second mounting layers each having a nominal thickness of at most about 5 millimeters.
[0098] 22. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0099] the first and second mounting layers (any of layers 1042 , 1043 , 1155 , 1442 , 1443 , 1542 , 1543 , e.g.) each having a nominal thickness of at least about 3 millimeters.
[0100] 23. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0101] the first and second mounting layers each having a nominal thickness of at most about 3 centimeters.
[0102] 24. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0103] the fascia expansion overlap lips (any of lips 1150 , 1250 , 1450 , 1550 , e.g.) each having a nominal length of at least about 2 millimeters.
[0104] 25. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0105] the fascia expansion overlap lips each having a nominal length of at most about 2 centimeters.
[0106] 26. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0107] the fascia expansion overlap lips each having a length greater than its thickness.
[0108] 27. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0109] a railpost support interface (any of interfaces 260 , 360 , 960 , e.g.) that includes a first mounting layer and a second mounting layer welded together and both welded to a substrate of the railpost support interface, the first mounting layer of the railpost support interface constructed and arranged to be supported by a first joist that also supports the first deck fascia board (any of deck fascia boards 133 , 232 , 1032 , 1232 , 1433 , 1532 , e.g.), the second mounting layer of the railpost support interface being constructed and arranged to be supported by a second joist that also supports the second deck fascia board.
[0110] 28. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0111] a railpost support interface that includes a substrate supporting several baseplate support bosses (four or more bosses 513 , 713 , e.g.) and a rigid undercarriage welded to the substrate, the railpost support interface being supported by one or more fasteners having been (inserted through a joist and) self-tapped into the undercarriage, the railpost support interface constructed and arranged to be supported by (at least) a first joist that also supports the first deck fascia board.
[0112] 29. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0113] a railpost support (any of items 320 , 520 , 920 , e.g.) that includes a baseplate and a plurality of flexible finger mounts and a sleeve section, one or more tensile elements (screws configured to extend downward through the baseplate into a threaded portion of the railpost support interface, e.g.) being configured to hold the baseplate removably in rigid engagement with a railpost support interface mounted adjacent at least one of the first deck fascia board or the second deck fascia board, (a top of the railpost support interface being nominally flush with a top of the deck, e.g.) the sleeve section configured to be supported by the baseplate and to support the flexible finger mounts in contact with a railpost inserted (nominally vertically, e.g.) into the sleeve section.
[0114] 30. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0115] a deck (deck 100 or deck 300 , e.g.) comprising first and second joists and the first deck fascia board mounted on the first joist and the second deck fascia board mounted on the second joist and the fascia-expansion-accommodation corner covering substantially covering both a front of an end portion of the first deck fascia board and a front of an end portion of the second deck fascia board.
[0116] 31. The decking system of any of the above SYSTEM CLAUSES further comprising:
[0117] a deck that includes the fascia-expansion-accommodation corner covering, the first and second deck fascia boards, and one or more other deck or deck railing components identified in the respective SYSTEM CLAUSE(S).
[0118] 32. A decking method comprising:
[0119] configuring a first joist and a second joist to form a corner therebetween; mounting a first deck fascia board medially covering a front of the first joist but not distally covering the front of the first joist;
[0120] mounting a second deck fascia board medially covering a front of the second joist but not distally covering the front of the second joist;
[0121] mounting a fascia-expansion-accommodation corner covering as described in any of the above SYSTEM CLAUSES so that the fascia expansion overlap lip of the first mounting layer thereof is configured to remain in front of (laterally adjacent, e.g.) the first deck fascia board irrespective of a longitudinal expansion of or contraction of the first deck fascia board and so that the fascia expansion overlap lip of the second mounting layer thereof is configured to remain in front of (laterally adjacent, e.g.) a second deck fascia board irrespective of a longitudinal expansion of or contraction of the second deck fascia board.
[0122] All of the patents and other publications referred to above (not including websites) are incorporated herein by reference generally—including those identified in relation to particular new applications of existing techniques—to the extent not inconsistent herewith. While various system, method, article of manufacture, or other embodiments or aspects have been disclosed above, also, other combinations of embodiments or aspects will be apparent to those skilled in the art in view of the above disclosure. The various embodiments and aspects disclosed above are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated in the final claim set that follows.
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Structures and protocols are presented for providing enhanced assembly tolerances (for thermal or manufacturing variations, e.g.) in constructing gazebos or other standalone decking systems, decks adjoining a house or other primary structure, or other such structures for walkways or human occupancy.
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BACKGROUND OF THE INVENTION
The invention relates to a support assembly for semi-trailers or the like and consists of two driven spindle-jacks each with two telescoping inner and outer tubing and each with one bevel-gear drive, one of these drives being actuated by spur-gearing itself actuated by a handcrank, the bevel-gear shaft of this bevel-gear drive penetrating the spur-gearing and forming part of the same and being supported at the opposite end as well as between its ends in the outer tubing.
It has been conventional practice so far in spindle-jacks used in such support assemblies to support the bevel-gear shaft at one end as well as between its ends in the outer square-section of a spindle-jack and to support it at its other end in the spur-gear drive-housing, and to do this by means of a plurality of sleeve bearing, e.g., three bearings. However, to prevent undue friction and accordingly low efficiency, the sleeve bearings must be carefully aligned in the assembly of the jack, whereby difficulties are encountered in mass production, as the spindle jacks in question are welded together, extruded, molded or rolled components being used in part. For instance the roller outer square-sections may not be satisfactorily right-angular in cross-section. If the sleeve bearings are improperly aligned, the bevel-gear shaft may cant, or the angularly offset seating of the bevel-gear may result in the further drawback that the bevel-gear rests by its shoulder against the inside wall of the outer square tubing and thereby moves within it only on one side, whereby there is degradation in the functioning of the spindle-jack.
SUMMARY OF THE INVENTION
The present invention addresses the problem of eliminating the problems cited above and to create equipment, namely a support-assembly with spindle-jacks, wherein the support of the bevel-gear shaft and the installation of the spur-gearing is simplified under the conditions cited above, and whereby improved functioning and efficiency is achieved.
This problem is solved by the present invention for a support-assembly of the initially discussed type in that the support of the bevel-gear shaft between its ends is achieved using an anti-friction bearing, i.e., a roller or ball bearing, in the form of an annular oblique bearing of which the outer race comprises a radially outward, annular projection at the inside end, the bearing resting by means of said projection in a suitable bore in the outer tubing, in that the spur-gear drive housing by means of a suitable bore plugs in self-centering manner on a shoulder extending from the inside end of the outer race to the outside, and in that the gear and bevel-gear adjacent to the bearing are maintained by the inside race at an axial distance from the outer race and, where appropriate, from the inside wall of the gear housing or the outer tubing.
The annular oblique bearing is fixed in place by means of the annular, outwardly radial projection, and upon subsequent installation of the gearing housing, the latter is properly positioned on the outwardly projecting shoulder of the outer race, so that the input or drive shaft of the spur-gearing is made to assume a position substantially parallel to the bevel-gear shaft, even when for instance the angles made by the sides of the outer square section when viewed in cross-section deviate from the proper angles. After this emplacement of the gearing housing on the outer tube of the spindle-jack, the gearing housing may for instance be welded or screwed on the outer tube. Because the inside race of the bearing maintains the adjacent bevel-gear and the gear axially away from the outer race and from the inside wall of the outer tube, or the gearing housing, the friction is reduced compared to the state of the prior art and the efficiency of the spindle-jack is further improved. The elimination of the previously conventional third support bearing for the bevel-gear shaft in view of its overhung support in turn results in an advantageous simplification in construction. Because of the above steps of the invention a sensible increase in efficiency compared to the prior state of the art is made possible and achieved.
According to a further embodiment of the invention, the bearing is designed to be self-latching by means of a split lock washer on a radially offset, axial extension of the inside race, and the inside race is provided with a toothed spline, whereby an easily installed and dismantled roller bearing is achieved, of which the inside race is reliably moved along by the bevel-gear shaft, which shaft anyway is equipped with bevel-gearing for the rotationally-secure mounting of the bevel-gear and of a further spur-gear, the inside race then also meshing with said bevel gearing.
To prevent erroneous installation of the bearing, a further embodiment of the invention provides, for instance, several wart-like protrusions or the like at the inside of the gearing housing near the bore and inside the outer diameter of the projection at the ouer race of the bearing. These protrusions immediately reveal an erroneous emplacement of the bearing on the bevel-gear shaft because the adjacent spur gears then do not permit being put into their proper assembly positions on the bevel-gear shaft.
The invention may also be implemented in an especially economical manner when the inside and/or outside race of the bearing is an extruded or molded component.
As discussed above, the oblique annular bearing serves both to support the bevel-gear shaft between its ends and as a centering means to emplace the input or drive shaft in the spur-gearing housing parallel to the bevel-gear shaft when assembling the spur-gearing housing to the outer tubing, whereby the gears of the driving unit will properly mesh. When the spur-gearing housing is welded to the outer tubing, it is necessary however to carefully cover the exposed parts of the annular oblique bearing--which at this time is in its assembly position--, to prevent soiling from the welding procedure. It is alternatively possible when assembling the spur-gearing housing to the outer tubing of the spindle-jack, to use first a centering template the shape of the annular oblique bearing in lieu of the actual one, and to remove it after welding and replacing it by the genuine annular oblique bearing. This annular oblique bearing comprises an outer race with two stepped, annular sections, of which only one is centered or matchingly integrated into a bore in the outer tubing or in a bore in the spur-gearing housing, the section with the larger diameter resting against the inside of the outer tubing and/or the outside of the spur-gearing housing. This embodiment offers the advantage that only one particular bore in the outer tubing or spur-gearing housing and only one of the stepped, annular sections of the outer race require precise machining, so that the assembly of the annular tapered bearing into the spindle-jack is simplified. The axial thrust generated by the bevel-gear in spindle-jack operation is transmitted through the outer race to the outer tubing and/or the gearing housing, or reliably absorbed by these components.
A further feature of the invention is that the inside race of the bearing keeps the bevel-gear against a stop on the latter's shaft so as to be precisely meshing with its opposite bevel-gear. Accordingly, the inside race serves advantageously an additional function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevational view, partly in section, of two drive-couple spindle-jacks of a support assembly for semi-trailers;
FIG. 2 is an elevational view, partly in section, of the spur-gearing and of the bevel-gear drive of a spindle-jack;
FIG. 3 is an enlarged partial section similar to the cut-out Z in FIG. 1, showing another embodiment of the invention; and
FIG. 4 is a partial sectional view similar to FIG. 3, showing still another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The two spindle-jacks 10, also termed spindle-props, shown in FIG. 1, are of the same design and while spaced apart are fastened by securing-plates 11 to the underside of a semi-trailer at its front part, so that after separating the semi-trailer from its tractive means, it will rest on these spindle-jacks.
Each spindle-jack 10 comprises two relatively displaceable inner and outer, substantially square sections of tubular form 12 and 13, rollers or articulating feet (not shown) being mounted to the lower end of the inside square section 12 to prop the semi-trailer on the ground. The relative motion of the inside and outside square sections is implemented by rotating a threaded spindle 14 which is held axially fixed but rotationally displaceable in a bearing plate 15 welded into the outer square tubing 13 and which holds a nut 16 fastened to the upper end of the inside square tubing 12.
A bevel-gear 17 meshing with another bevel-gear 18 is pinned to the upper end of the threaded spindle 14, bevel-gear 18 being rigidly mounted with respect to relative motion on a bevel-gear shaft 19 and 19a. Bevel-gear shaft 19, as shown in FIG. 1, extends leftwards and into a spur-gearing housing 20 consisting of two molded or stamped pieces 21 and 22, which are joined together at 23. Two gears 24 and 25 are mounted so as to be secured against relative rotation on that part of the bevel-gear shaft 19 which enters the spur-gearing housing 20, one of which (FIG. 2) meshes with gear 24 by means of pinion 26, while gear 25 meshes with gear 27. Pinion 26 and gear 27 are mounted on an axially displaceable drive shaft 28 which can be rotated by a hand-crank (not shown), the various set positions of drive shaft 28 being secured by a spring 29. This spring lock 29 functions by means of annular grooves 30 in drive shaft 28. FIG. 2 shows the spur-gearing in a particular setting corresponding to operation under load. When the equipment is set for rapid (unloaded) operation, gear 27 meshes with gear 25.
FIG. 1 discloses that the bevel-gear shafts 19 and 19a are drive-connected by means of a ganging shaft 31, so that when this shaft rotates, both spindle jacks 10 are actuated simultaneously. However, each spindle-jack may also be provided with its own hand-crank drive.
The bevel-gear shaft 19 is supported at one end in a bearing sleeve 32 mounted to the outside square tubing 13 and furthermore between its ends in a ball bearing 33 which is designed as an annular oblique bearing. That part of the bevel-gear shaft 19 supporting gears 24 and 25 projects freely into gearing housing 20, that is, it "overhangs" or is cantilevered. Bearing 33 is provided with an outer race 34 and an inner race 35, and is designed to remain in place by itself. To that end a split lock-washer 37 is mounted in a corresponding groove on a radially offset, axial extension 36 of the inner race 35. The outer race 34 comprises at its inside end an annular, radially outward projection 38 fitted to and inserted into a bore 39 in the outer square tubing 13. Component 21 of gearing housing 20 is provided with a bore 40 through which passes with a close fit an outwardly extending shoulder 41 of outer race 34. When gearing-housing part 21 is slipped on this shoulder, the required alignment of gears 26 and 27 with respect to gears 24 and 25, respectively, is ensured, shafts 19 and 28 assuming substantially axially parallel positions. After slipping this component 21 onto shoulder 41, component 21 can be connected with the outer square tubing 13, for instance, by welding or bolting, as indicated in FIG. 2 at 42.
Bevel-gear shaft 19 is provided with toothed spline sections 43 and 44; bevel-gear 18, inside race 35 and gear 24 are mounted by means of matching splines on section 43, secured on same against relative rotation, while gear 25 is seated on section 44 with a respective matching spline, also secured against relative rotation. A spacing bush 45 is mounted between gears 24 and 25 and a split lock washer 46 seated in a groove 47 of the bevel-gear shaft 19 secures components 25, 45, 24, 35 and 18 to bevel-gear shaft 19 in the positions shown.
Inside race 35 extends axially in both directions beyond outer race 34, thereby ensuring that bevel-gear 18 and gear 24 are axially spaced from outer race 34. Several wart-like protrusions 48 provided at the inside of component 21 of gearing-housing 20--only one being shown in FIGS. 1 and 2--prevent incorrect assembly of bearing 33.
Bearing 33 is slipped on the splined section 43a of bevel-gear shaft 19a and corresponds to the bearing discussed above. Shoulder 41 of outside race 34 in this case extends however through a bore 49 in the mounting plate 11, and the inner race 35 and the bevel-gear 18 are axially fastened to bevel-gear shaft 19a by means of a split lock-washer 51 mounted in a groove 50 in this instance. In this variation, the inside race 35 again serves to space the bevel-gear 18 laterally away from the outer race 34 to prevent frictional losses.
The outer race 34 of ball bearing 33a in FIG. 3 is inserted as a close fit by means of its annular section 38 in a bore 39 in the outer square tubing 13, while the annular and offset section 41' of the outer race extends with radial play into a bore 40' of gearing-housing 20. Therefore, only bore 39 and the outer circumference of section 38 require precise machining. The required coaxial arrangement of bores 39 and 40' and of the bore seating the bearing sleeve 32 (FIG. 1) is implemented by using a template (not shown) corresponding to the annular oblique bearing 33a when welding the gearing-housing 20 to the outer square tubing 13, or alternatively by first welding the gearing-housing to the outer square tubing and then machining in one stage all the bores for the bevel-gear shaft 19, for instance, by means of a step-drill, namely axially parallel to the drive shaft 28 of the spur-gearing.
Whereas in the embodiment of FIG. 3, the annular section 38 with the larger diameter is installed in close fitting manner into bore 39 of the outer square tubing 13, the offset annular section 41 according to the embodiment of FIG. 1 and comprising the ball bearing 33b, and of a smaller diameter, is installed centered or ready-to-match in bore 40 of the spur-gearing housing 20. Between section 38' with the larger diameter and bore 39', there is a radial play, that is, neither section 38' nor bore 39' require precise machining.
According to a further characteristic of the invention, the inner race 36 keeps the bevel-gear 18 forced against a stop 52 formed by the left rim of an enlarged-diameter section 53 of the bevel-gear shaft 19, whereby precise meshing between bevel gears 18 and 17 is ensured. The axial thrusts exerted when operating the spindle-jack by bevel-gear 18 toward the spur-gearing are transmitted by the inner race 35, by the balls of the annular oblique bearing and by the outer race 34 to gearing-housing 20 and are absorbed by it, because the annular section 38 of outer race 34 with the larger diameter fully rests against the outside 54 of this housing (FIGS. 3 and 4). The above description also applies to the annular oblique bearing 33 slipped on the splined section 43a of bevel-gear shaft 19a.
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A support member for semi-trailers or the like comprising two driven spindle-jacks each with two telescoping inner and outer tubing and each with one bevel-gear drive, one of these drives being actuated by spur-gearing itself actuated by a handcrank, the bevel-gear shaft of this bevel-gear drive penetrating the spur-gearing and forming part of same and being supported at the opposite end as well as between its ends in the outer tubing.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to an electrical junction box for being mounted on a rear face of an on-vehicle instrument in overlapping relation to an adjuster of this instrument.
[0002] Instruments, including a speedometer, are mounted within an instrument panel or a steering column of a vehicle. In this kind of on-vehicle instrument, a movement is angularly moved in accordance with a speed measurement signal or the like, and a pointer, moving in interlocked relation to the movement, indicates a speed value or the like. In this kind of on-vehicle instrument, an adjuster for setting and adjusting the behavior and indication value of a pointer, etc., is, in many cases, provided at a rear side of the movement, with a base board interposed therebetween.
[0003] On the other hand, electrical junction boxes (called a junction block or a junction box), containing a branch connector of a wire harness, functional circuits, etc., are mounted in a vehicle. Among such electrical junction boxes, there is the type which is located within an instrument panel or a steering column, and particularly is located at a rear side of an on-vehicle instrument as disclosed in Japanese Patent Publication No. 2003-146223A. In this case, there are occasions when such an electrical junction box is mounted in overlapping relation to the adjuster provided on the rear face of the on-vehicle instrument.
[0004] However, once the electrical junction box is mounted in the above position, it is very difficult to operate the adjuster of the on-vehicle instrument from the exterior since the electrical junction box is disposed in overlapping relation to the adjuster. Therefore, for operating the adjuster, it is necessary to once remove the mounted electrical junction box. Then, it is necessary to again mount the electrical junction box in position. Namely, it is necessary to perform detaching and attaching operation of the electrical junction box in addition to the originally-intended adjusting operation.
[0005] In recent years, there are extensively used combination meters having a plurality of indicators (including a speedometer, a tachometer for an engine, a temperature indicator, etc.,) integrally incorporated therein. In this case, it is necessary to adjust movements corresponding respectively to the plurality of indicators, and the frequency of adjustments of the adjusters increases more and more. Namely, it becomes essential to reduce the time and labor required for the above adjusting operation.
SUMMARY OF THE INVENTION
[0006] It is therefore an object of this invention to provide an electrical junction box which enables an adjuster of an on-vehicle instrument to be operated, with the electrical junction box kept mounted on this instrument, so that the time and labor, required for the adjusting operation, can be reduced.
[0007] In order to achieve the above object, according to the invention, there is provided an electrical junction box located so as to oppose to an adjuster which is provided on a rear face of an on-vehicle instrument, comprising:
a first face, which faces the on-vehicle instrument; and a second face, which is opposite to the first face, wherein: at least one through hole is formed so as to communicate the first face and the second face; and the electrical junction box is configured to be disposed such that the through hole opposes the adjuster.
[0012] With this configuration, even when the electrical junction box is located so as to overlap with the adjuster of the on-vehicle instrument, the adjuster can be actuated through the through hole. Therefore, the time and labor, required for the adjusting operation, can be greatly reduced.
[0013] Preferably, the through hole also serves as a pilot hole used when the electrical junction box is assembled.
[0014] With this configuration, since the pilot hole is originally provided in this kind of electrical junction box, it is not necessary to provide a new hole for exclusive use as the adjustment hole.
[0015] Preferably, the through hole opposes to a rear face of a movement for moving a pointer of the on-vehicle instrument.
[0016] In order to adjust the pointer, it is necessary to adjust the movement, and in many cases, the adjuster is provided at the rear side of the movement. Therefore, by providing the through hole at the position opposing to the rear face of the movement, the adjustment of the pointer can be reliably executed while the electrical junction box kept mounted on the instrument.
[0017] Preferably, the through hole opposes each of adjusters for a speedometer, an engine tachometer and a temperature indicator included in the on-vehicle instrument.
[0018] Since the frequency of adjustments of the instrument including a plurality of indicators is high, the claimed configuration is useful because the electrical junction box which enables the adjusters to be actuated while the electrical junction box kept mounted on such an instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
[0020] FIG. 1 is a schematic perspective view of an electrical junction box according to one embodiment of the invention, showing a state before the electrical junction box is mounted on an on-vehicle instrument;
[0021] FIG. 2 is a section view of the electrical junction box, showing a state after the electrical junction box is mounted on the on-vehicle instrument;
[0022] FIG. 3 is a perspective view of the electrical junction box, showing a disassembled state thereof;
[0023] FIG. 4A is a front view of the electrical junction box of an assembled state; and
[0024] FIG. 4B is a rear view of the electrical junction box of the assembled state.
DETAILED DESCRIPTION OF THE INVENTION
[0025] One embodiment of the present invention will be described below in detail with reference to the accompanying drawings.
[0026] As shown in FIGS. 1 and 2 , an electrical junction box 1 is mounted on a rear or back side of an instrument 21 fitted in a steering column 2 . An adjustment hole 1 h is formed through that portion of the electrical junction box 1 corresponding to an adjuster 21 p of the instrument 21 . As is well known, the steering column 2 comprises a front cover 22 , a rear cover 23 , and a lower cover 24 . A turn signal switch 25 , a wiper switch 26 and an ignition switch 27 are provided on a side face of the steering column 2 , and a steering wheel 28 is mounted on a front side of the steering column 2 . Although the instrument 21 , illustrated here, is a single-eye meter basically forming a speedometer, it can be replaced by a well-known combination meter including a speedometer, a tachometer, a temperature indicator, etc.
[0027] As is well known, the instrument 21 , fitted in the steering column 2 , comprises: a base board 21 d on which a pointer 21 a indicating a speed value, a movement 21 b for turning a pointer 21 a , an electronic component 21 c such as a microcomputer, the adjuster 21 p , a light source element (not shown), etc., are mounted; a dial plate 21 e having a design (speed scales and others) formed thereon; a light-guide plate 21 f for efficiently guiding light from the light source element to the dial plate 21 e ; an end plate 21 g secured to a front side of the dial plate 21 e ; a front glass panel 21 h provided in front of the dial plate 21 e to cover the same; and a casing 21 i , as shown in FIG. 2 . The adjuster 21 p is provided for setting and adjusting the behavior and indication value of the pointer, etc. The adjuster 21 p can be operated, for example, by a microscrew-driver or a small-diameter wrench which is inserted into the adjustment hole 21 h in a direction of an arrow in FIG. 2 .
[0028] The electrical junction box 1 is mounted on the rear face of the instrument 21 , and more specifically on the rear face of the base board 21 d . The electrical junction box 1 is mounted in this position in such a manner that a connector 113 , formed on a front face thereof is fitted to a connector (not shown) formed on the rear face of the instrument 21 .
[0029] As shown in FIG. 3 , the electrical junction box 1 comprises an undercover 11 , a wiring unit 12 , a bus bar unit 13 , and a main cover 14 . Although the electrical junction box 1 further includes an electronic circuit section or the like, the showing of these parts is omitted since they are not particularly necessary for the understanding of the subject matter of the invention.
[0030] The undercover 11 is made of resin, and includes: a base portion 111 having a generally trapezoidal shape when viewed from the upper side; and a holder 112 having a generally square shape when viewed from the upper side for receiving the wiring unit 12 , the bus bar unit 13 , etc. A through hole 1 h 1 is formed through a generally central portion of a bottom of the holder 112 , and this through hole 1 h 1 forms part of the adjustment hole 1 h.
[0031] The wiring unit 12 comprises a wiring holder 121 , and wires 122 installed on this wiring holder 121 . The wiring holder 121 is made of an insulative material such as resin, and has generally the same plan shape (as viewed from the upper side) as a bus bar holder 133 (described later). The disk-shaped wiring holder 121 has a plurality of retainers for retaining the wires 121 in a predetermined position. The wires 122 are connected to small-current bus bars 131 to transfer small current such as data signals and control signals. A through hole 1 h 2 is formed through a generally central portion of the wiring holder 121 , and this through hole 1 h 2 forms part of the adjustment hole 1 h.
[0032] The bus bar unit 13 comprises the small-current bus bars 131 , large-current bus bars 132 , and the bus bar holder 133 .
[0033] Each of the small-current bus bars 131 are formed of a metal sheet, and mainly transfer small current such as data signals and control signals of a microcomputer and various electrical circuits. The small-current bus bars 131 have tab-like terminals formed integrally therewith and projecting perpendicularly therefrom. The small-current bus bar layer 131 is mounted on the bus bar holder 133 in such a manner that the tab-like terminals extend through the bus bar holder 133 .
[0034] On the other hand, each of the large-current bus bars 132 are formed of a metal sheet, and mainly transfer large current supplied as electric power from an alternator or a battery. The large-current bus bars 132 also have tab-like terminals formed integrally therewith and projecting perpendicularly therefrom. The large-current bus bar layer 132 is mounted on the bus bar holder 133 in such a manner that the tab-like terminals extend through the bus bar holder 133 .
[0035] The bus bar holder 133 is made of an insulative material such as resin, and the small-current bus bar layer 131 and the large-current bus bar layer 132 are mounted on the opposite sides of the bus bar holder 133 , respectively. A through hole 1 h 3 is formed through a generally central portion of the bus bar holder 133 , and this through hole 1 h 3 forms part of the adjustment hole 1 h.
[0036] The main cover 14 is made of resin, and when viewed from the upper side, this main cover 14 has a generally square shape corresponding to the shape of the holder 112 of the undercover 11 , and is open downwardly (in this figure). A plurality of connector receivers 141 for respectively receiving socket-shaped connectors (not shown), fuse receivers 142 for respectively receiving fuses (not shown), and other portions are formed on an upper face of the main cover 14 . A through hole 1 h 4 is formed through a generally central portion of the main cover 14 , and this through hole 1 h 4 forms part of the adjustment hole 1 h.
[0037] When the assembling of the electrical junction box 1 is completed, the through holes 1 h 1 to 1 h 4 are vertically aligned with one another to form the adjustment hole 1 h extending straight through the electrical junction box 1 . Therefore, the electronic circuit portion, the board and others, received within the electrical junction box 1 , are arranged to avoid the adjustment hole 1 h . Although members used for combining the main cover 14 and the undercover 11 together) are provided at the main cover 14 and the undercover 11 , the showing of such members is omitted in FIG. 3 .
[0038] When the assembled electrical junction box 1 is viewed from the front side (upper side) thereof, it can be seen from FIG. 4A that the generally-square main cover 14 , having the connector receivers 141 , the fuse receivers 142 , etc., formed thereon, is attached to the undercover 11 to cover the holder 112 , and that the adjustment hole 1 h ( 1 h 4 ) is formed through the generally central portion of the main cover 14 .
[0039] When the assembled electrical junction box 1 is viewed from the rear side thereof, it can be seen from FIG. 4B that the adjustment hole 1 h ( 1 h 1 ) is formed through the generally central portion of the undercover 11 , and that the connector 113 is disposed at the left side of this adjustment hole 1 h.
[0040] The adjustment hole 1 h also serves as a guide hole when mounting the bus bar unit 13 and the wiring unit 12 , using pilot holes 1 h ′ as a reference, that is, the adjustment hole 1 h also serves as a pilot hole used as a positioning member when the electrical junction box 1 is assembled. The electrical junction box 1 is mounted on the instrument 21 in such a manner that the adjustment hole 1 h is aligned with (or coincides with) the adjuster 21 p as shown in FIG. 2 . According to the provision of this adjustment hole 1 h , the adjuster 21 p can be operated, with the electrical junction box 1 kept mounted on the instrument 21 , and therefore the time and labor, required for the adjusting operation, can be greatly reduced. And besides, the adjustment hole 1 h serves also as the pilot hole which is originally provided in this kind of electrical junction box, and therefore it is not necessary to provide a new hole for exclusive use as the adjustment hole. Therefore, it is not necessary to change the various layouts and the wire installation arrangement within the electrical junction box.
[0041] When the electrical junction box 1 is used with a combination meter (which contains a speedometer, a tachometer for an engine, a temperature indicator, etc.,) instead of with the illustrated single-eye meter, the electrical junction box 1 is more useful. Namely, the frequency of adjustments of the combination meter (containing the plurality of indicators) is high, and therefore the electrical junction box which enables the adjuster to be operated with the electrical junction box kept mounted on the instrument will be utilized many times, and therefore is useful.
[0042] Although the present invention is shown and described with reference to specific preferred embodiments, various changes and modifications will be apparent to those skilled in the art from the teachings herein. Such changes and modifications as are obvious are deemed to come within the spirit, scope and contemplation of the invention as defined in the appended claims.
[0043] For example, the adjustment hole in the electrical junction box of the invention is not limited to the illustrated construction in the above embodiment. For example, when there are provided a plurality of adjusters, a plurality of adjustment holes, corresponding respectively to these adjusters, may be provided, or an adjustment hole may be provided in alignment only with that adjuster which is most frequently used. With respect to the position of formation of the adjustment hole, the adjustment hole may not be formed in the generally central portion of the electrical junction box, but may be formed in any other suitable portion of the electrical junction box in so far as the adjustment hole coincides with the corresponding adjuster. Further, the adjuster which can be operated through the adjustment hole can be designed so as to enable the adjustment of any other suitable portion than the pointer and the movement.
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An electrical junction box is located so as to oppose to an adjuster which is provided on a rear face of an on-vehicle instrument. The electrical junction box has a first face which faces the on-vehicle instrument, and a second face which is opposite to the first face. At least one through hole is formed so as to communicate the first face and the second face. The electrical junction box is configured to be disposed such that the through hole opposes the adjuster.
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BACKGROUND OF THE INVENTION
In one aspect, the invention relates to a fiber mat suitable for incorporating into a molding composition. In another aspect, the invention relates to a process for forming the fiber mat. In yet another aspect, the invention relates to molding composition containing the fiber mat.
For many applications, it is desirable to provide finished parts with electromagnetic interference (EMI) shielding characteristics. In the automotive field, EMI shielding is required for plastic hoods, fenders, and fire walls. Office business machines require some form of shielding over parts of their internal areas. By regulation, emissions from all digital computing devices must be within certain radiation limits. Regulation of emissions is necessary because of increasing complaints of electrical malfunctions caused by electromagnetic interference. Examples include TV snow, flight instrument malfunctions caused by pocket calculators and activation of electrically controlled devices by citizen band radios.
Methods presently used to shield electronic components have been ranked in order of preference. The methods, in order of preference, include silver paint application, nickel paint application, conductive filler utilization, silver reduction, cathode sputtering, foil application, copper paint, vacuum metalizing, electroplating, flame/arc spraying and graphite paint application. With the exception of conductively filled plastics, all of the shielding methods suffer from either a limited life due to chipping, cracking, peeling or the fact that they involve costly secondary operations.
The most desirable method of shielding is with conductively filled plastic because the shielding material is an integral part of the plastic and will not chip or blister and does not require a secondary operation. However, incorporating conductive fillings in plastics frequently reduces product properties in an unacceptable extent because of the high amount of filler required to provide acceptably high shielding characteristics.
OBJECTS OF THE INVENTION
It is an object of this invention to provide a fiber reinforcement for polymer components which imparts superior mechanical properties.
It is another object of the invention to provide a polymer sheet containing the fiber reinforcement which exhibits good mechanical properties.
It is yet another object of the invention to be able to use lesser amounts of conductive filler in a polymer sheet without reducing shielding effectiveness.
It is still a further objective of this invention to provide a process for forming a conductive fiber mat which is easily processed and provides good properties when incorporated into a polymer sheet.
STATEMENT OF THE INVENTION
In accordance with the first embodiment of the invention, there is provided a fiber mat suitable for deploying as an EMI shield in a polymer matrix. The mat comprises a first layer formed from a nonwoven reinforcing fiber and a second layer carried by the first layer comprising metal whiskers or fibers formed from a ductile metal or metal alloy. By using these metal whiskers or fibers in a second layer, low metal concentrations are possible in the final product because of the high aspect ratio (1/d) of the fiber. By carrying the metal whiskers on the reinforcing mat the second layer can be present in an amount which would otherwise be inadequate to provide sufficient structural integrity for independent handling.
In another aspect of the invention, the above described two layer mat is incorporated into a polymer matrix to form a composite. The resulting composite is suitable for use as panels and the like requiring EMI shielding. The nonwoven layers of fiber are flowable under stamp molding conditions and thus the composite is highly suitable for use as stampable sheet or sheet molding compound.
In another aspect of the invention, a conductive mat suitable for use in a polymer matrix to provide good mechanical properties and EMI shielding is provided by a process comprising conveying a mat of nonwoven fabric beneath a distributor of metal whiskers and distributing metal whiskers onto the mat from the distributor in an amount sufficient to impart conductivity to the resultant blend. The procedure provides advantages in (1) ease of fabrication and economy in the use of conductive material (2) ease of handling of the resulting two component mat.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with a first embodiment of the invention, a fiber mat suitable for incorporating into a polymer or resin to provide reinforcement and EMI shielding therein comprises a first layer and a second layer. The first layer comprises a nonwoven reinforcing fiber mat. Conventional reinforcing fibers can be used if desired, the exact type depending on the properties desired to be imparted to the matrix and cost. Nonwoven fiberglass mat is presently preferred since it is readily available and inexpensive, especially fiberglass in which the fiber is continuous because of the resulting properties in the composite although chopped glass or chopped or continuous carbon fiber can be used if desired. Carbon fibers, either chopped or continuous, also provide a desirable alternative.
The second layer of the mat is carried on the first layer and comprises nonwoven metal whiskers or fibers of a ductile conductive metal or metal alloy. Preferably, the metal whiskers have a sufficient length to diameter ratio (aspect ratio) so as to provide good EMI shielding at a low concentration. To provide good EMI shielding it is important that a sufficient amount of the metal whiskers be deposited on the nonwoven reinforcing fiber mat so that a conductive network is formed and that the deposit be sufficiently dense to yield the desired degree of EMI shielding. Normally, the second layer will provide a screen on top of the first layer that can be seen through since the wavelengths to be shielded are generally greater than 30 centimeters. Open areas defined by interconnected individual whiskers on the first layer of up to about one square centimeter are thus satisfactory. Various ductile conductive metals or metal alloys are suitable for forming the whiskers. The metals which can be used for electrical conductors are suitable, such as for example, aluminum, copper, silver, or gold. Other metals, such as nickel, tin, and lead are also expected to work well, provided that the resins selected does not interact with the metal selected, such as by corrosion.
Whisker diameter is not particularly important provided that the whisker is not so fragile as to be broken during the thermoforming process. For economy, the whiskers should be of relatively small diameter, preferably in the range of 0.01 to 1 millimeter. Suitable whisker length ranges from 1 millimeter to continuous strand. Preferably, each whisker has a length of greater than 1 centimeter to provide a high aspect ratio and good effectiveness for EMI shielding. Preferably, a major portion of the whiskers have a length in the range of 0.5 to 20 centimeters, more preferably in the range of 1 to 10 centimeters, for ease of processing and most desirable shielding properties. Diameters of the whiskers are preferably in the range of from 0.05 millimeters to 0.5 millimeters although whiskers of other dimensions will work. A preferred metal whisker is comprised of alumimum. Whiskers of this type are formed by the Transmet Corp. (Columbus, Ohio) by distributing molten aluminum on a rapidly spinning wheel followed by a rapid quenching.
The polymer used to form a resin matrix around the first layer and second layer of the fibers can be either thermoplastic or thermoset resin. Polyethylene, polypropylene, and polyester resins are believed highly suitable where high performance properties are not required. Other suitable resins include polystyrene, ABS, other acrylic polymers and copolymers polyethers, polyamides, PVC (polyvinylchlorides), polycarbonates, epoxy resins, phenolic resins, melamines and polyarylene sulfides such as polyphenylene sulfide, polyphenylene sulfide sulfone, polyphenylene sulfide ketone, polyphenylene ether ketone, polyphenylene ether polyphenylsulfone and the like. Almost any polymer which is suitably strengthened by incorporating glass mat can be made into a conductive composite by the inclusion of glass mat on which is deposited a conductive amount of aluminum fiber.
The relative amounts of polymer matrix, reinforcing fiber, and shielding fiber can vary depending upon the reinforcing and shielding properties desired. Generally, the two layer mat can be formed with a weight ratio of reinforcing fiber, generally glass, to metal whiskers such as aluminum, in the range of 4:1 to 1:1. It is believed that by providing the mat with a ratio of glass fiber to aluminum in the range of 3:1 to 1:1 on a weight basis will provide very good results for most applications. The amount of polymer in the composite will generally range from about 25 to 75 percent by weight. A polymer content in the composite ranging from about 40 to 60 percent by weight will provide good results in the case of engineering thermoplastics. Greater amounts of inexpensive polymer such as polypropylene can be used in applications where the mechanical properties are adequate. It is a relatively simple matter when using the invention to attain EMI shielding of at least 40 decibels (dB) and EMI shielding of at least 50 dB such as in the range 50 to 70 dB can be attained without undo experimentation.
To form the conductive mat of the present invention, the nonwoven reinforcing fabric can be passed beneath a distributor of metal whiskers and the metal whiskers are distributed onto the mat from the distributor in an amount sufficient to impart the desired conductivity to the mat. Entanglement between layers can be avoided by interspersing layers of paper of film, such as a film of the polymer to be used as the matrix, between layers of conductive mat in the stack or on the roll. Good results are expected where the glass fibers are continuous and the metal whiskers have a length in the range of 0.5 to 20 centimeters and are distributed on the nonwoven mat in an amount sufficient to impart to the resulting 2-layer conductive mat in the range of 25 to 50 weight percent metal. In a preferred embodiment of the invention, a major portion of the metal whiskers have length in the range of 1 to 10 centimeters.
EMI shielded stampable sheet can be formed on a compaction line in accordance with the invention simply by substituting the conductive mat for the nonconductive mat normally used in such applications. The conductive mat is sandwiched between films of polymer and subjected to sufficiently elevated conditions of temperature and pressure to form the stampable sheet. To form EMI shielded stampable sheet from thermo setting materials the conductive mat is passed through a bath of the thermo setting resin, withdrawn and allowed to partially cure.
The invention is illustrated by the following example:
EXAMPLE 1
Continuous glass fiber mat (Owens-Corning Fiberglass OCF M-8608) was pressed in a laminate with polyphenylene sulfide (PPS) at 600° F. for 1.5 minutes at contact pressure and then at 100 psi and 600° F. for 2 minutes followed by 3 minutes at 100 psi in a room temperature press. Properties of the laminate are shown in Table I.
EXAMPLE 2
PPS-Glass Fiber-Aluminum Fiber Composites
Aluminum fiber (0.75-inch; Transmet Corp., Columbus, Ohio) was placed between layers of continuous glass fiber mat (OCF M-8608) at the desired weight level and laminated with PPS as in Example I. Properties of the laminates at various ratios of glass and aluminum to polymer are shown in Table I.
Comparisons of the data show that EMI shielding varies in relation concentration of the aluminum fiber but as the aluminum fiber content increases from 5 to 20 percent and simultaneously the glass fiber content decreases from 35 to 20 percent, the impact strength (notched Izod) decreases from 16.7 to 11.8 ft.-lb/inch. A good balance of properties is obtained in a composite comprised of 33 percent glass, 17 percent aluminum fibers and 50 percent PPS. Raising the glass fiber content to 40 percent and the aluminum to 20 percent provides a small increase in EMI shielding but at the expense of a distinct reduction of impact strength.
TABLE I__________________________________________________________________________Properties of Polyphenylene Sulfide (PPS)--Glass Fibers - Aluminum FibersComposites__________________________________________________________________________Glass Fibers (%) 40 35 30 25 20 33 40 32Al° Fibers (%) 0 5 10 15 20 17 20 18.sup.aResin (%) 60 60 60 60 60 50 40 50Tensile Strength.sup.c 23 23.6 24.8 17.2 16.9 22.5 22.1 9.6(×10.sup.3 psi)Flexural Strength.sup.d 34.5 40.9 39.8 40.5 29.5 40.2 32.5 17.8(×10.sup.3 psi)Flexural Modulus.sup.e 1.45 1.35 1.29 1.33 1.12 1.34 1.3 0.8(×10.sup.6 psi)Notched Izod.sup.f 14.0 16.7 16.6 13.0 11.8 14.8 12.6 0.8(ft-lb/in)Unnotched Izod.sup.g 25.0 29.6 25.6 27.0 21.3 22.3 19.0 3.2(ft-lb/in)Heat Deflection.sup.h 273 252 271 266 101 272 244 176Temperature, °C.@ 264 psiElongation (%).sup.i 1.9 2.49 2.35 1.52 2.05 4.3 1.24 2.7EMI Shielding.sup.j -- 26-35 38-45 32-55 46-41 57-54 62-69.sup.bfrom 0.1-1000 MHz__________________________________________________________________________ .sup.a Continuous aluminized glass supplied by .sup.b 0.5-1000 MHz .sup.c ASTM D638 .sup.d ASTM D790 .sup.e ASTM D790 .sup.f ASTM D256 .sup.g ASTM D256 .sup.h ASTM D648 .sup.i ASTM D638 .sup.j ASTM ES 783
EXAMPLE 3
Polypropylene (PP)-Glass Fiber Composite
The procedure was the same as in Example 1 except that polypropylene was used and a molding temperature of 500° F. was used. The properties of the composite are shown in Table II.
EXAMPLE 4
PP-Glass Fiber-Aluminum Fiber Composite
The procedure was the same as in Example 2 except that PP was used and a molding temperature of 500° F. was used. The properties of the composite are shown in Table II. At the 33 percent glass fiber--17 percent Al fiber loading the EMI shielding is very good and the change in physical properties due to the addition of the Al fiber is within acceptable limits.
EXAMPLE 5
Polyethylene Terephthalate (PET)-Glass Fiber Composite
The procedure was the same as in Example 1 except that PET was used and the molding temperature was 525° F. Properties are shown in Table II.
EXAMPLE 6
PET-Glass Fiber-Aluminum Fiber Composite
The procedure was the same as in Example 2 except that PET was used and the molding temperature was 525° F. Properties are shown in Table II.
TABLE II______________________________________Properties of Other Polymer - Glass Fibers -Aluminum Fibers CompositesPolymer PP PP PET PET______________________________________Glass Fibers (%) 40 33 40 33Al Fibers (%) 0 17 0 17Resin 60 50 60 50Tensile Strength 16.7 12.6 31.2(×10.sup.3 psi)Flexural Strength 14.9 12.3 44.2(×10.sup.3 psi)Flexural Modulus 0.6 0.67 1.2(×10.sup.6 psi)Notched Izod 20.9 19.3 21.0(ft-lb/in)Unnotched Izod 27.9 24.4 34.6(ft-lb/in)Heat Deflection 156 156 254Temperature °C.Elongation (%) 2.6 1.57 2.26EMT Shielding from -- 60-47 -- 47-530.1-1000 MHz______________________________________
EXAMPLE 7
Preparation of Aluminum Fiber on Glass Mat
Transmet Corp., (Columbus, Ohio) a producer of aluminum fibers using a spinning wheel and quick quench method, STET produced aluminum fibers deposited directly onto a glass mat at 0.5 oz/ft 2 and 1.0 oz/ft 2 . This aluminum fiber-glass fiber mat was used without further treatment.
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EMI shielded stampable sheet contains two fiber mats, one of which provides primarily reinforcing function, the other of which provides primarily EMI shielding function.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Ser. No. 60/945,487, filed Jun. 21, 2007, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to certain spirocyclic compounds that are inhibitors of 11-β hydroxyl steroid dehydrogenase type 1 (11βHSD1), compositions containing the same, and methods of using the same for the treatment of diabetes, obesity and other diseases.
BACKGROUND OF THE INVENTION
[0003] The importance of the hypothalamic-pituitary-adrenal (HPA) axis in controlling glucocorticoid excursions is evident from the fact that disruption of homeostasis in the HPA axis by either excess or deficient secretion or action results in Cushing's syndrome or Addison's disease, respectively (Miller and Chrousos (2001) Endocrinology and Metabolism, eds. Felig and Frohman (McGraw-Hill, New York), 4 th Ed.: 387-524). Patients with Cushing's syndrome (a rare disease characterized by systemic glucocorticoid excess originating from the adrenal or pituitary tumors) or receiving glucocorticoid therapy develop reversible visceral fat obesity. Interestingly, the phenotype of Cushing's syndrome patients closely resembles that of Reaven's metabolic syndrome (also known as Syndrome X or insulin resistance syndrome) the symptoms of which include visceral obesity, glucose intolerance, insulin resistance, hypertension, type 2 diabetes and hyperlipidemia (Reaven (1993) Ann. Rev. Med. 44: 121-131). However, the role of glucocorticoids in prevalent forms of human obesity has remained obscure because circulating glucocorticoid concentrations are not elevated in the majority of metabolic syndrome patients. In fact, glucocorticoid action on target tissue depends not only on circulating levels but also on intracellular concentration, locally enhanced action of glucocorticoids in adipose tissue and skeletal muscle has been demonstrated in metabolic syndrome. Evidence has accumulated that enzyme activity of 11βHSD1, which regenerates active glucocorticoids from inactive forms and plays a central role in regulating intracellular glucocorticoid concentration, is commonly elevated in fat depots from obese individuals. This suggests a role for local glucocorticoid reactivation in obesity and metabolic syndrome.
[0004] Given the ability of 11βHSD1 to regenerate cortisol from inert circulating cortisone, considerable attention has been given to its role in the amplification of glucocorticoid function. 11βHSD1 is expressed in many key GR-rich tissues, including tissues of considerable metabolic importance such as liver, adipose, and skeletal muscle, and, as such, has been postulated to aid in the tissue-specific potentiation of glucocorticoid-mediated antagonism of insulin function. Considering a) the phenotypic similarity between glucocorticoid excess (Cushing's syndrome) and the metabolic syndrome with normal circulating glucocorticoids in the latter, as well as b) the ability of 11βHSD1 to generate active cortisol from inactive cortisone in a tissue-specific manner, it has been suggested that central obesity and the associated metabolic complications in syndrome X result from increased activity of 11βHSD1 within adipose tissue, resulting in ‘Cushing's disease of the omentum’ (Bujalska et al. (1997) Lancet 349: 1210-1213). Indeed, 11βHSD1 has been shown to be upregulated in adipose tissue of obese rodents and humans (Livingstone et al. (2000) Endocrinology 131: 560-563; Rask et al. (2001) J. Clin. Endocrinol. Metab. 86: 1418-1421; Lindsay et al. (2003) J. Clin. Endocrinol. Metab. 88: 2738-2744; Wake et al. (2003) J. Clin. Endocrinol. Metab. 88: 3983-3988).
[0005] Additional support for this notion has come from studies in mouse transgenic models. Adipose-specific overexpression of 11βHSD1 under the control of the aP2 promoter in mouse produces a phenotype remarkably reminiscent of human metabolic syndrome (Masuzaki et al. (2001) Science 294: 2166-2170; Masuzaki et al. (2003) J. Clinical Invest. 112: 83-90). Importantly, this phenotype occurs without an increase in total circulating corticosterone, but rather is driven by a local production of corticosterone within the adipose depots. The increased activity of 11βHSD1 in these mice (2-3 fold) is very similar to that observed in human obesity (Rask et al. (2001) J. Clin. Endocrinol. Metab. 86: 1418-1421). This suggests that local 11βHSD1-mediated conversion of inert glucocorticoid to active glucocorticoid can have profound influences whole body insulin sensitivity.
[0006] Based on this data, it would be predicted that the loss of 11βHSD1 would lead to an increase in insulin sensitivity and glucose tolerance due to a tissue-specific deficiency in active glucocorticoid levels. This is, in fact, the case as shown in studies with 11βHSD1-deficient mice produced by homologous recombination (Kotelevstev et al. (1997) Proc. Natl. Acad. Sci. 94: 14924-14929; Morton et al. (2001) J. Biol. Chem. 276: 41293-41300; Morton et al. (2004) Diabetes 53: 931-938). These mice are completely devoid of 11-keto reductase activity, confirming that 11βHSD1 encodes the only activity capable of generating active corticosterone from inert 11-dehydrocorticosterone. 11βHSD1-deficient mice are resistant to diet- and stress-induced hyperglycemia, exhibit attenuated induction of hepatic gluconeogenic enzymes (PEPCK, G6P), show increased insulin sensitivity within adipose, and have an improved lipid profile (decreased triglycerides and increased cardio-protective HDL). Additionally, these animals show resistance to high fat diet-induced obesity. Taken together, these transgenic mouse studies confirm a role for local reactivation of glucocorticoids in controlling hepatic and peripheral insulin sensitivity, and suggest that inhibition of 11βHSD1 activity may prove beneficial in treating a number of glucocorticoid-related disorders, including obesity, insulin resistance, hyperglycemia, and hyperlipidemia.
[0007] Data in support of this hypothesis has been published. Recently, it was reported that 11βHSD1 plays a role in the pathogenesis of central obesity and the appearance of the metabolic syndrome in humans. Increased expression of the 11βHSD1 gene is associated with metabolic abnormalities in obese women and that increased expression of this gene is suspected to contribute to the increased local conversion of cortisone to cortisol in adipose tissue of obese individuals (Engeli, et al., (2004) Obes. Res. 12: 9-17).
[0008] A new class of 11βHSD1 inhibitors, the arylsulfonamidothiazoles, was shown to improve hepatic insulin sensitivity and reduce blood glucose levels in hyperglycemic strains of mice (Barf et al. (2002) J. Med. Chem. 45: 3813-3815; Alberts et al. Endocrinology (2003) 144: 4755-4762). Furthermore, it was recently reported that selective inhibitors of 11βHSD1 can ameliorate severe hyperglycemia in genetically diabetic obese mice. Thus, 11βHSD1 is a promising pharmaceutical target for the treatment of the Metabolic Syndrome (Masuzaki, et al., (2003) Curr. Drug Targets Immune Endocr. Metabol. Disord. 3: 255-62).
A. Obesity and Metabolic Syndrome
[0009] As described above, multiple lines of evidence suggest that inhibition of 11βHSD1 activity can be effective in combating obesity and/or aspects of the metabolic syndrome cluster, including glucose intolerance, insulin resistance, hyperglycemia, hypertension, and/or hyperlipidemia. Glucocorticoids are known antagonists of insulin action, and reductions in local glucocorticoid levels by inhibition of intracellular cortisone to cortisol conversion should increase hepatic and/or peripheral insulin sensitivity and potentially reduce visceral adiposity. As described above, 11βHSD1 knockout mice are resistant to hyperglycemia, exhibit attenuated induction of key hepatic gluconeogenic enzymes, show markedly increased insulin sensitivity within adipose, and have an improved lipid profile. Additionally, these animals show resistance to high fat diet-induced obesity (Kotelevstev et al. (1997) Proc. Natl. Acad. Sci. 94: 14924-14929; Morton et al. (2001) J. Biol. Chem. 276: 41293-41300; Morton et al. (2004) Diabetes 53: 931-938). Thus, inhibition of 11βHSD1 is predicted to have multiple beneficial effects in the liver, adipose, and/or skeletal muscle, particularly related to alleviation of component(s) of the metabolic syndrome and/or obesity.
B. Pancreatic Function
[0010] Glucocorticoids are known to inhibit the glucose-stimulated secretion of insulin from pancreatic beta-cells (Billaudel and Sutter (1979) Horm. Metab. Res. 11: 555-560). In both Cushing's syndrome and diabetic Zucker fa/fa rats, glucose-stimulated insulin secretion is markedly reduced (Ogawa et al. (1992) J. Clin. Invest. 90: 497-504). 11βHSD1 mRNA and activity has been reported in the pancreatic islet cells of ob/ob mice and inhibition of this activity with carbenoxolone, an 11βHSD1 inhibitor, improves glucose-stimulated insulin release (Davani et al. (2000) J. Biol. Chem. 275: 34841-34844). Thus, inhibition of 11βHSD1 is predicted to have beneficial effects on the pancreas, including the enhancement of glucose-stimulated insulin release.
C. Cognition and Dementia
[0011] Mild cognitive impairment is a common feature of aging that may be ultimately related to the progression of dementia. In both aged animals and humans, inter-individual differences in general cognitive function have been linked to variability in the long-term exposure to glucocorticoids (Lupien et al. (1998) Nat. Neurosci. 1: 69-73). Further, dysregulation of the HPA axis resulting in chronic exposure to glucocorticoid excess in certain brain subregions has been proposed to contribute to the decline of cognitive function (McEwen and Sapolsky (1995) Curr. Opin. Neurobiol. 5: 205-216). 11βHSD1 is abundant in the brain, and is expressed in multiple subregions including the hippocampus, frontal cortex, and cerebellum (Sandeep et al. (2004) Proc. Natl. Acad. Sci. Early Edition: 1-6). Treatment of primary hippocampal cells with the 11βHSD1 inhibitor carbenoxolone protects the cells from glucocorticoid-mediated exacerbation of excitatory amino acid neurotoxicity (Rajan et al. (1996) J. Neurosci. 16: 65-70). Additionally, 11βHSD1-deficient mice are protected from glucocorticoid-associated hippocampal dysfunction that is associated with aging (Yau et al. (2001) Proc. Natl. Acad. Sci. 98: 4716-4721). In two randomized, double-blind, placebo-controlled crossover studies, administration of carbenoxolone improved verbal fluency and verbal memory (Sandeep et al. (2004) Proc. Natl. Acad. Sci. Early Edition: 1-6). Thus, inhibition of 11βHSD1 is predicted to reduce exposure to glucocorticoids in the brain and protect against deleterious glucocorticoid effects on neuronal function, including cognitive impairment, dementia, and/or depression.
D. Intra-Ocular Pressure
[0012] Glucocorticoids can be used topically and systemically for a wide range of conditions in clinical ophthalmology. One particular complication with these treatment regimens is corticosteroid-induced glaucoma. This pathology is characterized by a significant increase in intra-ocular pressure (IOP). In its most advanced and untreated form, IOP can lead to partial visual field loss and eventually blindness. IOP is produced by the relationship between aqueous humour production and drainage. Aqueous humour production occurs in the non-pigmented epithelial cells (NPE) and its drainage is through the cells of the trabecular meshwork. 11βHSD1 has been localized to NPE cells (Stokes et al. (2000) Invest. Ophthalmol. Vis. Sci. 41: 1629-1683; Rauz et al. (2001) Invest. Ophthalmol. Vis. Sci. 42: 2037-2042) and its function is likely relevant to the amplification of glucocorticoid activity within these cells. This notion has been confirmed by the observation that free cortisol concentration greatly exceeds that of cortisone in the aqueous humour (14:1 ratio). The functional significance of 11βHSD1 in the eye has been evaluated using the inhibitor carbenoxolone in healthy volunteers (Rauz et al. (2001) Invest. Ophthalmol. Vis. Sci. 42: 2037-2042). After seven days of carbenoxolone treatment, IOP was reduced by 18%. Thus, inhibition of 11βHSD1 in the eye is predicted to reduce local glucocorticoid concentrations and IOP, producing beneficial effects in the management of glaucoma and other visual disorders.
E. Hypertension
[0013] Adipocyte-derived hypertensive substances such as leptin and angiotensinogen have been proposed to be involved in the pathogenesis of obesity-related hypertension (Matsuzawa et al. (1999) Ann. N.Y. Acad. Sci. 892: 146-154; Wajchenberg (2000) Endocr. Rev. 21: 697-738). Leptin, which is secreted in excess in aP2-11βHSD1 transgenic mice (Masuzaki et al. (2003) J. Clinical Invest. 112: 83-90), can activate various sympathetic nervous system pathways, including those that regulate blood pressure (Matsuzawa et al. (1999) Ann. N.Y. Acad. Sci. 892: 146-154). Additionally, the renin-angiotensin system (RAS) has been shown to be a major determinant of blood pressure (Walker et al. (1979) Hypertension 1: 287-291). Angiotensinogen, which is produced in liver and adipose tissue, is the key substrate for renin and drives RAS activation. Plasma angiotensinogen levels are markedly elevated in aP2-11βHSD1 transgenic mice, as are angiotensin II and aldosterone (Masuzaki et al. (2003) J. Clinical Invest. 112: 83-90). These forces likely drive the elevated blood pressure observed in aP2-11βHSD1 transgenic mice. Treatment of these mice with low doses of an angiotensin II receptor antagonist abolishes this hypertension (Masuzaki et al. (2003) J. Clinical Invest. 112: 83-90). This data illustrates the importance of local glucocorticoid reactivation in adipose tissue and liver, and suggests that hypertension may be caused or exacerbated by 11βHSD1 activity. Thus, inhibition of 11βHSD1 and reduction in adipose and/or hepatic glucocorticoid levels is predicted to have beneficial effects on hypertension and hypertension-related cardiovascular disorders.
F. Bone Disease
[0014] Glucocorticoids can have adverse effects on skeletal tissues. Continued exposure to even moderate glucocorticoid doses can result in osteoporosis (Cannalis (1996) J. Clin. Endocrinol. Metab. 81: 3441-3447) and increased risk for fractures. Experiments in vitro confirm the deleterious effects of glucocorticoids on both bone-resorbing cells (also known as osteoclasts) and bone forming cells (osteoblasts). 11βHSD1 has been shown to be present in cultures of human primary osteoblasts as well as cells from adult bone, likely a mixture of osteoclasts and osteoblasts (Cooper et al. (2000) Bone 27: 375-381), and the 11βHSD1 inhibitor carbenoxolone has been shown to attenuate the negative effects of glucocorticoids on bone nodule formation (Bellows et al. (1998) Bone 23: 119-125). Thus, inhibition of 11βHSD1 is predicted to decrease the local glucocorticoid concentration within osteoblasts and osteoclasts, producing beneficial effects in various forms of bone disease, including osteoporosis.
[0015] Small molecule inhibitors of 11βHSD1 are currently being developed to treat or prevent 11βHSD1-related diseases such as those described above. For example, certain amide-based inhibitors are reported in WO 2004/089470, WO 2004/089896, WO 2004/056745, and WO 2004/065351. Additional small molecule inhibitors of 11βHSD1 are reported in US 2005/0282858, US 2006/0009471, US 2005/0288338, US 2006/0009491, US 2006/0004049, US 2005/0288317, US 2005/0288329, US 2006/0122197, US 2006/0116382, and US 2006/0122210.
11) INCY0035 (US 2007/0066584)
[0016] Antagonists of 11βHSD1 have been evaluated in human clinical trials (Kurukulasuriya, et al., (2003) Curr. Med. Chem. 10: 123-53).
[0017] In light of the experimental data indicating a role for 11βHSD1 in glucocorticoid-related disorders, metabolic syndrome, hypertension, obesity, insulin resistance, hyperglycemia, hyperlipidemia, type 2 diabetes, androgen excess (hirsutism, menstrual irregularity, hyperandrogenism) and polycystic ovary syndrome (PCOS), therapeutic agents aimed at augmentation or suppression of these metabolic pathways, by modulating glucocorticoid signal transduction at the level of 11βHSD1 are desirable.
[0018] As evidenced herein, there is a continuing need for new and improved drugs that target 11βHSD1. The compounds, compositions and methods described herein help meet this and other needs.
SUMMARY OF THE INVENTION
[0019] The present invention provides, inter alia, inhibitors of 11βHSD1 having Formula I:
[0000]
[0000] or pharmaceutically acceptable salts thereof, wherein the variables are defined below.
[0020] The present invention further provides compositions comprising a compound of Formula I, or a pharmaceutically acceptable salt thereof, and at least one pharmaceutically acceptable carrier.
[0021] The present invention further provides methods of inhibiting 11βHSD1 by contacting the 11βHSD1 with a compound of Formula I, or a pharmaceutically acceptable salt thereof.
[0022] The present invention further provides methods of inhibiting activity of 11βHSD1 comprising contacting the 11βHSD1 with a compound of Formula I, or a pharmaceutically acceptable salt thereof.
[0023] The present invention further provides methods of inhibiting the conversion of cortisone to cortisol in a cell comprising contacting the cell with a compound of Formula I, or a pharmaceutically acceptable salt thereof.
[0024] The present invention further provides methods of inhibiting the production of cortisol in a cell comprising contacting the cell with a compound of Formula I, or a pharmaceutically acceptable salt thereof.
[0025] The present invention further provides methods of treating various diseases including any one of the following disorders, or any combination of two or more of the following disorders: obesity; diabetes; glucose intolerance; insulin resistance; hyperglycemia; hypertension; hyperlipidemia; cognitive impairment; depression; dementia; glaucoma; cardiovascular disorders; osteoporosis; inflammation; metabolic syndrome; androgen excess; or polycystic ovary syndrome (PCOS) in a patient comprising administering to the patient a therapeutically effective amount of a compound of Formula I, or a pharmaceutically acceptable salt thereof.
DETAILED DESCRIPTION
[0026] The present invention provides, inter alia, inhibitors of 11βHSD1 having Formula I:
[0000]
[0000] or pharmaceutically acceptable salts thereof, wherein:
[0027] R 1 is F, Cl, Br, or I; and
[0028] R 2 and R 3 are independently selected from H, C 1-6 alkyl, and C 3-6 cycloalkyl.
[0029] In some embodiments:
R 1 is F and Cl; and R 2 and R 3 are independently selected from H and C 1-4 alkyl.
[0032] In some embodiments, R 1 is F or Cl.
[0033] In some embodiments, R 1 is F.
[0034] In some embodiments, R 1 is Cl.
[0035] In some embodiments, R 2 and R 3 are independently selected from H, methyl, and ethyl.
[0036] In some embodiments, at least one of R 2 and R 3 is other than H.
[0037] In some embodiments, the compounds of the invention have Formula II:
[0000]
[0038] At various places in the present specification, substituents of compounds of the invention are disclosed in groups or in ranges. It is specifically intended that the invention include each and every individual subcombination of the members of such groups and ranges. For example, the term “C 1-6 alkyl” is specifically intended to individually disclose methyl, ethyl, C 3 alkyl, C 4 alkyl, C 5 alkyl, and C 6 alkyl.
[0039] It is further appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, can also be provided separately or in any suitable subcombination.
[0040] As used herein, the term “alkyl” is meant to refer to a saturated hydrocarbon group which is straight-chained or branched. Example alkyl groups include methyl (Me), ethyl (Et), propyl (e.g., n-propyl and isopropyl), butyl (e.g., n-butyl, isobutyl, t-butyl), pentyl (e.g., n-pentyl, isopentyl, neopentyl), and the like.
[0041] As used herein, “cycloalkyl” refers to non-aromatic 3-7 membered carbocycles including, for example, cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl.
[0042] The compounds described herein are asymmetric (e.g., having one or more stereocenters). All stereoisomers, such as enantiomers, are intended unless otherwise indicated. Compounds of the present invention that contain asymmetrically substituted carbon atoms can be isolated in optically active or racemic forms. Methods on how to prepare optically active forms from optically active starting materials are known in the art, such as by resolution of racemic mixtures or by stereoselective synthesis. Cis and trans isomers of the compounds of the present invention are described and may be isolated as a mixture of isomers or as separated isomeric forms.
[0043] Compounds of the invention can also include tautomeric forms. Tautomeric forms result from the swapping of a single bond with an adjacent double bond together with the concomitant migration of a proton. Tautomeric forms include prototropic tautomers which are isomeric protonation states having the same empirical formula and total charge. Example prototropic tautomers include ketone—enol pairs, amide—imidic acid pairs, lactam—lactim pairs, amide—imidic acid pairs, enamine—imine pairs, and annular forms where a proton can occupy two or more positions of a heterocyclic system, for example, 1H- and 3H-imidazole, 1H-, 2H- and 4H-1,2,4-triazole, 1H- and 2H-isoindole, and 1H- and 2H-pyrazole. Tautomeric forms can be in equilibrium or sterically locked into one form by appropriate substitution.
[0044] Compounds of the invention can also include all isotopes of atoms occurring in the intermediates or final compounds. Isotopes include those atoms having the same atomic number but different mass numbers. For example, isotopes of hydrogen include tritium and deuterium.
[0045] All compounds, and pharmaceutically acceptable salts thereof, may be obtained in various solid forms, including solvated or hydrated forms. In some embodiments, the solid form is a crystalline form. Methods for preparing and discovering different solid forms are routine in the art and include, for example, X-ray powder diffraction, differential scanning calorimetry, thermogravimetric analysis, dynamic vapor sorption, FT-IR, Raman scattering methods, solid state NMR, Karl-Fischer titration, etc.
[0046] In some embodiments, the compounds of the invention, and salts thereof, are substantially isolated. By “substantially isolated” is meant that the compound is at least partially or substantially separated from the environment in which it was formed or detected. Partial separation can include, for example, a composition enriched in the compound of the invention. Substantial separation can include compositions containing at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95%, at least about 97%, or at least about 99% by weight of the compound of the invention, or salt thereof. Methods for isolating compounds and their salts are routine in the art.
[0047] The present invention also includes pharmaceutically acceptable salts of the compounds described herein. As used herein, “pharmaceutically acceptable salts” refers to derivatives of the disclosed compounds wherein the parent compound is modified by converting an existing acid or base moiety to its salt form. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids; and the like. The pharmaceutically acceptable salts of the present invention include the conventional non-toxic salts of the parent compound formed, for example, from non-toxic inorganic or organic acids. The pharmaceutically acceptable salts of the present invention can be synthesized from the parent compound which contains a basic or acidic moiety by conventional chemical methods. Generally, such salts can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton, Pa., 1985, p. 1418 and Journal of Pharmaceutical Science, 66, 2 (1977), each of which is incorporated herein by reference in its entirety.
[0048] The phrase “pharmaceutically acceptable” is employed herein to refer to those compounds, materials, compositions, and/or dosage forms which are, within the scope of sound medical judgment, suitable for use in contact with the tissues of human beings and animals without excessive toxicity, irritation, allergic response, or other problem or complication, commensurate with a reasonable benefit/risk ratio.
[0049] Compounds of the invention can modulate activity of 11βHSD1. The term “modulate” is meant to refer to an ability to increase or decrease activity of an enzyme or receptor. Accordingly, compounds of the invention can be used in methods of modulating 11βHSD1 by contacting the enzyme or receptor with any one or more of the compounds or compositions described herein. In some embodiments, compounds of the present invention can act as inhibitors of 11βHSD1. In further embodiments, the compounds of the invention can be used to modulate activity of 11βHSD1 in an individual in need of modulation of the enzyme or receptor by administering a modulating amount of a compound of the invention.
[0050] The present invention further provides methods of inhibiting the conversion of cortisone to cortisol in a cell, or inhibiting the production of cortisol in a cell, where conversion to or production of cortisol is mediated, at least in part, by 11βHSD1 activity. Methods of measuring conversion rates of cortisone to cortisol and vice versa, as well as methods for measuring levels of cortisone and cortisol in cells, are routine in the art.
[0051] The present invention further provides methods of increasing insulin sensitivity of a cell by contacting the cell with a compound of the invention. Methods of measuring insulin sensitivity are routine in the art.
[0052] The present invention further provides methods of treating disease associated with activity or expression, including abnormal activity and overexpression, of 11βHSD1 in an individual (e.g., patient) by administering to the individual in need of such treatment a therapeutically effective amount or dose of a compound of the present invention, or pharmaceutically acceptable salt thereof, or a pharmaceutical composition thereof Example diseases can include any disease, disorder or condition that is directly or indirectly linked to expression or activity of the enzyme. An 11βHSD1-associated disease can also include any disease, disorder or condition that can be prevented, ameliorated, or cured by modulating enzyme activity.
[0053] Examples of 11βHSD1-associated diseases include obesity, diabetes, glucose intolerance, insulin resistance, hyperglycemia, hypertension, hyperlipidemia, cognitive impairment, dementia, depression (e.g., psychotic depression), glaucoma, cardiovascular disorders, osteoporosis, and inflammation. Further examples of 11βHSD1-associated diseases include metabolic syndrome, type 2 diabetes, androgen excess (hirsutism, menstrual irregularity, hyperandrogenism) and polycystic ovary syndrome (PCOS).
[0054] As used herein, the term “cell” is meant to refer to a cell that is in vitro, ex vivo or in vivo. In some embodiments, an ex vivo cell can be part of a tissue sample excised from an organism such as a mammal. In some embodiments, an in vitro cell can be a cell in a cell culture. In some embodiments, an in vivo cell is a cell living in an organism such as a mammal. In some embodiments, the cell is an adipocyte, a pancreatic cell, a hepatocyte, neuron, or cell comprising the eye (ocular cell).
[0055] As used herein, the term “contacting” refers to the bringing together of indicated moieties in an in vitro system or an in vivo system. For example, “contacting” the 11βHSD1 enzyme with a compound of the invention includes the administration of a compound of the present invention to an individual or patient, such as a human, having 11βHSD1, as well as, for example, introducing a compound of the invention into a sample containing a cellular or purified preparation containing the 11βHSD1 enzyme.
[0056] As used herein, the term “individual” or “patient,” used interchangeably, refers to any animal, including mammals, preferably mice, rats, other rodents, rabbits, dogs, cats, swine, cattle, sheep, horses, or primates, and most preferably humans.
[0057] As used herein, the term “treating” or “treatment” refers to one or more of (1) preventing the disease; for example, preventing a disease, condition or disorder in an individual who may be predisposed to the disease, condition or disorder but does not yet experience or display the pathology or symptomatology of the disease; (2) inhibiting the disease; for example, inhibiting a disease, condition or disorder in an individual who is experiencing or displaying the pathology or symptomatology of the disease, condition or disorder; and (3) ameliorating the disease; for example, ameliorating a disease, condition or disorder in an individual who is experiencing or displaying the pathology or symptomatology of the disease, condition or disorder (i.e., reversing the pathology and/or symptomatology) such as decreasing the severity of disease.
[0058] When employed as pharmaceuticals, the compounds of the invention can be administered in the form of pharmaceutical compositions which is a combination of a compound of the invention and at least one pharmaceutically acceptable carrier. These compositions can be prepared in a manner well known in the pharmaceutical art, and can be administered by a variety of routes, depending upon whether local or systemic treatment is desired and upon the area to be treated. Administration may be topical (including ophthalmic and to mucous membranes including intranasal, vaginal and rectal delivery), pulmonary (e.g., by inhalation or insufflation of powders or aerosols, including by nebulizer; intratracheal, intranasal, epidermal and transdermal), ocular, oral or parenteral. Methods for ocular delivery can include topical administration (eye drops), subconjunctival, periocular or intravitreal injection or introduction by balloon catheter or ophthalmic inserts surgically placed in the conjunctival sac. Parenteral administration includes intravenous, intraarterial, subcutaneous, intraperitoneal or intramuscular injection or infusion; or intracranial, e.g., intrathecal or intraventricular, administration. Parenteral administration can be in the form of a single bolus dose, or may be, for example, by a continuous perfusion pump. Pharmaceutical compositions and formulations for topical administration may include transdermal patches, ointments, lotions, creams, gels, drops, suppositories, sprays, liquids and powders. Conventional pharmaceutical carriers, aqueous, powder or oily bases, thickeners and the like may be necessary or desirable.
[0059] This invention also includes pharmaceutical compositions which contain, as the active ingredient, one or more of the compounds of the invention above in combination with one or more pharmaceutically acceptable carriers. In making the compositions of the invention, the active ingredient is typically mixed with an excipient, diluted by an excipient or enclosed within such a carrier in the form of, for example, a capsule, sachet, paper, or other container. When the excipient serves as a diluent, it can be a solid, semi-solid, or liquid material, which acts as a vehicle, carrier or medium for the active ingredient. Thus, the compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, emulsions, solutions, syrups, aerosols (as a solid or in a liquid medium), ointments containing, for example, up to 10% by weight of the active compound, soft and hard gelatin capsules, suppositories, sterile injectable solutions, and sterile packaged powders.
[0060] In preparing a formulation, the active compound can be milled to provide the appropriate particle size prior to combining with the other ingredients. If the active compound is substantially insoluble, it can be milled to a particle size of less than 200 mesh. If the active compound is substantially water soluble, the particle size can be adjusted by milling to provide a substantially uniform distribution in the formulation, e.g. about 40 mesh.
[0061] The compounds of the invention may be milled using known milling procedures such as wet milling to obtain a particle size appropriate for tablet formation and for other formulation types. Finely divided (nanoparticulate) preparations of the compounds of the invention can be prepared by processes known in the art, for example see International Patent Application No. WO 2002/000196.
[0062] Some examples of suitable excipients include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, water, syrup, and methyl cellulose. The formulations can additionally include: lubricating agents such as talc, magnesium stearate, and mineral oil; wetting agents; emulsifying and suspending agents; preserving agents such as methyl- and propylhydroxy-benzoates; sweetening agents; and flavoring agents. The compositions of the invention can be formulated so as to provide quick, sustained or delayed release of the active ingredient after administration to the patient by employing procedures known in the art.
[0063] The compositions can be formulated in a unit dosage form, each dosage containing from about 5 to about 100 mg, more usually about 10 to about 30 mg, of the active ingredient. The term “unit dosage forms” refers to physically discrete units suitable as unitary dosages for human subjects and other mammals, each unit containing a predetermined quantity of active material calculated to produce the desired therapeutic effect, in association with a suitable pharmaceutical excipient.
[0064] The active compound can be effective over a wide dosage range and is generally administered in a pharmaceutically effective amount. It will be understood, however, that the amount of the compound actually administered will usually be determined by a physician, according to the relevant circumstances, including the condition to be treated, the chosen route of administration, the actual compound administered, the age, weight, and response of the individual patient, the severity of the patient's symptoms, and the like.
[0065] For preparing solid compositions such as tablets, the principal active ingredient is mixed with a pharmaceutical excipient to form a solid preformulation composition containing a homogeneous mixture of a compound of the present invention. When referring to these preformulation compositions as homogeneous, the active ingredient is typically dispersed evenly throughout the composition so that the composition can be readily subdivided into equally effective unit dosage forms such as tablets, pills and capsules. This solid preformulation is then subdivided into unit dosage forms of the type described above containing from, for example, 0.1 to about 500 mg of the active ingredient of the present invention.
[0066] The tablets or pills of the present invention can be coated or otherwise compounded to provide a dosage form affording the advantage of prolonged action. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permit the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids and mixtures of polymeric acids with such materials as shellac, cetyl alcohol, and cellulose acetate.
[0067] The liquid forms in which the compounds and compositions of the present invention can be incorporated for administration orally or by injection include aqueous solutions, suitably flavored syrups, aqueous or oil suspensions, and flavored emulsions with edible oils such as cottonseed oil, sesame oil, coconut oil, or peanut oil, as well as elixirs and similar pharmaceutical vehicles.
[0068] Compositions for inhalation or insufflation include solutions and suspensions in pharmaceutically acceptable, aqueous or organic solvents, or mixtures thereof, and powders. The liquid or solid compositions may contain suitable pharmaceutically acceptable excipients as described supra. In some embodiments, the compositions are administered by the oral or nasal respiratory route for local or systemic effect. Compositions in can be nebulized by use of inert gases. Nebulized solutions may be breathed directly from the nebulizing device or the nebulizing device can be attached to a face masks tent, or intermittent positive pressure breathing machine. Solution, suspension, or powder compositions can be administered orally or nasally from devices which deliver the formulation in an appropriate manner.
[0069] The amount of compound or composition administered to a patient will vary depending upon what is being administered, the purpose of the administration, such as prophylaxis or therapy, the state of the patient, the manner of administration, and the like. In therapeutic applications, compositions can be administered to a patient already suffering from a disease in an amount sufficient to cure or at least partially arrest the symptoms of the disease and its complications. Effective doses will depend on the disease condition being treated as well as by the judgment of the attending clinician depending upon factors such as the severity of the disease, the age, weight and general condition of the patient, and the like.
[0070] The compositions administered to a patient can be in the form of pharmaceutical compositions described above. These compositions can be sterilized by conventional sterilization techniques, or may be sterile filtered. Aqueous solutions can be packaged for use as is, or lyophilized, the lyophilized preparation being combined with a sterile aqueous carrier prior to administration. The pH of the compound preparations typically will be between 3 and 11, more preferably from 5 to 9 and most preferably from 7 to 8. It will be understood that use of certain of the foregoing excipients, carriers, or stabilizers will result in the formation of pharmaceutical salts.
[0071] The therapeutic dosage of the compounds of the present invention can vary according to, for example, the particular use for which the treatment is made, the manner of administration of the compound, the health and condition of the patient, and the judgment of the prescribing physician. The proportion or concentration of a compound of the invention in a pharmaceutical composition can vary depending upon a number of factors including dosage, chemical characteristics (e.g., hydrophobicity), and the route of administration. For example, the compounds of the invention can be provided in an aqueous physiological buffer solution containing about 0.1 to about 10% w/v of the compound for parenteral administration. Some typical dose ranges are from about 1 μg/kg to about 1 g/kg of body weight per day. In some embodiments, the dose range is from about 0.01 mg/kg to about 100 mg/kg of body weight per day. The dosage is likely to depend on such variables as the type and extent of progression of the disease or disorder, the overall health status of the particular patient, the relative biological efficacy of the compound selected, formulation of the excipient, and its route of administration. Effective doses can be extrapolated from dose-response curves derived from in vitro or animal model test systems.
[0072] The compounds of the invention can also be formulated in combination with one or more additional active ingredients which can include any pharmaceutical agent such as anti-viral agents, vaccines, antibodies, immune enhancers, immune suppressants, anti-inflammatory agents, analgesics, and drugs for the treatment of diabetes or obesity, hyperglycemia, hypertension, hyperlipidemia, and the like. Agents for treatment of metabolic disorders with which a compound of the invention could be combined include, but are not limited to, amylin analogues, incretin mimetics, inhibitors of the incretin-degrading enzyme dipeptidyl peptidase-IV, agonists of peroxisome proliferator-activated receptor (PPAR)-a and PPAR-g, and CB1 cannabinoid receptor inhibitors.
[0073] The invention will be described in greater detail by way of specific examples. The following examples are offered for illustrative purposes, and are not intended to limit the invention in any manner. Those of skill in the art will readily recognize a variety of noncritical parameters which can be changed or modified to yield essentially the same results.
EXAMPLES
[0074] All compounds were purified by either flash column chromatography or reversed-phase liquid chromatography using a Waters FractionLynx LC-MS system with mass directed fractionation. Column: Waters XBridge C 18 5 μm, 19×100 mm; mobile phase A: 0.15% NH 4 OH in water and mobile phase B: 0.15% NH 4 OH in acetonitrile; the flow rate was 30 ml/m, the separating gradient was optimized for each compound using the Compound Specific Method Optimization protocol as described in literature [“Preparative LC-MS Purification: Improved Compound Specific Method Optimization”, K. Blom, B. Glass, R. Sparks, A. Combs, J. Combi. Chem., 2004, 6, 874-883].
[0075] The separated product was then typically subjected to analytical LC/MS for purity check under the following conditions: Instrument; Agilent 1100 series, LC/MSD, Column: Waters Sunfire™ C 18 5 μm, 2.1×5.0 mm, Buffers: mobile phase A: 0.025% TFA in water and mobile phase B: 0.025% TFA in acetonitrile; gradient 2% to 80% of buffer B in 3 min with flow rate 1.5 mL/min.
Example 1
5-{3-Fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}-N-methylpyridine-2-carboxamide
[0076]
Step 1: 1-benzyl 3-ethylpiperidine-1,3-dicarboxylate
[0077]
[0078] Benzyl chloroformate (Aldrich, cat #:119938) (191 mL, 1.34 mol) was slowly added to a cooled (at 0° C.) mixture of ethyl piperidine-3-carboxylate (Aldrich, cat #:194360) (200 g, 1.27 mol) and triethylamine (266 mL, 1.91 mol) in methylene chloride (1000 mL). The reaction mixture was allowed to gradually warm to ambient temperature and stirred for 3 h. The reaction was quenched by the addition of 1N HCl aq. solution and the product was extracted several times with methylene chloride. The combined extracts were washed with water, saturated aq. NaHCO 3 , water, brine, dried over MgSO 4 , filtered and concentrated under reduced pressure to afford the desired product as oil (359.8 g, 97%). LC/MS 292.2 (M+H) + .
Step 2: 1-benzyl 3-ethyl 3-(3-methylbut-2-en-1-yl)piperidine-1,3-dicarboxylate
[0079]
[0080] To a solution of 1-benzyl 3-ethyl piperidine-1,3-dicarboxylate (120.0 g, 0.412 mol) in THF (400 ml) cooled at −78° C. was added dropwise 270 mL of sodium bis(trimethylsilyl)amide solution (1M solution in THF from Aldrich, cat #:245585) over 2 h. The mixture was stirred at −78° C. for additional 1 h. Then 1-bromo-3-methylbut-2-ene (Aldrich cat #: 249904) (71 mL, 0.62 mol) was added slowly over 1 h. The mixture was stirred at −78° C. for 30 min, and allowed to warm to r.t. and stirred for an additional 3 h. The reaction mixture was quenched with 1N HCl aq. solution. Most of THF was removed under reduced pressure. The residue was extracted with ethyl acetate. The combined extracts were washed with sat. aq. NaHCO 3 and brine, then dried over MgSO 4 , filtered and concentrated under reduced pressure. The crude residue was purified by flash column chromatography on a silica gel column with 10˜20% ethyl acetate in hexane to yield the desired product (140 g, 94%). LC/MS: m/e=332.2 (M+H) + .
Step 3: 1-benzyl 3-ethyl 3-(2-oxoethyl)piperidine-1,3-dicarboxylate
[0081]
[0082] Ozone was passed through a solution of 1-benzyl 3-ethyl 3-(3-methylbut-2-en-1-yl)piperidine-1,3-dicarboxylate (35.2 g, 0.0979 mol) in methylene chloride (800 mL) at −78° C. until the color of the solution turned blue. The reaction mixture was then flushed with nitrogen until the blue color dissipated. Dimethylsulfide (Aldrich, cat #: 274380) (14 mL, 0.19 mol) and triethylamine (26.5 mL, 0.19 mol) were added and the mixture was stirred at ambient temperature overnight. The volatile solvent were removed under reduced pressure and purified directly by flash chromatography on a silica gel column with 20% ethyl acetate in hexanes to afford the desired product in quantitative yield. LC/MS 334.2 (M+H) + .
Step 4: Benzyl 2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate
[0083]
[0084] To a suspension of cis-4-aminocyclohexanol hydrochloride (Available from Sijia Medchem Lab, China) (13.8 g, 0.0910 mol) and 1-benzyl 3-ethyl 3-(2-oxoethyl)piperidine-1,3-dicarboxylate (31.0 g, 0.0930 mol) in 1,2-dichloroethane (250 mL) was added triethylamine (23.3 mL, 0.167 mol) at room temperature. The mixture was stirred at 40° C. overnight. Sodium triacetoxyborohydride (Aldrich, cat #: 316393) (49.3 g, 0.232 mol) was added to the above mixture and stirred at r.t. for 1 h. LC/MS data indicated that the starting material was consumed, and an intermediate product with m/e: 433.2 (M+H) + was observed.
[0085] The mixture was then heated at 80° C. for 4 h or until LC/MS showed the intermediate amine (m/e: 433.2) was consumed. The reaction mixture was quenched with aq. NaHCO 3 . The organic layer was washed with brine, dried over MgSO 4 , filtered and concentrated under reduced pressure. The crude material was dried under reduced pressure overnight to give colorless viscous oil (26.9 g, 66.8%). LC/MS m/e 387.2 (M+H) + .
Step 5: Benzyl (5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate
[0086]
[0087] The racemic mixture obtained from above step (26.9 g) was purified on an Agilent 1100 series preparatory system using a Chiralcel OD-H column (3.0×25 cm, 5 micron particle size, Chiral Technologies) eluting with 30% ethanol/hexanes (isocratic, 22 mL/min.). The column loading was approximately 150 mg/injection and peak collection was triggered by UV absorbance at 220 nM. Peak 1 eluted at approximately at 8.5 min. and Peak 2 eluted at approximately 9.8 min. The fractions of Peak 2 were combined and concentrated to provide the desired product (11.9 g) as a white foamy solid. The optical purity of the pooled material from peak 2 was determined by using an Agilent 1100 series analytical system equipped with a Chiralcel OD-H column (4.6×250 mm, 5 micron particle size, Chiral Technologies) and eluting with 30% ethanol/hexanes (isocratic, 0.8 mL/min.). LC/MS m/e 387.2 (M+H) + . The absolute stereochemistry of the peak 2 was established based on X-ray single crystal structure determination of close analogs: Benzyl (5S)-2-(trans-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate and (5S)-2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one prepared as described in Steps 5a-c.
Step 5a: Benzyl 2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate
[0088]
[0089] To a stirred solution of benzyl 2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate (60.00 g, 155.2 mmol) in anhydrous N,N-dimethylformamide (160 mL) at r.t. was added 1H-imidazole (32.0 g, 466 mmol) and tert-butyldimethylsilyl chloride (36.2 g, 233 mmol). The reaction mixture was stirred at r.t. for 4 h, quenched with water (150 mL), and extracted with EtOAc (3×150 mL). The combined organic layers were washed with brine, dried over sodium sulfate, filtered and concentrated under reduced pressure to afford the crude product (84 g). The pure product (55.4 g) was obtained by re-crystallization of the crude product from heptane. The mother liquor was concentrated and subjected to purification by flash chromatography on a silical gel column eluting with AcOEt/Haxane to give additional 14.4 g of the product with a total 89.7% yield.
Step 5b: 2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one
[0090]
[0091] To a solution of benzyl 2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate (18.0 g, 35.9 mmol) in methanol (150 mL) was added 10% palladium on carbon (Aldrich, cat #: 520888) (1.8 g, 1.5 mmol) under the atmosphere of nitrogen. The reaction mixture was hydrogenated and shaken at 50 psi for 20 h. The reaction mixture was filtered through a pad of Celite and then washed with methanol (300 mL). The filtrate was concentrated under reduced pressure to give the desired product as a white solid in quantitative yield.
Step 5c: (5S)-2-(cis-4-{[tert-butyl(dimethyl)silyl[oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one
[0092]
[0093] 2-(cis-4-{[tert-Butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one (7.00 g, 19.1 mmol) was dissolved in acetonitrile (50 mL) and methanol (7 mL) at r.t. After the starting material was completely dissolved, the solution was heated up to 70° C. To the above solution was slowly added a solution of (2R)-hydroxy(phenyl)acetic acid (1.45 g, 9.55 mmol) in acetonitrile (20 mL) at 65-70° C. After addition, the solution was heated at 74° C. for 10 min, and allowed to cool slowly to room temperature overnight. The crystalline formed was collected by filtration to afford 3.38 g of the desired product as (2R)-hydroxy(phenyl)acetic acid salt. The resulting salt (3.38 g) was dissolved in water (50 mL), and adjusted to pH˜12 with 40 mL aq K 2 CO 3 solution (2.0 M). The mixture was extracted with dichloromethane (3 times). The combined organic layers were dried with magnesium sulfate, filtered, and concentrated under reduced pressure to afford the desired product as a free base (colorless crystalline solid) (2.37 g). The absolute stereochemistry of this compound was established by X-ray single crystal structure determination of (2R)-hydroxy(phenyl)acetic acid salt of (5S)-2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one.
Step 6: (5S)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-]-one
[0094]
[0095] Benzyl (5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]decane-7-carboxylate prepared in Step 5 (0.266 g, 0.000688 mol) was dissolved in methanol (5.0 mL) and stirred under an atmosphere of hydrogen in the presence of 10% palladium on carbon (Aldrich, cat #: 520888) (20.0 mg) at r.t. for 2 h. The reaction mixture was filtered and the volatile solvents were removed under reduced pressure to afford the desired product in quantitative yield. LC/MS m/e 253.2 (M+H) + .
Step 7: (5S)-7-(4-bromo-2-fluorophenyl)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-1-one
[0096]
[0097] A mixture of (5S)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-1-one (1.04 g, 0.00412 mol), 4-bromo-2-fluoro-1-iodobenzene (Aldrich, cat #: 283304) (1.85 g, 0.00615 mol), copper(I) iodide (Aldrich, cat #: 215554) (0.122 g, 0.000640 mol), potassium phosphate (2.63 g, 0.0124 mol) and 1,2-ethanediol (0.48 mL, 0.0086 mol) in 1-butanol (3.90 mL) was heated at 100° C. under nitrogen for 2 d. The reaction was quenched with water, and extracted with ether. The organic layers were combined, washed with water, brine, dried over Na 2 SO 4 , and filtered. The filtrate was evaporated under reduced pressure. The residue was purified by flash column chromatography on a silica gel column eluting with 0 to 5% methanol in DCM to yield the desired product (950 mg, 54.2%). LC/MS m/e 425.1/427.0 (M+H) + .
Step 8: 5-3-fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl-N-methylpyridine-2-carboxamide
[0098] Potassium phosphate (637 mg, 0.00300 mol) in water (3.00 mL) was added to a mixture of (5S)-7-(4-bromo-2-fluorophenyl)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-1-one (425 mg, 0.00100 mol), N-methyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide (Frontier Inc., cat #: M10074) (393 mg, 0.00150 mol) and tetrakis(triphenylphosphine)palladium (Aldrich, cat #: 216666) (35 mg, 0.000030 mol) in 1,4-dioxane (3.00 mL). The resulting mixture was heated at 120° C. for 24 h. The mixture was diluted with ethyl acetate and washed with water and brine. The organic layer was dried over Na 2 SO 4 , filtered, concentrated under reduced pressure. The residue was purified by flash column chromatography on a silica gel column eluting with 5% methanol in DCM to yield the desired product (285 mg, 59.3%). LC/MS m/e 481.2 (M+H) + . 1 H-NMR (400 MHz, DMSO-d 6 ): 8.89 (1H, dd, J=2.5, 0.6 Hz), 8.76 (1H, q, J=4.7 Hz), 8.22 (1H, dd, J=8.4, 2.5 Hz), 8.03 (1H, dd, J=8.4, 0.6 Hz), 7.65 (1H, dd, J=14.2, 2.1 Hz), 7.56 (1H, dd, J=8.5, 2.1 Hz), 7.13 (1H, t, J=8.5 Hz), 4.37 (1H, d, J=3.1 Hz), 3.78 (1H, m), 3.71 (1H, m), 3.21-3.38 (3H, m), 3.07 (1H, d, J=11.4 Hz), 2.81 (3H, d, J=4.7 Hz), 2.64-2.74 (2H, m), 2.18-2.26 (1H, m), 1.60-1.91 (8H, m), 1.39-1.51 (3H, m), 1.21-1.30 (2H, m).
Example 2
5-{3-Fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}-N,N-dimethylpyridine-2-carboxamide
[0099]
Step 1: 5-bromo-N,N-dimethylpyridine-2-carboxamide
[0100]
[0101] Oxalyl chloride (20.0 mL, 0.236 mol) was added to a solution of 5-bromopyridine-2-carboxylic acid (Alfa Aesar, cat #: B25675) (10.1 g, 0.0500 mol) in methylene chloride (60 mL) at r.t. followed by 5 drops of DMF. The mixture was stirred at r.t. for 2 h. The volatiles were evaporated under reduced pressure. The residue was azotropically evaporated with toluene twice. The residue was then dissolved in DCM (30 mL) followed by the addition of 30 mL of dimethylamine in THF solution (2.0 M) (Aldrich, cat #: 391956) and Hunig's base (20.0 mL) (Aldrich, cat #: 496219). The mixture was stirred at r.t. for 3 h. The reaction mixture was diluted with DCM (100 mL) and washed with water, 1N HCl and brine. The organic phase was dried over Na 2 SO 4 , filtered and concentrated to give the desired product (10.5 g, 91.7%).
Step 2: N,N-dimethyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide
[0102]
[0103] A mixture of 5-bromo-N,N-dimethylpyridine-2-carboxamide (5.73 g, 0.0250 mol), 4,4,5,5,4′,4′,5′,5′-octamethyl-[2,2′]bi[[1,3,2]dioxaborolanyl] (6.98 g, 0.0275 mol) (Aldrich, cat #: 473294), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II) complexed with dichloromethane (1:1) (0.6 g, 0.0007 mol) (Aldrich, cat #: 379670), 1,1′-bis(diphenylphosphino)ferrocene (0.4 g, 0.8 mmol) (Aldrich, cat #: 177261), and potassium acetate (7.36 g, 0.0750 mol) in 1,4-dioxane (100 mL) was heated at 120° C. for 20 h. After cooling, the mixture was concentrated, diluted with ethyl acetate and washed with sat'd NH 4 Cl solution, water, brine; dried over Na 2 SO 4 . After filtration, the filtrate was concentrated and the crude material was further purified on a silica gel column eluting with ethyl acetate/hexane to give the desired product (4.7 g, 68%).
Step 3: 5-{3-Fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}-N,N-dimethylpyridine-2-carboxamide
[0104] This compound was prepared by using procedures that were analogous to those described for the synthesis of Example 1, Step 8 starting from N,N-dimethyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide and (5S)-7-(4-bromo-2-fluorophenyl)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-1-one. LC/MS m/e 495.3 (M+H) + . 1 H-NMR (400 MHz, DMSO-d 6 ): 8.86 (1H, d, J=1.7 Hz), 8.15 (1H, dd, J=8.1, 2.3 Hz), 7.51-7.65 (3H, m), 7.12 (1H, t, J=8.9 Hz), 4.37 (1H, d, J=3.1 Hz), 3.78 (1H, m), 3.71 (1H, m), 3.22-3.38 (3H, m), 3.06 (1H, d, J=11.7 Hz), 3.00 (3H, s), 2.97 (3H, s), 2.64-2.74 (2H, m), 2.18-2.27 (1H, m), 1.60-1.91 (8H, m), 1.39-1.51 (3H, m), 1.22-1.30 (2H, m).
Example 3
N-Ethyl-5-{3-fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}pyridine-2-carboxamide
[0105]
Step 1: N-ethyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide
[0106]
[0107] This compound was prepared by using procedures that were analogous to those described for the synthesis of Example 2, Steps 1 & 2 starting from 5-bromopyridine-2-carboxylic acid.
Step 2: N-Ethyl-5-{3-fluoro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}pyridine-2-carboxamide
[0108] This compound was prepared by using procedures that were analogous to those described for the synthesis of Example 1, Step 8 starting from N-ethyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide and (5S)-7-(4-bromo-2-fluorophenyl)-2-(cis-4-hydroxycyclohexyl)-2,7-diazaspiro[4.5]decan-1-on. LC/MS m/e 495.3 (M+H) + .
Example 4
5-{3-Chloro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}-N-ethylpyridine-2-carboxamide
[0109]
Step 1: (5S)-7-(4-bromo-2-chlorophenyl)-2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one
[0110]
[0111] A mixture of (5S)-2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one (0.282 g, 0.000769 mol), 4-bromo-2-chloro-1-iodobenzene (0.293 g, 0.000922 mol) (Lancaster, cat #: 19245), copper(I) iodide (0.015 g, 0.000077 mol), potassium phosphate (0.490 g, 0.00231 mol) and 1,2-ethanediol (0.0857 mL, 0.00154 mol) in 1-butanol (0.75 mL) was heated at 100° C. under nitrogen for 2 d. The reaction mixture was filtered, concentrated under reduced pressure, and the residue was purified by flash chromatography on a silica gel column (eluting with 0 to 50% ethyl acetate in hexanes) to afford the desired product.
Step 2: 5-{3-chloro-4-[(5S)-2-(cis-4-hydroxycyclohexyl)-1-oxo-2,7-diazaspiro[4.5]dec-7-yl]phenyl}-N-ethylpyridine-2-carboxamide
[0112] To a stirred mixture of (5S)-7-(4-bromo-2-chlorophenyl)-2-(cis-4-{[tert-butyl(dimethyl)silyl]oxy}cyclohexyl)-2,7-diazaspiro[4.5]decan-1-one (20 mg, 0.00004 mol), [1,1 ′-bis(diphenylphosphino)ferrocene]dichloropalladium(II) complex with dichloromethane (1:1) (2.0 mg), tetrakis(triphenylphosphine)palladium (1.0 mg) and potassium carbonate (14.9 mg, 0.000108 mol) in anhydrous N,N-dimethylformamide (1 mL) was added N-ethyl-5-(4,4,5,5-tetramethyl-1,3,2-dioxaborolan-2-yl)pyridine-2-carboxamide (14.5 mg, 0.054 mmol). The resulting reaction mixture was heated at 150° C. and stirred overnight, followed by the removal of TBS protecting group by the addition of 1.7 M of fluorosilicic acid in water (0.10 mL) and the mixture was stirred at r.t. overnight. The reaction mixture was then directly purified by RP-HPLC to afford the desired product. LC/MS m/e 511.2 (M+H) + . 1 H-NMR (400 MHz, DMSO-d 6 ): 8.92 (1H, d, J=2.3 Hz), 8.84 (1H, t, J=5.9 Hz), 8.26 (1H, dd, J=8.2, 2.3 Hz), 8.06 (1H, d, J=8.2 Hz), 7.89 (1H, d, J=2.2 Hz), 7.74 (1H, dd, J=8.5, 2.2 Hz), 7.30 (1H, t, J=8.5 Hz), 4.39 (1H, d, J=3.1 Hz), 3.80 (1H, m), 3.72 (1H, m), 3.24-3.44 (5H, m), 3.01 (1H, d, J=11.4 Hz), 2.63-2.74 (2H, m), 2.40-2.53 (1H, m), 1.64-1.91 (8H, m), 1.41-1.53 (3H, m), 1.20-1.32 (2H, m), 1.13 (3H, t, J=7.2 Hz).
Example 5
Enzymatic Assay of 11βHSD1
[0113] All in vitro assays were performed with clarified lysates as the source of 11βHSD1 activity. HEK-293 transient transfectants expressing an epitope-tagged version of full-length human 11βHSD1 were harvested by centrifugation. Roughly 2×10 7 cells were resuspended in 40 mL of lysis buffer (25 mM Tris-HCl, pH 7.5, 0.1 M NaCl, 1 mM MgCl 2 and 250 mM sucrose) and lysed in a microfluidizer. Lysates were clarified by centrifugation and the supernatants were aliquoted and frozen.
[0114] Inhibition of 11βHSD1 by test compounds was assessed in vitro by a Scintillation Proximity Assay (SPA). Dry test compounds were dissolved at 5 mM in DMSO. These were diluted in DMSO to suitable concentrations for the SPA assay. 0.8 μL of 2-fold serial dilutions of compounds were dotted on 384 well plates in DMSO such that 3 logs of compound concentration were covered. 20 μL of clarified lysate was added to each well. Reactions were initiated by addition of 20 μL of substrate-cofactor mix in assay buffer (25 mM Tris-HCl, pH 7.5, 0.1 M NaCl, 1 mM MgCl 2 ) to final concentrations of 400 μM NADPH, 25 nM 3 H-cortisone and 0.007% Triton X-100. Plates were incubated at 37° C. for one hour. Reactions were quenched by addition of 40 μL of anti-mouse coated SPA beads that had been pre-incubated with 10 μM carbenoxolone and a cortisol-specific monoclonal antibody. Quenched plates were incubated for a minimum of 30 minutes at RT prior to reading on a Topcount scintillation counter. Controls with no lysate, inhibited lysate, and with no mAb were run routinely. Roughly 30% of input cortisone is reduced by 11βHSD1 in the uninhibited reaction under these conditions.
Example 6
Cell-Based Assay for 11βHSD1 Activity
[0115] Peripheral blood mononuclear cells (PBMCS) were isolated from normal human volunteers by Ficoll density centrifugation. Cells were plated at 4×10 5 cells/well in 200 μL of AIM V (Gibco-BRL) media in 96 well plates. The cells were stimulated overnight with 50 ng/ml recombinant human IL-4 (R&D Systems). The following morning, 200 nM cortisone (Sigma) was added in the presence or absence of various concentrations of compound. The cells were incubated for 48 hours and then supernatants were harvested. Conversion of cortisone to cortisol was determined by a commercially available ELISA (Assay Design).
[0116] Various modifications of the invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description. Such modifications are also intended to fall within the scope of the appended claims. Each reference, including all patent, patent applications, and publications, cited in the present application is incorporated herein by reference in its entirety.
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The present invention relates to certain spirocyclic compounds that are inhibitors of 11-β hydroxyl steroid dehydrogenase type 1 (11βHSD1), compositions containing the same, and methods of using the same for the treatment of diabetes, obesity and other diseases.
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